08 tm es 400 500 0501 3 en1007 new feed .pdf



Nom original: 08_tm_es 400_500 0501-3 en1007 new feed.pdfTitre: ELECTRIC SYSTEM, technical

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DI 400 / 500
ELECTRIC SYSTEM

GND X1

X10

X11

3 4 5 6

1

1

1 2 3 4 5 6 7 8 9

X20

X30

X40

X41

X70

X60

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

X90

X100

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 29 1 2

1 2 3 4 5 6 7 8

2

7 8 9 10 10 11 12 13 14 15 16 17 18 15 16 17 18 19 20 21 22 23 24 25 26 27 28 14 15 16 17 18 19 20 21 22 23 24 25 26 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 9 10 11 12 13 14

16 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 3 4

11 12 13 14 19 20 21 22 23 24 25 26 27 29 30 31 32 33 34 35 36 37 38 39 40 41 42 27 28 29 30 31 32 33 34 35 36 37 38 39 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 17 18 19 20 21 22 23 24 17 18 19 20 21 22 23 24 17 18 19 20 21 22 23 24 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 5 6

1K1 1K2

1K3

1K4

1K5

1K6

1K7

1K8

1K9

2x

2x

2x

2x

2x

2x

2x

2x

1x

1K10 1K11 1K12 1K13 1K14 1K15 1K16 1K17 1K18 1K19

2x

2x

2x

2x

2x

2x

2x

2x

2x

12K1 12K2

2x

2x

32A

32A

32A 32A

1A

1A

1A

6A

16A

16A

6A

2x

K2

6A

XFA XFB XFC XFD XF1 XF2 XF3 XF4 XF5 XF6 XF7 XF8

XT

1K20 1K21 1K22 1K23 1K24 1K25 1K26 1K27 1K28 1K29 1K30 1K31 1K32 1K33 1K34 1K35 1K36 1K37 1K38

T1 KT1 KT2 KT3 KT4 KT5
2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

1

K1

2

2x

2x

2x

2x

DC Input

1D

2D

3D

4D

DM 14

DM 14

DM 14

DM 14

2x

Relay Output

BSM1

TRAFO
24V - 12V

1K39 1K40 1K41 1K42 1K43

SMC

GND

2 (55)

DI 400 / 500
tm 0501-3 en1007

ELECTRIC SYSTEM

CONTENTS
1.

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.

LOCATION OF THE MAIN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4.

FUSES, LOCATION AND DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1. Main fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2. Fuses inside the main electric box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3. Fuses in the cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5.

COMPONENTS IN THE MAIN ELECTRIC BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1. Function of the components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2. Time relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2.1. Location and standard parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2.2. Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2.3. How to connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6.

LOCATION OF CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

7.

INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.1. Air filter indicators of the engine and compressor . . . . . . . . . . . . . . . . . . . 19
7.2. Lubticator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.3. Engine oil pressure and coolant temperature . . . . . . . . . . . . . . . . . . . . . . . 21
7.4. Engine speed and coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.5. Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.6. Compressor oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.7. Compressor temperature and pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

8.

DRILLING STOP DEVICE (SAFETY WIRE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

9.

THROTTLE POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

10. ECM FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10.1. Event codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11. PROXIMITY SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
12. BACK UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
13. WIRING, SCHEMATIC OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
14. BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
14.1. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
14.1.1.First aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
14.2. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
14.2.1.Charging technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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DI 400 / 500
ELECTRIC SYSTEM

tm 0501-3 en1007

14.2.2.Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
14.2.3.Check the battery before winter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
14.3. Jump start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
14.3.1.Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
14.3.2.Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
14.3.3.1.3 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
14.3.4.1.4 Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
15. FEED, ROTATION FUNCTIONS AND ADJUSTING PROCEDURE . . . . . . . . . . . . 43
15.1. How to adjust the proportional valve Y90 (Feed pressure) . . . . . . . . . . . . . 43
15.1.1. Setup of measuring instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
15.1.2. Schematic electric wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
15.1.3. Schematic hydraulic plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
15.1.4. How the powerplug is working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
15.1.5. How to start up the power plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
15.1.6. Settings instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
15.2. How to adjust the proportional valve Y91 (Rotation speed). . . . . . . . . . . . 49
15.2.1. Setup of measuring instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
15.2.2. Schematic electric wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
15.2.3. Schematic hydraulic plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
15.2.4. How the powerplug is working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
15.2.5. How to start up the power plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
15.2.6. Settings instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
16. APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
16.1. Electric circuit diagrams / file name: e500-006.pdf . . . . . . . . . . . . . . . . . . . 55
16.2. Chapter PneuAlpha2 / Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4 (55)

DI 400 / 500
ELECTRIC SYSTEM

tm 0501-3 en1007

1.

GENERAL DESCRIPTION

These instructions describe the operating principle, testing and adjusting procedures of the
DI 400 / 500 electric system.

2.

SAFETY

Always follow the safety instructions and be careful with your work.
Service and adjustment procedures are only allowed to persons who
have been given specific service training. Read the instructions before
any adjusting or repairing.
CAUTION

Hazardous moving and rotating parts. Do the service and repair work
only when the rig is not running. Make sure that accidental starting or
moving of the rig is prevented during service.
WARNING

Danger of high-pressure oil jets. High-pressure oil jets can cause serious personal injuries. Release the pressure in the hydraulic circuit
before opening caps or connections.
WARNING

Risk of electric shock. Electric shock may cause death of severe
burns. Always cut off the main power with the main switch before
repair or maintenance work.
WARNING

5 (55)

DI 400 / 500
ELECTRIC SYSTEM
3.

tm 0501-3 en1007

LOCATION OF THE MAIN SWITCH

Power OFF

Power ON

Never turn the main switch off when the engine is running. This may
damage the alternator or the voltage regulator.
CAUTION

55

6 (55)

DI 400 / 500
ELECTRIC SYSTEM

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4.

FUSES, LOCATION AND DESCRIPTION
Always switch the main power off before changing a fuse.
CAUTION

Replace a blown fuse only with identical fuse.
CAUTION

4.1. Main fuses
2F1= 50A Main supply
50A

50A

2F2= 50A Alternator

2F3= 50A Option Hydraulic oil filter
50A

50A

2F4= 50A Option Fuel filling

7 (55)

DI 400 / 500
ELECTRIC SYSTEM

tm 0501-3 en1007

4.2. Fuses inside the main electric box

GND X1

X10

X11

3 4 5 6

1

1

1 2 3 4 5 6 7 8 9

X20

X30

X40

X41

X70

X60

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

X90

X100

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 29 1 2

1 2 3 4 5 6 7 8

2

7 8 9 10 10 11 12 13 14 15 16 17 18 15 16 17 18 19 20 21 22 23 24 25 26 27 28 14 15 16 17 18 19 20 21 22 23 24 25 26 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 9 10 11 12 13 14

16 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 3 4

11 12 13 14 19 20 21 22 23 24 25 26 27 29 30 31 32 33 34 35 36 37 38 39 40 41 42 27 28 29 30 31 32 33 34 35 36 37 38 39 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 17 18 19 20 21 22 23 24 17 18 19 20 21 22 23 24 17 18 19 20 21 22 23 24 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 5 6

Fuses
1K1 1K2

1K3

1K4

1K5

1K6

1K7

1K8

1K9

2x

2x

2x

2x

2x

2x

2x

2x

1x

1K10 1K11 1K12 1K13 1K14 1K15 1K16 1K17 1K18 1K19

2x

2x

2x

2x

2x

2x

2x

2x

2x

12K1 12K2

2x

2x

32A

32A

32A 32A

1A

1A

1A

6A

16A

16A

6A

2x

K2

6A

XFA XFB XFC XFD XF1 XF2 XF3 XF4 XF5 XF6 XF7 XF8

XT

1K20 1K21 1K22 1K23 1K24 1K25 1K26 1K27 1K28 1K29 1K30 1K31 1K32 1K33 1K34 1K35 1K36 1K37 1K38

T1 KT1 KT2 KT3 KT4 KT5
2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

1

K1

2

2x

2x

2x

2x

DC Input

1D

2D

3D

4D

DM 14

DM 14

DM 14

DM 14

2x

Relay Output

Main electric box

A29

55

A28

BSM1

TRAFO
24V - 12V

1K39 1K40 1K41 1K42 1K43

SMC

GND

8 (55)

DI 400 / 500
ELECTRIC SYSTEM

tm 0501-3 en1007

Fuse

Size (A)

XFA
XFB

32
32

XFC

32

XFD

32

XF1
XF2
XF3
XF4
XF5
XF6
XF7
XF8
FT12

1
1
1
6
6
16
6
6
6.3

Function
Supply for fuses F1, F2, F3, F4, F13 in the dashboard
Supply for fuses F5, F14 in the dashboard
Supply for fuses F6, F7, F11in the dashboard and XF4,
XF5 in the main electric box
Supply for fuses F8 in the dashboard and XF8 in the
main electric box
Engine maint. lamp
Engine diagnostic lamp
Engine warning lamp
12V supply
Emergency circuit supply
Engine supply
Option seat heating
Option engine lights
Fuse in the transformer (24V - 12V)

9 (55)

DI 400 / 500
ELECTRIC SYSTEM

tm 0501-3 en1007

F10 F9 F8 F7 F6
F14 F13 F12 F11
F5 F4 F3 F2 F1

4.3. Fuses in the cabin

55

Fuse

Size (A)

F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14

7.5
7.5
10
7.5
7.5
7.5
15
7.5
20
5
7.5
7.5
7.5
7.5

Function
Wipers, Cigarette Lighter
Working Lights, Cabine Lights
Tramming Lights, Reversing Lights
Angle Indicator
Air Condition
Engine Preheater
Boom, Feed, Drilling, Tramming
Ingnition Key
Webasto Heating
Webasto Heating
Feed Functions (Magacine...)
Option Stair Lights
Horn
Air Condition

10 (55)

DI 400 / 500
ELECTRIC SYSTEM

tm 0501-3 en1007

5.

COMPONENTS IN THE MAIN ELECTRIC BOX

2

1

1

GND X1

1

X10

X11

3 4 5 6

1

1

1

1 2 3 4 5 6 7 8 9

1

X20

X30

1

1

X40

1

X41

1

1

X70

X60

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

1
X90

X100

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 29 1 2

1 2 3 4 5 6 7 8

2

7 8 9 10 10 11 12 13 14 15 16 17 18 15 16 17 18 19 20 21 22 23 24 25 26 27 28 14 15 16 17 18 19 20 21 22 23 24 25 26 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 9 10 11 12 13 14

16 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 3 4

11 12 13 14 19 20 21 22 23 24 25 26 27 29 30 31 32 33 34 35 36 37 38 39 40 41 42 27 28 29 30 31 32 33 34 35 36 37 38 39 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 17 18 19 20 21 22 23 24 17 18 19 20 21 22 23 24 17 18 19 20 21 22 23 24 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 5 6

9
1K1 1K2

1K3

1K4

1K5

1K6

1K7

1K8

1K9

2x

2x

2x

2x

2x

2x

2x

2x

1x

10

8

1K10 1K11 1K12 1K13 1K14 1K15 1K16 1K17 1K18 1K19

2x

2x

2x

2x

2x

2x

2x

2x

2x

13

12K1 12K2

2x

2x

32A

32A

32A 32A

1A

1A

1A

6A

16A

16A

6A

2x

K2

6A

XFA XFB XFC XFD XF1 XF2 XF3 XF4 XF5 XF6 XF7 XF8

13

7

T1 KT1 KT2 KT3 KT4 KT5
2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

XT

4

1K20 1K21 1K22 1K23 1K24 1K25 1K26 1K27 1K28 1K29 1K30 1K31 1K32 1K33 1K34 1K35 1K36 1K37 1K38

12

1

12

11

GND

1

K1

2

SMC
2x

2x

2x

2x

DC Input

1D

2D

3D

4D

DM 14

DM 14

DM 14

DM 14

2x

15

Relay Output

6

Pos.
1
2
3
4

BSM1

Components

14 5

Pos.

TRAFO
24V - 12V

1K39 1K40 1K41 1K42 1K43

3

Components

Clamp 2,5mm²
Clamp 4mm²
Transformer 24V - 12V
Multi-function relay
Packaging unit with diode and
ohmic resistance

10
11
12
13

Circuit breaker 16A
Circuit breaker 6A
Relay
Power relay

14

Diode

6

Diode module

15

Controller for
dustcollector+magacie

7
8
9

Transformer 24V - 10V
Circuit breaker 1A
Circuit breaker 32A

5

11 (55)

DI 400 / 500
ELECTRIC SYSTEM

tm 0501-3 en1007

5.1. Function of the components

COMPONENTS
2F1
2F2
2F3
2F4
XFA
XFB
XFC
XFD
XF1
XF2
XF3
XF4
XF5
XF6
XF7
XF8
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
FT12

55

FUNCTION
Main fuse to supply XFA, XFB, XFC, XFD
Main fuse to supply the alternator
Main fuse to option hydraulic oil filling
Main fuse for option fuel filling
Supply for fuses F1, F2, F3, F4, F13 in the dashboard
Supply for fuses F5, F14 in the dashboard
Supply for fuses F6, F7, F11in the dashboard and XF4, XF5 in
the main electric box
Supply for fuses F8 in the dashboard and XF8 in the main
electric box
Engine maint. lamp
Engine diagnostic lamp
Engine warning lamp
12v supply
Emergency circuit supply
Engine supply
Option seat heating
Option engine lights
Wipers, Cigarette Lighter
Working Lights, Cabine Lights
Tramming Lights, Reversing Lights
Angle Indicator
Air Condition
Engine Preheater
Boom, Feed, Drilling, Tramming
Ingnition Key
Webasto Heating
Webasto Heating
Feed Functions (Magacine...)
Option Stair Lights
Horn
Fuse in the Transformer 24V -12V

12 (55)

DI 400 / 500
tm 0501-3 en1007

COMPONENTS
K1
K2
KT1
KT2
KT3
KT4
KT5
T1
T12
1K1
1K2
1K3
1K4
1K5
1K6
1K7
1K8
1K9
1K10
1K11
1K12
1K13
1K14
12K1
12K2
1K15
1K16
1K17
1K18
1K19

ELECTRIC SYSTEM

FUNCTION
Power relay for the main supply
Power relay for the main supply
Time relay for the lamp test
Time relay for the lubricator
Time relay to stop the rotary head at the thread breaking
position
Time relay to stop the compressor and shut down the engine
after 10sec
Time relay for the Anti jamming system
Constant voltage supply 10V
Transformer 24V to 12V
Protect the starter of restarting after the engine is running
Emergency circuit
Emergency circuit
Hold function for Compressor ON
Switch on the Ether valve
Signals the engine oil pressure
Cylinder functions (Boom swing + Lift)
Cylinder functions (Telescop + Opton Roll Over)
Switch on the drilling supply
Switch on the second tramming speed and the light
Reversing alarm
RPM controlling
Hold function for Flushing On
Hold function for Flushing and Suction On
For the running signal from the alternator
For the running signal from the alternator
Switch off Flushing or Flushing and Suction
Switch the pump to full volume
Is engaged at fast feed and switch the feed pressure to max,
and switch off Y23a
RPM controlling and
Siwtch on the compressor cooler

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COMPONENTS
1K20
1K21
1K22
1K23
1K24
1K25
1K26
1K27
1K28
1K29
1K30
1K31
1K32
1K33
1K34
1K35
1K36
1K37
1K38
1K39
1K40
1K41
1D-4D
BSM1
PA2
1K42
1K43

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FUNCTION
Switch off the lubrication by fail functions
Switch off the lubrication by fail functions of the lubricator
Switch on the lubricator
Is engaged by the Upper clamp pressure switch and stop the
depth meter
Switch the 3S1 joustick to the second joustick level
Switch the 3S1 joustick to the second joustick level
Switch the 3S2 joustick to the second joustick level and
engaged the joustick
Switch the 3S2 joustick to the second joustick level and close
the circuit Pipe in road chnger jaws
Stops the feed if the depth which is setted in the inclinometer is
ready
Switch off the tramming lights
Stops the fast feed at the proximity switch 1B6
Gives the information if the "Road changer arms" are in
magacine position
Gives the information if the pipe is in the jaws
Gives the information if the rotary head in the magacine
position
Switch off the fast feed at magacine position
Gives the information if the jaws are open
Stops the rotary head at the "Collision position"
Also for the "Collision position" circuit
Switch on the engine preheater
Switch on the hydraulic supply for the feed
Option "Boom sensor"
Switch on the horn
Diodes to protect the electric system
Packing module for for diodes and ohmic resistance
Controll system for the dust collector and the magacine
Rig with Roll over: For the proximity switch "Magacine
clockwise"
Rig with Roll over: For the proximity switch "Magacine
counter clockwise"

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5.2. Time relays
The time relays in the main electric box are for lamp test (KT1), stopping the feed at the drill
thread breaking position (KT3), for engine shut down (KT4), optional anti-jamming system(KT5) and for the lubricator function (KT2).
Location and standard parameter

GND X1

X10

X11

3 4 5 6

1

1

1 2 3 4 5 6 7 8 9

X20

X30

X40

X41

X70

X60

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

X90

X100

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 29 1 2

1 2 3 4 5 6 7 8

2

7 8 9 10 10 11 12 13 14 15 16 17 18 15 16 17 18 19 20 21 22 23 24 25 26 27 28 14 15 16 17 18 19 20 21 22 23 24 25 26 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 9 10 11 12 13 14

16 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 3 4

11 12 13 14 19 20 21 22 23 24 25 26 27 29 30 31 32 33 34 35 36 37 38 39 40 41 42 27 28 29 30 31 32 33 34 35 36 37 38 39 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 17 18 19 20 21 22 23 24 17 18 19 20 21 22 23 24 17 18 19 20 21 22 23 24 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 5 6

1K1 1K2

1K3

1K4

1K5

1K6

1K7

1K8

1K9

2x

2x

2x

2x

2x

2x

2x

2x

1x

1K10 1K11 1K12 1K13 1K14 1K15 1K16 1K17 1K18 1K19

2x

2x

2x

2x

2x

2x

2x

2x

2x

12K1 12K2

2x

2x

32A

32A

32A 32A

1A

1A

1A

6A

16A

16A

6A

2x

K2

6A

XFA XFB XFC XFD XF1 XF2 XF3 XF4 XF5 XF6 XF7 XF8

Time relay
XT

1K20 1K21 1K22 1K23 1K24 1K25 1K26 1K27 1K28 1K29 1K30 1K31 1K32 1K33 1K34 1K35 1K36 1K37 1K38

T1 KT1 KT2 KT3 KT4 KT5
2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2x

2

1K39 1K40 1K41 1K42 1K43

SMC
2x

2x

2x

2x

DC Input

1D

2D

3D

4D

DM 14

DM 14

DM 14

DM 14

2x

Relay Output

10

R2 Delay

100

25

40

20

10

R2 Delay

10

10

R2 Inst.

R2 Left

1

20
10

R2 Inst.

GND

1

K1

2x

BSM1

TRAFO
24V - 12V

5.2.1.

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5.2.2.

Settings

KT1, KT2, KT3, KT4, KT5

90

10 0
%

%

%

1 0%

80%

30%

60 %

Fine adjustment
of time relay

3 00
1 00
s

s

50 %

%

%
40

70

20

s
30
10s

Time delay range

300m
30
m
30

h

h

1s

3 00

3s

Configuration of relay R2

1

Function mode

1

1

Example of time settings:
t=(30% x 10s) / 100 = 3s

On-delay time delay
Pulse-on energisation function

1

Off-delay flasher function
On-delay flasher function
Off-delay time delay opening, low-level control
Pulse-on energisation at contact opening

1

1

Star-delta function with double delay at energisation
Star-delta function with pulse on energisation

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5.2.3.

ELECTRIC SYSTEM

How to connect

On the four pictures you can see, how to connect the multi function relay, when you have
choosen an function.
Also you have to choose the function mode on the front side of the relay

KT1, KT2, KT3, KT4, KT5

A1 Y1

A2

15

16 18

1

1

1

Z1 X1

Z2

1

25(21)

28(24) 26(22)

1

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6.

LOCATION OF CONNECTORS

Connectors/Location
1S1
1S2
ST1
ST2
ST3
ST4
ST5
ST5.1
ST5.2
ST5.3
ST6
ST6.1
ST6.2
ST6.3
ST7
ST8
ST9
ST10
ST16
ST17
ST18
ST19
ST22
ST23
ST25
ST26
ST99
ST100
P61
P403
P800
SX1
SX2
SX3
SX4
SX6

55

Joystick Boom/Feed
Joystick Telescope/Optional roll-over
Window wiper
Lights
Control lever, carrier right
Air condition
Air condition
Engine compartment
Air condition
Air condition
Control lever, carrier left
Control lever, carrier left
Control lever, carrier left
Emergency stop - armrest
Control lever, carrier right
Dust collector
Digital panel
Digital panel
Tramming 2. gear
Armrest down counter
Horn
Radio
PQ - Angie indicator (not shown)
PQ - Angie indicator (not shown)
Webasto coolant heating
Oiler
Ether start valve
Engine speed sensor
CAT Electronic control module
Throttle position
Coolant level sensor
Control desk right
Control desk right
Control desk right
Control desk right
Control desk right

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ST5.1
ST5.2
ST26

ST5.3
P800

ST100

ST8

ST99

ST16
ST17

P61

ST1

ST19

ST2

ST4
ST5
P403 ST3
1S2
1S1

SX1,2,3
4,6
ST25
ST9
ST10

ST7

ST6
ST6.1
ST6.2
ST6.3

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INDICATORS

7.1. Air filter indicators of the engine and compressor

2B8

2B14

2H8 = Engine air filter = 2B8
2H14 = Compressor air filter = 2B14

If an indicator lamp for the air filter
in the control panel is lit, replace the filter
element.
If the filter element is clean and indicator
lamp is lit, the pressure switch is
defective and must be replaced.

2H8

55

2H14

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ELECTRIC SYSTEM

7.2. Lubricator

2B11

1H6
1H7

2B10

1H6 = Function = 2B10
1H7 = Oil level = 2B11

The function of the lubricator is shown
in the cabin with the lamp 1H6 (green).
The lamp is lit every time the lubriator injects oil
into the compressed air system.
If the oil level in the lubricator is low,
the lamp 1H7 (red) is lit.

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7.3. Engine oil pressure and coolant temperature

2R11

2B2

2H2

2H2 = Engine air filter = 2B2
2H21 = Compressor air filter = 2R11

After the lamp test the engine
oil pressure lamp remains on. The lamp
goes off after starting. If the oil pressure of
the engine is too low, the engine shut down.
If the coolant temperature indicator goes
in the red zone, the engine will derate.
After derating, the operator must
shut down the engine.

2H21

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7.4. Engine speed and coolant level

2H20 = RPM sensor of the engine = B100

Coolant level sensor = EMS

B100

Coolant level
sensor

2H16 = Engine warning lamp
2H17 = Engine flash code
2H20 = RPM sensor of the engine = B100

If the RPM - sensor is changed
it must be adjusted by turning
it to the minimum and then 3 turns outwards.
If the coolant level is low,
the engine flash code lamp flashes and
the engine error warning lamp is lit
If the operator doesn‘t stop the engine,
the warning lamp will continue flashing
and after a while the engine will derate.
If the flash code 62 is flashing,
the engine must be shut down
and cooling system must be filled.

2H16

2H17

2H20

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7.5. Hydraulic oil

2B9.1

2B9

2B5

2H5 = Hydraulic oil level = 2B5
2H9 = Hydraulic oil filter = 2B9.1
2H9 = Hydraulic oil filter = 2B9

If the lamp for the hydraulic oil level is lit,
hydraulic oil must be added.
If the lamp for the hydraulic oil filter is lit,
the filter must be replaced.

2H16

55

2H20

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7.6. Compressor oil and filter

2R12

2B15

2H15 = Compressor oil filter = 2B15
2H22 = Tank level = 2R12

If the lamp for the compressor oil fiter is lit
the filter must be replaced..

2H15

2H22

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7.7. Compressor temperature and pressure

2B6

2B1

2B4

2R13 2B6 2B1

2H6 = Compressor temperature first stage = 2B6
(55°C = the fan of the oil cooler ON)
2H6 = Compressor temperature second stage = 2B1
2H23 = Compressor temperature = 2R13

2H6
Indicator (2H23) shows the compressor
temperature.
If the temperature rises too high,
the warning light (2H6) is lit,
and the engine is shut down.
At 55°C (131°F) the sensor 2B6 switches
on the compressor oil cooler fan.
If the pressure in the first stage
of the compressor rises over 8bar,
the lamp (2H13) is lit and the engine
is shut down.

2H13
55

2H23

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8.

ELECTRIC SYSTEM

DRILLING STOP DEVICE (SAFETY WIRE)

Cable recommendation: Ø2,5 mm galvanized steel with 3.2 mm red casing, coefficent of expansion =< 0.7
mm/m for 60°C
Fix the unit firmly to a rigid support. (a) Threaded holes for 13 mm compression gland: CM12 or
PG13 or 1/2NPT or M20x1.5.
Fix the cable supports, if any one or several rigid elements.
Fix the spring on the last support.
Fix the end of the cable on the spring.
Pass the cable through the supports.
Cut the cable to lengh at the button in order to obtain the lenght necessary for correct winding:
1,5 turns minimum.
Engage the cable on the tensioner.
Turn the adjustment nut to the center of the index (b): index - (c): authorized operating zone.
Reset, release and repeat the operation.
Check the position of the index and recenter it if necessary. (d): green - (e): yellow
To slacken the cable, push on the attachmentring with your finger and then loosen the nut until
the required cable tension is obtained.
Electrical connection of the unit: on stirrup screw terminals min 1x0,5 mm, max 1x2,5mm

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THROTTLE POSITION SENSOR

Right dashboard

The throttle position sensor (TPS) eliminates the mechanical throttle and governor linkages.
The TPS converts the position of the throttle lever into an electric signal which is sent to the ECM.
The throttle position signal and the engine speed/timing signal
are processed by the ECM in order to precisely control the engine speed.
Turning the throttle position sensor to the left increases and to the right decreases running speed of the engine.
Pressing the sensor decreases the engine speed to the minimum.

Connection:

Main
electrical
box

W403
A
B
C

Bl/Wh
BL-WH
OR/BK

X2:175
X2:176
X2:177

X2:248

ECM

W41
14

65

P61 J61

Risk of damaging the electronic engine controller. If TPS is damaged,
replace it only with an original spare part. Never try to use any other
potentiometer, or try to repair the TPS.
CAUTION

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10.

ECM FLASH CODES

Flash codes represent diagnostic codes
in the electronic system in order to alert
the operator that a problem in the system exists.
The flash code is a two digit number indicated
by a series of diagnostic lamp flashes.

Engine warning lamp

Engine flash code

The engine warning lamp is ether on or flashes, it does not indicate a code.

Note: Flash codes can represent more than one diagnostic code (CID/FMI or DPD/FMI code).
Notice all the diagnostic codes that are represented by a particular flash code.
After the diagnostic codes have been determined,refer to Troubleshooting.
Diagnostic codes are used by the electronic system in order to alert the operator that a problem exists.
A diagnostic code also indicates the nature of the problem to the service technician.
Diagnostic Codes can only be viewed by using the Electronic Technician (ET) from Cat.

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Possible Performance Effect of Active Diagnostic Codes
Flash
code

CID/FMI
Code

DPN/FMI
Code Description of Code Engine Misfires

Reduced
Engine Speed Engine Shutdown

Atmospheric
Pressure open/short
to +batt

274-03

108-03

274-04

108-04

110-03

110-03

Engine Coolant
Temperature
open/short to +bat

X

X

X

110-04

110-04

Engine Coolant
Temperature short
to ground

X

X

X

28

91-13

91-13

X

X

32

91-08

91-08

X

X

320-02

190-02

320-11

190-11

342-02

723-02

342-11

723-11

94-03

94-03

Fuel Pressure
open/short to +batt

94-04

94-04

Fuel Pressure short
to ground

172-03

172-03

Intake Manifold Air
Temp open/short to
+batt

172-04

172-04

42

261-13

228-13

51

168-02

168-02

53

254-12

26

27

34

37

38

55

Low Power

Atmosperic
Pressure short to
ground

Throttle Position
signal abnormal
Throttle Position
calibration required
Speed/Timing
Sensor Loss of
Signal
Speed/Timing
Sensor mechanical
failure
Loss of Secondary
Engine Speed signal

Secondary Engine
Speed Sensor
mechanical failure

Intake Manifold Air
Temp short to
ground
Engine Timing
calibration required
System Voltage
intermittent/erratic
Elevtronic Control
Module Error

X

X(1)

X

X(1)

X

X(1)

X

X(1)

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

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Possible Performance Effect of Active Diagnostic Codes
Flash
code

CID/FMI
Code
253-02

56
268-02

58

247-09

1-11
72
2-11
3-11
73
4-11
5-11
74
6-11
(1)
(2)

DPN/FMI Description of Engine
Code
Code
Misfires
Personality
234-02 Module
mesmatch
Check
1111-02 Programmable
Parameters
J1939 Data
Link
639-09
communication
s
Injector
651-11 Cylinder #1
X
fault
Injector
652-11 Cylinder #2
X
fault
Injector
653-11 Cylinder #3
X
fault
Injector
654-11 Cylinder #4
X
fault
Injector
655-11 Cylinder #5
X
fault
Injector
656-11 Cylinder #6
X
fault

Low
Power

Reduced
Engine
Engine
Speed
Shutdown
X(2)

X

X
X
X
X
X
X

The engine will shut down if both speed/timing sensors are lost
Fuel injection will not occure and the engine will not start.

X

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10.1. Event Codes

The ECM logs events. Events refer to engine operating such as low oil pressure
or high coolant temperature.
Logged events usually indicate a mechanical problem instead of an electrical sytem problem.

Output voltage from a typical analog temperature sensor (Coolant temperature sensor shown)

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The ECM will generate a flash code that will be displayed on the diagnostic lamp. The warning
Lamp will display the following conditions:
Flash
ACTION
code
EID/FMI Codes
SPN/FMI Codes Description of Code
Engine Overspeed
Shutdown

Shutdown

Engine Overspeed

Warning

0110-15

High Engine Coolant
Temperature

Warning

025

0172-16

High Inlet Air
Temperature

64

027

0172-15

46

039

0100-18

46

100

0100-17

65

056

0174-15

High Inlet Air
Temperature
Low Engine Oil
Pressure
Low Engine Oil
Pressure
High Fuel
Temperature

62

057

0111-18

Low Engine Coolant
Level

Derate

62

059

0111-17

Low Engine Coolant
Level

Warning

63

095

0094-00

Fuel Filtre Restriction

Warning

63

096

0094-00

High Fuel Pressure

Warning

35

004

0190-16

35

190

0190-00

61

017

64

Derate
Warning
Derate
Warning
Warning

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PROXIMITY SWITCHES

1B4 1B6
(1) (2)

1B7
(3)

1B5
(2)
1B2
(3)

1B1
(3)

1B3
(3)

Proximity switch types
The close contact type proximity switches are used in Titon 500 ( 1,2,3)
(2)

5m

(3)
Max.5mm

Max.20mm

5m

M18x1,5

Max.20mm
M18x1,5

M30x1,5

(1)

5m

The negative signal is switched to the output, when a mass is brought
in the detection range of the proximity switch.

How to connect the proximity switch
bn = positive Signal
bl = negative Signal
bk = switched Signal
wh = not connected

55

bn
bl
bk
wh

5m

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1B5 1B6

1B7 1B4

GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND

20

21

21

20

20

22

22

20

20

23

23

20

20

19

24

25

24

20

25

19

18

17

26

26

18

16

27

28

27

17

28

16

16

29

29

16

15

14

30

31

30

15

31

14

13

32

32

13

12

11

33

34

33

12

34

11

10

9

35

35

10

8

36

36

9

7

37

37

8

6

38

38

7

5

39

39

6

4

40

40

5

3

41

41

4

2

42

42

3

1

43

44

43

2

44

1

GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND

2,5² ge-gr

1B6:

1B5:

1B4:

bl = pin GND bl = pin GND bl = pin GND
bn = pin 20
bn = pin 20
bn = pin 20
bk = pin 21
bk = pin 22
bk = pin 23

1

2

3

4

5

6

7

8

9

10 11 12 13 14 15

1B1 1B2 1B3

1B1:

1B2:

1B3:

bl = pin 1 bl = pin 4 bl = pin
bn = pin 2 bn = pin 5 bn = pin
bk = pin 3 bk = pin 6 bk = pin

Function of the proximity switches:
1B1 = Threading position
1B2 = Magacine position
1B3 = Collision position
1B6 = Fast feed stop
1B5 = Road changer arm in magacine
1B4 = Pipe in road changer jaws
1B7 = Clamp open

1B7:

bl = pin GND
bn = pin 20
bk = pin 24

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BACK UP ALARM

Location
1B4 Pressure switch

Backup beeper

How to connect
1B4
1
3

X31
18
GND

W1B4

18

18

W30

GND

X30:18

X40:9

W40

X40:GND

St13
Yebl
bn

3
7

Re
Bk

1HH5
Backing alarm

Main electrical box

Pressure switch

Connector

Electrical box
on the valve plate

How to adjust the pressure switch

Adjusting
screw

55

Screw the adjusting screw fully
in and then 3 turns back

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13.

ELECTRIC SYSTEM
tm 0501-3 en1007

A29

1B2

X22
1B1

1B3

A27

A25

A28

Right control desk
Control lever carrier right

Battery
Battery
Control lever carrier left

P2

Main electrical box
Webasto

1B4

1B5

1B7

X21

1B6

2B5

2B9

2B8

2G2

P61

100M1
200M1

2R12

2F1
2F2
2F3
2F4

2S0

Y31

C10

X31

2B15

2M1

Dust
collector

6M1

P800

2B10
2B11

6B1
6B2

Compressor

4H6

6Y1

1HH5

4H7

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ELECTRIC SYSTEM

Engine wire harness (Engine, compressor
backing lights, back up alarm)
Main supply +
Main supply GND
Elecrical box - valve plate
Oiler and air condition
Coolant level sensor
Cable for Y301 and Y405
Engine wire harness to Cat customer connector
Cable to Y31 (Oil cooler valve)
Cable to 2B5 (Hydraulik oil level)
Cable to 2B9 (Hydraulik oil filter)
Cable to 2B8 (Engine air filter)
Cable to dust collector
Cable to left control lever carrier
Cable to right control lever carrier
First cable to right control desk
Second cable to right control desk
Cable for the Webasto coolant heating
Wire harness to the feed
Cables for the angiel indicator
Cable feed, from X21 to X22
Cable to 1B1
Cable to 1B2
Cable to 1B6
Cable to 1B4
Cable to 1B5
Cable to 1B7
Cable to 1B3

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14.

BATTERY

14.1. Safety
Always obey instructions on the battery and in the instructions manual of the battery and
the rig.
Risk of eye injury. Always use protective goggles or other eye protection when handling batteries.
WARNING

Risk of chemical burns. Battery acid is extremely corrosive. When
handling batteries, wear protective gloves. Do not tilt batteries,
because acid can escape from the gas vent openings.
WARNING

WARNING

Risk of explosion. A highly explosive mixture of hydrogen and oxygen
gases is evolved during battery charging. Sparks, open flames and
smoking are prohibited. Avoid causing sparks when handling cables
and electrical equipment. Avoid short-circuits!
Do not place batteries in direct daylight without protection.
Discharged batteries may freeze up, therfore do not store them in cold
conditions.

WARNING

Always aim to protect the environment. Dispose of old batteries
according to local regulations.
CAUTION

14.1.1. First aid
Rinse off acid splashed in the eyes immediately for several minutes with clear water. Then
consult a doctor immediately. Neutralize acid splash on skin or clothes immediately with
acid neutralizer (soda) or soaps suds and rinse with plenty of water. If acid is consumed,
consult a doctor immediately.

14.2. Maintenance
If you want your engine to start properly after cold nights outside, you need to pay a little
extra attention to the battery. Even a maintenance - free battery needs a bit of care if you
want it to last a long time.
The battery delivers electricity by means of a chemical reaction. If the battery fails, poor
maintenance of the vital automotive power store is usually the cause. The starter is one of
the most energy-hungry parts of the electrical system, and the battery has to supply it with a
great deal of power to start the engine. Obviously this is easier on a warm summer day than
cold winter morning when temperature is several degrees below zero centigrades.

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The capacity and performance of automotive batteries are essentially designed to cope with
poor winter conditions. The batteries in new machines can handle temperatures down to 24°C or -28°C. However, as the engine gets older, it becomes less cooperative and the
power potential of the battery falls. In general, this poses no major problems in summer, but
on frosty winter mornings it can soon become maddening for the operator. Poorly maintained batteries are brought to their knees by the hard work which the starter has to do to
get the engine going. The colder it is, the weaker the chemical reactions in the battery.
Temperatures of -20°C will halve the energy stores of any automotive battery. Viscous oil in
the engine also hamper a smooth start, so all the battery´s starting power is required. It is
therefore particulary important to ensure that the battery is properly charged in winter. Careful maintenance will keep the battery going.
14.2.1. Charging technology
Ideally, an electronic charging device should be used. These devices complete charging
automatically. Follow the device operating instructions!
• Remove the battery from the vehicle or disconnect the battery cables. - DISCONNECT
THE NEGATIVE TERMINAL FIRST!
• Connect the positve terminal of the battery with the positve output of the charging device.
Then repeat for the negative terminal.
• Only switch on the charging device following battery connection and only switch off after
charging.
• Charged power: 1/10 in amperes of the battery capacity.
• Interrupt charging at acid temperatures of over 55°C.
• Following charging, check the electrolyte level, and if necessary, top up with distilled
water (to the mark or 1cm above the plates).
• Ensure good ambient ventilation! An explosive hydrogenoxygen gas mixture is created
during charging. Smoking, open flames and sparks (e.g. due to a short circuit) are strictly
forbidden!
Only use approved starting cables. The electrolyte level is frequently
very low due to the misuse of the battery. This must be corrected
before charging.
CAUTION

14.2.2. Cleanliness
It is particulary important to keep the battery and its surrounding area clean. Dirty or moist
surfaces may result in small contiuous currents, flowing from one terminal of the battery to
the other. The contacts also need to be clean, dry and lightly greades, and the electrical
connections need to be secure.

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14.2.3. Check the battery before winter
If you want the engine to start first time on cold winter days, you should pay little more
attention to your battery. All starter batteries require a certain amount of maintenance:
• The surface of the battery should always be clean and dry, otherwise power can trickle
out, gradually discharging the battery.
• Check at regular intervals that the battery and its cables connections are firmly in place,
and tighten if necessary.
• The fluid level should be checked at regular intervalls. During the warmer months of the
year, it is normal to use some water, but the control voltage should be checked by an
expert if consumption seems execssively high.
• If the fluid level of the battery is too low, it should be toppes up with distilled water only never acid.
• When storing starter batteries,the following also applies:
• Always keep the battery as fully charged as possible to prevent the formation of larger
lead sulfate crystals. Never leave the battery standing when flat (or partly discharged).
Check charged batteries in storage at regular intervals and recharge at the latest when
the acid density falls below 1.20kg/l.

14.3. Jump start
14.3.1. Preparation
1.

Use jump start cable suitable for big diesel engines.

2.

The capacity of the starter battery delivering current must not be significantly less than
that of the discharged starter battery.

3.

Only batteries of the same nominal voltage (e.g. 12V) can be connected together using
the jump leads.

4.

Make sure there is no body contact between the vehicles.

5.

Sources of ignition (e.g. open flame, burning cigars, cigarettes or electric sparks) must
be kept away from the starter batteries (danger of explosion).

6.

Keep distance from the starter batteries (danger of chemical burns). The electrolyte of
the discharged battery is liquid even at sub-zero temperatures.

7.

The discharged starter battery must not be disconnected from its associated on-board
electrical system during or for a jump-start.

8.

Switch off the vehicles ignitions before connecting the jump-start cable.

9.

Lay the jump lead cables in such a way that the rotating parts in the engine compartment cannot touch them.

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14.3.2. Connections
Risk of short circuit. Never connect the red and black cable together!

WARNING

2
+
Helper vehicle´s
batteries

3

1
+
Batteries of
vehicle
needing help

4

First connect the cable with the red
terminal clamps to the positive pole of the
discharged starter battery (see Figure,
Position 2).
Then connect the cable with black
terminal clamps to the negative pole of
the donor battery (see Figure, Position 3)
and the to the earthing strap or some
other bare metal point on the engine
block (see Figure, Position 4) as far away
as possible from the starter battery, to
prevent ignition of any explosive gas
mixture that may have been evolved.

14.3.3. 1.3 Starting
After connecting the jump lead cables, the engine of the donor vehicle must be started and
set to medium revolution speed.Then the engine of the vehicle with the dead battery is
started. After each start attempt, which must not last longer than 15 seconds, a waiting time
of at least 1 minute must be interposed. After successfully starting the engine, wait 2 to 3
minutes until it is running smoothly.
14.3.4. 1.4 Disconnecting
Disconnect the jump lead cables in the reverse order:
First remove the black terminal clamp from the earthing strap or engine block (see Figure,
Position 4) of the vehicle which needed assistance. Then remove the other black terminal
clamp from the negative pole of the donor battery (see Figure, Position 3). Next remove the
two red terminal clamps in any order (see Figure, Position 1 and 2). When removing the
jump lead cables, take care to ensure that they do not come into contact with the rotating
parts of the engines.

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The amplifier has a power inlet of 24VDC. (Pin 1 and 2)
At the pins 3 and 4 the potentiometer is connected.
To measure the current, which is provided by the amplifier, it is necessary to put in
between the outlet X1 and the solenoid an ampere meter connected in series.

1.) Connect the amplifier plug as described. Before you mount the plug on the
valve check if all the functions are working properly. The supplying voltage
should be in between 20 to 28 V DC.
2.) With the help of the mounted LED check now the function of the plug:
The LED must light up, if a signal is received which is bigger than 100mV.
DO NOT SET THE SIGNAL VOLTAGE HIGHER THAN 10V.
a) If a signal is received which is lower than 100mV the LED must not
indicate. If there are some malfunctions the power plug has to be
exchanged.
3.) Switch of the power supply. Afterwards put the power plug on the valve and
screw it tight. But always check the proper seat of the sealing, only if the
sealing is in, the proper way the plug will have protection according to IP 65.
4.) By obeying the usual security settings continue as listed:
• Connect the power supply again .
• Check if the LED is working according to paragraph 2. A malfunction is a
sign of a short circuit on the magnet.
1. Go on function „feed forward“ and leave the joystick in this position (Feed forward
on block)
2. Turn the potentiometer for feed to position 8.
3. Adjust the gain of the power plug on valve Y90 with the screw for gain setting till
the feed pressure gauge for feed pressure in the cab shows 200 bar.
4. The ampere meter should show 300mA.
5. Turn the potentiometer for feed to position 10.
6. The pressure should be 245 bar.
7. Turn the potentiometer for feed to position 0.
The pressure should be 0bar.

The speed of the rotary head is varied via a potentiometer (1R2) which is located on
the right operating panel. To visualize the pilot pressure it is necessary to install a
pressure gauge with a scale of 0 – 60bar on the pump 1 port “Y”.

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15.

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FEED, ROTATION FUNCTIONS AND ADJUSTING PROCEDURE

15.1. How to adjust the proportional valve Y90 (feed pressure)
The feed pressure is varied via a potentiometer (1R1) which is located on the right operating panel.
The pressure is shown on the pressure gauge under the front screen.
The feed circuit is supplied from pump 2 which is pressure compensated.
The compensated pressure is adjusted by the pressure relief valve in the pressure control block
to 245bar which builds then the max. possible feed pressure.
By means of the proportional controlled pressure reducing valve Y90,
then the feed pressure can be varied on the desired level. (0 245bar).
For this purpose Y90 has an amplifier which converts
the variable inlet voltage (Potentiometer) in an amplified current for the solenoid.

1R1 Feed pressure Potentiometer

Y90
55

Gauge 0 - 245 bar

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15.1.1. Setup of measuring instruments

The amplifier has a power inlet of 24VDC. (Pin 1 and 2)
At the pins 3 and 4 the potentiometer is connected.
To measure the current, which is provided by the amplifier, it is necessary to put in
between the outlet X1 and the solenoid an ampere meter connected in series.

15.1.2. Schematic electric wiring

Amperemeter

Solenoid

Connection potentiometer (in the right dashboard of the cab)
BL/RE = Z1
GR/BK = Z2
GR/RE = n->
Connection amplifier (on the valve plate in the engine compartment)
wire 1 = 1
wire 2 = 3
wire 3 = 2 and 4

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FEED

Wires for
the
power plug

ROTATION

FEED

ROTATION

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15.1.3. Schematic hydraulic plan

PRESSURE
GAUGE UNDER
FRONT
SCREEN.
(0-245bar)

93

FEED

1
X

98

R

L

A

B

FAST FEED FORWARD
CONTROL BLOCK

96

33 TRAMMING/DRILLING

B

A

FULL DEFLECT PUMP

A

Y66 B
T

T

95
BR

94

17

12-30

P

ANTI
JAMMING
SYSTEM

97

Y23

16 A

Y24

34.1

A

B

P

T

38
Y34

Y22

DRILLING CONTROL UNIT

P T

B1

A1

4

B

Y35

F

10

10

15
14

36.2

B

A
Y23a

36.1

P

P T

T B A

Y90

19

B

A

T

B

9 1 92

1

2

4

P

T

P

A

20

3

Y33

A

E

8.1

1

3
12

Y62
2

3

2

P

T

39

TRAMMING

P

3

P1

M3

M1

1

2

PILOT OIL SUPPLY

31 UNIT

25 24
BV

Y21

A

2

Y4

B

M

66

a

32

M A2 G Y

PRESSURE CONTROL BLOCK

X T1 T2 R
B

P

Y63

0,32 l

P2

T

30

PV

320

200

35 bar

165

PS

88

P1

P2

Vg

60

max

Vg

P1
min

60

P

T

B

P

A

Y64

A

b

SOLENOID ENGAGED

T

S

M1

67.2

67.1

34.2

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15.1.4. How to start up the powerplug is working

Settings:
Ramp setting:
set down to 0
Gain setting:
to be adjusted according
to setting below
Deadband compensation:
set down to 0

15.1.5. How to start up the power plug
1.) Connect the amplifier plug as described. Before you mount the plug on the valve check if all the
functions are working properly. The supplying voltage should be in between 20 to 28 V DC.

2.) With the help of the mounted LED check now the function of the plug:
The LED must light up, if a signal is received which is bigger than 100mV.
DO NOT SET THE SIGNAL VOLTAGE HIGHER THAN 10V.
a) If a signal is received which is lower than 100mV the LED must not indicate. If there are
some malfunctions the power plug has to be exchanged.
3.) Switch of the power supply. Afterwards put the power plug on the valve and screw it tight. But
always check the proper seat of the sealing, only if the sealing is in, the proper way the plug will
have protection according to IP 65.
4.) By obeying the usual security settings continue as listed:
²
Connect the power supply again .
²
Check if the LED is working according to paragraph 2. A malfunction is a sign of a short
circuit on the magnet.
After the successful passing the tests the power plug and the valve are now setted to get in operation.

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15.1.6. Settings instruction
1. Go on function „feed forward“ and leave the joystick in this position (Feed forward on block)
2. Turn the potentiometer for feed to position 8.
3. Adjust the gain of the power plug on valve Y90 with the screw for gain setting till the feed pressure
4.
5.
6.
7.
8.

gauge for feed pressure in the cab shows 200 bar.
The ampere meter should show 300mA.
Turn the potentiometer for feed to position 10.
The pressure should be 245 bar.
Turn the potentiometer for feed to position 0.
The pressure should be 0bar.

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15.2. How to adjust the proportional valve Y91 (Rotation speed)

The speed of the rotary head is varied via a potentiometer (1R2) which i
located on the right operating panel.
To visualize the pilot pressure it is necessary to install
a pressure gauge with a scale of 0 60bar on the pump 1 port “Y”.

1R2 Rotation feed Potentiometer

Port (Y) at Pump 1

Y91

“drilling” block.
By means of the proportional controlled pressure reducing valve Y91 the pumps pilot pressure can
be varied between 6 and 35 bar which causes an increase of rotary speed from 0 to 83 1/min.
For this purpose Y91 has an amplifier which converts the variable inlet voltage (Potentiometer)
in an amplified current for the solenoid. The speed range with OMTS 350 is 0 to 66 1/min.

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15.2.1. Setup of measuring instruments
The amplifier has a power inlet of 24VDC. (Pin 1 and 2)
At the pins 3 and 4 the potentiometer is connected.
To measure the current, which is taken from the potentiometer, it is necessary to put in between the outlet
X1 and the valve an ampere meter connected in series.

15.2.2. Schematic electric wiring

Amperemeter

Solenoid

Connection potentiometer (in the right dashboard of the cabine):
BL/GN = ->
BL/BK = Z2
BL/RE = Z1
Connection amplifier (on the valve plate in the engine compartment):
wire 1 = 1
wire 2 = 3
wire 3 = 2 and 4


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