CC 4800 SN:41023

Electric and Hydraulic Schematics

 B301 Loadcell
Winch W3 (fitted in first section)

Fuel Tank

E-Drum
X2 Winch W2
Hoist H2
Battery Box
Reeving Winch Hoist H1
Winch W1 (Hoist 3 when runner is fitted)

Slewing Gear X2 Electric Cabinate

Winch Drum Layout

B300.3

B300.2
B300.1
A

B
P1
320 bar max

P2
320 bar max

P3
320 bar max

P4.1
210 bar max

P4.3
32 bar pilot pressure to
the control levers
P1 adjustment
0 to 35 bar

P2 adjustment
0 to 35 bar
8

Main Boom Electrics

S5/S6

18

1 2
S 1.2 S 1.1
B304
2
6 1 10
B305
Superlift Mast Loadcell

9
17 11
B305 is mounted
8 instead on the mast
head sheaves for the
bridle on SN:41023
5

12

Angle sensor 7

4
3

3 4
7

14 15 16
Z 20 272

12/61 342−3080−031
 Assembling the Main Boom and Fly Jib with Superlift 8

8.2.2 Main Boom Electric Layout

(Z 20 272)

1 Boom distributor box

2 Boom distributor box load limit device
3 Cable drum for control and safety electrics
4 Cable drum for load limit device
5 Line for anemometer
6 Hoist limit switch for main boom
7 Angle transmitter
8 Transmitter for wind speed
9 Line boom distributor box − hoist limit switch
10 Load cell
11 Line for load cell
12 Line cable drum − boom distributor box
13 Line cable drum load limit device −
distribution box load limit device
14 Line crane operator’s cab − cable drum
15 Line crane operator’s cab − angle transmitter
16 Line crane operator’s cab − cable drum load limit device
17 Balance indicator
18 Camshaft controller for fly jib ”raise”

342−3080−031 13/61
8

1
Luffing Fly Jib Electrics

B304
Luffer Angle Sensor
B303
Luffing Loadcell

12
7
6
2

10 1

S2.2 S2.1
9
7
11
12

2 5
8
3
6
4

Z 20 273

18/61 342−3080−031
 Assembling the Main Boom and Fly Jib with Superlift 8

8.2.4 Luffing Fly Jib Electric Layout

(Z 20 273)

1 Junction box in the universal boom point

2 Cable drum for electrical control and safety equipment
3 Line from distribution box main boom − cable drum fly jib
4 Line from distribution box load limit device − load cell
5 Line from distribution box − limit switch on the back stroke
cylinder HI
6 Load cell
7 Angle transducer
8 Line from boom distribution box load limit device − angle
transmitter
9 Hoist limit switch for fly jib
10 Line from junction box − hoist limit switch fly jib
11 Line from cable drum − junction box in the universal boom
point
12 Limit switch on the back stroke cylinder HI

342−3080−031 19/61
S27 S24.1

S9 S24.2

S7
S8
S8a

S23

S53.3

S23 Info

S8b 80 degree cam switch

S16 (2 option types, cam switch or roller type)

 X1 Terminal rail - Cabin
Main Fuse
X2 Terminal rail - Superstructure

X3.1 STG Supply - Main Boom

Alternator X3.2 LMB supply Main Boom

X4 Luffing Fly Jib

Battery Charge Light Superstructure Right Side

Superstructure Left Side

Superstructure Engine
Engine Start Relay

Start enable relay

Switch Cabinate 380v Elictric-Drive

Carrier Electric - 380v Electric Drive

Starter Motor

Winch 3

Counterweight Wagon
Battery Main supply fuse

Main Battery Isolator switch

Ignition switch

Diode
Ignition Switch

Batteries and Main Diode Protection to Supply voltage to

Startermotor Alternator Hour Meter
Isolator switch control voltage the Eleectric Drive
 engine oil temp

Injection pump temp engine locking / enable

Engine Stop low oil

pressurer
stop
relay

starter
Switchover relay

48

Locking Drive
Temperature Sensors Oil and Fuel temp Engine Stop Oil pressure in pump distributor gear of
Diesel Engine Electric Motor Solenoid the diesel engine too low
too low for starting
Engine Oil Injection Pump Diesel Engine Electric Drive Stand by Standby
 Hydraulic Oil
Coolant Temperature Control Diesel Engine Oil Pressure Fuel Gauge Engine Air filter Control Coolant Level Control
Temperature
 Rotaflare Light Superstructure Cabin outside light Cabin outside light Instrument
Horn Cab Light
(Beacons) outside light Front Rear dash lighting
 Y70 determins whether the gear oil from
pump 5.3 returns back to the electric
drive box or the diesel drive box

Windscreen Wipers 24v Power point sockets Engine Radiator Changeove Lubrication Oil Pump drive
Front Window Top Window Fan Motor control
Superstructure Cabin
 X5.5 box is inside the superstructure over the slew ring to the LHS of the H3 front winch

Info : Winch shutdown logic chart

H1
Proximity
W2
switch

H2
Proximity
switch

5.5.18
S8b
stops the Main Boom H3 W1 (H3)
(tower) leaning out Proximity Proximity
past 80 degrees in 5.5.19 switch Switch

A2B info SWSL mode 169

Hoist Limit Switch Override - Hoist limit Switches Lower Limit Switches (3 wraps) Hoists 1-3 Lifting Hoists 1-3 Lowering
Winches 2 & 3 Lowering Winches 2 & 3 Lowering
Luffing Fly Jib Luffing Fly Jib
Main Boom Main Boom E- Drum Hoists 1 - 3 Winche 2 & 3 E-Drum Lowering E-Drum Lowering
Runner Runner
 15.2

S16 info

Pressure rating Mast support E-Drum Raising Derricking Rope - E Drum

Mainboom Raising - upper limit Luffing Fly Jib
Mainboom Winch 2 Raising Max loose Min tension
With Luffing Without Luffing Winch 3 Raising
Lowering Lowering Raising (Backstop Cylinders) sagging Slack
Fly Jib - 88 degrees Fly Jib - 85 degrees
 15.2

S23 info

Switch - Over Switch - Over E / W3 Switch - Over W2 Control Lever Switch - Over H1 / H2 Syncronise gear
control
E - Drum Winch 3 Circuit 2 Circuit 3 Left - Lever 3 Right - Lever 11 H1 Brake H2 Brake H1 / H2
 15.2

Permissible only with the Wagon unladen

High Range Hydraulic Motor - Trimot (High speed)

Hoist 1 / 2 Winch 2 Slew Gear Carrier Drive Wagon Drive Hoist 1 / 2 Hoist 3 Winch 3
 15.2

all "A"s connect here

enables pump adjustment

from manual lever control

Brake Brake Brake Brake E-Drum and Brake Brake Carrier Travel Slew Control
E-Drum Winch 3 E-Drum Winch 3 Winch 2 / 3 Winch 2 Hoist 3 Forwards / Backwards Left / Right Pump Displacement
Raise Raise Lower Lower Lower Raise Raise
 15.2

Brakes released

Slew direction alinement

Slew brake
open

ensures wagon and

carrier are facing
the same direction
as travel is only
Dummy Plugs into X205 allowed if wagon is
(Wagon not connected) to the rear of the
carrier

a
Travel enabled

H222.0 < 100mm ground clearance

H222.1 > 100mm ground clearance
H222.1 > 200mm ground clearance
H222.1 > 300mm ground clearance
H222.1 > 400mm ground clearance

Lockout of Travel Travel Brake Operation with Moving with Slewing with the
Tray or Cwt Wagon Flow Control Valve Wagon against
Slew Brake and Indication Carrier and Cwt Wagon Cwt Wagon
Ground Clearance Cwt Wagon Cwt Wagon increased resistence
Carrier
 15.2 30

Carrier Outriggers selection Selector Switch Outriggers Dolly Outriggers Backstop Cylinders Slewing without High Voltage
Carrier and adjustment of Mainboom & wagon against Wind speed anenometer and Display
Carrier Outriggers Alarm
Front Rear (Release) axle position Backmast increased resistance
Loadcell E-Drum (derricking)

Main Boom Angle Sensor

Luffing Fly jib loadcell

Luffing Fly Jib Angle Sensor

Superlift Mast Loadcell

B300.1

Basic Component

Voltage Arrangement

136

Central unit DS 350 KD with Indicator & operating panel DS 350

Basic component X1 Auxilary Panel display Loadcell Loadcell Angle sensor Angle sensor Loadcell
Voltage arrangement X3 for E-Force Luffing Fly Jib E-Drum (derricking) Luffing Fly jib Main Boom Superlift Mast
Estension component X5
B300.1

Basic Component Auxilary Component

Heating Control

X2

Operation Operation Control Light Control Light Control light Control light
Indicator and remote consol Operation Derricking gear derricking gear
Main Boom Luffer LMB Override Main Boom Fly jib operation SL operation
Superlift force too small force too small
Mainboom SL Luffer SL operation
 30

Circulating Pump Control unit Fuel preheater

Heater - On for hot water Heater
heater
Heat exchanger Heat exchanger Air Conditioning Selector switch with Compressor with
Motor Battery box unit Thermostat low and high Condenser Fan Evaporator Fan Evaporator Fan
series resistor
pressure switches
Error code Listing

Error code E 01
Error Fallen below radius or angle range exceeded

Cause Fallen below the minimum radius or exceeding the maximum angle in main
boom operation by booming up too far.

Elimination Boom down to a radius or angle listed in the load chart

Error code E 02
Error Radius range exceeded or fallen below minimum angle

Cause Radius range exceeded or fallen below the minimum angle by booming
down too far.

Elimination Boom up to a radius or angle listed in the load chart.

Error code E 04
Error No operating mode available

Cause 1. Operating mode is not selected or incorrectly set.

2. Operating mode was changed and is not acknowledged
3. Digital input(s) is (are) missing
4. Crane definition switch or connecting cable is defective
5. Console is defective
6. Electronical failure on main board
7. Operating mode is electronically locked

Elimination 1. Select the operating mode according to the operating mode sheets or
the load chart.
2. Acknowledge the operating mode on the console.
3. Put the crane is position to trigger the input switches.
4. Replace defective switch(es) and cable(s).
5. Replace console
6. Replace main board.
7. Contact PAT or crane manufacturer for information.
Error code E 05
Error Prohibited length range

Cause 1. Boom is not extended according to the load chart

2. Wrong operating mode selected
3. Length adjustment is wrong
4. Coupling between length potentiometer and drive is defective or slippery
5. No supply voltage to the length sensor
6. Length potentiometer is defective
7. Digital input switch is defective
8. Cable between the length sensor and the central unit is defective
9. Electronical defect on main board

Elimination 1. Move the boom to a length according to the load chart

2. Select the correct operating mode according to the operating mode
sheets or the load chart
3. Reset the length potentiometer adjustment
4. Clean the coupling or replace it if not successful
5. Check cable between the central unit and the length sensor. Replace
main board.
6. Replace crane definition switch
7. Replace cable
8. Replace main board

Error code E 06
Error Fallen below minimum angle

Cause Fallen below the minimum angle by booming down too far in luffing jib
operation.

Elimination Boom up to an angle listed in the load chart.

Error code E 07
Error No acknowledgment from overload relay

Cause 1. Overload relay is stuck, defective or not triggered.

2. Main board is defective

Elimination 1. Replace relay

2. Replace main board
Error code E 08
Error No acknowledgment from A2B switch relay

Cause 1. A2B switch relay is stuck, defective or not triggered.

2. Main board is defective

Elimination 1. Replace relay

2. Replace main board

Error code E 09
Error No acknowledgment from relay 2

Cause 1. Relay is stuck, defective or not triggered.

2. Main board is defective

Elimination 1. Replace relay

2. Replace main board

Error code E 11
Error Fallen below limit in measuring channel #1 “Main boom length”

Cause 1. Cable between length sensor and central unit is defective, not
connected or water inside the connectors
2. Length potentiometer is defective
3. Electronic component in measuring channel #1 is defective

Elimination 1. Check cable and connectors and replace them if necessary

2. Replace length potentiometer
3. Replace main board

Error code E 12
Error Fallen below limit in measuring channel #2 “Pressure piston side”

Cause 1. Cable between pressure transducer and central unit is defective, not
connected or water inside the connectors
2. Pressure transducer is defective
3. Electronic component in measuring channel #2 is defective

Elimination 1. Check cable and connectors and replace them if necessary

2. Replace pressure transducer
3. Replace main board
Error code E 13
Error Fallen below limit in measuring channel #3 “Pressure rodside”

Cause 1. Cable between pressure transducer and central unit is defective, not
connected or water inside the connectors
2. Pressure transducer is defective
3. Electronic component in measuring channel #3 is defective

Elimination 1. Check cable and connectors and replace them if necessary

2. Replace pressure transducer
3. Replace main board

Error code E 14
Error Fallen below limit in measuring channel #4 “Force transducer”

Cause 1. Cable between force transducer and central unit is defective, not
connected or water inside the connectors
2. Force transducer is defective
3. Electronic component in measuring channel #4 is defective

Elimination 1. Check cable and connectors and replace them if necessary

2. Replace force transducer
3. Replace main board

Error code E 15
Error Fallen below limit in measuring channel #5 “Main boom angle”

Cause 1. Cable between angle sensor and central unit is defective, not connected
or water inside the connectors
2. Angle sensor is defective
3. Electronic component in measuring channel #5 is defective

Elimination 1. Check cable and connectors and replace them if necessary

2. Replace angle sensor
3. Replace main board
Error code E 16
Error Fallen below limit in measuring channel #6 “Luffing jib angle”

Cause 1. Cable between angle sensor and central unit is defective, not connected
or water inside the connectors
2. Angle sensor is defective
3. Electronic component in measuring channel #6 is defective

Elimination 1. Check cable and connectors and replace them if necessary

2. Replace angle sensor
3. Replace main board

Error code E 17
Error Fallen below limit in measuring channel #7 “Boom length 2”

Cause 1. Cable between length sensor and central unit is defective, not
connected or water inside the connectors
2. Length potentiometer is defective
3. Electronic component in measuring channel #7 is defective

Elimination 1. Check cable and connectors and replace them if necessary

2. Replace length potentiometer
3. Replace main board

Error code E 19
Error Reference voltage out of range

Cause Total of supply - and reference voltages on measuring point 10 (MP10) is

less than 2.7V.
Electronical defect on main board.

Elimination Check the connected sensors and cables for shortened circuit.
Replace main board

Error code E 20
Error Analog voltages missing

Cause Crane supply voltage too low

DC/DC converter defective

Elimination Check crane supply voltage and eliminate cause of low voltage
Replace main board
Error code E 21
Error Upper limit exceeded in measuring channel #1 “Main boom length”

Cause 1. Cable between length sensor and central unit is defective, not
connected or water inside the connectors
2. Length potentiometer is defective
3. Electronic component in measuring channel #1 is defective

Elimination 1. Check cable and connectors and replace them if necessary

2. Replace length potentiometer
3. Replace main board

Error code E 22
Error Upper limit exceeded in measuring channel #2 “Pressure piston side”

Cause 1. Cable between pressure transducer and central unit is defective, not
connected or water inside the connectors
2. Pressure transducer is defective
3. Electronic component in measuring channel #2 is defective

Elimination 1. Check cable and connectors and replace them if necessary

2. Replace pressure transducer
3. Replace main board

Error code E 23
Error Upper limit exceeded in measuring channel #3 “Pressure rodside”

Cause 1. Cable between pressure transducer and central unit is defective, not
connected or water inside the connectors
2. Pressure transducer is defective
3. Electronic component in measuring channel #3 is defective

Elimination 1. Check cable and connectors and replace them if necessary

2. Replace pressure transducer
3. Replace main board
Error code E 24
Error Upper limit exceeded in measuring channel #4 “Force transducer”

Cause 1. Cable between force transducer and central unit is defective, not
connected or water inside the connectors
2. Force transducer is defective
3. Electronic component in measuring channel #4 is defective

Elimination 1. Check cable and connectors and replace them if necessary

2. Replace force transducer
3. Replace main board

Error code E 25
Error Upper limit exceeded in measuring channel #5 “Main boom angle”

Cause 1. Cable between angle sensor and central unit is defective, not connected
or water inside the connectors
2. Angle sensor is defective
3. Electronic component in measuring channel #5 is defective

Elimination 1. Check cable and connectors and replace them if necessary

2. Replace angle sensor
3. Replace main board

Error code E 26
Error Upper limit exceeded in measuring channel #6 “Luffing jib angle”

Cause 1. Cable between angle sensor and central unit is defective, not connected
or water inside the connectors
2. Angle sensor is defective
3. Electronic component in measuring channel #6 is defective

Elimination 1. Check cable and connectors and replace them if necessary

2. Replace angle sensor
3. Replace main board
Error code E 27
Error Upper limit exceeded in measuring channel #7 “Boom length 2”

Cause 1. Cable between length sensor and central unit is defective, not
connected or water inside the connectors
2. Length potentiometer is defective
3. Electronic component in measuring channel #7 is defective

Elimination 1. Check cable and connectors and replace them if necessary

2. Replace length potentiometer
3. Replace main board

Error code E 29
Error Reference voltage out of range

Cause 1. Total of supply - and reference voltages on measuring point 10 (MP10)

is more than 3.3V.
2. Electronical defect on main board.

Elimination 1. Check the connected sensors and cables for shortened circuit.
2. Replace main board

Error code E 31-35

Error Error in system EPROM

Cause System EPROM defective

Elimination Replace system EPROM

Error code E 37
Error Error in logical program flow

Cause 1. System EPROM defective

2. Error in system EPROM
3. Electronical defect on main board

Elimination 1. Replace system EPROM

2. Replace main board
3. Contact PAT service department
Error code E 38
Error Wrong system EPROM in CPU

Cause System EPROM does not match with the programming in the data EPROM

Elimination Insert system EPROM which will match the programming of the data
EPROM

Error code E 41
Error Error in RAM

Cause Error in internal RAM of CP 80C31

Elimination Replace main board

Error code E 42
Error Error in RAM

Cause Error in external RAM

Elimination Replace main board

Error code E 45
Error Error in address processing in A/D converter

Cause A/D converter on main board does not respond or responds wrong

Elimination Replace main board

Error code E 47
Error Monitored RAM disturbed

Cause CRC-test of RAM gives a non conforming result

Elimination Replace main board

Error code E 48
Error Error in RAM

Cause Error in internal RAM of CP 80C31 during cyclic test of RAM

Elimination Replace main board

Error code E 49
Error Wrong data with online operation

Cause After loading of data in online-operation, there are no valid data in the RAM
of the extension

Elimination 1. Replace extension board

2. Replace online-interface
3. Replace main board

Error code E 51 – E 58
Error Error in data EPROM

Cause Data EPROM defective

Elimination Replace data EPROM

Error code E 71
Error No acknowledgment from relay #1

Cause 1. Relay is stuck, defective or not triggered.

2. Ribbon cable between terminal board and main board is defective
3. Terminal board is defective
4. Main board is defective

Elimination 1. Replace relay

2. Replace ribbon cable
3. Replace terminal board
4. Replace main board

Error code E 72 – E 78
Error No acknowledgment from relay #2 to relay #8

Cause See E71 but for relay #2 to Relay #8 respectively

Elimination Carry out as described in E71

Error Code E80

Error Force in boom hoist exceeded

Cause The force in the boom hoist has exceeded the value programmed as the second
load point

Elimation Reduce force in boom hoist

Error Code E85

Error Error in the radius reading

Cause The calculated radius is too small (negative bending).

Elimination Check programming in the data EPROM.

Error Code E88

Error Incorrect angular position of the main boom when operating

Cause Main boom not in specified angle range during operations with luffing jib
Angle transmitter of the main boom defective

Elimation Adjust main boom so that it is within allowed range with a luffing jib
Check main boom angle transmitter

Error Code E89

Error Incorrect angle setting of fixed jib on a main boom

Cause In operations requiring a fixed angle with the boom, the jib is not in the specified
angle range
Elimation Move the jib to within the required range
Jib angle transmitter defective
Check transmitter
Error code E 91
Error No data transfer from the console to the central unit

Cause 1. No supply voltage to the console

2. No connection or shortage in the data line
3. Electronical defect on the console board
4. Electronical defect on the main board

Elimination 1. Check supply voltage at the console

2. Check the data line for proper connection
3. Replace console board
4. Replace main board

Error code E 92
Error Error in data transfer from the console to the central unit

Cause 1. No supply voltage to the console

2. No connection or shortage in the data line
3. Electronical defect on the console board
4. Electronical defect on the main board

Elimination 1. Check supply voltage at the console

2. Check the data line for proper connection
3. Replace console board
4. Replace main board

Error code E 93
Error Error in data transfer from the central unit to the console

Cause 1. Wrong jumper setting on the console board

2. No supply voltage to the console
3. No connection or shortage in the data line
4. Electronical defect on the console board
5. Electronical defect on the main board

Elimination 1. Carry out jumper setting according to the console board description
2. Check supply voltage at the console
3. Check the data line for proper connection
4. Replace console board
5. Replace main board
Error code E 94
Error No data transfer from the central unit to the console

Cause 1. Wrong jumper setting on the console board

2. No data EPROM installed
3. No supply voltage to the console
4. No connection or shortage in the data line
5. Electronical defect on the console board
6. Electronical defect on the main board

Elimination 1. Carry out jumper setting according to the console board description
2. Install data EPROM
3. Check supply voltage at the console
4. Check the data line for proper connection
5. Replace console board
6. Replace main board

Error code E 95
Error Error in console EPROM

Cause 1. Console EPROM is defective

2. Wrong jumper setting on console board
3. Electronical defect on the console board

Elimination 1. Replace console EPROM

2. Check jumper setting on console board
3. Replace console board

Error code E 96
Error Error in internal RAM of CPU on the console board

Cause 1. CPU 8031 is defective

2. Electronical defect on the console board

Elimination 1. Replace CPU 8031

2. Replace console board

Error code E 97
Error Error in external RAM on the console board

Cause Electronical defect on the console board

Elimination Replace console board

Error code E 98
Error Wrong jumper setting on the console board

Cause 1. Jumper setting on the console board does not match with the central
unit
2. Electronical defect on the console board

Elimination 1. Check jumper setting on the console board

2. Replace console board
Input for hoist limit switch (A2B switch)
There is one input especially reserved for the A2B switch. This input is connected on the
main board to the cut-off relay for A2B (hoist limit). The return signal from the A2B switch has
to be within a certain window otherwise the system goes into alarm. This is to ensure that the
cable to the A2B switch is connected and is not cut or bypassed.

+UB

IC

Max. Signal

Resistor Signal
4,7 kΩ A2B switch
Min. Signal

PAT A2B weight

MAIN BOARD

A resistor of 4,7 kΩ is installed at the A2B switch. This resistor in combination with the
resistor matrix on the main board and an IC are checking the cable for possible damage. If
the cable is shortened then the return signal of the A2B switch is too small and if the cable is
cut or not connected then the return signal is too big. In both cases the system will give an
alarm.
Analog input channel and Measuring points

Input channel #1 ‘Length main boom’

The length signal is measured by means of a potentiometer. A cable drum drives the
potentiometer whenever the boom is extended or retracted. The potentiometer will always
give a signal back to the central unit.
The supply voltage for the length sensor is –5,000 Volts. The incoming signal for the
retracted boom is always 0,500 Volts. The signal for the extended depends on the length of
boom and can be different from crane to crane.
The incoming signal can be measured at terminal #10 on the terminal board. The evaluated
signal can be measured at the measuring point MP6 on the main board. Since the gain of the
input amplifier is -1 and the offset is 0,000 both signal have the same voltage but different
polarity.
When the input is put to Ground, i.e. terminal #8, the voltage on MP6 must be 0,000 Volts.
If the signal voltage on MP6 falls below 0,500 Volts or exceeds 4,500 Volts the error codes
E11 or E21 are generated.
Input channel #2 ‘Pressure piston side’

The pressure signal for the bottom side of the lift cylinder is measured by means of a
pressure transducer. The pressure transducer is registering all the pressure changes in the
lift cylinder and will always give a signal back to the central unit.
The supply voltage for the pressure transducer is ±5,000 Volts. The incoming signal for no
pressure is 0,000 Volts. The maximum signal for the nominal pressure is –1,000 Volts.
The incoming signal can be measured at terminal #21 on the terminal board. The evaluated
signal can be measured at the measuring point MP4 on the main board. The signal is 0,500
Volts for no pressure and 4,500 Volts for nominal pressure.
When the input is put to Ground, i.e. terminal #19, the voltage on MP4 must be 0,500 Volts.
If the signal voltage on MP4 falls below 0,500 Volts or exceeds 4,500 Volts the error codes
E12 or E22 are generated.
Input channel #3 ‘Pressure rod side’

The pressure signal for the rod side of the lift cylinder is measured by means of a pressure
transducer. The pressure transducer is registering all the pressure changes in the lift cylinder
and will always give a signal back to the central unit.
The supply voltage for the pressure transducer is ±5,000 Volts. The incoming signal for no
pressure is 0,000 Volts. The maximum signal for the nominal pressure is –1,000 Volts.
The incoming signal can be measured at terminal #16 on the terminal board. The evaluated
signal can be measured at the measuring point MP4 on the main board. The signal is 0,500
Volts for no pressure and 4,500 Volts for nominal pressure.
When the input is put to Ground, i.e. terminal #14, the voltage on MP4 must be 0,500 Volts.
If the signal voltage on MP5 falls below 0,500 Volts or exceeds 4,500 Volts the error codes
E13 or E23 are generated.
Input channel #4 ‘Force transducer’

The force signal is measured by means of a force transducer, tensiometer or load pin. The
sensors are registering all the changes in force at their location and are always giving a
signal back to the central unit.
The supply voltage for the force transducer is ±9,000 Volts. The incoming signal for no force
is 0,000 Volts. The maximum signal for the nominal force is +2,500 Volts.
The incoming signal can be measured at terminals #28 and #29 on the terminal board. The
evaluated signal can be measured at the measuring point MP3 on the main board. The
signal is 0,500 Volts for no force and 4,500 Volts for nominal force.
When the input is shortened, i.e. jumper between terminal #28 and #29, the voltage on MP3
must be 0,500 Volts.
If the signal voltage on MP3 falls below 0,500 Volts or exceeds 4,500 Volts the error codes
E14 or E24 are generated.
Input channel #5 ‘Angle sensor main boom’

The angle signal for main boom is measured by means of a potentiometer. A pendulum
drives the potentiometer whenever the boom is raised or lowered. The potentiometer will
always give a signal back to the central unit.
The supply voltage for the angle sensor is –5,000 Volts. The incoming signal at 90 degrees is
-1,875 Volts. At 0 degrees the incoming signal is –3,125 Volts.
The incoming signal can be measured at terminal #9 on the terminal board. The evaluated
signal can be measured at the measuring point MP8 on the main board. The signal is 0,500
Volts at 90 degrees and 4,500 Volts at 0 degrees.
When the input is put to Ground, i.e. terminal #8, the voltage on MP8 must be +5,500 Volts.
If the signal voltage on MP8 falls below 0,500 Volts or exceeds 4,500 Volts the error codes
E15 or E25 are generated.
Input channel #6 ‘Angle sensor jib boom’

The angle signal for jib boom is measured by means of a potentiometer. A pendulum drives
the potentiometer whenever the boom is raised or lowered. The potentiometer will always
give a signal back to the central unit.
The supply voltage for the angle sensor is –5,000 Volts. The incoming signal at 90 degrees is
-1,875 Volts. At 0 degrees the incoming signal is –3,125 Volts.
The incoming signal can be measured at terminal #24 on the terminal board. The evaluated
signal can be measured at the measuring point MP9 on the main board. The signal is 0,500
Volts at 90 degrees and 4,500 Volts at 0 degrees.
When the input is put to Ground, i.e. terminal #8, the voltage on MP8 must be +5,500 Volts.
If the signal voltage on MP8 falls below 0,500 Volts or exceeds 4,500 Volts the error codes
E16 or E26 are generated.
Input channel #7 ‘Length sensor 2’

The length signal is measured by means of a potentiometer. A cable drum drives the
potentiometer whenever the boom is extended or retracted. The potentiometer will always
give a signal back to the central unit.
The supply voltage for the length sensor is –5,000 Volts. The incoming signal for the
retracted boom is always 0,500 Volts. The signal for the extended depends on the length of
boom and can be different from crane to crane.

When the input is put to Ground, i.e. terminal #8, the voltage on MP6 must be 0,000 Volts.
If the signal voltage on MP6 falls below 0,500 Volts or exceeds 4,500 Volts the error codes
E11 or E21 are generated.

Note:
This input does not exist with the central unit 0725. Therefore no terminal numbers are given.
Input channel #1 and #5 ‘Length and angle sensor’

The angle signal for jib boom is measured by means of a potentiometer. A pendulum drives
the potentiometer whenever the boom is raised or lowered. The potentiometer will always
give a signal back to the central unit.
The supply voltage for the angle sensor is –5,000 Volts. The incoming signal at 90 degrees is
-1,875 Volts. At 0 degrees the incoming signal is –3,125 Volts.
The incoming signal can be measured at terminal #24 on the terminal board. The evaluated
signal can be measured at the measuring point MP9 on the main board. The signal is 0,500
Volts at 90 degrees and 4,500 Volts at 0 degrees.
When the input is put to Ground, i.e. terminal #8, the voltage on MP8 must be +5,500 Volts.
If the signal voltage on MP8 falls below 0,500 Volts or exceeds 4,500 Volts the error codes
E16 or E26 are generated.
Input channel #7 ‘Length sensor 2’

The length signal is measured by means of a potentiometer. A cable drum drives the
potentiometer whenever the boom is extended or retracted. The potentiometer will always
give a signal back to the central unit.
The supply voltage for the length sensor is –5,000 Volts. The incoming signal for the
retracted boom is always 0,500 Volts. The signal for the extended depends on the length of
boom and can be different from crane to crane.

When the input is put to Ground, i.e. terminal #8, the voltage on MP6 must be 0,000 Volts.
If the signal voltage on MP6 falls below 0,500 Volts or exceeds 4,500 Volts the error codes
E11 or E21 are generated.

Note:
This input does not exist with the central unit 0725. Therefore no terminal numbers are given.
Input channel #1 and #5 ‘Length and angle sensor’

The length and angle sensor combines two geometry sensors in one housing for measuring
the length and the angle of the main boom at telescopic cranes. For easy reference please
check the descriptions for length main boom and angle sensor main boom.
Relay output
Every system has an overload power relay that provides a potential free contact which can
be connected to a shut-off device on the crane.
Usually shut-off devices like solenoid valves or electric relays are supplied with +24V when
the crane is in safe operating conditions and are not supplied with any voltage when in
unsafe working conditions. If the supply voltage to the solenoid is +24V then it is possible to
connect the fuse directly to terminal #X1/1, X1/2 or X1/5 at the terminal board since these
terminals are the terminals for main power supply to the system.

1
2
POWER TO BE CONNECTED 5
EITHER TO TERMINAL #2
OR TO BE FEED EXTERNALY

FUSE
47 POWER IN

48 TO SHUT-OFF DEVICE

49

Power relay

The mains supply for the solenoid shall be connected to the fuse. There is a loosen terminal
inside the system which is connected to the fuse. This feeds mains supply to the common of
the cut-off relay. The output of the relay at terminal #X1/48 (normally closed) shall be
connected to the solenoid. This ensures that the solenoid is not energized in case of
overload.
X5
 1 1

2 2

Z 15 611

’A’
Luffer foot section Schnitt ’A’−’B’
Sectional view ’A’−’B’
E

Main Boom Head S5

S6.1
’B’ S6.2
Z 16 496
 Functions of the Limit Switches

Switch designa- Quantity Figure No. Switch type Function Switching point
tion

Hoist limit switch, 2 Z 15 611 Rope traction Prevents the hook block from inadmissibly ap- According to size of
head adapter on limit switch proaching the head adapter on main boom hook block, 3.5 − 5.5 m
main boom when the hook block has reached its highest distance between head
S 1.1 position. When the switching point is reached, adapter on main boom
S 1.2 the hook block lifts the frame (3, Z 15 611), the and hook block roller
ropes (2) are relieved of strain and the limit set
switches (1) break the electric circuit.

Hoist limit switch, 2 Z 15 611 Rope traction Prevents the hook block from inadmissibly ap- According to size of
universal boom limit switch proaching the fly jib head when the hook block hook block, 3.5 − 5.5 m
point Hi has reached its highest position. When the distance between fly jib
S 2.1 switching point is reached, the hook block lifts roller set and hook
S 2.2 the frame (3, Z 15 611), the ropes (2) are re- block roller set
lieved of strain and the limit switches (1) break
the electric circuit.

Limit switch, low- 1 Z 16 496 Camshaft Prevents an inadmissibly high position of the fly 87° between fly jib and
est position of fly controller jib. If the switching position is reached, a con- main boom longitudinal
jib trol cam on the limit switch (E) is actuated axis (main boom in
S5 which then breaks the electric circuit (fitted on working position)
jib foot).

Limit switch for 1 Z 16 496 Camshaft Prevents an inadmissible high position of the fly 12° between fly jib and
highest position controller jib. If the switching position is reached, a con- main boom longitudinal
of fly jib trol cam on the limit switch (E) is actuated axis (main boom in
S 6.1 which then breaks the electric circuit (fitted on working position)
S 6.2 jib foot).
 Ansicht ’X’ Ansicht ’Y’
View ’X’ View ’Y’
2
S8 1
2
1
’X’
S7 ’Y’

3970 3850

87° 89°

Z 16 494 Z 16 495

Front
CWT Tray

A-Frame

2 1 S9

1 S13

Z 16 500 Z 24 479
 Continuation: Functions of the limit switches
Switch des- Quan- Figure Switch Function Switching point
ignation tity No. design

Limit switch, 1 Z 16 494 Swing le- Prevents the highest permissible Main boom angle
main boom ver switch position of the main boom being ex- 87° to horizontal.
87° with roller ceeded during main boom operation.
S7 If the switching position is reached,
the limit switch (1, Z 16 494) is actu-
ated by the piston rod (2) which then
breaks the electric circuit (fitted on
left−hand main boom back stop cyl-
inder).

Limit switch, 1 Z 16 495 Swing le- Prevents the highest permissible Main boom angle
main boom ver switch position of the main boom being ex- 89° to horizontal.
89° with roller ceeded during fly jib operation. If the
S8 switching position is reached, the
limit switch (1, Z 16 495) is actuated
by the piston rod (2) which then
breaks the electric circuit (fitted on
right−hand main boom back stop cyl-
inder).

Limit switch, 1 Z 16 500 Swing le- Prevents the A−frame being lowered 14° to horizontal
A−frame to ver switch too far to the rear. If the switching to the rear.
rear with roller position is reached, a cam on the A−
S9 frame foot section (2) actuates the
limit switch (3). The electric circuit is
thus broken and lowering of the A−
frame interrupted (fitted on A−frame
foot bearing).

Limit switch, 1 Z 24 479 Swing le- Prevents the superstructure being When the Superlift
Superlift ver switch slewed when the Superlift counter- counterweight
counterweight with roller weight is in contact with the ground. comes in contact
in contact If the switching position is reached, with the ground
with the the limit switch (1, Z 24 479) is actu-
ground ated. The electric circuit is thus bro-
S 13 ken and the slewing of the super-
(cwt tray) structure interrupted.
Luffer backstop cylinder
1

2
2

1
S18

Z 16 497 Z 15 612

3 3

S23 H1 H2
1

Z 16 502
 Continuation: Functions of the limit switches
Switch des- Quan- Figure Switch Function Switching point
ignation tity No. design

Limit switch 1 Z 16 497 Swing le- Prevents an inadmissible high posi- 13.0° between fly
for highest ver switch tion of the fly jib. If the switching jib and longitudinal
position of fly with roller position is reached, the limit switch axis of the main
jib (1, Z 16 497) is actuated which then boom).
S 18 breaks the electric circuit (fitted on
fly jib back stop cylinder).

Limit switches 1 Z 16 502 Rollers The limit switch (1, Z 16 502) moni- With the synchro
− synchro pivot lever tors whether the pinion of the syn- pinion fully en-
pinions of the switch chron gear (2) between hoists 1 and gaged between
hoist meshed 2 is engaged with the gear wheels of hoist 1 and hoist
S 23 the rope drums (3). If the pinion is 2.
engaged, the circuit is closed. (Re-
quired for operation with the double
hook block).
Lower limit 1 Z 15 612 Induction Prevents the rope being completely Three coils re-
switch, limit switch unreeled from the rope drum. If the maining on rope
hoist 1 third last coil of the rope is unreeled, drum.
hoist 2 a switch (1, Z 15 612) breaks the
S 25.1 electric circuit. The slip ring (2) en-
S 25.2 sures the electrical connection when
the rope drum is turned.

Lower limit 1 Z 15 612 Induction Prevents the rope being completely Three coils re-
switch for luf- limit switch unreeled from the rope drum. If the maining on rope
fing gear 1 third last coil of the rope is unreeled, drum.
(H3) a switch (1, Z 15 612) breaks the
luffing gear 2 electric circuit. The slip ring ensures
S 26.1 the electrical connection when the
S 26.2 rope drum is turned.

Note S26.1 is a cam switch mounted on the LHS of winch 2 which is controlled by an external gear,
because winch 2 has double drive motors mounted on each end of the drum, so using an internal
proximity switch is not possible
 Main Boom Foot section
Front

A-Frame

2 1 S27

Z 16 501 Z 20 244

5
2
4 1
S24.2 S24.1

Z 20 245
 Continued: Functions of the limit switches
Designation Quan- Image Model of Function Switching point
of the switch tity no. switch
Limit switch 2 Z 16 501 Roller Prevents prohibited further lowering 30 degrees to the
A−frame to rotary con- of the A−frame forwards. If the horizontal.
the front trol switch switch position has been reached, a
S 27 cam on the A−frame foot bearing
(2, Z 16 502) actuates the limit
switch (1). This opens the circuit and
interrupts lowering of the A−frame
(fitted on the left−hand A−frame).
Limit switch 1 Z 20 244 Roller Bridging of the lower limit switches of Main boom posi-
main boom rotary con- all winches (H1; H2; W1; W2) and of tion 27 degrees to
foot section trol switch the limit switches for the highest fly the horizontal.
S 16 jib position, in order to set down the
boom combination in the out-
stretched position and to unreel the
hoist ropes and the luffing ropes
from the rope drums without any
rope remaining.
Limit switch 1 Z 20 245 Roller Monitors whether the derricking rope The derricking
rocker arm in rotary con- is loose or tensioned. The limit rope is loose and
the trol switch switch (1, Z 20 245) is actuated by is tensioned only
derricking the control cam (2) on the rocker when the Superlift
gear S 24.1 arm (3) of the derricking gear and counterweight lifts
switches on the indicator light (48) in off the ground.
the cab. With Superlift operation, the
derricking rope must be loosened be-
fore beginning a lifting operation until
the indicator light (48) lights up.
Limit switch 1 Z 20 245 Roller Monitors whether the derricking rope When the derrick-
rocker arm in rotary con- is loosened too far. The limit switch ing rope is loos-
the trol switch (4, Z 20 245) is actuated by the con- ened too far, the
derricking trol cams (2) on the rocker arm (3) of reeved ropes can
gear S 24.2 the derricking gear and switches on become twisted.
the indicator light (49) in the cab. For
Superlift operation, the derricking
rope must be reeled in before begin-
ning a lifting stroke until the indicator
light (49) goes out.
Winch 2

S26.1
 Winch Functions Shut Down When the Limit Switches
are Actuated
Designation Effective when Crane functions shut down (x) Cancellation of switch
of effect
switch Hoist Hoist Hoist Luffing Luffing Der-
1 2 3 gear 1 gear 2 ricking
gear

R L R L R L R L R L R L

Load limit de- Permissible load exceeded. Using key−operated push

x x x x x x
vice button (59) (see Sect. 4).

Hoist limit Highest permissible hook posi- Using key switch S203.1
switch, tion on main boom exceeded.
main boom x x x x x x
S 1.1
S 1.2

Hoist limit Highest permissible hook posi- Using key switch S203.1
switch, fly jib tion on fly jib exceeded.
x x x x x x
S 2.1
S 2.2

Limit switch Flattest position of the fly jib By raising the fly jib with luf-
Fly jib flat x x x x x fing gear 1
S5

Limit switch Fly jib in highest position. By ”lowering” the fly jib using
highest position luffing gear 1
fly jib x x x
S 6.1
S 6.2

Limit switch, Highest position reached during By ”lowering” derricking gear

main boom main boom operation. during main boom operation.
x x x
87° By ”lowering” luffing gear 2
S7 during Superlift operation.

Limit switch, Highest position reached during By ”lowering” derricking gear

main boom fly jib operation (protection of during main boom operation.
89° main boom back stops). x x x By ”lowering” luffing gear 2
S8 during Superlift operation.

Limit switch Su- Ground contact of SL counter- By increasing the working

perlift counter- weight. radius of the load.
weight Slewing of superstructure shut down.
S 13
Limit switch Steepest position of the fly jib By lowering the fly jib with
highest position luffing gear 1
x x x
fly jib
S 18

∗ If there is no ”X” marked for a limit switch, the switch does not
shut down any winch functions but merely switches on an in-
dicator light in the cab.
 Continued: Shut down winch functions when the limit
switches are activated
Designation Activated when Shut down crane functions (x) Switch release
of the
switch Hoist 1 Hoist 2 Luffing gear Luffing gear Derricking
1 2 gear
H S H S H S H S H S
Limit switch syn- Synchro pinion Hoist 1 and hoist 2
chron gear between meshed between switched together for op-
−
the hoists hoist 1 and hoist 2. eration with the double
S 23 hook block
Lower limit switch Only three turns re- By ”raising” hoist 1 and/or
hoist 1 maining on the rope by means of limit switch S
S 25.1 drum of hoist 1 X X 29 when lowering the
main boom below 27 de-
grees.
Lower limit switch Only three turns re- By ”raising” hoist 2 and/or
hoist 2 maining on the rope by means of limit switch S
S 25.2 drum of hoist 2 X X 29 when lowering the
main boom below 27 de-
grees.
Lower limit switch Only three turns re- By ”raising” the luffing
luffing gear 1 maining on the rope gear 1 and/or by means of
S 26.1 drum of luffing gear X X X limit switch S 29 when
1 lowering the main boom
below 27 degrees.
Lower limit switch Only three turns re- By ”raising” the luffing
luffing gear 2 maining on the rope gear 2 and/or by means of
S 26.2 drum of luffing gear X X X limit switch S 29 when
2 lowering the main boom
below 27 degrees.
Limit switch A− Lowest A−frame By ”raising” the derricking
frame to the front position to the front gear.
X X X X X
(30°)
S 27
Limit switch rocker Derricking rope min.
arm in the derricking sag
gear and/or −
S 24.1 derricking rope max.
S 24.2 sag
Limit switch main Main boom position
boom low position 27 degrees to the −
S16 front

∗ If an ”X” does not appear by a limit switch, it does not shut

down any winch functions, instead it activates an indicator
light in the cab.
 43

Trimot (highspeed on the hoist motors) High speed

Slew Brake Carrier travel brake Carrier W3 or E selection Flow control Wagon brake

54

24

2B
2A

P2 adjustment

P1 adjustment 19B
19A
P4.3
Feed control pressure

Filter
 Note

P3
P1 P2
P4.1

Radiator

Anticavation
Anticavation valves valves

Bleed-off
valves

gear oil

Feed Control Pressure P4.3

Oil Cooler
(Radiator)

Transfer gearbox
gear oil (P5.3)

gear oil

Hydraulic oil
 P4.1
P4.2
P4.3

P3 P5.1

P1 P5.2

P5.3
P2
 1 - Slew, E,
W2,W3, HW

24 - Track Drive

43 - Cab Tilt

54 - Hand Trottle

2A - H1 or H2

2B - H3
19B - Pump 2 adjustment
3 - Outrigger, W2
19A - Pump 1 adjustment
 Engine trottle fluid reservoir

Y36A

Engine Trottle Pedal

Cab tilt control lever

Y64
Slew Brake Pedal
Cab Tilt Cylinder
Superstructure Left side

X5.3

H4
H3
H2
Y11
H1

Pressure
relief Valve

Y12
50 Bar reducing valve

60 Bar Pressure Relief

100 bar (B1)

100 bar (B2)

Filter

150 bar (P4.3)

 Superstructure Right side

X5.5

X506

X5.1

X5.2

X5.4
 Travel Motors
Track Support Left

Rear Outriggers

Locking Lever

Centre Section (Carbody)

Track Support Left

Front Outriggers
 Centre Post

Front Outriggers
Left Track

Right Track
Rear Outriggers
 Counterweight Dolly - Wagon
Suspension Suspension

Frame
Travel gear 1 Travel gear 2
Travel gear 3

Rocker Arm
Steering Cylinder
Outrigger Cylinder
Hydrostatic Motor
Axle - Driven Support plate
Travel gear 4
Axle non driven Trunion Retainer
Rigger jacks

Drive Motors

Steering Cylinders