BoomSupportPlus

Installation Manual - 190130-EN

PARTNR-90000494.*.**.**.F.I.K.
C02 | C03 | C04 | CE01
Tools required

Spanner Spanner Allen key Electrical Drill

10 mm 30mm 4 mm drill 4 mm
13 mm 8,5 mm
17 mm 12,5 mm
19 mm
22 mm

Pen and paper Pipe wrench Wire cutter Screwdriver Oil catchers
Minus
X

Builders level Multimeter

01* *Only for Condor C02 machines, hydraulic overview
Parts
Nr. # Description Part.nr.

4 Hose L3050 7129545

1 Hose L5600 7120866

1 Coupling 35-15 90051284.0
2 Coupling 15-12 7320759
1 Coupling 12 7320556

1 ERW 12 7320286
1 ERL 15 7320249
1 ERW 15 7320289
6 Coupling 12 7320554
Information about the hydraulic overview
• 7129545: A port <-> rod side lifting cylinder.
• 7129545: Bottom side of lifting cylinder<-> tank manifold 10-fold.
• 7120866: Tank manifold 10-fold <-> return pipe (right-side of frame).
 Parts
02 Nr. # Description Part.nr.

8 M5 x 85 3311134

2 Hydr. valve 7216922

1. Exchange the valves with the BoomSupportPlus

valves.

Parts
03 Nr. # Description Part.nr.

1 2 Throttle 7210612
valve
2 2 Coupling 12 7320554
3 2 Coupling 7321443
4* 2 Cylinder C02 90051284.0

*Condor C02 with serial number lower than C02.5100 need to change the cylinders.
1. Dismount the hoses from the variable geometry cilinder.
2. Remove the restrictors.
3. Mount the throttle valve on the rod side of the cylinder.
 Parts
04 Nr. # Description Part.nr.

1 2 M12 x 100 3055682

2 2 M14 nut 3142140

3 2 M20 nut 3142200
4 2 M12 nut 3154506
5 1 M16 nut 3157680
6 4 M12 washer 3764120
7 2 M14 washer 3765140
8 3 M20 washer 3765200
9 1 Bearing 5010068
1. Dismount the brake strip, spring and nut.
2. Drill holes in the box for the plate. 10 1 Cylinder 8258700
3. Mount the cylinder under the centre frame. 11 1 Pen 90001108.0
12 1 Springs 90001109.0
13 1 Bracket 90001110.0
14 1 Contra plate 90001111.0

Parts
05 Nr. # Description Part.nr.

1 2 Chains 0910106

2 2 M12 x 60 3020632
3 4 M8 nut 3154504
4 2 M12 nut 3154506
5 2 M8 schakle 3601080
6 2 M8 washer 3764080
7 2 M12 washer 3764140
8 2 Spring 4830310
9 2 M8 U-clamp 8250601

1. Mount the springs. 10 2 Brackets 90081499.0

 Electrical BoomSupportPlus overview
Lifting valve

Requierments
• When you zip-tie cables on movable parts, provide enough slack to allow sufficient
movement.
• Be sure that the boom control panel is turned off before connecting the cable.

Information
• Connect nr. 5 with the blue-red wire. The wire is located in the cable harness of nr. 2.
on the boom control panel connector side.
• OUT1 and CAN2-1 are located at the motorprint.
• Nr. 7, for C04 and CE01 machines, connect the cable with the right VCU on X5.
• Nr. 7, for C02 and C03 machines, connect the cable with the section module on X3 pin
9 untill 13
• The standard connectors of the valves, needs to be connected with nr. 10 and nr. 12.
• Nr 16. needs to be mounted at the right side of the hydraulic 10-manifold on the centre
frame.
• The cable position on nr. 16 does not matter.
• If the machine has the option: ‘Automatic grease system’ the OUT1 connector is
already used. Connect the cable on pos. 3. in the OUT1 connector.
Parts
Nr. # Description Part.nr. Where?

1 1 Boom control panel 7216949 Cabin

2 1 Power cable 7216947 Cabin to hydr. 7 manifold

3 3 Coupler 2-way 7216944 Cabin and Boom
4 1 CAN2-1 cable 90004472.0 Elektro box

5 1 OUT1 cable (connect with Blue- 90004473.0 Elektro box

Red wire)
6 1 Main cable 7216948 7 manifold to centreframe
7 1 GND cable 90004474.0 or .1 Centre frame
8 2 6 Pin Plug 7216945 Centre frame
9 1 Cable 5 m 7216939 Centre frame
10 1 Valve connection cable 90004475.1 Hydr. 10 manifold
11 1 Extension cable valves 90004415.1 10 manifold to 7-nifold
12 1 Lifting valve cable 90004471.0 or .1 Hydr. 7 manifold
13 1 BoomSupportPlus valves cable 7216934 Hydr. 10 manifold
14 1 Roll sensor with GND 7216943 Centre frame
15 1 Roll sensor 7216942 Lifting frame
16 1 Coupler 8-way 7216946 Centre frame
17 2 Cable 20m 7216938 Centre frame to boom
18 2 Coupler 2-way with terminator 7216945 Boom
19 3 BoomSupportPlus sensor 7216933 Boom and centre frame
20 1 Cable 5m 7216940 Centre frame
21 1 Bracket centre frame sensor 7216923 Centre frame
 Parts
06 Nr. # Description Part.nr.

2 M5 x 35 3311134

2 M6 washer 3751264
1 Coupler 8-way 7216946

2 6 Pin plug 7216945

1. Mount the coupler 8-way on the left side of the hydraulic 10-manifold.
2. Mount if you have 3 sensors, the 6 pin plug on 2 positions of the 8-way coupler.

Parts
07 Nr. # Description Part.nr.

4 M8 x 100 3055605

4 M8 nut 3154504
8 M8 washer 3764080

1 Bracket sensor 7216923

1 BoomSupport- 7216933
Plus sensor
1 Coupler 2-way 7216944

1 Cable 5 M 7216939

1 Contraplate 90020666.0

1 Bracket 90020665.0

1. Connect the BoomSupportPlus sensor with: #3, #20 and #16 (see overview).
2. Mount the sensor on the bracket on the middle of the centre frame.
 Parts
08 Nr. # Description Part.nr.

4 M8 x 40 3055586

4 M8 spring 3764305
washer
4 M8 washer 3764080

1 Roll sensor with 7216943

GND
1 Roll sensor 7216942

1. Mark dots for the holes to drill.

2. Mount both roll sensors.
3. Connect both roll sensors with the coupler 8-way.
4. Connect the GND ringtongue with a bolt on the 10-manifold.
Parts
09 Nr. # Description Part.nr.

1. Connect the lifting valve cable #12 with the

valve on the hydraulic 7-manifold.
 Parts
10 Nr. # Description Part.nr.

1 1 Sensor stop 90001531.0

1 1 Bracket R 90001505.0
1 1 Valve R 90050541.0

1 2 Strip for sup- 9142130

port
1 4 M8 x 60 3055592

1 8 M8 washer 3764080

1 4 M8 nut 3154504

1 1 Arm long R 90001504.0

1. Mount the arm and sensor stop on the boom.

2. Connect the BoomSupportPlus sensor with: #18 - #17 and #16.
3. Provide enough slack to allow sufficient movement.

Parts
11 Nr. # Description Part.nr.

1. Connect the valves with the cylinder.

2. Adjust the pneumatic pressure regulator from 6 Bar to 0 Bar on the centre frame.
3. Connect the T-coupling with the existing pressure line.
 Parts
12 Nr. # Description Part.nr.

1 1 Sensor 90001531.0
stop
1 1 Bracket L 90020309.0
1 1 Valve L 90052659.0

1 2 Strip for 9142130

support
1 4 M8 x 60 3055592

1 8 M8 washer 3764080

1 4 M8 nut 3154504

1 1 Arm long L 90001506.0

1. Mount the arm and sensor stop on the boom.

2. Connect the BoomSupportPlus sensor with: #18 - #17 and #16.
3. Provide enough slack to allow sufficient movement.

Parts
13 Nr. # Description Part.nr.

1. Connect the valves with the cylinder.

2. Connect the T-coupling with the existing pressure line.
3. Adjust the pneumatic pressure regulator from 0 Bar to 6 Bar on the centre frame.
 Parts
14 Nr. # Description Part.nr.

2 Valve cable 90004476.0

4 AMP contact 7787390

1. Connect the valve connector cable between the

NC/NO valves and the nearest section module
on X3.

Parts
15 Nr. # Description Part.nr.

1. Write down the adress for each BoomSupportPlus sensor:

• Sensor arm
• Module number
• Cable 1, Pin position NO valve
• Cable 1, Pin position NC valve
 Parts
16 Nr. # Description Part.nr.

1 1 Bracket 90001527.0

1 1 Boom control 7216949

panel
1 2 M5x12 bolt 3054012

1. Mount the boom control panel on the bracket

and on the display bracket in the cabin.

17

Information about BoomSupportPlus 5 sensors

BoomSupportPlus is standard 3 sensors. (1 untill 3)
Optional is BoomSupportPlus 5 sensors (1 untill 5)

Repeat step: 10 till 15 when you have the option with 5 sensors and mount the 2 extra
sensors on position: 4 and 5 (the first boom part).
 Before going to step 18, Check if the machine has the option:

• MountainMasterPlus C04
Go to step: A1
• ProActiveBalancePlus C02 - C03 - C04 - CE01
Go to step: B1
• HighTechAirPlus C02 - C03 (untill 5100) - CE01
Go to step C1
• Suspendend centre frame CE01
Go to step D1

18 Address the section modules

Standard address the section modules, 3 sensors, centre frame and boom part 3 or 4
ID# Description
3DCA Value is 0.0 when the sensor is mounted on the centre frame.
3DCB Value is 0.0 when the sensor is mounted on the centre frame.
3DD0 Boom part where LEFT and RIGHT sensor arm is mounted.
3DC0 LEFT, Address section module pin for cylinder IN.
3DC2 LEFT, Address section module pin for cylinder OUT.
3DC5 RIGHT Address section module pin for cylinder IN.
3DC7 RIGHT, Address section module pin for cylinder OUT.

Optional, address the section modules, +2 sensors, boom part 2

Only when you have 5 BoomSupportPlus sensors you need to fill in the following ID# values:
ID# Description
3DD1 Boom part where LEFT and RIGHT sensor arm is mounted.
3DC1 LEFT, Address section module pin for cylinder IN.
3DC3 LEFT, Address section module pin for cylinder OUT.
3DC6 RIGHT Address section module pin for cylinder IN.
3DC8 RIGHT, Address section module pin for cylinder OUT.
19 How to operate the BoomSupportPlus? See oparetor manual.
 BoomSupportPlus
A1 in combination with the option: MountainMasterPlus
Condor: C04

1. Disconnect the roll sensor from the lifting frame.

2. Change the unit in the BoomSupportPlus display. See picture below.

3. Change the SC4 profile, this is standard “off” and needs to be “HM3”. Use the + and -
buttons to navigate.
4. Change the value of the parameter 73 to “240”.
• Panel in manual mode.
• Press and hold together: “ ” and “ ” until PWD: 0 comes.
• Click until comes PWD : 10
• Toggle until the parameter 73.
• Change the value of parameter 73 to 239
• To exit, press and hold until the panel is restarting.

Tips:
To change parameter number: increase and decreases the parameter number.
To change parameter value: increase and decreases the parameter value.
To scroll faster through the list press and hold while you click for << + >> and
for << - >>, the parameter number will jump 10 by 10.
 A2 Parts
Nr. # Description Part.nr.

1 4 M5 x 120 3311137

2 1 Pressure 7210600
valve
3 1 4/3 valve 7228991.1

4 1 Return valve 7229311

5 1 1-manifold 7229423

6 1 Plug 7320100

7 2 Plug 7320115

8 2 Coupling 10 7320539
1. Drill two Ø 12,5 mm holes in the section box if 9 2 Coupling 12 7320556
is necessary.
2. Mount the cylinder on the centre frame.

A3
Parts
Nr. # Description Part.nr.

1 2 M8 nut 3154504

2 2 M8 x 70 3055596
3 1 Bracket 90020715.0

- 4 M8 x 20 3054125

- 8 M8 washer 3764080

- 1 Wire loom 90034611

VCU X5
RIGHT

1. Drill two Ø 8,5 mm holes in the centre frame.

2. Mount the BoomSupportPlus valve.
3. Connect the wire loom with the RIGHT VCU pos.
X5.
 Parts
A4 Nr. # Description Part.nr.

1 2 M12 x 100 3055682

2 4 M12 washer 3764120

3 1 Plate 90001111.0

4 2 M12 nut 3154506

5 1 Bracket 90020717.0

6 1 Pin 90020716.0

7 1 M20 nut 3154509

8 1 M20 washer 3764200

9 2 M16 washer 3764160

1. Drill two Ø 12,5 mm holes in the section box if 10 2 M12 washer 3764120
is necessary. 11 1 Coupling 12 7320556
2. Mount the cylinder 90020147.0 on the centre
frame. 12 1 ERL 12 7320246

A5
From: To: Hose part. nr.

1-manifold port A Rod side cylinder 7128043.1

1-manifold port B Bottom side cylinder 7128043.1

10-manifold P 1-manifold P 7129475

10-manifold R 1-manifold R 7129475

1. Adjust the 1-manifold to 100 Bar.

 BoomSupportPlus
B1 in combination with the option: ProActiveBalancePlus
Condor: C02 - C03 - C04 - CE01

1. Dismount the rod

2. Mount the bracket
Parts
3. Disconnect the ProActiveBalancePlus valve. Nr. # Description Part.nr.
4. Set manually the balance horizontal.
5. Drill 2 holes with M4. 1 Bracket 90000800.0
6. Mount the angle sensor, pointed to the right. 1 Grommet 5370865
7. Measure with a multimeter the voltage. It needs to be
±2500 mV. If not, correct the angle sensor. 2 M6 x 16 3054064
8. Mount the axle from the angle sensor.
9. Connect the connectors from the balance valve. 2 M6 washer 3764060
10. Set the ID# 3A25 on 500 mV. 2 M6 spring 3764304
11. Set the ID# 3A26 on 4500mV. washer
12. Set the balance manual to the left, Fill the value in.
13. Set the balance manual to the right. Fill the value in. 1 Axle 90021175.0
B2 Write down the user settings
B3 Uploading software files
 BoomSupportPlus
C1 in combination with the option: HighTechAirPlus
Condor: C02 - C03.5000 until C03.5100 and CE01

Parts
Nr. # Description Part.nr.

1 1 Sensor stop 90001531.0

1 1 Bracket R 90001505.0
1 1 Valve R 90050541.0

1 2 Strip for sup- 9142130

port
1 4 M8 x 60 3055592

1 8 M8 washer 3764080

1 4 M8 nut 3154504

1 1 Arm long R 90001504.0

1. Mount the arm and sensor stop on first left boompart instead of the centre frame.
2. Connect the BoomSupportPlus sensor with: #18 - #17 and #16.
3. Provide enough slack to allow sufficient movement.

Parts
C2 Nr. # Description Part.nr.

1. Connect the valves with the cylinder.

2. Connect the T-coupling with the existing pressure line.
 Parts
C3 Nr. # Description Part.nr.

2 Valve cable 90004476.0

4 AMP contact 7787390

1. Connect the valve connector cable between the

NC/NO valves and the nearest section module
on X3.

Parts
C4 Nr. # Description Part.nr.

1. Write down the adress for the BoomSupportPlus sensor:

• Sensor arm
• Module number
• Cable 1, Pin position NO valve
• Cable 1, Pin position NC valve
 C5

The following steps (C6-C7) are for each sensor on the boom (3 or 5 sensors).
The HighTechAirPlus valves occures errors in the BoomSupportPlus sensors.
The solution is to mount a HighTechAirPlus valve in a range of 3 meter from the sensor ( 1,5
meter left and 1,5 right of the sensor.)

Parts
C6 Nr. # Description Part.nr.

21 Valve 90050533.0

21 Hose 0,3M 2212957

1. Mount the HighTechAirPlus valve with 2 zip-ties on the water pipe.

2. Dismount the air hose from the HighTechAirPlus nozzle.
3. Mount the air hose from the HighTechAirPlus nozzle on the HighTechAirPlus valve.
4. Connect the new hose between the HighTechAirPlus valve and the water pipe.
 C7

1. Cut the airline from the HighTechAirPlus Parts

nozzle holder.
Nr. # Description Part.nr.
2. Mount a Y-coupler.
3. Connect the Y-coupler with the 21 Y-coupling 7370458
HighTechAirPlus nozzle and valve.
4. Repeat the steps C6 and C7 on the other 21 Hose 0,2M 2412101
sensors and nozzles.
 BoomSupportPlus
D1 in combination with the option: Suspendend centre frame
Condor Endurance: CE01

1. Dismount the brake strip, spring and nut.

2. Drill holes in the box for the plate.
Parts
3. Mount the cylinder under the centre frame. Nr. # Description Part.nr.

1 1 M20x90 3055830

2 2 M20 washer 3764200

3 1 Bearing 90081423.0

4 1 M16 nut 3157680

5 1 Cylinder 8258700

6 1 M14 washer 3764140

7 1 M14 nut 3154507

8 1 M20 nut 3154509

9 1 Bracket 90081422.0
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