Manitou 120AETJ

R
BP 249 Z. I.
44 158 ANCENIS CEDEX FRANCE
TEL : +33 (0)2 40 09 10 11
YOUR CONCESSIONAIRE
REF : 547 363 EN (05 / 04)
ACCESS
PLATFORM
120 AETJ
REPAIRS MANUAL
1st EDITION
06 / 2002
ISSUE DATE
COMMENTS
06/2002
1st edition
11/2003
Updated
12/2003
Variable speed drive unit parameters modification
05/2004
Updated
35-8-21-M.84
80-6-M.84
80-8-11-M.84
80-8-85-M.84
CONTENTS
GROUPS
0
0-1-M.84 EN
30
30-2-63-M.84 EN
SECTIONS
General Points
Technical characteristics
Removing the wheel reducer / brake

Steering Axle
35-8-21-M.84 EN
Free-wheeling
55-2-21-M.84 EN
70
120 AETJ
0-1-M.84
120 AETJ
30-2-63-M.84
120 AETJ
35-8-21-M.84
120 AETJ
55-2-21-M.84
Reducer
35
55
MACHINES
Arms - Platform
Removing the wear pads
Hydraulics
70-2-52-M.84 EN
Removing the distributor elements
120 AETJ
70-2-52-M.84
70-2-80-M.84 EN
Removing the cylinders
120 AETJ
70-2-80-M.84
70-5-M.84 EN
Hydraulic pressure
120 AETJ
70-5-M.84
70-6-M.84 EN
Hydraulic layout
120 AETJ
70-6-M.84
80
Electricity
80-2-11-M.84 EN
Removing the variable speed drive unit
120 AETJ
80-2-11-M.84
80-2-12-M.84 EN
Removing the traction batteries
120 AETJ
80-2-12-M.84
80-2-13-M.84 EN
Removing the electrical cable looms
120 AETJ
80-2-13-M.84
Electrical layouts
120 AETJ
80-6-M.84
Checking the operation of the Sevcon

variable speed drive unit
120 AETJ
80-8-11-M.84
80-6-M.84 EN
80-8-11-M.84 EN
CONTENTS
GROUPS
SECTIONS
MACHINES
80-8-85-M.84 EN
Testing the manipulator
120 AETJ
80-8-85-M.84
80-8-86-M.84 EN
Positioning and adjusting the contactors
120 AETJ
80-8-86-M.84
120 AETJ
100-M.84
100
100-M.84 EN
Troubleshooting
Troubleshooting
GROUPS 0
GENERAL
POINTS
TECHNICAL CHARACTERISTICS
120 AETJ
0-1-M.84 EN
11 / 2003
0-1-M.84
0-1-M.84
CHARACTERISTICS
ELECTRIC
PUMP
- Electrical supply
3,7 KW
- Cubic capacity
4,8 cm3
- Pressure
200 bars
ELECTRIC
0-1-M.84
48 V
- Output
WHEEL MOTORS
- Type
T 17 - 2 KW
ELECTRICAL
CIRCUIT
- Battery
48 V - 300 Ah
- Charger
50 Ah (single-phase)
BOARD
FUSES
- Motherboard :
10 A
- Output
325 A
- Electric pump
100 A
- Emergency pump
100 A
120 AETJ
SPECIFICATIONS
- Use
Indoors
Outdoors
- Capacity
230 Kg
120 Kg
i.e.
i.e.
2 people
1 person
+wind 45Km/h
0-1-M.84
- Control system
Electro-hydraulic
- Turret rotation
350
- Operating speed
0,6 km/h
- Transport speed
6 km/h
- Operating height
11950 mm
- Floor height
9950 mm
- Max off-centring
7000 mm
- Access platform weight

Empty
6550 kg
Under nominal load
6780 kg
- No. of gears
- Traversable gradient
25%
- Max permissible slope
5% or 3
TYRES
DIMENSIONS
TYPE
600 X 190
BANDAGE
LOAD PER
TYRE EMPTY
F
R
1655 KG
UNDER MAX LOAD+ OFF

SUPPORT SURFACE
CENTRING ON 1 WHEEL
FOR 1 WHEEL ON GROUND
F/R
1620 KG
4200 KG
Tightening torque for the front and rear wheel nuts
212 CM2
STAMPING
20 DAN/CM2
19 daNm
DIMENSIONS
120AETJ
5477
3740
1200
2163
1650
104
2228
1550
3250
3340
2138
J
F
A1
A2
0-1-M.84
A1
A2
B
C
D
E
F
G
H
I
J
120AETJ
K1
K2
K3
K4
L1
L2
L3
L4
2483
3242
6506
4353
9950
8794
4773
595
0-1-M.84
8
12
K1
11
L1
10
L2
9
8
K2
7
6
L3
5
4
K3
K4
L4
FILTER ELEMENT
0-1-M.84
DESCRIPTION
1 - Hydraulic return oil filter cartridge
REFERENCE
REPLACE
599004
Every 900 H
LUBRICANTS
COMPONENTS TO BE LUBRICATED
CAPACITY
RECOMMENDATION
PACKAGING
REFERENCE
HYDRAULIC OIL RSERVOIR
12 Litres
MANITOU
HYDRAULIC OIL ISO 46
20 L.
55 L.
209 L.
582 297
546 108
546 109
WHEEL MOTOR (EACH ONE)
0.8 Litre
SHELL
SPIRAX OIL A90
2 L.
20 L.
50 L.
661 998
661 950
661 950
TURRET ROTATION MOTOR
1.5 Litres
cartridge
400 Gr.
161 589
GENERAL GREASING
SHELL RETINAX HD
GREASE
BEARING TURRET RING GREASING
SHELL ALVANIA EP LF 2
GREASE
1 Kg
545 836
TURRET RING TEETH LUBRICATION
SHELL MALLEUS GL 205

OIL
Aerosol
545 834
GROUPS 30
REDUCER
REMOVING THE WHEEL

REDUCER/BRAKE
120 AETJ
30-2-63-M.84 EN
11 / 2003
30-2-63-M.84
REMOVING THE WHEEL REDUCER / BRAKE

UP TO
PLATFORM NO. 505578: REDUCER 598694
- Set the lower arm to maximum for optimum accessibility.

- Raise the rear of the platform and place a wedge under the chassis.
- Remove the rear wheels 1 (Fig. A) (10 bolts, No. 19 spanner).
- Open the rear cover 2 (Fig. A) (4 bolts, No. 4 hex spanner).
- Mark and remove the electric motor power cables.
2
1
30-2-63-M.84
- 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) (16 bolts, No. 10 spanner).
RE-ASSEMBLY
- Same operations as above in reverse order.
FROM
PLATFORM NO. 505579: REDUCER 599538
- Same procedure as for removing reducer 598694.
RE-ASSEMBLY
When fastening reducers 599538, position the CHC M12x45 bolts at

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

machine with significant braking performance, in order to hold it: the
two machines must be connected by a tow bar.
- To set the platform to free wheel, it must not be subject to any translation stresses from slopes. The wheels must be able to turn freely.
A
1
- If possible, raise the platform to free the drive wheels in order to facilitate the operation.
- Loosen bolt 1 (Fig. A) on each wheel 22 mm from the edge, up to the
resistance point, without forcing it (20 Nm).
35-8-21-M.84
- The machine can be towed as a trailer.
Warning: do not loosen the bolt more than 22 mm,

otherwise it may break.
RE-INSTALLATION
- Turn the wheel gently from left to right to reset the gear while retightening the screws (1) (Fig. A). Pay attention to the torque when tightening (150 Nm).
GROUPS 55
ARMS
PLATFORM
REMOVING THE WEAR PADS

120 AETJ
55-2-21-M.84 EN
55-2-21-M.84
11 / 2003
INDEX
A - REMOVING
THE TELESCOPE CYLINDER WEAR PADS ...........................
B - REMOVING
THE TELESCOPE ARM WEAR PADS
C - REMOVING
THE MOBILE TUBE WEAR PADS .......................................
P2
.................................. P 2
P2
55-2-21-M.84
A - REMOVING
THE TELESCOPE CYLINDER WEAR PADS
A1
- Remove the telescope cylinder: see the REMOVING THE TELESCOPE CYLINDER section.
- Remove the wear pads 1 (Fig. A1) (8 bolts, No. 10 spanner).
1
RE-ASSEMBLY
B - REMOVING
55-2-21-M.84
THE TELESCOPE ARM WEAR PADS
B1
- Lift the basket with a hoist to relieve the pads.
- Remove the top of the jib pad fasteners 2 (Fig. B1) (16 bolts, No. 6
hex spanner).
- Pay attention to the position of the adjustment plates 3 (Fig. B1).
2
- Remove the pads.
RE-ASSEMBLY
- If necessary, position the adjustment plates:
Plates 3 (Fig. B1): see PR catalogue for reference.
C - REMOVING
THE MOBILE TUBE WEAR PADS
C1
- Lift the basket with a hoist to relieve the pads.

- Remove the upper and lower top of the jib pad fasteners 4 (Fig. C1)
(8 bolts, No. 19 spanner, No. 6 hex spanner).
- Pay attention to the position of the adjustment plates 5 (Fig. C1).
- Remove the pads.
- Remove the mobile tube mobile, holding the tube with a hoist and
the basket with a forklift truck.
C2
- Remove the base of the jib pads 6 (Fig. C2) (hammer, chisel).
- Pay attention to the position of the adjustment plates 7 (Fig. C2).
6
7
RE-ASSEMBLY
- Same operations as above in reverse order: the base of the jib pads
must be forcibly emmancher with a hammer.
- If necessary, position the adjustment plates:
Plates 7 (Fig. C2): see PR catalogue for reference.
55-2-21-M.84
N:
505421
JUSQU'A LA MACHINE
BIS DER MASCHINE
HASTA LA MAQUINA
UP TO MACHINE
34
33
5 BA 240
34
35
36
37
38
40
41
10
39
31
32
14
16
15
18
11
42
29
30
FLECHE TELESCOPIQUE
TELESKOPAUSELEGER
AGUILON TELESCOPICO
TELESCOPIC JIB
17
27 19
28
6
28
12
13
12
20
20
24
23
3
21
55-2-21-M.84
23
24
25
43
26
5
44
45
22
12 / 04 / 02
120 AETJ
P.A.O
GROUPS 70
HYDRAULICS
REMOVING THE DISTRIBUTOR

ELEMENTS
120 AETJ
70-2-52-M.84 EN
70-2-52-M.84
11 / 2003
REMOVING THE DISTRIBUTOR ELEMENTS

A
- Switch off the electrical power supply.

- Open the right-hand cover.
- Remove the hoses (Spanners Nos. 19, 24, 27, 30).

- Mark each solenoid 1 (Fig. A) (Adhesive and marker) according to the
writing on the yellow rings on the power cable looms and then remove 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 replaced (various flat and hex

spanners).
B
3
Before removing any hose or distributor component, operate the tappets on the electro-valves by pulling and then pushing them in order
to decompress the circuit (Fig. C)
70-2-52-M.84
M1
M2
B9
A7
B7
EV3
A6
B6
B1
A2
B2
A3
B3
B5
PR
.
ESS
23BASKET
A4
15
15
14
17
16
ARM 1 / 2 RAISING SYSTEM EV6-EV7
TELESCOPE ARM RAISING SYSTEM EV8-EV9
12 / 04 / 02
Distributor
Plug
35-BAR reducer
150-BAR restrictor
Main 180-BAR restrictor
Electro-valve
Plug
180-BAR balancing valve
80-BAR overload valve
Electro-valve
Electro-valve
Electro-valve
Electro-valve
Non-return valve
Plug
100-BAR reducer
2-BAR non-return valve
Solenoid
Solenoid
Connection port
TILTING SYSTEM EV14-EV15
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
120 AETJ
TLESCOPE
A5
EEXTENSION SYSTEM EV10-EV11
B4
BASKET ROTATION
SYSTEM H16-H17
A1
T1
EV2
13
PENDULAR ARM EV12- EV13
20
STEERING SYSTEM EV1-EV5
11
PLATFORM ROTATION SYSTEM H18-H19
A9
A8
B8
10
12
PARA FIG : 6 - 10 - 11 - 12 - 13
FOR ITEM : 6 - 10 - 11 - 12 - 13
PARA FIG : 6 - 10 - 11 - 13
FOR ITEM : 6 - 10 - 11 - 13
POUR REP : 6 - 10 - 11 - 12 - 13
19 FUR HINW : 6 - 10 - 11 - 12 - 13
POUR REP : 6 - 10 - 11 - 13
18 FUR HINW : 6 - 10 - 11 - 13
ANTI-ROLLOVER BARS H20-H21
POUR REP : 12
FUR HINW : 12
PARA FIG : 12
FOR ITEM : 12
10 DA 213
DISTRIBUTEUR
KOMMANDOSTEUERVENTIL
DITRIBUIDOR
VALVE BLANK
P.A.O
70-2-52-M.84
REMOVING THE CYLINDERS

120 AETJ
70-2-80-M.84 EN
70-2-80-M.84
11 / 2003
INDEX
A - REMOVING
THE STEERING CYLINDER ................................................P
B - REMOVING
THE TELESCOPE CYLINDER
C - REMOVING
THE ANTI-ROLLOVER BAR CYLINDERS ...............................P
.............................................P 4
6
70-2-80-M.84
A - REMOVING
THE STEERING CYLINDER
A1
- Raise the front of the platform and place a wedge under the chassis.
- Remove the front wheels 1 (Fig. A1) (12 nuts, No. 30 spanner).
- Decompress the cylinder supply hoses: see the REMOVING THE

DISTRIBUTOR ELEMENTS section.
- Mark and remove the hydraulic hoses (No. 19 spanner).
- Remove the articulation shaft 2 (Fig. A2) (1 bolt, No. 13 spanner).
- Remove the articulation shaft 3 (Fig. A3) (2 circlips, circlips clamp).
- Remove the steering cylinder 4 (Fig. A3).
A2
RE-ASSEMBLY
2
70-2-80-M.84
Remember to install the steering latch 5 (Fig. A2) before installing the
shaft 2 (Fig. A2).
A3
3
4
10 CE 34
S
INT
JO
DE
TE ATZ S
T
E
CH GS TA
PO HTUNE JUN
DIC GO D
E
JU L KIT
A
SE
A
B
C
D
E
F
G
25 mm
Course - Hub - Carrera - Stroke : 179 mm
HYDRAULIQUE (Vrin de direction)

HYDRAULIK (Lenkungzylinder)
HYDRAULICO (Cilindro de direccin)
HYDRAULIC (Steering cylinder)
70-2-80-M.84
12 / 04 / 02
120 AETJ
P.A.O
B - REMOVING
THE TELESCOPE CYLINDER
B1
- Raise the basket to access the cylinder foot axle 6 (Fig. B1).
- In horizontal position, extend the telescope enough to access the
articulation shaft 7 (Fig. B1).
- Wedge the basket in place with lifting equipment.

- Remove the protective casing 8 (Fig. B1) (2 bolts, No. 10 spanner).

- Remove the articulation shaft 7 (Fig. A3) (2 circlips, circlips clamp).
- Remove the cylinder supply hoses 9 (Fig. B2) (No. 24 spanner).
B2
- Remove the articulation shaft 6 (Fig. A2) (1 bolt, No. 13 spanner).

- Remove the telescope cylinder by extending the arm from the front
(Fig. B3).
RE-ASSEMBLY
70-2-80-M.84

9
The cylinder's chambers contain oil under pressure. To remove the

valve block, you must equalize the pressures by progressively unscrewing the 4 bolts 10 (Fig. B3) (No. 6 hex spanner) and letting the
oil escape.
B3
10
10 CC 82
S
INT
JO
DE
TE ATZ S
T
E
CH GS TA
PO HTUNE JUN
DIC GO D
E
JU L KIT
A
SE
A
B
C
D
E
F
G
H
35 mm
HYDRAULIQUE (Vrin de tlescopage)

HYDRAULIK (Zusammenstroll zylinder)
HYDRAULICO (Cilindro de telescopaje)
HYDRAULIC (Telescope cylinder)
70-2-80-M.84
12 / 04 / 02
120 AETJ
P.A.O
C - REMOVING
THE ANTI-ROLLOVER BAR CYLINDERS
C1
- Set the platform in transport position (Telescope retracted, arms in

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

13
- Mark and remove the hydraulic hoses 11 (Fig. C1) (No. 19 spanner).
- Remove the articulation shafts 12 (Fig. C1) (8 circlips, circlips
clamp).
- Remove the cylinders 13 (Fig. C1).
RE-ASSEMBLY
70-2-80-M.84
12
10 CF 38
T
OIN
EJ
E D TZ
T
S
ET A
CH GS TA
PO HTUNE JUN
DIC GO D
E
JU L KIT
A
SE
A
B
C
D
E
F
G
18 mm
HYDRAULIQUE (Vrin de stabilisation)

HYDRAULIK (Stabilizer zylinder)
HYDRAULICO (Cilindro de estabilizador)
HYDRAULIC (Stabilizer cylinder)
70-2-80-M.84
12 / 04 / 02
120 AETJ
P.A.O
HYDRAULIC PRESSURE
120 AETJ
70-5-M.84 EN
70-5-M.84
11 / 2003
ADJUSTING THE HYDRAULIC PRESSURES

A
Most of the adjustments are made by two people: one works the
controls on the base console, the other adjusts the valves
- Open the right-hand cover 1 (Fig. A) and remove it.
Adjusting the anti-rollover bar pressure reducer (Hydraulic layout

No. 2).
1
- Switch the platform on.
- Connect the manometer to pressure port M2 (Fig. B).
M2
- Raise the platform a few centimetres to release deployment of the

anti-rollover bars.
- Fully extend the telescope and hold down the extend control while
making the adjustment
- Adjust the tare on pressure reducer 2 (Fig. B) (No. 17 spanner, No. 4
hex spanner) to 40 bar.
- Disconnect the manometer and re-insert the bung.
70-5-M.84
Adjusting the pressure reducer (Hydraulic layout No. 7).

M1

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

- Connect the manometer to pressure port M (Fig. D) on the distributor block.
- Adjust the tare on pressure reducer 4 (Fig. C) (No. 13 spanner, No.
4 hex spanner) to 180 bar.
1
Adjusting the compensation / tilt balancing valve (Hydraulic

layout No. 17).
- Switch off the machine and disconnect the electrical circuit.
- Decompress the compensation / tilt control hoses: see the REMOVING THE DISTRIBUTOR ELEMENTS section.
12
9
- Remove hose 5 (Fig. E) (No. 24 spanner) connected to A5.
- Insert a T connector (M/M/F12S) 7 (Fig. E) between hose 5 and

connection 6.
- Add a straight connector (M/F 16x150-12S) 8 (Fig. E) and then
connect the manometer 9 (Fig. E) to this.
- Switch the machine on.
10
- Raise the telescope arm 10 (Fig. F) to mid-stroke on the cylinder and

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

layout No. 18).
G
14

- Decompress the compensation / tilt control hoses: see the REMOVING THE DISTRIBUTOR ELEMENTS section.
- Remove hose 13 (Fig. G) (No. 24 spanner) connected to B5.
- Insert a T connector (M/M/F12S) 7 (Fig. E) between hose 13 and
connection 14.
- Add a straight connector (M/F 16x150-12S) 8 (Fig. E) and then
connect the manometer 9 (Fig. E) to this.
- Raise the telescope arm 10 (Fig. F) to mid-stroke on the cylinder and
then extend the tilting cylinder 11 (Fig. F) to the maximum extent.
- Raise the telescope and adjust the tare on balancing valve 15 (Fig.
F) (No. 13 spanner, No. 4 hex spanner) during ascent to 80 bars.
- Switch off the machine, remove the manometer and then reconnect
hose 13 in its original configuration.
13
15
9
7
8
Adjusting the pressure stat (Hydraulic layout No. 19).

17
- Open the right-hand turret cover.

- Remove the sealing screw 16 (Fig. H) (No. 3 hex spanner) located
between the terminals on the pressure stat 17 (Fig. H) to access the
setting screw.
- Remove hose 18 (Fig. I) (No. 24 spanner) connected to B6.
16
- Insert a T connector (M/M/F12S) 7 (Fig. I) between hose 18 and

connection 19.
- Add a straight connector (M/F 16x150-12S) 8 (Fig. I) and then

connect the manometer 20 (Fig. I) (Minimum capacity 250 bar) to
this and take the manometer into the basket.
19
7
18
- Instruct the platform to travel without operating the steering 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 20
bar.
- At 20 bar, pressure stat triggers and then the pump.
Pressure increases in the brake line. Pump and pressure
stat cut out.
- Repeated at regular intervals.
- If the pressure stat triggers below 20 bar, adjust it by tightening the
setting screw to increase the trigger pressure.
20
70-5-M.84
J
P(bar)
120
100
80
- If the pressure stat triggers above 20 bar, loosen the setting screw by
several turns to proceed as described above: Adjustment is always
made by tightening the screw.
60
40
20
- Conduct a new travel test.

- When adjustment is complete, switch the machine off, reconnect
hose 18 in its original configuration and re-insert the sealing screw
16.
20bars
t(s)
HYDRAULIC LAYOUT
120 AETJ
70-6-M.84 EN
70-6-M.84
11 / 2003
HYDRAULIC LAYOUT
70-6-M.84
GROUPS 80
ELECTRICITY
REMOVING THE VARIABLE SPEED

DRIVE UNIT
120 AETJ
80-2-11-M.84 EN
80-2-11-M.84
11 / 2003
REMOVING THE VARIABLE SPEED DRIVE UNIT

UP
TO PLATFORM NO . 505490
- Switch off the electrical supply and then disconnect the batteries: see
the REMOVING THE TRACTION BATTERIES section.
- Open the rear cover (4 bolts, No. 4 hex spanner).

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

120 AETJ
80-2-12-M.84 EN
80-2-12-M.84
11 / 2003
REMOVING THE TRACTION BATTERIES

UP
TO PLATFORM NO . 505490 :
BATTERIES 598121
A
- Raise the platform a few centimetres to release the engagement of

the anti-rollover bars 1 (Fig. A).
- Switch off the electrical supply.
- Remove the left-hand and right-hand battery covers 2 (Fig. A) (4 butterfly bolts).
- Disconnect the cable looms connected to the + and - terminals (No.
16 spanner).
- Remove the battery fasteners 3 (Fig. B) (4 bolts, No. 12 hex spanner).
- Remove the batteries (individual weight: 248.5 kg) from their housing
using a hoist and slings fastened to the side flanges on the tank 4
(Fig. B) or using a forklift truck's forks.
B
3
RE-ASSEMBLY
4
FROM PLATFORM NO. 505490: BATTERIES 599364

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

- Remove the left-hand and right-hand battery covers 2 (Fig. A).
- Disconnect the cable looms connected to the + and - terminals (No.

16 spanner).
- Remove the battery fasteners 5 (Fig. C) (4 bolts, No. 12 hex spanner).
- Remove the batteries (individual weight: 263 kg) from their housing
using a hoist and slings fastened to the side flanges on the tank 6
(Fig. C) or using a forklift truck's forks.
RE-ASSEMBLY
When re-assembling, remember to fit the cross-strut 7 (Fig. C) at the

back of the tank between the tank flange and the side of the chassis.
80-2-12-M.84
REMOVING THE CABLE LOOMS

120 AETJ
80-2-13-M.84 EN
80-2-13-M.84
11 / 2003
INDEX
A - LOCATION
B - BASKET
OF THE CABLE LOOMS....................................................
CONSOLE CABLE LOOM
C - MAIN
BOX CABLE LOOM
D - BASE
CONSOLE CABLE LOOM
E - OTHER
P2
.................................................... P 3
................................................................ P 6
..................................................... P 10
CABLE LOOMS .................................................................
P 12
80-2-13-M.84
A - LOCATION
OF THE CABLE LOOMS
7
4
6
80-2-13-M.84
No.
CABLE LOOM
1
2
3
4
5
6
7
Basket console
BUS CAN extension
Main box
Base console
Variable speed drive
Distributor
Overload cable loom
B - BASKET
CONSOLE CABLE LOOM
-1
80-2-13-M.84
No.
DESCRIPTION
J4
H6
H7
H8
H9
H10
H14
H15
H16
H17
S13
S14
S15
S17
S18
S19
S20
S21
S22
Clip pin
Overload light
Slope light
Travel light
Arms 1/2 raising light
Arm 3 raising light
Tilt light
Telescope light
Pendular arm light
Buzzer
Travel switch
Raising arms 1/2 switch
Raising arm 3 switch
3-position selector
Tilt switch
Telescope switch
Pendular arm switch
Horn button
Emergency Stop
BASKET
CONSOLE CABLE LOOM
CARD CONNECTIONS
CABLE CONNECTION CONTACT DESCRIPTION
113
112
315
318
0
328
327
322
321
323
329
331
320
330
80-2-13-M.84
319
311
312
316
317
306
310
309
304
303
305
308
307
302
CAN
CAN
CAN
CAN
CAN
CAN
A-IN
A-IN
A-IN
A-IN
A-IN
A-IN
A-IN
A-IN
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
1
2
3
4
5
6
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Spare
Spare
Spare
Spare
Info. Bus Can.
Info. Bus Can.
Manipulator side analogue input 0V / 2.5V / 5V
Manipulator longitudinal analogue input 0V / 2.5V / 5V
Spare
Spare
Spare
Spare
Spare
Spare
Spare
0V card - lower arm LED
0V card - upper arm LED
0V card - telescope LED
0V card - pendular arm LED
Spare
0V card - compensation arm LED
Spare
Spare
Spare
Spare
Spare
0V card - travel LED
0V card - overload alarm LED
0V card - buzzer
0V card - slope LED
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
0V manipulator trigger
Spare
0V travel switch
Spare
0V overload contactor
0V steer left switch
0V steer right switch
0V movement selector
0V lower arm switch
0V upper arm switch
0V telescope switch
0V pendular arm switch
0V compensation switch
0V movement selector (basket rotation)
0V movement selector (turret rotation)
0V horn
BASKET
CONSOLE CABLE LOOM
CABLE
CONNECTION
311
309
304
303
310
305
121
121
121
121
121
302
121
121
306
307
308
331
330
329
328
327
323
322
321
106
121
106
106
106
106
106
106
106
320
106
106
316
317
318
319
103
106
315
BRIDGE
S13/D-IN-3
S15/D-IN-10
S19/D-IN-11
S20/D-IN-12
S14/D-IN-9
S18/D-IN-13
S18/S20
S20/S19
S19/S15
S15/S13
S13/S14
S21/D-IN-16
S21/S17
S17/S17
S17/D-IN-8
S17/D-IN-15
S17/D-IN14
H6/D-OUT-14
H7/D-OUT-16
H8/D-OUT-13
H9/D-OUT-2
H10/D-OUT-3
H14/D-OUT-7
H15/D-OUT-4
H16/D-OUT-5
J4-106/H14
S18/S17
H14/H16
H16/H15
H15/H10
H10/H8
H8/H9
H9/H6
H6/H7
H17/D-OUT-15
H17/J4-106
J4-106/B+
D-IN-6/P CLIPS 6V-2
D-IN-7/P CLIPS 6V-3
A-IN-2/P CLIPS 6V-4
D-IN-1/P CLIPS 3V
NEG/P CLIPS 3V
B+/P CLIPS 3V
A-IN-1/P CLIPS 6V-1
S17/S17
CABLE ALLOCATION
COLOUR DESCRIPTION
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
RED
YELLOW
RED
RED
RED
RED
RED
RED
RED
YELLOW
RED
RED
YELLOW
YELLOW
YELLOW
YELLOW
WHITE
RED
YELLOW
YELLOW
80-2-13-M.84
C - MAIN
BOX CABLE LOOM
-3
80-2-13-M.84
80-2-13-M.84
No.
DESCRIPTION
J2-107
Clip pin
J2-109
Clip pin
J2-111
Clip pin
J2-118
Clip pin
J4-103
Clip pin
J4-105
Clip pin
J4-106
Clip pin
J4-121
Clip pin
J4-123
Clip pin
KA3
24V relay
KA4
24V relay
KA5
24V relay
S4
Emergency pump switch
7
MAIN
BOX CABLE LOOM
CARD CONNECTIONS
CABLE CONNECTION CONTACT DESCRIPTION
113
112
227
231
226
220
224
221
225
228
219
222
223
234
229
101
80-2-13-M.84
217
218
230
233
238
235
215
214
213
212
211
208
207
205
206
201
202
209
210
204
203
216
CAN
CAN
CAN
CAN
CAN
CAN
A-IN
A-IN
A-IN
A-IN
A-IN
A-IN
A-IN
A-IN
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-OUT
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
D-IN
1
2
3
4
5
6
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Spare
Spare
Spare
Spare
Info. Bus Can.
Info. Bus Can.
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
0V card - lower arm electro-valve
0V card - overload LED
0V card - upper arm electro-valve
0V card - anti-rollover arm output electro-valve
0V card - pendular arm electro-valve
Spare
0V card - turret rotation electro-valve
0V card - telescope electro-valve
0V card - KA3 raise / lower selection coil
0V card - jib rotation electro-valve
0V card - basket rotation electro-valve
Spare
0V card - compensation / tilt electro-valve
0V card - steer left electro-valve
0V card - steer right electro-valve
Counting info - timer input 01
Spare
0V card - horn
0V card - rotating light
0V card - maintenance alarm LED
0V card - brake reservoir electro-valve
0V card - anti-rollover bar return electro-valve
0V card - KM3 steering pump coil
0V jib rotation right switch
0V lower arm raising switch
0V lower arm lowering switch
0V upper arm raising switch
0V upper arm lowering switch
0V turret left rotation switch rotation
0V turret right rotation switch rotation
0V telescope retraction switch
0V telescope extension switch
0V compensation raising switch
0V compensation lowering switch
0V pendular arm raising switch
0V pendular arm lowering switch
0V basket left rotation switch
0V basket right rotation switch
0V jib left rotation switch
MAIN
BOX CABLE LOOM
CABLE
CABLE ALLOCATION
CONNECTION
211
S11/D-IN-5
212
S11/D-IN-4
206
S6/D-IN-9
205
S6/D-IN-8
216
S8/D-IN-16
215
S8/D-IN-1
210
S7/D-IN-13
209
S7/D-IN-12
204
S9/D-IN-14
203
S9/D-IN-15
202
S12/D-IN-11
201
S12/D-IN-10
214
S10/D-IN-2
213
S10/D-IN-3
207
S5/D-IN-7
208
S5/D-IN-6
102
PL-8/VARIABLE SPEED DRIVE
122
101
PL-1/D-OUT-17
121
S3/J4-121
104
S2/VARIABLE SPEED DRIVE
108
106
J4-106 F. AV/J4-106 C.
230
D-OUT-21/CI 5002001
231
D-OUT-3/CI 5002001
110
S2/CHARGER
105
J4-105/CHARGER
107
S3/J2-107
105
J4-105/S3
228
D-OUT-10/KA3-A1
106
KA3-A2/J4-106
106
KA3-11/J4-106
235
D-OUT-24/VAR SPEED DRIVE
117
KA4-14/VAR SPEED DRIVE
118
J2-118/VAR SPEED DRIVE
111
109
106
J4-106/J4-106
106
J4-106 C./VAR SPEED DRIVE
103
103
J4-103/NEG.
112
CAN-6/VAR SPEED DRIVE
113
CAN-5/VAR SPEED DRIVE
106
J4-106/B+
103
KA4-A2/J4-106
103
KA5-A2/J4-103
103
KA5-11/J4-103
BRIDGE
KA5-14/KA4-11
103
KA4-A2/J4-103
103
J4 121/J4 103
S4/EMERGENCY PUMP
S4/EMERGENCY PUMP
COLOUR
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
RED
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
RED
RED
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
RED
RED
WHITE
WHITE
YELLOW
YELLOW
RED
WHITE
WHITE
WHITE
YELLOW
WHITE
WHITE
WHITE
BROWN
DESCRIPTION
80-2-13-M.84
D - BASE
CONSOLE CABLE LOOM
-4
80-2-13-M.84
No.
DESCRIPTION
5002001
CRESTO CIRCUIT
Clip pin
Timer
Emergency Stop
3-position selector
Turret rotation switch
Telescope switch
Pendular arm switch
Jib rotation switch
Basket rotation switch
Arms 1 / 2 raising switch
Arm 3 raising switch
Reverse tilt switch
Dead man's switch
J4
PL
S2
S3
S5
S6
S7
S8
S9
S10
S11
S12
S23
10
BASE
CONSOLE CABLE LOOM
CABLE ALLOCATION
CABLE
CONNECTION
211
212
206
205
216
215
210
209
204
203
202
201
214
213
207
208
242
242
242
242
242
242
242
106
102
122
106
101
106
121
108
242
104
108
106
106
230
231
110
107
105
S11/D-IN-5
S11/D-IN-4
S6/D-IN-9
S6/D-IN-8
S8/D-IN-16
S8/D-IN-1
S7/D-IN-13
S7/D-IN-12
S9/D-IN-14
S9/D-IN-15
S12/D-IN-11
S12/D-IN-10
S10/D-IN-2
S10/D-IN-3
S5/D-IN-7
S5/D-IN-6
S12/S5
S5/S10
S10/S11
S11/S6
S6/S8
S8/S7
S7/S9
S3/S3
PL-2/J4-106
PL-1/D-OUT-17
J4-106/S3
S3/J4-121
S3/S23
S23/S12
J4-106 F. AV/J4-106 C
J4-106/CI 5002001
D-OUT-21/CI 5002001
D-OUT-3/CI 5002001
S2/CHARGER
S3/J2-107
J4-105/S3
COLOUR DESCRIPTION
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
RED
YELLOW
YELLOW
RED
YELLOW
RED
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
RED
RED
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
11
80-2-13-M.84
E - OTHER
VARIABLE
CABLE LOOMS
SPEED DRIVE CABLE LOOM
-5
Bridge
80-2-13-M.84
Bridge
12
DISTRIBUTOR
CABLE LOOM
-6
80-2-13-M.84
13
ELECTRICAL LAYOUTS
120 AETJ
80-6-M.84 EN
80-6-M.84
05 / 2004
INDEX
A - POWER
B - BASE
SECTION
SINGLE MANIPULATOR ..........................................P
SINGLE MANIPULATOR ..............................P
CONTROL SECTION
C - BASKET
D - POWER
E - BASE
SINGLE MANIPULATOR ..........................P
DUAL MANIPULATOR ............................................P
CONTROL SECTION
SECTION
CONTROL SECTION
DUAL MANIPULATOR ...............................P
F - BASKET
CONTROL SECTION
1-
DUAL MANIPULATOR ........................P
G - BASKET
CONTROL SECTION
2-
DUAL MANIPULATOR
10
12
.......................P 14
80-6-M.84
A - POWER
SECTION
SINGLE MANIPULATOR
80-6-M.84
80-6-M.84
B - BASE
CONTROL SECTION
SINGLE MANIPULATOR
80-6-M.84
80-6-M.84
C - BASKET
CONTROL SECTION
SINGLE MANIPULATOR
80-6-M.84
80-6-M.84
D - POWER
SECTION
DUAL MANIPULATOR
80-6-M.84
677523
1
4
80-6-M.84
Lower arm
Telescope retracted
E - BASE
CONTROL SECTION
DUAL MANIPULATOR
80-6-M.84
10
120 AETJ
677523
Version 1
Page 2/4
80-6-M.84
11
F - BASKET
CONTROL SECTION
DEAD
MAN'S
1-
DUAL MANIPULATOR
JIB rotation
selection
Basket rotation
selection
Horn
Basket rotation
JIB rotation
Emergency stop 01
green
SQ5
Overload
detection
yellow (x)
grey (y)
brown
white
Left joystick A5
80-6-M.84
Interface
2-axis
joystick
12
Overload
alarm
(red)
Slope
Horn
120 AETJ
677523
Version 1 - Page 3/4
Slope
cut-out
Slope cut-out
Horn
Pendular arm selection
Telescope selection
Compensation selection
JIB rotation
Turret rotation
Basket rotation
Upper arm selection
Lower arm selection
Translation selection
Overload
Out-of NEUTRAL
Buzzer
Pendular arm
Telescope
Compensation
JIB rotation
Turret rotation
Basket rotation
Upper arm
Lower arm
Translation
Slope
Faults/alarm
+5V supply
Rotation instructions
Steer left
Steer right
Traction instructions
Dead man's
(Optional)
Slope
Travel
(Optional)
Lower
arm
(Optional)
Upper
arm
(Optional)
Basket
Rotation
(Optional)
Turret
Rotation
(All the LEDs are supplied with 24V)
13
(Optional)
JIB
Rotation
(Optional)
Compensation
(Optional)
Telescope
(Optional)
Pendular harm
80-6-M.84
G - BASKET CONTROL SECTION 2 - DUAL MANIPULATOR
Pendular arm
selection
Compensation
selection
Telescop
selection
Translation
green
yellow
blue
black
grey
violet
red
pink
brown
white
Right joystick A7
Traction
80-6-M.84
14
Out-of NEUTRAL
(48V) DEAD
MAN's led
Telescop selection
Pendular arm selection
DEAD MAN's
120 AETJ
677523
Version 1 - Page 4/4
Lower arm
selection
Pendular selection
Telescope selection
Lower arm selection
Travel selection
Lower arm selection
Out-of NEUTRAL
Steer left
Steer right
Traction instructions
80-6-M.84
15
CHECKING THE OPERATION OF THE

SEVCON VARIABLE SPEED DRIVE UNIT
120 AETJ
80-8-11-M.84 EN
80-8-11-M.84
05 / 2004
INDEX
SPEED DRIVE PARAMETERS ..............................................P
THE VARIABLE SPEED DRIVE ...............................................P
MESSAGES .........................................................................P
A - VARIABLE
B - TESTING
C - ERROR
D - DIAGNOSTIC
E - USING
LED STATUSES
THE CALIBRATOR
............................................................P 7
.................................................................P 8
80-8-11-M.84
A - VARIABLE
SPEED DRIVE PARAMETERS
Microprocessor W598800.007 : Single manipulator

Microprocessor W598800.008 : Dual manipulator
80-8-11-M.84
Minimum
Value
Maximum
Value
Step
Actual
Value
Armature I Max (A)
50
350
10
500
Field I Max (A)
10
50
50
Traction Accel Delay (s)
0.1
5.0
0.1
1.8
Traction Decel Delay (s)
0.1
5.0
0.1
0.1
Traction Direction Decel Delay (s)
0.1
5.0
0.1
0.8
Calibrator
Reference
CAN Name
1.1.1A
1.1.1F
1.1.2
Description
1.1.3
1.1.3A
100
1.1.4
Traction Creep Speed (%)
25
1.1.5
Flat Regen Direction Braking (A)
50
350
10
400
1.1.6
91
Tilt Regen Direction Braking (A)
50
350
10
500
1.1.7
Traction Regen Time (ms)
300
10
10
1.1.8
Brake Threshold (V)
0,09
3,20
0,016
0.8
100
1.1.9
Traction Maximum Speed (%)
100
1.1.10
Elevated Speed (%)
100
12
1.1.11
10
Tilt Speed (%)
100
100
1.1.12
11
Traction Cut 3 Speed (%)
100
100
1.1.13
12
Review delay (h)
100
50
1.1.14
13
Customers Options
1.1.15
102
Low Speed Traction Speed (%)
100
100
1.1.16
16
Low Battery Start (V)
14.5
48.0
0.5
18.0
1.1.17
17
Low Battery Cutout (V)
14.5
48.0
0.5
14.5
1.1.18
18
High Battery Start (V)
14.5
75.0
0.5
65.0
1.1.19
19
High Battery Cutout (V)
14.5
75.0
0.5
70.0
1.1.20
20
Battery Protection Level (V)
14.5
48.0
0.5
14.5
1.1.21
21
Battery Protection Delay (s)
0.1
2.5
0.1
0.5
1.1.22
61
Traction Alarm
Calibrator
Reference
CAN Name
1.4.2
22
BDI Battery Voltage (V)
24
96
48
1.4.3
23
BDI Reset Level (V)
2.00
2.50
0.01
2.15
1.4.4
24
BDI Discharge Level (V)
1.50
1.99
0.01
1.73
1.4.5
25
BDI Warning Level (%)
90
30
1.4.6
26
BDI Cutout Level (%)
90
20
Minimum
Value
Maximum
Value
Step
Actual
Value
On
Minimum
Value
Description
Maximum
Value
Step
Actual
Value
Calibrator
Reference
CAN Name
1.6.1
95
CAN Mode
Aboma
1.6.2
39
Chop Select
On
1.6.3
40.3
BDI
On
1.6.4
40.1
Fault Log
On
1.6.5
40.2
Service Log
On
1.6.6
40.4
EU / US Functionality
EU
1.6.7
94
1.6.8
1.6.9
101
Calibrator
Reference
CAN Name
Description
Traction Full Speed (KPH)
160
Traction Full Speed (MPH)
100
21
13
Centre-Pot
Accelerator Characteristic
Description
Minimum
Value
Maximum
Value
Step
Actual
Value
90
1.7.1
33
Armature I Low (A)
10
240
10
1.7.2
34
Field I Low (A)
25
1.7.3
35
Armature I Mid (A)
100
500
10
200
1.7.4
36
Field I Mid (A)
40
25
1.7.5
37
Armature I High (A)
260
350
10
400
1.7.6
38
Field I High (A)
25
50
40
1.7.7
44
Armature Resistance (mOhm)
255
13
1.7.8
45
Field Resistance (Ohm)
0,25
2.50
0.01
1.26
4
1.7.9
41
Drive Proportional Gain
255
1.7.10
42
Drive Integral Gain
16
1.7.11
43
Brake Proportional Gain
255
40
1.7.12
92
Brake Integral Gain
16
15
1.7.13
93
Speed Estimate Gain
2.50
0.01
1.5
EPROM
W598800.007
Minimum
Value
Maximum
Value
Actual
Value
Calibrator
Reference
CAN Name
1.8.1
31
Display Default Hours
1.8.2
32
Display Status Type
1.8.3
30
Display Contrast
1.8.4
27
FFD Indicator 1
Off
Description
EPROM
W598800.008
Step
Key
Off
127
30
1.8.5
28
FFD Indicator 2
Off
1.8.6
29
Display Fault Messages
Off
Calibrator
Reference
CAN Name
Minimum
Value
50
Description
Maximum
Value
350
Step
Actual
Value
2.1.1
46
Pump I Max
10
350
2.1.2
47
Ramp Up Delay
0.1
5.0
0.1
3.0
2.1.3
48
Ramp Down Delay
0.1
0.5
0.1
0.5
2.1.4
49
Pump Creep Speed
25
19
Calibrator
Reference
CAN Name
Actual
Value
2.3.1
67
2.3.2
Minimum
Value
Maximum
Value
Step
Boom 1 Up Speed (%)
100
90
68
Boom 1 Down Speed (%)
100
40
40
2.3.3
56
Boom 1 Cutback Speed (%)
100
100
100
2.3.4
69
Boom 2 Up Speed (%)
100
63
59
2.3.5
70
100
39
35
2.3.6
57
100
100
100
2.3.7
71
Jib Up Speed (%)
100
40
36
2.3.8
72
Jib Down Speed (%)
100
25
2.3.8A
103
Jib Rotate Left Speed (%)
100
32
2.3.8B
104
Jib Rotate Right Speed (%)
100
32
2.3.9
73
Tele In Speed (%)
100
100
100
2.3.10
74
Tele Out Speed (%)
100
100
100
2.3.11
75
Slew Left Speed (%)
100
32
26
2.3.12
76
Slew Right Speed (%)
100
32
26
2.3.13
98
Cage Rotate Left Speed (%)
100
32
20
2.3.14
99
Cage Rotate Right Speed (%)
100
32
20
2.3.15
96
Cage Level Forward Speed (%)
100
70
67
2.3.16
97
Cage Level Reverse Speed (%)
100
35
30
2.3.17
14
Y-Axis Forward Voltage (V)
0.00
5.00
0.02
4.06
4.48
2.3.18
15
Y-Axis Reverse Voltage (V)
0.00
5.00
0.02
0.52
0.52
2.3.19
50
X-Axis Left Voltage (V)
0.00
5.00
0.02
0.52
4.48
2.3.20
51
X-Axis Right Voltage (V)
0.00
5.00
0.02
4.06
0.52
Calibrator
Reference
CAN Name
Minimum
Value
0
Maximum
Value
100
Description
Description
Without
JIB
With
JIB
With JIB
100
22
30
30
Step
Actual
Value
100
2.5.1
77
Boom 1 Up Speed (%)
2.5.2
78
100
90
2.5.3
58
100
100
2.5.4
79
Boom 2 Up Speed (%)
100
100
2.5.5
80
100
70
2.5.6
59
100
25
2.5.7
81
Jib Up Speed (%)
100
90
2.5.8
82
Jib Down Speed (%)
100
75
2.5.9
83
Tele In Speed (%)
100
100
2.5.10
84
Tele Out Speed (%)
100
100
2.5.11
85
Slew Left Speed (%)
100
60
2.5.12
86
Slew Right Speed (%)
100
60
2.5.13
87
Cage Level Forward Speed (%)
100
50
2.5.14
88
Cage Level Reverse Speed (%)
100
60
2.5.15
89
Cage Rotate Left Speed (%)
100
50
2.5.16
90
Cage Rotate Right Speed (%)
100
50
2.5.17
60
Overload Cutback Speed (%)
100
50
80-8-11-M.84
B - TESTING
THE VARIABLE SPEED DRIVE
STATUS
Setting Max
Step
Log info
1.2.1
Battery voltage
0V
127 V
0.1 V
1.2.2
Armature Motor voltage
0V
127 V
0.5 V
1.2.3
Field Motor Voltage
0V
127 V
0.5 V
1.2.4
Armature Motor Current
12:00 AM
625 A
5:00 AM
1.2.5
Field Motor Current
12:00 AM
64 A
0.25 A
1.2.6
Armature MOSFET Voltage
0V
127 V
0.5 V
1.2.7
Controller temp.
-30 C
+225 C
1 C
1.2.8
Capacitor Voltage
0V
127 V
0.5 V
Calibrator reference
Parameter displayed
Setting Min
1.2.9
Speed estimation
0%
100%
0.50%
1.2.10
Speed estimation
0 KPH
60 KPH
1.0 KPH
1.2.11
Speed estimation
0 MPH
60 MPH
1.0 MPH
1.2.12
Key Switch Hours Count
0 Hrs
65279.9 Hrs
0.1 Hrs
1.2.13
Traction Pulsing Hours Count (Drive)
0 Hrs
65279.9 Hrs
0.1 Hrs
1.2.14
CAN fail node
None
Output, EOutput
n/a
1.2.15
CAN error count
1.2.16
CAN error code
Service Log Reset
+ -
Press + followed by - to reset service log

TRACTION VARIATOR
Input displayed
Setting Max
Step
1.3.1
Accelerator %
range
0%
100 %
1%
1.3.2
Accelerator voltage
range
0.0 V
5.0 V
0.02 V
1.3.3
Deadman
switch
Open
Closed
1.3.4
Joystick Forward
switch
Open
Closed
1.3.5
Joystick Reverse
switch
Open
Closed
1.3.6
Steer Left
switch
Open
Closed
1.3.7
Steer Right
switch
Open
Closed
1.3.8
Horn switch
switch
Open
Closed
1.3.9
Traction select
switch
Open
Closed
1.3.10
Tilt switch
switch
Open
Closed
1.3.11
Boom rest
switch
Open
Closed
1.3.12
8m high
switch
Open
Closed
1.3.13
Brake release
switch
Open
Closed
1.3.14
BDI Input
switch
Open
Closed
1.3.15
Frame fault
switch
Open
Closed
1.3.16
Drive Inhibit
switch
Open
Closed
1.3.17
Bars sens
switch
Open
Closed
1.3.18
Joystick NTRL switch
switch
Open
Closed
1.3.19
LS traction switch
switch
Open
Closed
1.3.20
Software
xxxxxx
xxxxxx
1.3.21
Controller Serial number
99999999
1.3.22
Controller type
xxnnn
Log info
PUMP STATUS
80-8-11-M.84
Min display
Max display
Step size
Log info
2.2.1
Battery voltage
0V
127 V
0.1 V
2.2.2
Motor voltage
0V
127 V
0.5 V
2.2.3
Motor current
12:00 AM
625 A
5:00 AM
2.2.4
MOSFET voltage
0V
127 V
0.5 V
-30 C
+225 C
1 C
2.2.5
-
Parameter displayed
Controller temp.
Service Log Reset
Press + followed by
- to reset service log
+ -
UPPER BOX TEST INFORMATION

Min display
Max display
2.4.1
Y axis joystick %
Range
0%
100%
1%
2.4.2
Y axis joystick voltage
Range
0.0 V
5.0 V
0.02 V
2.4.3
X axis joystick %
Range
0%
100%
1%
2.4.4
X axis joystick voltage
Range
0.0 V
5.0 V
0.02 V
2.4.5
Deadman
Switch
Open
Closed
2.4.6
Joystick Forward
Switch
Open
Closed
2.4.7
Joystick Reverse
Switch
Open
Closed
2.4.8
Steer Left
Switch
Open
Closed
2.4.9
Steer Right
Switch
Open
Closed
2.4.10
Traction select
Switch
Open
Closed
2.4.11
Boom 1 select
Switch
Open
Closed
2.4.12
Boom 2 select
Switch
Open
Closed
2.4.13
Jib select
Switch
Open
Closed
2.4.14
Tele select
Switch
Open
Closed
2.4.15
Slew select
Switch
Open
Closed
2.4.16
Cage level select
Switch
Open
Closed
2.4.17
Cage rotate
Switch
Open
Closed
Input displayed
Step size
80-8-11-M.84
C - ERROR
MESSAGES
Calibrator display
Display
Led Description & comments
Checks-Actions
OK
Stdt
YES Traction operational and OK.
No action required.
TESTING
RUN TESTS
Displayed briefly when the unit is switYES ched on.

No action required.
YES Wrong choice of calibration protocol.
PLEASE WAIT
Set the calibration protocol to "AUTO".
BDI CUTOUT
BDI CUT
7F
The BDI has triggered a cut-out at the

Charge the batteries.
programmed battery level.
THERMAL CUTBACK
OVER TEMP.
8F
Let the variable speed drive cool down Temperature of variable speed drive
higher than 75 - Let the drive cool down. Check its installation, the overall cleanliness and the fan.
ACCEL. FAULT
ACCEL. FAULT
6F
Accelerator activated when unit switched on.
Release the dead man's contact - Check

the accelerator cable, personality accelerator zero and max.
SEQUENCE FAULT
SEQ. FAULT
2F
Dead man's contact activated or joystick

pushed when machine switched on.
Release the dead man's contact and the

joystick - Check the dead man's signals
and the joystick's instructions.
2 DIR. FAULT
2 DIR. FAULT
2F
Two directions selected at the same

time.
Release the steering and dead man's

controls - Check the steering switch
cables.
BATTERIE LOW
BAT. LOW
7F
Battery level lower than low battery

setting.
Release the dead man's control or the

reverser - Check the battery voltage and
charge.
BATTERIE HIGH
BAT. HIGH
7F
Battery level lower than low battery

setting.
Release the dead man's control or the

reverser - Check the battery voltage and
charge and whether B+ is connected.
PERS ERROR
PERS ERRORF
1F
Parameters set outside the range.
Change the defective settings.
CRC ERROR
CRC ERROR
1F
One or more settings have been corrupted. Check all the settings.
Switch off the machine - Check whether
the coils are short-circuiting, whether the
control is connected directly to B+ and
the cabling.
Reset FS1 or the reverser to zero Check A, F1, F2, the B- cable and whether MOSFET is short-circuiting.
COIL S/C
COIL S/C
9F
A contactor coil is short-circuiting or

wrongly connected
MOSFET S/C
FET S/C
3F
MOSFET short-circuiting.
SYSTEM FAULT
CAN FAULT
12 F The modules are not communicating.
Switch off the machine- Check the BUS

CAN cable looms and connections.
P. UP TRAC. WELD
P. UP WELD
OFF Line contactor contacts welded shut.
Check the line contactor and the power

and control cable looms.
VARIOUS INTERNAL
CONTROLLER POWER
UP MESSAGES
FAIL
If one of these messages appears, the

OFF variable speed drive has failed one of Contact SEVCON.
its internal power auto-tests.
80-8-11-M.84
D - DIAGNOSTIC
LED STATUSES
Led status
Illuminated
Unlit
1 Flashing
2 Flashing
3 Flashing
4 Flashing
5 Flashing
6 Flashing
7 Flashing
8 Flashing
9 Flashing
12 Flashing
Description
No problem, conditions normal
Problem with the internal variable speed drive
Personality out of reach
Incorrect start-up sequence
MOSFET short-circuiting
Power contactor short-circuiting or motor circuit open
Spare
Problem with accelerator, slave potentiometer
or sped sensor cable
Low/high battery voltage or BDI cut off
Temperature of variable speed drive too high
Coil contactor short-circuiting
BUS CAN connection fault
80-8-11-M.84
E - USING
THE CALIBRATOR
D1
DESCRIPTION
- The calibrator (Fig. D1) (Ref. 622813) is used to adjust and configure the variable speed drive. It is also used as a diagnostic tool,
displaying the variable speed drive's various voltage, current and
temperature values and the status of all its inputs.
SEVCON
CAN CALIBRATOR
Controller A
Menu
INSTALLATION
Value - +
- Please refer to the section on REMOVING THE VARIABLE SPEED

DRIVE to access the electronic module.
- Locate the loom cable connected to 2 (Fig. D2) on the electronic
module; then take the calibrator's plug 1 (Fig. D1) and, depending
on the circumstances:
D2
- Connect it to the spare socket on the loom.

- If the loom does not have a spare socket, slip the adaptor
cable (Ref. 677519) between the loom and the module's
connector and then connect it to the spare socket on this
cable.
CALIBRATOR MENU
- See the illustration below.
on
MiseSwitch
sous tension
1 Traction
2 Pump
OK
OK
80-8-11-M.84
2.1 Pump
2.2 Pump
2.3 Pump
2.4 Pump
2.5 Pump
2.6 Pump
Personalities
Status
Upper Box Pers
Upper Box Test
Lower Box Pers
Lower Box Test
1.1 Traction
1.2 Traction
1.3 Traction
1.4 Traction
1.5 Traction
1.6 Traction
1.7 Traction
1.8 traction
Personalities
Status
Test
BDI
Fault Log
Setup
Motor Setup
Display
1.1.1A Trac Pers
1.1.1F Trac Pers
1.1.2 Trac Pers
1.1.3 Trac Pers
1.1.4 Trac Pers
1.1.5 Trac Pers
1.1.6 Trac Pers
I. Max
I. Max
Accel
Decel
Creep Speed
Flat Regen
...
Controller B
TESTING THE MANIPULATOR

120 AETJ
80-8-85-M.84 EN
80-8-85-M.84
05 / 2004
INDEX
A - SINGLE
MANIPULATOR
....................................................................P 2
B - DUAL MANIPULATOR .......................................................................P 4
80-8-85-M.84
A - SINGLE
MANIPULATOR
With the calibrator

- Connect the calibrator (Ref. 622813) to the variable speed drive: see
Chapter CHECKING THE OPERATION FO THE SEVCON VARIABLE SPEED DRIVE, paragraph USING THE CALIBRATOR.
A1
4
- Climb into the platform's basket with the calibrator.
- Select menus 2-4-2 and 2-4-4 (UPPER BOX TEST) on the calibrator
and note the voltage values from the signals from the manipulator.
- Then select menus 2-3-17, 2-3-18, 2-3-19 and 2-3-20 (UPPER BOX
PERS) on the calibrator to adjust the limit values for the voltages delivered by the manipulator.
Menus 2-4-2 and 2-4-4
Signals from the manipulator
noted on the calibrator
0.5
Menus 2-3-17 to 2-3-20

0 0.52
Min/ max calibration values
for the signals from the manipulator
2.5
4.5
2.5
4.48
- Lastly, select menus 2-4-1 and 2-4-3 (UPPER BOX TEST) on the
calibrator and check :
- That the proportional signal shows a good progression (i.e.
0 to 100%).
- That it shows 0% in Neutral and 100% only when the manipulator arrives almost at the limit switch.
This procedure must be performed every time

the manipulator is replaced.
With a voltmeter
- Take the voltmeter and climb into the access platform's basket.
80-8-85-M.84
- Open the front of the basket console 3 (Fig. A1) (Flat screwdriver)
and then locate the wires (Fig. A2).
A2
OLD
NOUVELLE
ANCIENNE NEW
NORME
NORME
STANDART
STANDART
VERT
VERT
GREEN
GREEN
JAUNE (X)(X)
JAUNE (X)
YELLOW
(X) YELLOW
Y
X
+24V 3W
BLUE
BLEU
BLACK
NOIR
GREY
GRIS (Y)
VIOLET
VIOLET
RED
ROUGE
PINK
ROSE
0V BROWN
MARRON
BLANC
+48V WHITE
63V - 470f
(HORS
NEUTRE
- MANIPULATEUR)
(NEUTRAL
POSITION
- MANIPULATOR)
(COMMANDE
ROTATION TOURELLE)
(TURRET ROTATION)
YELLOW/BLACK
(STEER
LEFT
(BP DIRECTIONBUTTON)
GAUCHE)
JAUNE/NOIR
GREY/BLACK
(STEER
RIGHT DROITE)
BUTTON)
(BP
DIRECTION
GRIS/NOIR
GREY
(Y)
(LONGITUDINAL
AXIS)
(COMMANDE
TRANSLATION)
GRIS (Y)
GREEN/BLACK
(DEAD MAN'S
TRIGGER)
(GACHETTE
HOMME
MORT)
VERT/NOIR
BROWN/BLACK
(POWER SUPPLY
- TRIGGER)
- GACHETTE)
MARRON/NOIR (ALIMENTATION
(POWER SUPPLY--BP
STEERING
BUTTONS)
WHITE/BLACK
(ALIMENTATION
DIRECTION)
BLANC/NOIR
BROWN
(LONGITUDINAL- AXIS)
(ALIMENTATION
TRANSLATION)
MARRON
WHITE
BATTERY)
(( ++BATTERIE)
BLANC
- Place the voltmeter's wands on the connector's clips to take the measurements.
- To test the analogue outputs: work with the manipulator's casing 2
(Fig. A1) by moving it forwards, backwards, left or right and check the
values the voltmeter displays (Fig. A3).
A3
Y
4.5V GG(Y)
(Y)
0V
BM
Manipulateur
vers
Manipulator
FORWARD
L'AVANT
- AVANCE
FORWARD
TRANSLATION
Y
X
0V
BM
Manipulateur
GAUCHE
Manipulator to
THE LEFT
Rotation
tourelleROTATION
GAUCHE
LEFTde
TURRET
4.5V YJ (X)
2.5V YELLOW
JAUNE (X)
(X)
2.5V GREY
GRIS (Y)
(Y)
0V
MARRON
BROWN
0.5V YJ(X)
(X)
X
0V
BM
Manipulateur
DROITE
Manipulator
to THE
RIGHT
Rotation
de tourelle
DROITE
RIGHT TURRET
ROTATION
NEUTRE
NEUTRAL
Y
0.5V G
G (Y)
(Y)
B
M
0V
Manipulateur
vers
Manipulator
toTHE REAR
L'ARRIERE
- RECUL
REAR
TRANSLATION
- To test the logic outputs: operate the manipulator's dead man's pedal
1 (Fig. A1) and check the values the voltmeter displays (Fig. A4); then
press the manipulator's steering buttons 4 (Fig. A1) and check the
values the voltmeter displays (Fig. A5).
A4
80-8-85-M.84
OLD
NEW
ANCIENNE
NOUVELLE
STANDART
STANDART
NORME
NORME
OLD
NEW
ANCIENNE
NOUVELLE
STANDART STANDART
V VIOLET
VERT/NOIR
VIOLET
GREEN/BLACK
ROUGE
MARRON/NOIR
RED
BROWN/BLACK
0V BROWN
MARRON BROWN
MARRON
GREEN/BLACK
0V VIOLET
VERT/NOIR
VIOLET
RED
BROWN/BLACK
ROUGE
MARRON/NOIR
0V BROWN
MARRON BROWN
MARRON
NORME
Trigger inau
Gachette
NEUTRAL
NEUTRE
Trigger
Gachette
ACTIVATED
ACTIONNEE
NORME
A5
OLD
NEW
ANCIENNE
NOUVELLE
STANDART STANDART
O. S. N. S.
A. N.
N. N.
NORME
(G)Y/B
J/N
0V BB(L)
Steer
Direction
LEFT
GAUCHE
PR
0V BM
M/N
W/B
B M
NEUTRAL
NEUTRE
V BLUE
BLEU(L)
(G)
(R)
V BLACK
NOIR (D)
ROSE
PINK
0V BROWN
MARRON
YELLOW/BLACK
JAUNE/NOIR
GREY/BLACK
GRIS/NOIR
BLANC/NOIR
WHITE/BLACK
MARRON
BROWN
"V" indicates that a random voltage can be measured

on the indicated wire.
80-8-85-M.84
O. S. N. S.
A. N.
NORME
Steer
Direction
RIGHT
DROITE
N. N.
0V BN(R)
(D)G/BG/N
PR W/BM/N
0V BM B M
B - DUAL MANIPULATOR
With the calibrator
- Connect the calibrator (Ref. 622813) to the variable speed drive: see
Chapter CHECKING THE OPERATION FO THE SEVCON VARIABLE SPEED DRIVE, paragraph USING THE CALIBRATOR.
B1
8
7
5
- Climb into the platform's basket with the calibrator.

- Select menus 2-4-2 and 2-4-4 (UPPER BOX TEST) on the calibrator
and note the voltage values from the signals from the manipulator.
- Then select menus 2-3-17, 2-3-18, 2-3-19 and 2-3-20 (UPPER BOX
PERS) on the calibrator to adjust the limit values for the voltages delivered by the manipulator.
Menus 2-4-2 and 2-4-4
Signals from the manipulator
noted on the calibrator
0.5
Menus 2-3-17 to 2-3-20

0 0.52
Min/ max calibration values
for the signals from the manipulator
2.5
4.5
2.5
4.48
- Lastly, select menus 2-4-1 and 2-4-3 (UPPER BOX TEST) on the
calibrator and check :
- That the proportional signal shows a good progression (i.e.
0 to 100%).
- That it shows 0% in Neutral and 100% only when the manipulator arrives almost at the limit switch.
This procedure must be performed every time

the manipulator is replaced.
With a voltmeter
- Take the voltmeter and climb into the access platform's basket.
- Remove and open the basket console 5 (Fig. B1) (4 bolts, No. 4 hex
spanner) and then locate the wires:
- Connected to the manipulator 6 (Fig. B1 - B2) (Translation +
Steering).
- Connected to the manipulator 7 (Fig. B1 - B3) (Turret rotation
+ Upper arm).
80-8-85-M.84
B2
OLD
NEW
ANCIENNE NOUVELLE
STANDART
NORME STANDART
NORME
+24V 3W
GREEN
VERT
BLEU
BLUE
NOIR
BLACK
GRIS (Y)
(Y)
GREY
VIOLET
VIOLET
ROUGE
RED
ROSE
PINK
0V BROWN
MARRON
BLANC
+48V WHITE
GREEN
VERT
JAUNE/NOIR
YELLOW/BLACK
GRIS/NOIR
GREY/BLACK
GRIS (Y)
GREY
(Y)
VERT/NOIR
GREEN/BLACK
MARRON/NOIR
BROWN/BLACK
BLANC/NOIR
WHITE/BLACK
MARRON
BROWN
BLANC
WHITE
(NEUTRAL
POSITION
- MANIPULATOR)
(HORS
NEUTRE
- MANIPULATEUR)
(BP
DIRECTION
GAUCHE)
(STEER
LEFT BUTTON)
(BP
DIRECTION
(STEER
RIGHT DROITE)
BUTTON)
(COMMANDE
TRANSLATION)
(LONGITUDINAL
AXIS)
(GACHETTE
HOMME
MORT)
(DEAD MAN'S
TRIGGER)
(ALIMENTATION
- GACHETTE)
(POWER SUPPLY
- TRIGGER)
(ALIMENTATION
DIRECTION)
(POWER SUPPLY- -BP
STEERING
BUTTONS)
(ALIMENTATION
(POWER SUPPLY- TRANSLATION)
- LONGITUDINAL AXIS)
( ++ BATTERIE)
BATTERY)
63V - 470f
B3
VERT
(HORS
NEUTRE
- MANIPULATEUR)
GREEN
(NEUTRAL
POSITION
- MANIPULATOR)
JAUNE
(X)
(COMMANDE
ROTATION)
YELLOW (X) (TURRET ROTATION)
X
Y
GRIS (Y)
GREY
(Y)
MARRON
BROWN
(COMMANDE
ELEVATION BRAS 3)
(UPPER ARM)
(ALIMENTATION)
(POWER SUPPLY)
BLANC
WHITE
( +(BATTERIE)
+ BATTERY)
- Place the voltmeter's wands on the connector's clips to take the measurements.
- To test the analogue outputs:
- Work with the manipulator's casing 6 (Fig. B1) (Translation
+ Steering) by moving it forwards, backwards and check the
values the voltmeter displays (Fig. B4).
B4
80-8-85-M.84
0.5V G
G (Y)
(Y)
0V
BM
Manipulator
toTHE
Manipulateur
vers REAR
REAR TRANSLATION
L'ARRIERE
- RECUL
2.5V GREY
GRIS (Y)
(Y)
MARRON
0V
BROWN
4.5V G (Y)
0V
M
B
Manipulator FORWARD
Manipulateur
vers
FORWARD
TRANSLATION
L'AVANT
- AVANCE
NEUTRAL
NEUTRE
- Work with the manipulator's casing 7 (Fig. B1) (Turret rotation

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

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

on the indicated wire.
80-8-85-M.84
GREEN/BLACK
VERT/NOIR
MARRON/NOIR
BROWN/BLACK
BLANC
WHITE
POSITIONING AND ADJUSTING

THE CONTACTORS
120 AETJ
80-8-86-M.84 EN
80-8-86-M.84
11 / 2003
INDEX
A - POSITION
OF THE SENSORS .............................................................P
B - ADJUSTING
THE ANTI-ROLLOVER BARS OUTPUT SENSOR ....................P
C - ADJUSTING
THE SLOPE SENSOR
D - ADJUSTING
THE LOW ARM SENSOR ..................................................P
E - ADJUSTING
THE RETRACTED TELESCOPE SENSOR..............................P
F - ADJUSTING
THE OVERLOAD SENSOR.................................................P
......................................................P 3
80-8-86-M.84
A - LOCATION
OF THE SENSORS
Retracted telescope
sensor
Low arm sensor
Overload sensor
80-8-86-M.84
Stabiliser output
sensor
Stabilisers
Slope sensor
B - ADJUSTING THE ANTI-ROLLOVER BARS' OUTPUT SENSOR

B1
UP TO PLATFORM No. 505490:

- Raise the platform a few centimetres to release full engagement of
the anti-rollover bars.
- Remove the left-hand and right-hand battery covers (4 butterfly
bolts).
- Unscrew the fixing screws 1 (Fig. B1) (2 screws, flat screwdriver).
- Trigger the sensors 2 (Fig. B1), one after the other, by placing them
in contact with the anti-rollover bar
- Re-tighten the screws.

- Check the setting by instructing the basket to rise: if its ascent is
interrupted, adjust the sensor setting.
B2
FROM PLATFORM No. 505491:

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

- Unscrew the fixing screws 3 (Fig. B2) (2 bolts, No. 13 spanner).
- Trigger the sensors 4 (Fig. B2), one after the other, by placing them
in contact with the stabilising bar
- Re-tighten the bolts.

- Check the setting by instructing the basket to rise: if its ascent is
interrupted, adjust the sensor setting.
C - ADJUSTING
THE SLOPE SENSOR
The slope sensors are preset by the manufacturer. The only

parameter that can be adjusted is the sensor initialisation.
- Set the platform on a horizontal surface and switch it on.
80-8-86-M.84
- Open the right-hand cover.

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

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

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

- Refit the protective cover.
D2
6
FROM PLATFORM No. 505422

- Locate the sensor 9 (Fig. D2) between the two sides of the intermediate joint.
- Same procedure as for adjusting platforms UP TO PLATFORM No.
505421 except for removing and refitting the protective cover.
E - ADJUSTING
THE RETRACTED TELESCOPE SENSOR
E1
- Locate the sensor 10 (Fig. E1) located at the front between the two
counterweights.
10
- The follow the same procedure as for ADJUSTING THE LOW ARM
SENSOR.
80-8-86-M.84
F - ADJUSTING
THE OVERLOAD SENSOR
F1
- Raise the basket 50cm above the floor in a horizontal position.

- Remove the protective cover 11 (Fig. F1) (2 bolts, No. 10 spanner).
- Place 250kg in the basket.
- Loosen bolt 12 (Fig. F2) (No. 14 spanner) until the overload sensor
13 (Fig. F2) triggers: the platform's alarm sounds.
11
F2
The contactor has a certain reaction time when the bolt is being
untightened. Stop at the limit for triggering the contactor.
12
- Relieve the weight on the basket: the platform's alarm no longer

sounds.
- Replace the weight in the basket: the platform's alarm sounds.
13
- Refit the protective cover.
80-8-86-M.84
GROUPS 100
TROUBLE
SHOOTING
TROUBLESHOOTING
120 AETJ
100-M.84 EN
100-M.84
11 / 2003
TROUBLE SHOOTING
100-M.84

Manitou 120AETJ

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R

REF : 547 363 EN (05 / 04)

Variable speed drive unit parameters modification

Removing the wheel reducer / brake

Removing the distributor elements

Removing the cylinders

Removing the variable speed drive unit

Removing the traction batteries

Removing the electrical cable looms

Checking the operation of the Sevcon

Testing the manipulator

Positioning and adjusting the contactors

- Access platform weight

Under nominal load

- Max permissible slope

UNDER MAX LOAD+ OFF

Tightening torque for the front and rear wheel nuts

HYDRAULIC OIL RSERVOIR

WHEEL MOTOR (EACH ONE)

TURRET ROTATION MOTOR

BEARING TURRET RING GREASING

TURRET RING TEETH LUBRICATION

SHELL MALLEUS GL 205

REMOVING THE WHEEL

REMOVING THE WHEEL REDUCER / BRAKE

PLATFORM NO. 505578: REDUCER 598694

- Set the lower arm to maximum for optimum accessibility.

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

- Same operations as above in reverse order.

PLATFORM NO. 505579: REDUCER 599538

- Same procedure as for removing reducer 598694.

When fastening reducers 599538, position the CHC M12x45 bolts at

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

- The machine can be towed as a trailer.

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

REMOVING THE WEAR PADS

THE TELESCOPE CYLINDER WEAR PADS ...........................

THE TELESCOPE ARM WEAR PADS

THE MOBILE TUBE WEAR PADS .......................................

THE TELESCOPE CYLINDER WEAR PADS

THE TELESCOPE ARM WEAR PADS

- Remove the pads.

THE MOBILE TUBE WEAR PADS

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

REMOVING THE DISTRIBUTOR

REMOVING THE DISTRIBUTOR ELEMENTS

- Switch off the electrical power supply.

- Remove the hoses (Spanners Nos. 19, 24, 27, 30).

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

ARM 1 / 2 RAISING SYSTEM EV6-EV7

TELESCOPE ARM RAISING SYSTEM EV8-EV9

PENDULAR ARM EV12- EV13

STEERING SYSTEM EV1-EV5

PLATFORM ROTATION SYSTEM H18-H19

ANTI-ROLLOVER BARS H20-H21

REMOVING THE CYLINDERS

THE STEERING CYLINDER ................................................P

THE TELESCOPE CYLINDER

THE ANTI-ROLLOVER BAR CYLINDERS ...............................P

THE STEERING CYLINDER

- Decompress the cylinder supply hoses: see the REMOVING THE

Course - Hub - Carrera - Stroke : 179 mm

HYDRAULIQUE (Vrin de direction)

THE TELESCOPE CYLINDER