Sandvik Di - 400

DI 400 / 500
ELECTRIC SYSTEM
GND X1 X10 X11 X20 X30 X40 X41 X60 X70 X90 X100
1 3 4 5 6 1 2 3 4 5 6 7 8 9 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 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 29 1 2
1 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 1K10 1K11 1K12 1K13 1K14 1K15 1K16 1K17 1K18 1K19 12K1 12K2
1x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x
K2
32A 32A 32A 32A 1A 1A 1A 6A 16A 16A 6A 6A
XFA XFB XFC XFD XF1 XF2 XF3 XF4 XF5 XF6 XF7 XF8
1K20 1K21 1K22 1K23 1K24 1K25 1K26 1K27 1K28 1K29 1K30 1K31 1K32 1K33 1K34 1K35 1K36 1K37 1K38 XT GND
T1 KT1 KT2 KT3 KT4 KT5 1
2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x K1 2
1K39 1K40 1K41 1K42 1K43
DC Input
SMC
1D 2D 3D 4D BSM1
24V - 12V
TRAFO
2x 2x 2x 2x 2x
DM 14 DM 14 DM 14 DM 14
Relay Output
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
3 (55)
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
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 seri-
ous 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
3. 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
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
4.2. Fuses inside the main electric box
GND X1 X10 X11 X20 X30 X40 X41 X60 X70 X90 X100
1 3 4 5 6 1 2 3 4 5 6 7 8 9 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 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 29 1 2
1 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
K2
32A 32A 32A 32A 1A 1A 1A 6A 16A 16A 6A 6A
1K39 1K40 1K41 1K42 1K43
DC Input
SMC
1D 2D 3D 4D BSM1
24V - 12V
TRAFO
2x 2x 2x 2x 2x
DM 14 DM 14 DM 14 DM 14
Relay Output
Main electric box
A28
A29
55
8 (55)
DI 400 / 500
Fuse Size (A) Function

XFA 32 Supply for fuses F1, F2, F3, F4, F13 in the dashboard
XFB 32 Supply for fuses F5, F14 in the dashboard
Supply for fuses F6, F7, F11in the dashboard and XF4,
XFC 32
XF5 in the main electric box
Supply for fuses F8 in the dashboard and XF8 in the
XFD 32
main electric box
XF1 1 Engine maint. lamp
XF2 1 Engine diagnostic lamp
XF3 1 Engine warning lamp
XF4 6 12V supply
XF5 6 Emergency circuit supply
XF6 16 Engine supply
XF7 6 Option seat heating
XF8 6 Option engine lights
FT12 6.3 Fuse in the transformer (24V - 12V)
9 (55)
DI 400 / 500
4.3. Fuses in the cabin
F5 F4 F3 F2 F1
F10 F9 F8 F7 F6
F14 F13 F12 F11
Fuse Size (A) Function

F1 7.5 Wipers, Cigarette Lighter
F2 7.5 Working Lights, Cabine Lights
F3 10 Tramming Lights, Reversing Lights
F4 7.5 Angle Indicator
F5 7.5 Air Condition
F6 7.5 Engine Preheater
F7 15 Boom, Feed, Drilling, Tramming
F8 7.5 Ingnition Key
F9 20 Webasto Heating
F10 5 Webasto Heating
F11 7.5 Feed Functions (Magacine...)
F12 7.5 Option Stair Lights
F13 7.5 Horn
F14 7.5 Air Condition
55
10 (55)
DI 400 / 500
5. COMPONENTS IN THE MAIN ELECTRIC BOX
2 1 1 1 1 1 1 1 1 1 1 1
GND X1 X10 X11 X20 X30 X40 X41 X60 X70 X90 X100
1 3 4 5 6 1 2 3 4 5 6 7 8 9 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 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 29 1 2
1 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 8 10
1K1 1K2 1K3 1K4 1K5 1K6 1K7 1K8 1K9 1K10 1K11 1K12 1K13 1K14 1K15 1K16 1K17 1K18 1K19 12K1 12K2 13
K2
32A 32A 32A 32A 1A 1A 1A 6A 16A 16A 6A 6A
13 7 1
11 12
XT
4
1K20 1K21 1K22 1K23 1K24 1K25 1K26 1K27 1K28 1K29 1K30 1K31 1K32 1K33 1K34 1K35 1K36 1K37 1K38
GND
12 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x K1 2
1K39 1K40 1K41 1K42 1K43
DC Input
SMC
1D 2D 3D 4D BSM1
24V - 12V
TRAFO
2x 2x 2x 2x 2x
DM 14 DM 14 DM 14 DM 14
15 Relay Output
6 14 5 3
Pos. Components Pos. Components

1 Clamp 2,5mm² 10 Circuit breaker 16A
2 Clamp 4mm² 11 Circuit breaker 6A
3 Transformer 24V - 12V 12 Relay
4 Multi-function relay 13 Power relay
Packaging unit with diode and
5 14 Diode
ohmic resistance
Controller for
6 Diode module 15
dustcollector+magacie
7 Transformer 24V - 10V
8 Circuit breaker 1A
9 Circuit breaker 32A
11 (55)
DI 400 / 500
5.1. Function of the components
COMPONENTS FUNCTION
2F1 Main fuse to supply XFA, XFB, XFC, XFD
2F2 Main fuse to supply the alternator
2F3 Main fuse to option hydraulic oil filling
2F4 Main fuse for option fuel filling
XFA Supply for fuses F1, F2, F3, F4, F13 in the dashboard
XFB Supply for fuses F5, F14 in the dashboard
Supply for fuses F6, F7, F11in the dashboard and XF4, XF5 in
XFC
the main electric box
Supply for fuses F8 in the dashboard and XF8 in the main
XFD
electric box
XF1 Engine maint. lamp
XF2 Engine diagnostic lamp
XF3 Engine warning lamp
XF4 12v supply
XF5 Emergency circuit supply
XF6 Engine supply
XF7 Option seat heating
XF8 Option engine lights
F1 Wipers, Cigarette Lighter
F2 Working Lights, Cabine Lights
F3 Tramming Lights, Reversing Lights
F4 Angle Indicator
F5 Air Condition
F6 Engine Preheater
F7 Boom, Feed, Drilling, Tramming
F8 Ingnition Key
F9 Webasto Heating
F10 Webasto Heating
F11 Feed Functions (Magacine...)
F12 Option Stair Lights
F13 Horn
FT12 Fuse in the Transformer 24V -12V
55
12 (55)
DI 400 / 500
COMPONENTS FUNCTION
K1 Power relay for the main supply
K2 Power relay for the main supply
KT1 Time relay for the lamp test
KT2 Time relay for the lubricator
Time relay to stop the rotary head at the thread breaking
KT3
position
Time relay to stop the compressor and shut down the engine
KT4
after 10sec
KT5 Time relay for the Anti jamming system
T1 Constant voltage supply 10V
T12 Transformer 24V to 12V
1K1 Protect the starter of restarting after the engine is running
1K2 Emergency circuit
1K3 Emergency circuit
1K4 Hold function for Compressor ON
1K5 Switch on the Ether valve
1K6 Signals the engine oil pressure
1K7 Cylinder functions (Boom swing + Lift)
1K8 Cylinder functions (Telescop + Opton Roll Over)
1K9 Switch on the drilling supply
1K10 Switch on the second tramming speed and the light
1K11 Reversing alarm
1K12 RPM controlling
1K13 Hold function for Flushing On
1K14 Hold function for Flushing and Suction On
12K1 For the running signal from the alternator
12K2 For the running signal from the alternator
1K15 Switch off Flushing or Flushing and Suction
1K16 Switch the pump to full volume
Is engaged at fast feed and switch the feed pressure to max,
1K17
and switch off Y23a
1K18 RPM controlling and
1K19 Siwtch on the compressor cooler
13 (55)
DI 400 / 500
COMPONENTS FUNCTION
1K20 Switch off the lubrication by fail functions
1K21 Switch off the lubrication by fail functions of the lubricator
1K22 Switch on the lubricator
Is engaged by the Upper clamp pressure switch and stop the
1K23
depth meter
1K24 Switch the 3S1 joustick to the second joustick level
1K25 Switch the 3S1 joustick to the second joustick level
Switch the 3S2 joustick to the second joustick level and
1K26
engaged the joustick
Switch the 3S2 joustick to the second joustick level and close
1K27
the circuit Pipe in road chnger jaws
Stops the feed if the depth which is setted in the inclinometer is
1K28
ready
1K29 Switch off the tramming lights
1K30 Stops the fast feed at the proximity switch 1B6
Gives the information if the "Road changer arms" are in
1K31
magacine position
1K32 Gives the information if the pipe is in the jaws
Gives the information if the rotary head in the magacine
1K33
position
1K34 Switch off the fast feed at magacine position
1K35 Gives the information if the jaws are open
1K36 Stops the rotary head at the "Collision position"
1K37 Also for the "Collision position" circuit
1K38 Switch on the engine preheater
1K39 Switch on the hydraulic supply for the feed
1K40 Option "Boom sensor"
1K41 Switch on the horn
1D-4D Diodes to protect the electric system
BSM1 Packing module for for diodes and ohmic resistance
PA2 Controll system for the dust collector and the magacine
Rig with Roll over: For the proximity switch "Magacine
1K42
clockwise"
Rig with Roll over: For the proximity switch "Magacine
1K43
counter clockwise"
55
14 (55)
DI 400 / 500
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 sys-
tem(KT5) and for the lubricator function (KT2).
5.2.1. Location and standard parameter
GND X1 X10 X11 X20 X30 X40 X41 X60 X70 X90 X100
1 3 4 5 6 1 2 3 4 5 6 7 8 9 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 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 29 1 2
1 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
K2
32A 32A 32A 32A 1A 1A 1A 6A 16A 16A 6A 6A
Time relay
1K39 1K40 1K41 1K42 1K43
DC Input
SMC
1D 2D 3D 4D BSM1
24V - 12V
TRAFO
2x 2x 2x 2x 2x
DM 14 DM 14 DM 14 DM 14
Relay Output
20 40 25 100 20
10 10 10 10 10
R2 Delay R2 Delay R2 Inst. R2 Left R2 Inst.
1
15 (55)
DI 400 / 500
5.2.2. Settings
KT1, KT2, KT3, KT4, KT5
10 0
1 0%
20 90
%
%
%
30%
80% Fine adjustment
of time relay
% %
40 70
60 %
50 %
s
s
3 00
1 00
m
30 s
30
Time delay range
300m
10s
30
h 3s
3 00
1s
h
Configuration of relay R2
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
1
Pulse-on energisation at contact opening
Star-delta function with double delay at energisation

1
Star-delta function with pulse on energisation
55
16 (55)
DI 400 / 500
5.2.3. 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 15
A2 16 18
1
1 1
Z1 X1 25(21)
Z2 28(24) 26(22)
1 1
17 (55)
DI 400 / 500
6. LOCATION OF CONNECTORS
Connectors/Location
1S1 Joystick Boom/Feed
1S2 Joystick Telescope/Optional roll-over
ST1 Window wiper
ST2 Lights
ST3 Control lever, carrier right
ST4 Air condition
ST5 Air condition
ST5.1 Engine compartment
ST5.2 Air condition
ST5.3 Air condition
ST6 Control lever, carrier left
ST6.1 Control lever, carrier left
ST6.2 Control lever, carrier left
ST6.3 Emergency stop - armrest
ST7 Control lever, carrier right
ST8 Dust collector
ST9 Digital panel
ST10 Digital panel
ST16 Tramming 2. gear
ST17 Armrest down counter
ST18 Horn
ST19 Radio
ST22 PQ - Angie indicator (not shown)
ST23 PQ - Angie indicator (not shown)
ST25 Webasto coolant heating
ST26 Oiler
ST99 Ether start valve
ST100 Engine speed sensor
P61 CAT Electronic control module
P403 Throttle position
P800 Coolant level sensor
SX1 Control desk right
55
18 (55)
DI 400 / 500
ST5.1
ST5.2
ST26 ST5.3
P800
ST100
ST8
ST99
ST16
ST17
P61
ST19
ST1
ST2 ST4 ST6
ST5
P403 ST3 ST6.1
1S2 ST6.2
1S1 ST7 ST6.3
SX1,2,3
4,6
ST25
ST9
ST10
19 (55)
DI 400 / 500
7. 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 2H14
55
20 (55)
DI 400 / 500
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.
21 (55)
DI 400 / 500
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
55
22 (55)
DI 400 / 500
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

23 (55)
DI 400 / 500
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 2H20
55
24 (55)
DI 400 / 500
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
25 (55)
DI 400 / 500
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 2H23
55
26 (55)
DI 400 / 500
8. 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
27 (55)
DI 400 / 500
9. 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
W403 box
Bl/Wh ECM
A
B BL-WH
X2:175
X2:176
W41
C OR/BK X2:177 X2:248
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
55
28 (55)
DI 400 / 500
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.
29 (55)
DI 400 / 500
Possible Performance Effect of Active Diagnostic Codes
Flash CID/FMI DPN/FMI Reduced

code Code Code Description of Code Engine Misfires Low Power Engine Speed Engine Shutdown
Atmospheric
274-03 108-03
Pressure open/short
to +batt
26
Atmosperic
274-04 108-04
Pressure short to
ground
110-03 110-03 Engine Coolant X X X

Temperature
open/short to +bat
27
110-04 110-04 Engine Coolant X X X

Temperature short
to ground
28 91-13 91-13 X X
Throttle Position
signal abnormal
32 91-08 91-08 X X
Throttle Position
calibration required
Speed/Timing
320-02 190-02
Sensor Loss of
X X(1)
Signal
Speed/Timing
320-11 190-11
Sensor mechanical
X X(1)
failure
34
342-02 723-02
Loss of Secondary
X X(1)
Engine Speed signal
342-11 723-11
Secondary Engine
X X(1)
Speed Sensor
mechanical failure
94-03 94-03 Fuel Pressure

open/short to +batt
37
94-04 94-04 Fuel Pressure short
to ground
172-03 172-03 Intake Manifold Air X X X

Temp open/short to
38 +batt
Intake Manifold Air

172-04 172-04 X X X
Temp short to
ground
42 261-13 228-13 X X X X
Engine Timing
calibration required
51 168-02 168-02 X X X
System Voltage
intermittent/erratic
53 254-12 Elevtronic Control X X X X

Module Error
55
30 (55)
DI 400 / 500
Possible Performance Effect of Active Diagnostic Codes
Reduced
Flash CID/FMI DPN/FMI Description of Engine Low Engine Engine
code Code Code Code Misfires Power Speed Shutdown
Personality
253-02 234-02 Module X(2)
mesmatch
56
Check
268-02 1111-02 Programmable X X
Parameters
J1939 Data
Link
58 247-09 639-09
communication
s
Injector
1-11 651-11 Cylinder #1 X X
fault
72
Injector
2-11 652-11 Cylinder #2 X X
fault
Injector
3-11 653-11 Cylinder #3 X X
fault
73
Injector
4-11 654-11 Cylinder #4 X X
fault
Injector
5-11 655-11 Cylinder #5 X X
fault
74
Injector
6-11 656-11 Cylinder #6 X X
fault
(1)
The engine will shut down if both speed/timing sensors are lost
(2)
Fuel injection will not occure and the engine will not start.
31 (55)
DI 400 / 500
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)
55
32 (55)
DI 400 / 500
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
35 004 0190-16 Engine Overspeed

Shutdown Shutdown
35 190 0190-00
Engine Overspeed Warning
61 017 0110-15 High Engine Coolant

Temperature Warning
64 025 0172-16 High Inlet Air

Temperature Derate
64 027 0172-15 High Inlet Air

Temperature Warning
Low Engine Oil
46 039 0100-18
Pressure Derate
Low Engine Oil
46 100 0100-17
Pressure Warning
High Fuel
65 056 0174-15
Temperature Warning
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
33 (55)
DI 400 / 500
11. PROXIMITY SWITCHES
1B4 1B6
1B7 (1) (2)
(3)
1B5
(2)
1B2 1B1 1B3
(3) (3) (3)
Proximity switch types

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

Max.20mm Max.5mm Max.20mm
M30x1,5
M18x1,5
M18x1,5
5m 5m 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 bn
bl = negative Signal bl
bk = switched Signal bk
wh
wh = not connected
5m
55
34 (55)
DI 400 / 500
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 20 20 20 19 18 17 16 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
20 20 20 20 19 18 17 16 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 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: 1B7:

bl = pin GND bl = pin GND bl = pin GND bl = pin GND
bn = pin 20 bn = pin 20 bn = pin 20 bn = pin 20
bk = pin 21 bk = pin 22 bk = pin 23 bk = pin 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
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
35 (55)
DI 400 / 500
12. BACK UP ALARM
Location
1B4 Pressure switch
Backup beeper
How to connect
X31 St13
1B4 W30 W40
18 W1B4 18 X40:9 Yebl Re 1HH5
1 18 X30:18 3
3 GND X40:GND bn Bk Backing alarm
GND 7
Pressure switch Main electrical box
Electrical box Connector

on the valve plate
How to adjust the pressure switch
Screw the adjusting screw fully

in and then 3 turns back
Adjusting
screw
55
1B6
1B7 1B4
X22 A25
1B2
1B1 1B3 X21 1B5
ELECTRIC SYSTEM
DI 400 / 500
WIRING, SCHEMATIC OVERVIEW
2B5
100M1 X31 Dust 2B10
6B1
Main electrical box

200M1 collector 2B11 6B2
6Y1
2B9
4H6
Y31
6M1
A28
2B15
A29 P800 1HH5
2B8
2R12
A27
Right control desk 2G2
C10
Control lever carrier right
4H7
Webasto
Battery
P61
Battery
2S0 2M1 Compressor
2F1
2F2
Control lever carrier left 2F3
2F4
P2
tm 0501-3 en1007
36 (55)
13.
37 (55)
DI 400 / 500
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
55
38 (55)
DI 400 / 500
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 protec-
tion 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
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
WARNING 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.
39 (55)
DI 400 / 500
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 main-
tained 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. Care-
ful 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.
55
40 (55)
DI 400 / 500
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 compart-
ment cannot touch them.
41 (55)
DI 400 / 500
14.3.2. Connections
Risk of short circuit. Never connect the red and black cable together!
WARNING
First connect the cable with the red

2 1 terminal clamps to the positive pole of the
discharged starter battery (see Figure,
+ + Position 2).
Batteries of
Then connect the cable with black
Helper vehicle´s
batteries
vehicle
needing help 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
3 4 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.
55
42 (55)
DI 400 / 500
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.
6. The pressure should be 245 bar.
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”.
43 (55)
DI 400 / 500
15. 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 Gauge 0 - 245 bar
Y90
55
44 (55)
DI 400 / 500
15.1.1. Setup of measuring instruments

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
45 (55)
DI 400 / 500
ROTATION
FEED
ROTATION
power plug
Wires for
the
FEED
55
46 (55)
DI 400 / 500
15.1.3. Schematic hydraulic plan
PRESSURE
FEED 93 GAUGE UNDER
1 FRONT
X SCREEN.
(0-245bar)
FAST FEED FORWARD
R L
98 A B CONTROL BLOCK
A B 33 TRAMMING/DRILLING FULL DEFLECT PUMP
96 A
Y66 B
T
T
17 P
ANTI A B 38
95 JAMMING Y23 16 A B 4
12-30 34.1 Y22 Y34
97 SYSTEM
Y24 DRILLING CONTROL UNIT P T
Y35
BR P T
A1 B1
94 F
15 10 10
14 36.2
A B
Y23a
36.1
P T P T B A
Y90
19 A B
A P T B
3 20
9 1 92
2 1
4 3
P 1
8.1 12
Y33 Y62
T E A
3 2 2
P
P
T
TRAMMING 39
3
P1 M1 M3 1
2
PILOT OIL SUPPLY

31 UNIT
25 24
BV A B M
Y21 Y4 2 a 66 PRESSURE CONTROL BLOCK
32 M A2 G Y X T1 T2 R
P B Y63
PS 0,32 l
P2 T
35 bar
PV 30
165
200
T B
88
320
P1 P1 P A
P2 Vg
max
Vg
min
P
60 60 Y64
A
b T S M1
67.2 67.1 34.2
SOLENOID ENGAGED
47 (55)
DI 400 / 500
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.
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.
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.
55
48 (55)
DI 400 / 500
15.1.6. Settings instruction

1. Go on function „feed forward“ and leave the joystick in this position (Feed forward on block)
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.
6. The pressure should be 245 bar.
8. The pressure should be 0bar.
49 (55)
DI 400 / 500
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.
55
50 (55)
DI 400 / 500
15.2.1. Setup of measuring instruments

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
51 (55)
DI 400 / 500
ROTATION
FEED
ROTATION
power plug
Wires for
the
FEED
55
52 (55)
DI 400 / 500
15.2.3. Schematic hydraulic plan
CONNECT A
PRESSURE
GAUGE (0-
60bar)
ON PORT
(Y) AT
PUMP1
53 (55)
DI 400 / 500
15.2.4. How 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
15.2.5. 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.
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.
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.
1.)
55
54 (55)
DI 400 / 500
15.2.6. Settings instructions

1.) Set the potentiometer down on 1, ramp setting on 0 and leave the Dither as it is.
U=1V (Clamps 3 und 4), p=6bar, I=0mA
2.) Set the potentiometer up to 6. The voltage is now 6 V. Turn the gain screw as long as the current is
indicating an amount of 310mA. At the same time the pressure gauge should indicated a pressure of
20 bar.
3.) Set the potentiometer up to 10. The voltage is now 10 V. At the same time the pressuregauge should
indicated a pressure of 36 bar and the amperemeter should show you 460mA.
55 (55)
DI 400 / 500
16. APPENDICES
16.1. Chapter PneuAlpha2 / Controller
16.2. Electric circuit diagrams
55
PneuAlpha2
Guidelines for the safety of the user and protection of αPneuAlpha2 simple
Application controllers
This manual provides information for the use of α PneuAlpha2 simple Application
controllers. The manual has been written to be used by trained and competent personnel.
The definition of such a person or persons is as follows;
a ) Any engineer who is responsible for the planning, design and construction of automatic
equipment using the product associated with this manual should be of a competent nature,
trained and qualified to the local and national standards required to full fill that role. These
engineers should be fully aware of all aspects of safety with regards to automated
equipment.
b ) Any commissioning or service engineer must be of a competent nature, trained and
qualified to the local and national standards required to ful fill that job. These engineers
should also be trained in the use and maintenance of the completed product. This includes
being completely familiar with all associated documentation for the said product. All
maintenance should be carried out in accordance with established safety practices.
c ) All operators of the completed equipment should be trained to use that product in a safe
and co-ordinated manner in compliance to established safety practices. The operators
should also be familiar with documentation which is connected with the actual operation of
the completed equipment.
Note: the term ‘completed equipment’ refers to a third party constructed device which
contains or uses the product associated with this manual.
Notes on the symbology used in this manual
At various times through out this manual certain symbols will be used to highlight points of
information which are intended to ensure the users personal safety and protect the integrity
of equipment. Whenever any of the following symbols are encountered its associated note
must be read and understood. Each of the symbols used will now be listed with a brief
description ofits meaning.
Hardware warnings
1 ) Indicates that the identified danger WILL cause physical and property damage.
2 ) Indicates that the identified danger could POSSIBLY cause physical and property
damage.
3 ) Indicates a point of further interest or further explanation.
Software warning
4 ) Indicates special care must be taken when using this element of software.
5 ) Indicates a special point which the user of the associate software element should
be aware of.
6 ) Indicates a point of interest or further explanation
SANDVIK CONTROLLER 1 von 21

1. Introduction
The αPneuAlpha2 Series Controllers provides supervisory control for use in the home, office
factory or wherever you need it. The αPneuAlpha2 series Controllers offers flexible I/O
control for varied applications:
Applications
The αPneuAlpha2 Series is designed to be used for automatic applications including:
-Lighting, air
-conditioning or watering control
-Opening and shutting of gates
-Security systems-Domestic systems
-Temperature control
However, the αPneuAlpha2 Series Controllers is not designed to be used in the

following applications:
-Applications where high reliabilities such as nuclear power control, railway facilities, airline facilities,
vehicles, combustion equipment and medical equipment are required.
-Applications in life critical situations
1.1 Special Features Display messages and Function Block data

1 ) Display messages and Function Block data
The αPneuAlpha2 Series can display the state of operation and the alarm on the LCDscreen
as a message. The values of timers and counters can be changed in RUN mode.
-Total characters on LCD display: 12 characters x 4 lines
-Display items: Message, values (current or set) of timers and counters, analogue values, etc.
2 ) Program Input
The user can program directly from the front panel or use the windows based ECC-PNAL-PCS/WIN-E
programming software Ver2.00. Pictorial representation of data is used to connect function blocks.
Please refer to the αPneuAlpha Software Manual.
3 ) Enhancement of clock function

The weekly and daily calendar timer function allows switch inputs that set the powerful time
dependent control capabilities.
4 ) Analog input, 0-10V/0-500

The DC input type for the α PneuAlpha2 Series accepts 0-10V signals with a resolution of
0-500.
5 ) High Speed Counter, max 1kHz

The α PneuAlpha2 Series has two dedicated high speed counters when using ECC-PNAL2-
4EX EI1 and EI2.
6 ) High current output

Relay output is 8A/COM in the main unit ECC-PNAL2-14MR-*: O01-6, ECC-PNAL2-24MR-D:
O01-04 and the transistor output is 1A/point in the extension module.
7 ) GSM Function
The α PneuAlpha2 Series Controller uses GSM to send a SMS to a mobile phone or
adedicated E-mail account via a standard service provider.

8 ) Dedicated Protocol
Introducing a Communication Device concept in the α PneuAlpha2 Series Controllers
allowing the user to monitor, modify and enter current and set values in Function Blocks via
dedicated protocol controlled from a personal computer.
9 ) Built-in EEPROM
The built in EEPROM eliminates the need for battery backed data
10 ) Supports 6 languages
The language option under the Top Menu can be changed to display: English, German,
French, Italian, Spanish and Swedish
11 ) LCD Screen
Enhanced LCD screen size allows the user to view data clearer and permits the
αPneuAlpha2 Series Controller to display bar graphs and other new intricate data
representation items
12 ) Increased Memory
The CPU memory for the new αPneuAlpha2 Series Controller allows a maximum of 200
function blocks to create a program algorithm and contains a 5000 byte capacity memory on
board.
This manual will describe the procedure by which the αPneuAlpha2 Series Controllers can
be programmed from the front panel, the functions of the keys, and the powerful function
block capabilities.
1.2 Model Name

The α PneuAlpha2 Series Controllers can be identified using the following format:
ECC-PNAL2- ** M R - A/D
PNAL2 → αPneuAlpha2 Series Controller
** → Total number of I/O
M → α PneuAlpha2 in Unit
R → Relay Type output
A → 100 ~240V AC
D → +24V DC

2.0 Front Panel Keys
The front panel keys can enter data into the program memory, move through menus or
programs, select programming options, or be used as extra inputs when the program is
running. There are eight keys which are referenced as K01 - K08.
Key Name Key Number Key Function

Used to enter menu options, confirm data entry, and manually force
(OK) K01 inputs ON/OFF in the monitor function.
Used to cancel an operation, move to a higher level screen, or to
(ESC) K02 move to a new menu.
Used to connect (or “add”) function blocks, increase Direct Set input
(+) K03 values or times, or move through programs or menus
Used to disconnect function blocks, decrease Direct Set values or
(-) K04 times, or move through programs or menus.
Scroll up through menu options (menus, keys, FB, Inputs,
(▲) K05 Outputs,etc.)
Scroll down through menu options (menus, keys, FB, Inputs,
(▼) K06 Outputs,etc.)
(►) K07 Move to the right on the LCD display, FB program, or Jump command
(◄) K08 Move to the left on the LCD display, FB program, or Jump command
2.1 Inputs
The α PneuAlpha2 Series Controller will accept both digital (On/Off) and analog (mV value
based) electrical information through the system Inputs. Please refer to the
α PneuAlpha2 Hardware Manual for electrical information, wiring diagrams and input
specifications.Depending on the chosen controller there are either 14 or 24 input version
types of the α PneuAlpha2 Series Controller. The Inputs are referenced to I01, I02, ..., I15.
Input type for the αPneuAlpha2 Series Controller
Input Input Description

Number
(Signal) I01 - I15 Maximum of 15 Inputs are allocated for use.
2.2 Outputs
Outputs for the α PneuAlpha2 Series Controller
Outputs Outputs Description

Number
O01 – O09 Signal output

PneuAlpha2
2.0 Front Panel Keys
24V I01-I15
Supply (A) (B) Signal Input
Slot
Display K01
K03
K07 K05 K06 K08 K04
K02
O01 O02 O03 COM O04 O05-O09
O01-O09
Signal Output
Inputsignal: Outputsignal:
I01- Signal Input for “Drilling” O01- Signal Output for “Dust Collector (Valve Y75)”
I02 - Signal Input for “Flushing” O02 - Signal Output for “Dust Collector (Valve Y76, Y77)”
I03 - Signal Input for “Magacin clockwise” O03 - Signal Output for “Hammer Centralizer close (Valve Y82), Magacine Supply (Valve Y301)”
I04 - Signal Input for “Magacin counter clockwise” O04 - Signal Output for “Magacine Supply (Valve Y301), Drill pipe close (Valve Y59)”
I05 - Signal Input for “Proximity switch 1B5” O05 - Signal Output for “Magacine clockwise (Valve Y39)”
I06 - Signal Input for “Joustick Hammer close (Valve Y82)” O06 - Signal Output for “Magacine counterclockwise (Valve Y40)”
I07 - Signal Input for “Joustick Drill pipe close (Valve Y59) ” O07 - Signal Output for “Magacine (Valve Y41)”
I08 - Signal Input for “Flushing” O08 - Signal Output for “Magacine Supply (Valve Y301)”
I09 - Not Connected O09 - Not Connected
I10 - Not Connected
I11 - Not Connected
I12 - Not Connected
I13 - Not Connected
I14 - Not Connected
I15 - Not Connected

3. System Menu
3.1 Menu Options Instructions
There are Systems Menus to help guide the user through the options available in the α
PneuAlpha2. The TopMenu has a Run Mode that is accessed while the α PneuAlpha2 is in
operation or a Stop Mode that is accessed when the α PneuAlpha2 is idle.
The Edit Menu and the Function Block Edit Menu can be accessed when in either ProgEdit
or Monitor. These menus can be used to create and/or change programs steps or values.
Use the “OK” key to enter a programming option or to enter data into memory. Set all the
data on the screen before using the “OK” key to write the data to the system memory. If
there are multiple data screens in an option, enter the required data and accept each screen
with the “OK” key.
The “ESC” key will move the screen back to a higher menu option. It will cancel any data
input that has not been accepted with the “OK” key.NoteUse the “ESC” key to exit the option
to the higher menu; at times, it will be necessary to press the “ESC” key a number of times to
move to through multiple programming layers.
3.2 The Stop Mode
3.2.1 Top Menu (Fig. 3.1)
When the α PneuAlpha2 is first turned On, the Input/Output Image Table will appear. Press
the “OK” and “ESC” keys simultaneously to move to the TopMenu. (If the TopMenu cannot
be accessed the Menu Key has been set to “Not Use”),
• Run:
Places the controller in Run mode.
• Setup TS:
Provides a simple method to edit Time Switches from the Top Menu (only selectable if a
TSm function block has been chosen.)
• ProgEdit:
Allows program editing/creation on the display using the front panel keys. The current
memory will be overwritten as changes are made to the program. Programs can be saved
on an ECC-PNAL2-EEPROM-2 memory cassette or in the ECC-PNAL-PCS/WIN-E soft-ware
Version 2.20 or above
• ClockSet:
Set the Real Time Clock or input a daily clock adjustment
• LANGUAGE:
Choose from 6 onscreen languages: English, German, French, Italian, Spanish, or Swedish
• Others...
3.2.2 The “Others... (Fig. 3.2)
• Version:
Displays CPU Version of the α PneuAlpha2 Series Controller.
• Scan Time:
Monitor the Current, Maximum, or Minimum program scan times. Upon controller reset
current, Maximum and Minimum values for scan times are reset to 0.
• Password:
Restrict entry to the ProgEdit and Monitor mode with a four digit password.
• DispPass:
Set up to three Passwords for Display function blocks.
• Menu Key:

Two settings are possible, “Not Use” or “OK + ESC”. “Not Use” is designed so that
unauthorised people cannot access the α PneuAlpha2 Top Menu in Run mode. If the “OK +
ESC” key setting is selected, simultaneously depress the “OK” and the “ESC” keys to access
the Top Menu.
• Summertime:
Choose the preferred daylight savings time: Cancel, Manual On, Date Type, UK type, US
type, or EU type.
• Serial Com: (Fig. 3.3; 3.4; 3.5; 3.6)
Choose the type of communication to be used for the right hand side serial communication
port - Not Use, Modem, GSM or Other Com.
• Light Time:
Set the backlight off delay time.
• ProgClear:
Completely clears the system memory including Password protected programs. Only the
active memory is cleared, i.e. if a memory cassette is installed, the memory cassette pro-
gram will be erased but the controller memory will be retained.
• ProgTran. (only appears if a cassette is installed):
Verify, Cassette (the cassette writes to the α PneuAlpha2 ), Cassette (the cassette
reads from the α PneuAlpha2 ), and ProtectSW are the options available.
3.3 The Run Mode Top Menu (Fig. 3.8; 3.9; 3.10; 3.11; 3.12; 3.13; 3.14)
When the αPneuAlpha2 program is running, the LCD defaults to the Image Table screen.
According to the Menu Key setting, proceed to the Stop Mode of the Top Menu by using
the“OK” and the “ESC” keys or reset the controller by powering down.
• Stop:
Takes the αPneuAlpha2 out of Run mode.
• Setup TS:
Provides a simple method to edit Time Switches from the Top Menu.
• Monitor:
Monitor the program settings while in the Run mode and perform limited editing to FB
parameters. The existing programming steps cannot be modified.
• ClockSet:
Set the Real Time Clock or input a daily clock adjustment.
• LANGUAGE:
Choose the on-screen language from English, German, French, Italian, Spanish, or Swedish.
• Others
3.4 The Edit Menu
The Edit Menu can be entered when the α PneuAlpha2 is in the ProgEdit or Monitor main
programming screen. If entering options or connecting FBs, these procedures have to be
finished or canceled before the Edit Menu can be entered. Press the “ESC” key at any place
in the main programming screen to enter the Edit Menu
• ProgSize:
Shows the numbers of FBs used and percentage of program memory used.
• Jump:
Leads to a screen that shows available places to go in the program. “M” - system bits; “I” -
system Inputs; “O” - System Outputs; “K” - Keys (1-8); “E” - ASi Inputs; “A” - ASi Outputs; “N”
- Control bits; “EI” - External Board inputs; “EO” - External Board outputs; and “B” - Function
Blocks existing in the program. Choose the desired block with the arrow keys and press the
“OK” key to jump to that spot in the program.
• New FB: Create a new Function Block from one of the available FBs.

• Exit:
Exits to the Top Menu.
• Mnemonic:
Gives a mnemonic display of the current programming run. Enter the programming mode by
pressing the “OK” key or return to the Edit Menu using the “ESC” key. (Not available in
Monitor Mode).
3.5 The Function Block Edit Menu
The Function Block Edit Menu can be entered only while in the ProgEdit or Monitor
mode.Move to the Function Block to edit and press the “OK” key when the Function Block
number is flashing.
• Setup FB:
Optimise variables in the Function Blocks for your application. See Chapter 6 for more details
on each Function Block’s Options. The logic functions in Chapter 5 do not have Setup
Options.
• Change No:
Change the Function Block Number
• Delete FB:
Delete Selected Function Block
3.6 Option Screen Setup
Various options have been provided for ease of use or for safety purposes. Please set as
your needs require. All of the options in this section can be accessed from either the Run or
the Stop Menu.
3.6.1 ProgEdit
Refer to the Direct programming chapter 4 for detailed combinations of key presses
to be able to program the α PneuAlpha2 Series Controller.
3.6.2 Change the Language Setting
1 ) Turn the αPneuAlpha2 On.

2 ) Press the “OK” and “ESC” button to go to the Top Menu or reset the controller.
3 ) Scroll to the “LANGUAGE” option and press the “OK” key. The spelling for “LANGUAGE”
does not change.
4 ) Scroll to the desired language and press the “OK” key. The languages available are
English, German, French, Italian, Spanish, and Swedish.
5 ) Use the “ESC” key to exit to the Topmenu.
3.6.3 ClockSET
To set the Clock:
1 ) From the TopMenu, scroll to “ClockSet” and press the “OK” key.
2 ) From the options that appear, choose “ClockSet” and press the “OK” key.
3 ) Use the arrow keys to move an area that needs to be changed.
4 ) Adjust with the “+” or “-” keys.
5 ) Repeat steps 3-4 until ALL changes have been accomplished.
6 ) Press the “OK” key to accept all the changes.
7 ) Press the “ESC” key to return to the Top Menu having discarded the clockset options.

To set the daily correction:
1 ) From the TopMenu, scroll to “ClockSet” and press the “OK” key.
2 ) From the options that appear, choose “Correct” and press the “OK” key.
3 ) Set the daily correction time with the “+” or “-” keys.
4 ) Press the “OK” key to accept the value and press the “ESC” key to return to the Top
Menu. Note: The date setting can be displayed as yyyy/mm/dd, dd/mm/yyyy, or
mm/dd/yyyyby manipulating the “+” and “-” keys. The day of the week will update
automatically as the date is changed.
3.6.4 SummerTime
The Summertime menu will display six choices when entered.

Cancel - Turns off the Summertime clock setting.
Manual On - Moves the clock one hour ahead immediately and will remain ON until
cancelled.
Date Type - Set the On date, Off date, and Time adjustment.
UK Type - Last Sunday of March to the last Sunday of October.US
Type - First Sunday of April to the last Sunday of October.EU
Type - Last Sunday of March to the last Sunday of October.
The time changes for the UK type take place at 1:00 AM in the Spring and 2:00 AM in the
Autumn. Time changes in the EU setting take place at 2:00 AM in the Spring and 3:00 AM in
the Autumn. The date settings are equivalent. If the display time has been adjusted for the
Summertime setting, an “s” will precede hour number on the screen.
How to Set the Summertime Setting:
1 ) Select “Others” from the Top Menu.

2 ) Select “Summertime”.
3 ) Scroll to the desired setting (see above for information on settings).
4 ) Press the “OK” key to accept.
5 ) If the display time has been adjusted, an “s” will precede hour number on the screen. If
the date is outside of the adjustment range, no visible sign will appear.
3.6.5 Password
The password consists of four digits and will prohibit entry into the ProgEdit, Monitor,
DispPass and Serial Com modes only. All other menu options can be accessed when a
Passwordis used.
To Enter a Password:
1 ) Select “Other” Menu Option.

2 ) Select “Password” from the “Other” Menu Options
3 ) Use the “+” and “-” keys to enter the desired password.
4 ) Press the “OK” key to accept and activate the password.
5 ) A key symbol will now be displayed at the top of the αPneuAlpha2 display.
To Cancel a Password:
1 ) Select the “Other” Menu Option.

2 ) Select “Password” from the “Other” Menu Options. “Cancel Password” should appear
on the top of the screen.
3 ) Use the “+” and “-” keys to enter the current password.
4 )Press the “OK” key to accept and deactivate the password.

5 )The key symbol will be removed from the αPneuAlpha2 display.
Note 1: A Password protected program in an ECC-PNAL2-EEPROM-2 Cassette can be run

from and be downloaded into the main body of the controller.
Note 2: A controller containing a Password protected program can accept or transfer
programs to an ECC-PNAL2-EEPROM-2.
Note 3: The Password can also be set/deleted from the ECC-PNAL-PCS/WIN-E software or
deleted by the “PROGCLEAR” command.
3.6.6 Serial Com
The modem function capability of the αPneuAlpha2 allows remote monitoring via a PC and
program upload/download. The communication must take place using the Visual
LogicSoftware (VLS) and the communication must be initiated accordingly. (The modem
connected to the αPneuAlpha2 is initialised upon the αPneuAlpha2 start-up. Dialing options
from a command or specific conditions are not available).
Command - Enter the AT command for the modem to be connected to the

controller.Reference the Modem User manual for details on that unit’s AT command. Choose
the first letter or symbol by using the (▲) and (▼) arrows. When the symbol is showing in
the command line, use the (◄) and (►) arrows to move to adjoining spaces. Enter up to 64
letters/symbols and accept the whole string with the “OK” key when finished inputting the
data. (There is no need to accept each letter with the “OK” key).
Delay - The Delay function sets the length of time the αPneuAlpha2 will wait after entering
the Run mode before turning on the modem. Choose a value of 0 - 10 seconds using the “+”
or “-” keys. The modem connected to the Personal Computer with the VLS software must be
set ON prior to the αPneuAlpha2 modem turning on.
The GSM function allows a SMS (Short Message Service) message to be sent to either a
mobile telephone or an email account. The SMS provides the remote user with the identical
LCD screen’s data. Refer to the αPneuAlpha2 Communication Manual for detailed
explanation concerning GSM parameters.
3.6.7 Memory cassette
The Memory Cassette EEPROM is the active memory whenever it is properly installed in the
αPneuAlpha2 controller. The controller must be Powered down before installing/removing
the memory cassette or an error will occur.
To Verify a Program:
1 ) Install the ECC-PNAL2-EEPROM-2. Refer to the ECC-PNAL2-EEPROM-2 instruction

manual.
2 ) Select “Others” in the Top Menu.
3 ) Select “ProgTran.”
4 ) Select “Verify”.
5 ) Choose “OK” to proceed or “ESC” to exit.
6 ) If the program is successfully verified, the work “Completed” will blink on screen.
7 ) If the programs are not the same, the words “Verify Error” will blink onscreen.

To Transfer a Program from the Cassette to the αPneuAlpha2:

manual.
3 ) Select “Prog Tran.”
4 ) Select “Cassette→”.
6 ) When the program is successfully transferred, “Completed” will blink on the display.
To Transfer a Program from the αPneuAlpha2 to the Cassette:

manual.
4 ) Select “Cassette←”.
6 ) When the program is successfully transferred, “Completed” will blink on the display.
To apply the “ProtectSW” Feature:
The “ProtectSW” will write protect the program in the memory cassette. The program cannot
be edited nor erased when the feature is ON.
1 ) Install the ECC-PNAL2-EEPROM-2 per the instruction manual.

4 ) Select “ProtectSW”.
5 ) Choose “On“ to activate the feature.
To Remove the “ProtectSW” Feature:

manual.
4 ) Select “ProtectSW”.
5 ) Choose “Off“ to de-activate the feature.
3.7 LCD Displays
There are a number of types of data and/or information that can be displayed on the LCD
display besides the menus listed previously.
3.7.1 Image Table
The first LCD display to appear is the Input/Output image table and the Real Time Clock. The
clock shows the current time as Set by the User. The Summer time mode is shown by an “s”
preceding the time if activated.
3.7.2 LCD Function
Display up to 12 different letters or characters on each of four lines. Options include

characteristings (design your own message), function block data, or analog data.

3.8 Block Items
Each block item contains an individual diagram that shows the block number, available
number of input pins, the output pin if applicable, and the block mnemonic. Connections
between blocks can be viewed at the pin locations when connected blocks are shown
individually on the LCD.
3.8.1 Input Blocks
The Input Blocks consist of System Inputs (I01 - I15), Key Inputs (K01-K08), and System Bits
(M01-M14). The input number is shown in the top right hand corner, the type of input in the
lower right hand corner, and the output pin is shown on the far right of the block. Input
Blocks provide information to the Function Blocks or Outputs.
3.8.2 Function Blocks
The individual Function Blocks are described in detail in Chapters 5 and 6. Function Block
scan have from 0 to 4 input pins shown on the left of the diagram and an output shown on
the far right. Some function blocks have data that can be used for comparison purposes only
or are used to display data onscreen. These blocks have no output pins. The number and
block mnemonic are shown in the top right and bottom right locations respectively.
3.8.3 Output Blocks
Output Blocks have one input and one output pin. They only have the capacity for one input
signal through the input pin. The Output Block number and Mnemonic are shown in the top
right and lower right hand corner of the diagram respectively.
3.8.4 Connected BlocksBlocks
That are connected can be shown simultaneously onscreen. The block providing the output
signal will be shown on the left of the screen. The input pin accepting the signal will flash.
Any input pin that is already connected will be shown as a solid triangle.

Figure 3.1: TopMenu in Stop Mode operation
OK
ESC
To p Me n u
10 : 19 F r i Ru n / S t o p Run Mode
I : •2• •5• • •9 Ru n S t o p →R u n
•1• • •5
O: 1 • •4• • •8 OK or ESC
E:1• •4
A : • 23 • Se t u p TS
Se t u p TS
EI :1• •4
EO : • 2 3 • NoDa t a
1
P r o gEd i t 2
C l o c k Se t C l o c kSe t
C l o c kSe t
C l o c kSe t d d / mm / y y y y
Co r r e c t 3 0 / 11 / 2 0 0 1
10 : 45 F r i
C l o c k Se t Co r r e c t
C l o c kSe t
Co r r e c t
• s /d
LANGUAGE L ANGUAGE
En g l i s h
G e r ma n
F r ench
I t a l i an
Sp a n i s h
Sw e d i s h
3
Ot he r s 4
Figure 3.2: Others Menu in Stop Mode operation

Ot he r s . . .
3 Ve r s i o n
Ve r s i o n
4
Ve r * . * *
S c a n T i me S c a n T i me
S c a n T i me Mo n i t o r Cu r . 0 ms
Re s e t Ma x . 1 2 ms
Mi n 0 ms
S c a n T i me Re s e t
Mo n i t o r S c a n T i me
Re s e t
OK or E SC
Se t u p
Pa s swo r d Pa s swo r d
D i s pPa s s Se t u p
D i s pPa s s
Leve l 1 D i s pPa s s
Leve l 2 Leve l 1
Leve l 3
Me n u K e y
Me n u K e y No Us e
ON + E SC
Ke y
S u mme r T i me
S u mme r T i me Ca n c e l
Ma n u a l O n
Da t a Ty p e S u mme r T i me
UK T y p e 31 / 03
US T y p e ~30 / 10
EU T y p e + 6 0m i n
S e r i a l Com 5
6
Se t u p
L i g h t T i me L i g h t T i me
2m
P r o gC l e a r
Pr ogc l ea r
OK or E SC
P r ogT r an

Figure 3.3: Serial Com in Stop Mode operation
Figure 3.4: Communication Format in Stop Mode Operation
Figure 3.5: GSM Menu in Stop Mode operation

Figure 3.6: Communication Format in Stop Mode operation

Figure 3.8: TopMenu in Run Mode Operation
Figure 3.9: Others Menu in Run Mode operation

Figure 3.10: Serial Com in Run Mode operation
Figure 3.11: Communication Format in Run Mode Operation
Figure 3.12: GSM Menu in Run Mode operation
Figure 3.13: Communication Format in Run Mode operation

Figure 3.14: Monitor Screen in Run Mode.

*+3& ..*& 3& ..5& 5./ *11 /*& 6 1 15.6- 0 15.6- 0 15.6- 0 > 15.6- 0
.4-/ 6 & * /&*11- 0 511 15.6- 0 .5 /-* .5 /-* ./*3
0 1 & 8
.
. . % F #
. % . % . %
#
0& 7 0
0
./
./
% < %
4 1<0 1<46 & . 4
9 B
: :
9
% < % % < %
% < % % < %
7 7 7
% % %
% < %
7
%
3
* * 7
C , - -
7 7
% %
% <
7 7 7
% < 2 2< %
: 0 : : 0 0
% < 2I 2I < %
4 7<0& 4 70 0&0
: 0 0 0
4
C C C
8 8 8
8 8 8 %
, , ,
% % % %
9 % %
3
15.6- 0 > .5 /-*
# % /" # 7%
- % % % !
## % ? #?

5 & 1 +3- 0 5 & 1 +3- 0 05- 1 +3 .4-/ 6*2 & 6 ++ & 6 ++ &
2- *3 2- 1*. &-11 3-3 /* % D*8./- 1 2 1 /& 1-J & /& 1-J &
1*. *3
% < % % < %
./ % 6 2! ,- , , !
*&4 &
. 1*. . &-06/ 1 /
% ; # # =
1 / &-06/
. %
*3
; G # =
./ %
. %
74 &
4
9
:
9
% < % % I < % % < %
% < % % < %
7
7 % 3
-
% 7 7 7 7 % <M
-
3 *
-
M < %
*
% < < %
.8 < %
% < 2 2< %
:
% < 2I 2I < %
: 0 0 0 0 0 0
48 48
/# G /# G
B 46 48 46 B 46 48 46 48 46 48 46
/# G /# G /# G /# G
B B B B
8 8 8 8 8 8
% % % %
% % % %
3
/ &- 0
# % G " 5 *531- 0 2-
- % % % !
## % ? #?

+ 0 J- + 0 J-
1* 74-. *5 / & 1* 74-.
.
% 1 / &-06/
./ %
4
9
:
9
% < < %
7
%
7 3
% %
%
% - - -
7
% * * * M
% < % 7
% < 2 2< %
:
4
9
% < 2I 2I < %
: 0 0
4 3
B
2I < %
48 46 48 46 48 46
/# G /# G /# G
B B B
8 8 8
3
+ 0 -
# % G "
- % % % !
## % ? #?

0 1 2 3 4 5 6 7 8 9
F F
DI 500
e500-006
E E
D D
construction or registered design entry in case!
Not allowed duplicating and passing on of this
plan and its contents without approval.
Reserve all rights for the patent
C C
e500-006
22.02.2008 SERVICE VOLT : STANDARD PROTECTION
WIRE COLOURS PLACE CHARACTERISTIC

COM.-NO. : CONTROL VOLT : PROTECTIVE MEASURE : LOW VOLTAGE PROTECTING
=10 MAIN ELECTRICAL BOX
WH WHITE
=20 DASHBOARD RIGHT SWITCHPANEL COM.-NO. SIGNAL VOLT :
OR ORANGE =30 DASHBOARD RIGHT DISPLAYPANEL
COMPRESSOR
B YE YELLOW
=40 CONTROL LEVER CARRIER RIGHT COMMISSIONIER : B
=50 CONTROL LEVER CARRIER LEFT
GR GREY =60 AIR CONDITIONER COMMISSIONIER
=70 CAB
BL BLUE
=80 OTHER PLACES
BR BROWN =90 VALVE PLATE
=100 FUEL & HYDRAULIC FILLING
ELECTRIC DIAGRAMS
BK BLACK
=110 FEED
RE RED =120 ENGINE COMPARTMENT DATE NAME
DRAW.
GN GREEN INSP.
A VI VIOLET NORM A
CROSS COLOURED (i.e. G-V) SHEET

LENGTHWAYS COLORED (i.e. G/V) M.NO.
SH.
DI 500 SH. 1- 36
NO. CORRECTION DATE NAME ORIG. SUBST. REPL.
0 1 2 3 4 5 6 7 8 9
D1 / 4.0
GND
2
1 1 1 1 1 1 1 1 1 1 1 1 1
F8
F1 F2 F3 F4 F13 F5 F14 F6 F7 F11 F9 F10 F12 25A
7,5A 15A 15A 7,5A 7,5A 10A 15A 15A 2 15A 10A 20A 5A 7,5A 1
2 2 2 2 2 2 2 2 2 2 2 2
BK WH BL/RE GR/BK HBL/RE BL/YE OR/BL RE RE RE WH/RE

2,5mm² 4mm²
SX1 3 1 2 SX3 3 SX2 2 SX3 1 SX6 1 SX3 2
BL
A1 A2 A3 A4 A5 B1 B2 C1 C2 C4 C5 C6
23.0 24.0 25.2 30.0 25.2 26.0 26.0 22.0 10.0 32.1 32.1 24.0
=20
W10 2,5²
10x bk 1wh 1bl 2re 6gr-re 4wh-re 3re-bk
X10 10 1 2 4 7 5 3
30
K2
/5.7 87A 87
C3 / 17.0
BK
2,5mm²
GND
BK
2,5mm²
GROUND
BOX
GND
RE RE RE
2,5mm² 2,5mm² 2,5mm²
0V / 4.0
1 RE 1 1 1 1 1
K1 2,5mm²
XF4 XF5 XF6 XF7 XF8
/4.1 2 4 6 6A 2 6A 2 16A 2 6A 2 6A 2
1 1 1 1 D2 / 4.0
XFA XFB XFC XFD B4 / 22.0
32A 2 32A 2 32A 2 32A 2
BK B3 / 7.0
2,5mm²
C7 / 4.0
=10 X1 1
C8 / 14.0
=120 GND RE
16mm² 2F2 / 4.0
GROUND 1 RE
ON 2F3 / 29.0
FRAME 2S0 16mm²
FUSES
RE
2 16mm² 2F4 / 29.0
FUSE HOLDER MAIN ELECTRIC BOX DASHBOARD
+ FH1 2 2 FH2 2 2
2G1.2 BK
95mm² 2F1 50A MAIN FUSE XFA 32A F1,F2,F3,F4,F13 F1 7,5A WIPERS, CIGARETTE LIGHTER
-
+
2F1 2F2 2F3 2F4 2F2
2F3
50A
50A
ALTERNATOR
OPTION HYDRAULIC OIL FILLING
XFB
XFC
32A
32A
F5,F14
F6,F7,F11,XF4,XF5
F2
F3
7,5A
10A
WORKING LIGHTS, CABINE LIGHTS
TRAMMING LIGHTS, REVERSING LIGHTS
50A 1 50A 1 50A 1 50A 1 2F4 50A OPTION FUEL FILLING XFD 32A F8,XF8 F4 7,5A ANGLE INDICATOR
XF1 1A ENGINE MAINT. LAMP F5 7,5A AIR CONDITION
2G1.1 XF2 1A ENGINE DIAGNOSTIC LAMP F6 7,5A ENGINE PREHEATER
XF3 1A ENGINE WARNING LAMP F7 15A BOOM, FEED, DRILLING, TRAMMING
-
BK XF4 6A 12V SUPPLY F8 7.5A IGNITION KEY
RE XF5 6A EMERGENCY CIRCUIT SUPPLY F9 20A WEBASTO HEATING
95mm²
16mm² XF6 16A ENGINE SUPPLY F10 5A WEBASTO HEATING
XF7 6A OPTION SEAT HEATING F11 7,5A FEED FUNCTIONS (MAGACINE ....)
JS / 4.0 XF8 6A OPTION ENGINE LIGHTS F12 7,5A OPTION STAIR LIGHT
F13 7,5A HORN
GND F14 7,5A AIR CONDITION
Date Page
24V SUPPLY DI 500
Draw. chseere 3
Insp. 22.02.2008 of
e500-006
Correct. Date Name Norm 36
0 1 2 3 4 5 6 7 8 9
IGNITION KEY STARTER ALTERNATOR
KT1
3.8 / D1
30
2S1
P012
15 50 58
RE WH
SX2 15 SX1 4
W11 W10
28x 2re 10x 8wh
X11 2 X10 9
=10
3.8 / C7 C7 / 5.0
11 22 24
1K1 12K1
.4 12 14 .5 21
1
1D1
2
U / 13.0
A1 2 A1 A1 A1 T / 8.0
K1 BSM1 1K1 12K1 12K2 A1 11
A2 BY255 1 A2 12V A2 12V A2 KT1 M 12K1
A2 .5 12 14
3.8 / D2
3.8 / 0V 0V / 5.0
X40 1 2 3 GND 3 GND 3 GND
=120 W40
2,5²
bk bnwh
16mm² RE WXS wh bk
3.5 / 2F2 W40 vibk bn vibk bn
3.5 / JS
XS
B+ R
X1 X1
BAT S 2G2
24V63A G HEL1 HEL2 XS
1 2
2M1 3˜ X2 X2
XS - + GND
JS X1
GND
GND HL
X2
GND GND
14 14
1 2 /3.3 14 18
12 11 .8 12 11 /22.3
4 /3.3
12 11 .3 24 24 16 15 /6.7
6 /3.4
22 21 .4 22 21 /22.5
Date Page
STARTER, ALTERNATOR DI 500
Draw. chseere 4
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
EMERGENCY STOP CABIN OPTION OPTION DOOR SWITCH SAFETY WIRE

ANSUL FIRE EMERGENCY STOP
EXTINGUISHER ENGINE COMPARTMENT
4.9 / C7 C7 / 6.0
C7.1 / 7.0
11
1K2
.4 12 14
A1 85 A1
1K2 K2 1K3
A2 86 A2
4.9 / 0V 0V / 6.0
=10 X90 18 19 X40 9 10 4 5 X11 23 24 X20 1 2
=30 =120 =70 W11 or/bk gr/bk

=110
W20
W90 SX2 1 2 41x1² 1 2
44x 18or-bl 19pi-ye W40 bk/wh wh/bk

WX22
Truck wh bk
2x1,5²
A21
SX22 1 2 X21 1 2
1 11 1
STL2 / 24.0
W24
1S0 4S0 P 2S0 .7 wh bl
2 12 2 W24
12 11 Truck
2x1,5² wh bk
3S10
13 14
INFORMATION: INFORMATION: INFORMATION: STL1 / 24.0

Without Option: Without Option: Option stair lights: 11 12
Bridge between Bridge between W24 = 4x1mm² 3S0
X40:9 and X40:10 X40:4 and X40:5 Wire 1 to 3S10:12
is mounted is mounted Wire 2 to 3S10:13
Wire 3 to 3S10:11
14 14
Wire 4 to 3S10:14 87
12 11 .7 12 11 /27.7
24 87A 30 /3.5 24
21 /8.8 21 /8.9
22 22
Date Page
EMERGENCY STOP DI 500
Draw. chseere 5
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
COMPRESSOR ON-OFF COMPRESSOR LOAD VALVE ON ENGINE COMPRESSOR

PREHEATER ON
5.9 / C7 C7 / 8.0
11
1K4
.3 12 14
5.9 / 0V 0V / 7.0
22 24 15 22 24
25 A2
1K4 KT1 1K5
KT4 1K4 .3 21 /4.7 16 18 /7.5 21
/8.6 26 28 A1
TEST / 8.0
4 6
1D2 1D3
3 5
=10 X11 4 5 3 X40 6 GND X90 12 2 15
=20 =120 =30

W90
W11 4bn-gn 5bn-bk 3bn-wh W40 or bn 44x 12gr-re 20or/wh 15bn
SX2 11 19 SX4 5 C7.2 / 9.4

A11
ST9 1 10 15
2S2 3 4 2 1 C7.3 / 8.0

+
x1 x1
2Y4.1
2H11 2H7
OFF
ON
-
0
x2 x2
14
12 11 .1
24
22 21 .7
Date Page
COMPRESSOR DI 500
Draw. chseere 6
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
RESET SERVICE LAMP ETHER VALVE FLUSHING/TRAMMING/DRILLING RPM ADJUSTING COOLANT LEVEL
3.8 / B3 =30 =120

6.9 / 0V 0V / 8.0
5.9 / C7.1
11 11
16 18 11 1R3 CLS
1K5 1K38
.5 12 14 /22.0 12 14
KT4 1K29
/8.6 15 /11.3 12 14
P403 A B C P800 A B C
14.9 9.0 8.9 A2

SL DL EL 1K5
42gegr
A1
41bn
40bl
21
W90 WCLS 1 2 3
XF1 XF2 XF3 1K10 21

1A 1 1A 1 1A 1 /11.4
22 24 1K18
/13.8 22 24
2 2 2
9.0 / 2H12
9.0 / 2H18
11 X90 40 41 42 X40 39 40 41
1K12
/12.4 12 14
=10 X90 38 37 X40 7 GND X41 1 2 3 4 5 6 7 8 9 10 11 12 X41 13 GND 14 15 16 17
=30 =120
38bl/wh
37wh/bl
W41
W90 W40 re bn 25x 1 2 3 4 5 6 7 8 9 10 11 12 13 ye/gn 14 15 16 17
GND
2S19
DIAGNOSE
A D E B
ST99 1 2 P61 12 1 31 32 26 13 24 25 38 22 27 28 10 8 15 36
DRILLING
800-2100 66 61 63 65 4 3 49
FLUSHING
6 48 52 53 70 30 28 29 22 10 44 45 8 9
+8V COOLANT LEVEL SENSOR

800-2100 TRAMMING
ETHER INJECTION VALVE
COOLANT LEVEL SENSOR
COOLANT LEVEL SENSOR

Y99 ECM 1700 DRILLING
ENGINE SHUT DOWN

MAINT. LAMP RESET
ADDITIONAL ETHER
DIAGNOSTIC LAMP
RPM ADJUSTMENT
ENGINE WARNING
+BAT SWITCHED
RPM ADJUSTING
MAINT. LAMP
DIAGNOSTIC
DIAGNOSTIC
CONNECTOR
CONNECTOR
INJECTION
GROUND
GROUND
GROUND
SUPPLY
SUPPLY
+ BAT
+ BAT
+ BAT
14
12 11 .1
24
22 21 /6.8
Date Page
ELECTRONIC ENGINE CONTROLLER DI 500
Draw. chseere 7
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
CHARGING CONTROL RESERVE HYDRAULIC OIL LEVEL RESERVE ENGINE HYDRAULIC ENGINE EMERGENCY
AIR FILTER OILER FILTER WARNING STOP
A11
6.9 / C7.3 C7.3 / 9.0
2H1 2H2 2H3 2H13 2H5 2H6 2H4 2H8 2H9 2H16 2H10
ST10 6 11 5 ST9 2 ST10 3 1 4 ST9 7 17 3 5
W90
44x 43pi 11wh 5or-wh 4or-wh 3wh-ye 1gr-bk gn-grRES 16bl-wh 17bl-re 22re-gn hbl
=30
X90 43 11 5 4 3 1 20 16 17 22 45
=10
7 9 11 13 17 21 25 27 1 3 5
4.9 / T
1D4 1D5 1D6 1D7 1D9 1D11 1D13 1D14 2D1 2D2 2D3
8 10 12 14 18 22 26 28 2 4 6
6.9 / TEST TEST / 9.0
EL / 7.4
6.9 / C7
22 24 22 24
A1
1K2 1K3
KT4 M
/5.4 21 /5.7 21
A2
15 19 23
1D8 1D10 1D12
16 20 24
A1 11
1K6 1K6
A2 .3 12 14
7.7 / 0V 0V / 9.0
KT4
X40 11 GND 12 GND 13 GND 14 15 GND 16 GND 16 GND 16 GND
=120
W2B5 W2B8 W2B9
Truck Truck Truck
W40 ye bn vi 2x1,5² bk wh W40 bn grre 2x1,5² wh bn 2x1,5² wh bn W40 re/wh bn wh/re bn
1 1 + 1 1 1
2B2 P 2B4 P 2B5 2B6 Θ 2B1 Θ 2B8 P 2B9 P 2B9.2 P 2B9.1 P
10,5 Bar /14.8 3 3 - 3 3 3
GND GND 18
14 16 15 /7.5
28
12 11 .3
26 25 /6.1
Date Page
CONTROL LAMPS DI 500
Draw. chseere 8
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
COMPRESSOR COMPRESSOR DIAGNOSTIC TRAMMING TRAMMING HOURMETER COOLANT TEMPERATURE FUEL TANK COMPRESSOR
AIR FILTER OIL FILTER 2.GEAR 1.GEAR LEVEL OIL TEMPERATURE
C7.3 / 14.0
A11
8.9 / C7.3
+ + + + +
2H20 2H21 2H22 2H23
2H14 2H15 2H17 2H12 2H18
h
G . . G G G
ST9 13 14 4 6 ST10 2 ST9 11 16 19 21 18 20 ST10 7 8 9
27bl-re
6.9 / C7.2
4
2S4
3
W90 13bl-gn 14bl-ye 23or-bk gr-bk ye-bl 10pi-bk 21bk 27bl-re 7gn-bk 8vi 9gr-bl
=30
X90 13 14 23 46 47 10 21 27 7 8 9
=10
7 9 11 13 15 INFORMATION:
2D4 2D5 2D6 2D7 2D8 Deep switch position
8 10 12 14 16 on the backside
8.9 / TEST of the panel for
7.4 / DL compessore temp.:
7.5 / 2H12 bn bn
100°C = 100100
7.6 / 2H18
110°C = 100001
130°C = 000001
8.9 / 0V 0V / 10.0
X40 17 GND X30 33 GND 19 GND 20 21 GND 22
=120 W30
W40 bk bn 41x 33 PE W40 rebk bn blre blwh bn bkye
A31 0V_3 / 10.1

ST100 1 2
X31 33 GND
Θ Θ
+ 1 2R11 2R12 2R13
B100
2B14 P 2B15 P
- 3
GND GND
Date Page
Draw. chseere 9
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
BOOM SWING FEED BOOM LIFT TELESCOPE OPTION ROLLOVER JOYSTICK FEED JOYSTICK TELESCOPE
SWING FEED FORWARD / BACKWARD
RE-BK RE-BK
3.5 / C2 C2.1 / 11.0
1S1 1 1S2 1
13 13
YE-RE
1S1 1S2
14 14
1S1 1S2
2 2
BL-WH BL-BK
SX2 3 SX2 12 SX4 2
W10
10x 5ye-re W11 17bl-wh 18bl-bk
=20
X10 6 X11 17 18
=10
C2 / 11.0
A1 A1
11 11
1K7 1K8
1K7 1K8 A2 A2
.7 12 14 .8 12 14
9.9 / 0V 0V / 11.0
X30 1 2 3 4
=90 W30
Oelflex 1 2 3 4
41x
A31
9.2 / 0V_3 -0V_3 / 11.0
X31 1 GND 2 GND 3 GND 4 GND
WY401 wh bn WY402 wh bn WY403 wh bn

WY404 wh bn
Truck Truck Truck Truck
2x 2x 2x 2x
1 1 1 1
Y401 Y402 Y403 Y404
3 3 3 3
14 14
12 11 .1 12 11 .4
Date Page
CYLINDER MOVEMENT DI 500
Draw. chseere 10
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
HYDRAULIC HYDRAULIC DRILLING TRAMMING MAGACINE SUPPLY OSZILLATION OPEN REVERSING REVERSING
PUMP PRESSURE PUMP PRESSURE ALARM ALARM
180BAR 245BAR
10.9 / C2.1
GND
RE-BK RE-BK
1-0-2 1S5
1 5 7 10 5 1 9
1H2
9 7 10
1S3
YE;YE WH-BK YE GR-RE GND
C2.2 / 13.8
SX2 18 17 6
W11 6ye 7wh-bk 11bl-wh
=20
X11 6 7 11
10.4 / C2 C2 / 12.0
11
1K9
.2 12 14
C2.3 / 12.0
C2.4 / 12.0
C2.5 / 22.0
11
1K39 11
11 A1 A1 A1 11 A1 /20.8 12 14 1K11
1K18 1K9 1K29 1K11 17 .5 12 14
/13.8 12 14 16A A2 A2 A2 12 14 A2 4D9
1K10 1K40 18
SY / 18.9
/22.1 C2.6 / 31.2
10.9 / 0V 0V / 12.0
=10 X30 5 6 7 8 11 9 GND GND 10 X40 23 GND
=90 W30
41x 5 6 7 8 11
A31 10.6 / 0V_3 0V_3 / 12.1

X31 GND 5 6 GND GND 7 8 GND GND 11
WY63 bn wh WY64 wh bn WY34 bn wh WY22 wh bn W1B4 bn wh WY301 wh bn bn wh W40 yebl bn

Truck Truck Truck Truck Truck Truck
2x 2x 2x 2x 2x 2x WY405 ST13 3 7
Truck
1 1 1 1 1 1 2x 1 RE BN
Y63 Y64 Y34 Y22 1B4 P Y301 Y405 1HH5

2 2 2 2 3 2 2
14
14 14 14
12 11 /27.6
12 11 .1 12 11 /7.6 24 12 11 .8
22 21 /7.5
Date Page
DRILLING - TRAMMING DI 500
Draw. chseere 11
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
COMPRESSOR PRESSURE DUST COLLECTOR HALF FLUSHING FLUSHING FLUSHING & FLUSHING AND
SWITCH 24BAR CONTROLLING FULL FLUSHING SUCTION SUCTION STOP
GND re bl ye
1S9
4S3 5 10 1S8 5 9 bl rt ge
1S9.1 1S9.2 1S9.3
1 9 1 10 gr sw gn
bk gr gn
GND
ST7 1 2 3 4
ST20 2 1
C2.8 / 13.0
W70
W11 bl/gn bl/whRES 25x 1 2 3 4 5 6
=30 =40
X11 9 20 X70 1 2 3 4 5 6
=10
11.9 / C2.3 C2.3 / 31.2
11.9 / C2.4 C2.4 / 14.0
21 21 11
1K13 1K14 1K15
.6 22 24 .7 22 24 .8 12 14
C2.7 / 16.0
11
1K21
/16.5 12 14
PA2 A1
O1 O2 1K12 11 11
+ - I1 I2 A2
1K13 1K14
.6 12 14 .7 12 14
A1 A1 A1
11.9 / C2
1K13 1K14 1K15
A2 A2 A2
11.9 / 0V 0V / 13.0
X40 GND 24 X30 12 13 31 X40 25 GND 26 GND
W30
=120 41x
12 13 31
A31
11.6 / 0V_3 0V_3 / 13.1 W40 bkgn bn grgn bn
W40 bn bk/gr
X31 12 GND 13 GND 31 GND
WDC 1 2 3 4 5 6
+ + +
Y75 Y76 Y77
2Y4 Y36 Y36.1
- - -
14 14 14 14
12 11 /7.6 12 11 .6 12 11 .7 12 11 .6
24 24 24
22 21 /28.1 22 21 .2 22 21 .2
Date Page
FLUSHING & SUCTION DI 500
Draw. chseere 12
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
ROTATION ROTATION FEED FEED BACKWARD FAST FEED DUST COLLECTOR

RIGHT LEFT FORWARD PRESSURE
OVERRIDE
11.9 / C2.2 -C2.2 / 28.0
12.9 / C2.8 C2.8 / 22.7 GND
1S9
2
1
0
1
2
2
1
0
1
2
08 8 04 4 3 03 7 07 06 6 02 2 1 01 5 05 1S4 5 10
1 9
C-D A-B
DBL-WH
W70 14
25x 7 8 16 9 10 11 W11 8bl-wh
=40
X70 7 8 16 9 10 11 X11 8
=10 11
1K30
20 19 /21.1 12 14
4.9 / U
2D10
11
22 21
1K34
18 2D11 /21.7 12 14
2D9 C2.9 / 21.0
17 11 15
24 23 11 11
1K36 KT3 1K43
2D12 /21.7 12 14 /21.5 16 18
1K37 /18.6
/21.8 12 14 A1 A1 12 14
26 25 11
11 1K17 1K18
1K28 A2 A2
2D13 /30.7 12 14
1K17
.8 12 14
28 27
2D14 9
2 1
4D5
10
A1 3D1 12 11
1K16 4 3 VDU / 28.6
A2 4D6
3D2
12.9 / 0V 0V / 14.0
X11 16 X30 14 15 16 17 18 19 20
=20 =90
W30
41x
14 15 16 17 18 19 20
W11 16wh
12.3 / 0V_3 0V_3 / 14.4

SX2 5
A31 X31 GND 14 15 GND GND 16 17 GND GND 18 GND 19 20 GND
+
WY30 WY29 WY24 WY23 WY23A WY33 WY62
Truck Truck Truck Truck Truck Truck Truck
1P1 h 2x bn wh 2x wh bn 2x bn wh 2x wh bk 2x bn wh 2x bn wh 2x wh bk
-
BN
1 1 1 1 1 1 2
GND
Y30 Y29 Y24 Y23 -Y62 Y33
2 2 2 2 2 2 1
Y23A
14 14
14
12 11 .6 12 11 /11.1
12 11 /14.5 24 24
22 21 /15.5 22 21 /7.6
Date Page
ROTATION AND FEED DI 500
Draw. chseere 13
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
MAGACINE THREADING SERVICE PUMP 1

OIL COOLER ON
POSITION POSITION FULL VOLUME
3.8 / C8 C8 / 27.2
12.9 / C2.4 C2.4 / 15.0
11 25 21 11 11 11 A1
1K33 KT3 1K42 1K16 1K19 1K42 1K19
/21.6 12 14 /21.5 26 28 /18.6 22 24 /13.3 12 14 .8 12 14 /18.6 12 14 A2
SL / 7.4
1H6 / 16.0
1H7 / 16.0
13.9 / 0V 0V / 15.0
X90 24 25 6 26 49 44 X30 21 22 35 X40 27 GND

=10
=30 =90 W30 =120
W90 24re-ye 25re-bk 6or-bk 26bk-wh vi/wh ye/gn 41x 21 22 35
W40 yegn bn
SX6 1
A31
X1 X1 13.9 / 0V_3 0V_3 / 15.1
X1 X1 X1
1H6 1H7 X31 GND 21 GND 22 GND 22
1H3 1H4 1H5 X2 X2
X2 X2 X2 4
WY35 bn wh
WY31 bn wh
WY302 bn wh
Truck Truck Truck 2B6 Θ
2x 2x 2x
BK-WH SX6 /8.5 6
2 1 1 1 50°C
Y35 Y31 Y302

GR-RE;GR-RE 3 3 3
9.9 / C7.3 C7.3 / 28.0
14
12 11 .6
Date Page
Draw. chseere OIL COOLER 14
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
FEED PRESSURE ROTATION SPEED POTENTIOMETER POTENTIOMETER

FEED ROTATION
14.9 / C2.4 C2.4 / 16.0

1
T1
24/10 VDC
2 4
21
1K17
/13.8 22 24
14.9 / 0V 0V / 16.0
10V / 28.0
=10 X30 23 24 25 26 X90 32 33 34 35 36
=90 =30
34gr/bk
33gr/re
35bl/gn
32bl/re
36bl/bk
W30
41x 23 24 25 26 W90
14.7 / 0V_3 0V_3 / 22.2
A31 X31 23 24 GND 25 26 GND
WY90 WY91
3x 1 2 3 3x 1 2 3
MIN MAX MIN MAX

1R1 1R2
Y90 1 3 2 4 Y91 1 3 2 4
1 2 1 2
1 1
2 2
Date Page
POTENTIOMETER FEED DI 500
Draw. chseere ROTATION 15
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
OILER LEVEL OILER FUNCTION OILER VALVE
12.9 / C2.7 C2.7 / 18.0

15.9 / C2.4 C2.4 / 21.0
A1 A1
A1
1K21 1K22
KT2 M
A2 A2
A2
12 14
1K20
.3 11
A2 11
1K20 1K22
A1 .6 12 14
14.9 / 1H6
15
14.9 / 1H7
KT2
.3 16 18
15.9 / 0V 0V / 17.0
=10 X40 28 29 30 31 GND
=120 W40 wh vi/wh gn bl/bk bn
SLU22 GND
13 23
S22
14 24 KT2
TIMER XSLU 16 14 10 5 1 7
XSLU 15 13 2 6 9 8
1
+
2B10 2B11 P
2
Y277
-
INFORMATION:
Factory setting: GND
RANGE = 6 GND
FINE = 6
18 14 14 14
16 15 .3 12 11 .6 12 11 /12.6 12 11 .4
Date Page
OILER DI 500
Draw. chseere 16
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
CENTERING 2. CENTERING UPPER UPPER NEUTRAL THREAD

CLOSED CLOSED CLAMP CLAMP POSITION BREAK
OPEN CLOSE
-C3.1 / 18.0
INFORMATION:
X1 X1 Joystick connection side
3H1 3H2 3S1 02 2 1 01
02 FORWARD
X2 X2 OPEN (Left) CLOSE (Right)

3S1 2 LEFT RIGHT
1
3S1.1
ST6 1 2 01 BACKWARD
W60
Oelflex
25x 1 2 3 4 5
04 4 3 03
=50
X60 1 2 3 4 5
=10
3.8 / C3 C3 / 18.0
5 6
3D3 7 8
C3.2 / 18.0
21
3D4
A1
1K24
1K23 /18.4 22 24
A2
11
1K24
/18.4 12 14
16.9 / 0V 0V / 18.0
X20 3 4 5 6 7 8
=110 W20 PE 3 4 5 6 7 8
41x1²
A21
0V_2 / 18.0
X21 GND 3 GND 4 GND 5 6 GND GND 7 8 GND
W3B1 W3B6 WY76 WY77 WY73 WY72

2x bn wh 2x bn wh 2x bn wh 2x wh bn 2x bn wh 2x wh bn
3B1 3B6
GND 1 2 3 GND 1 2 3 1 1 1 1
P P
Y76 -Y77 Y73 Y72
2 2 2 2
14
12 11 /30.5
Date Page
CENTERING DI 500
Draw. chseere UNCOUPLING DEVICE 17
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
UNDER UNDER GUIDE CLAMP SWITCHOVER HAMMER HAMMER

CLAMPING CLAMPING DRILL PIPE TO 2. JOYSTICLEVEL CENTRALIZER CENTRALIZER
DEVICE CLOSE DEVICE OPEN CLOSE OPEN
17.9 / C3.1 C3.1 / 19.0
INFORMATION:
ST6.2 1 Joystick connection side
02 FORWARD
3S9 14 14 RIGHT LEFT
3S1 CLOSE (Forward)
5 6 3 2 LEFT RIGHT
3S1.1 13 13
01 02 OPEN (Backward) 4 1
3S1.1
01 BACKWARD
ST6 3 4 ST6.2 2
04 4 3 03
W60 6 7 8 14 15
=50
X60 6 7 8 14 15
=10 9 10 23 24
17.9 / C3.2
3D5 11 12 3D12
C3.2 / 19.0 27 28
C3.3 / 20.0
16.9 / C2.7
3D6
C2.7 / 28.0 3D14
21
PA2
1K25
.5 I6
22 24
11 A1 A1 A1 A1 18.3 / Q4
1K25 1K24 1K25 1K42 1K43
.5 12 14 A2 A2 A2 A2 O3
I7 I8
PA2
Q4 / 18.7
15 16
O4
4D8
17.9 / C3 C3 / 19.0
13 14
SY / 11.9
4D7
17.9 / 0V 0V / 19.0
X20 9 10 11 12 32 33
=110 W20 9 10 11 12 32 33
41x1²
17.9 / 0V_2 0V_2 / 19.1

X21 GND 9 10 GND GND 11 12 GND GND 32 33 GND
A21
WY74 WY75 WY58 WY59 WY82 WY83

2x bn wh 2x wh bn 2x bn wh 2x wh bn 2x bn wh 2x wh bn
1 1 1 1 1 1
Y74 Y75 Y58 Y59 Y82 Y83
2 2 2 2 2 2
14 14 14 14
12 11 /17.4 12 11 .1 12 11 /14.7 12 11 /13.8

24 24 24 24
22 21 /17.5 22 21 .2 22 21 /14.4 22 21 /28.1
Date Page
CENTERING DI 500
Draw. chseere UNCOUPLING DEVICE 18
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
SWING IN DRILL PIPE CLAMPING CLAMPING CLAMPING JAWS GUIDING

MAGACINE INTO DRILLCENTER JAWS OPEN JAWS CLOSE
18.9 / C3.1
ST6.1 1
2S3 re bl
BACKWARD
FORWARD
/20.4 5 6
3 3 3
05 06 2S3.1 4 2S3.2 4 2S3.3 4

bk gr
ST6.1 2 3 4
W60 9 10 11 12 13
=50
X60 9 10 11 12 13
=10 TG / 22.0
18.9 / C3 C3 / 20.0
11 11 11
1K32 1K26 1K27
/21.2 12 14 .8 12 14 12 14 .8
13 14 17 18
3D7 3D9
15 16 19 20
18.6 / C3.2 C3.2 / 22.9
3D8 3D10
A1 A1
1K26 1K27
A2 A2
18.9 / 0V 0V / 20.0
X20 13 14 15 16
=110 W20 13 14 15 16
41x1²
A21 18.9 / 0V_2 0V_2 / 20.3
X21 GND 13 14 GND GND 15 16 GND 16 GND
WY45 bn wh WY46 wh bn
WY43 bn wh WY44 wh bn WY47 wh bn
Truck Truck Truck Truck Truck
2x 2x 2x 2x 2x
1 1 1 1 1
Y45 Y46 Y43 Y44 Y47
2 2 2 2 2
14 14
12 11 .4 12 11 .5
24 24
22 21 /20.1 22 21 /21.2
Date Page
MAGACINE DI 500
Draw. chseere 19
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
MAGAZINE MAGAZINE
CLOCKWISE COUNTERCLOCKWISE
2S3 2 1
/19.1 RIGHT LEFT
02 01
ST6.1 8 6 7
W60
=5 16 17 18
X60 16 17 18
=1
19.9 / C3 C3 / 21.0
21
1K32
/21.2 22 24
21
1K31
/21.2 22 24 PA2
I3 I4 I5
21
1K26 O5 O6 O7 Q8
/19.8 22 24
3D13
25 26
A1
18.9 / C3.3
1K39
A2
19.9 / 0V 0V / 21.0
X20 30 31 19
W20
=11 41x1²
30 31 19
A21
19.7 / 0V_2 0V_2 / 21.0
X21 GND 30 31 GND 19
W22
12x1,5² PE 6 7
A22
0V_21 / 21.4
X22 11 10 12 13
WY39 bn wh
WY40 wh bn
WY41 bn wh
Truck Truck Truck
2x 2x 2x
1 1 1
Y39 Y40 Y41
2 2 2
14
12 11 /11.6
24
22 21 /28.1
Date Page
MAGACINE DI 500
Draw. chseere 20
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
FAST FEED ROAD CHANGER PIPE IN CLAMP OPEN THREADING MAGACINE COLLISION
STOP ARM IN ROAD CHANGER POSITION POSITION POSITION
MAGACINE JAWS
16.9 / C2.4
13.9 / C2.9
20.9 / C3
A1 A1 A1 A1 A1 A1 A1 A1
1K30 1K31 21
1K35 KT3 M 1K33 1K34 1K36 1K37
A2 A2 A2 A2 A2 A2 A2 A2
1K27
/19.8 22 24
1 3
A1
4D1 4D2 11
2 4
1K32 1K31
A2 .2 12 14
20.9 / 0V 0V / 22.0
21 11
1K37 1K35
.8 22 24 .3 12 14
=10 X20 20 21 22 23 24 25 26 27 29 28
=110 W20
41x1²
20 21 22 23 24 25 26 27 29 28
A21
20.7 / 0V_2 0V_2 / 22.7
X21 20 GND 21 20 GND 22 20 GND 23 20 GND 24 25 26 27 29 28
W22
4 12x1,5² 1 2 3 5 4
A22
20.5 / 0V_21
W1B6 W1B5 W1B4 W1B7
3x bn bl bk 3x bn bl bk 3x bn bl bk 3x bn bl bk X22 2 1 3 5 4 6 8 7 9
KT3
W1B1 W1B2 W1B3
3x bn bl bk 3x bn bl bk 3x bn bl bk
bn bl bn bl bn bl bn bl bn bl bn bl bn bl
+ - + - + - + - + - + - + -
1B6 1B5 1B4 1B7 1B1 1B2 1B3
bk bk bk bk bk bk bk
14 14 18 14
14 14 14 14 14
12 11 .8 12 11 /19.2 16 15 /13.5 12 11 /13.7
12 11 /13.4 24 24 12 11 .8 28 12 11 /14.0 12 11 /13.7 12 11 /13.4 24
22 21 /20.1 22 21 /20.5 26 25 /14.1 22 21 .8
Date Page
FEED DI 500
Draw. chseere PROXIMITY SWITCHES 21
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
ENGINE PREHEATER SUCTION SUCTION

3.5 / C1 HOOD UP HOOD DOWN
OPTION
CANTRAL LUBRICATION OPTION
SYSTEM ST27 1 2 SEAT HEATING
GND 13.7 / C2.8 AFA/AJS/ 28.6
x1
3S2
5 10 SCL 10 5 H1
3S5
x2
GND 1 1 3 7 9
1 9 9 1
WST2A1 WST1A1 SH1 2 10

Truck bn wh wh bn
Truck
2x 2x
SX2 20
SX2 4 ST2A1 1 2 ST1A1 1 2
ye wh bn re
INFORMATION: STH1 1 2
Beka Max System

H Z 15 31 is only connected W70 W70
W11 24or-wh
to the connector W11 1ye/bk 25x 15 PE 25x 12 13
CLS
Lincoln
MOUNTED ON BOOM
ST27
=20 =70
X11 10 X11 1 X70 15 GND 12 13
=10 5 6
3.8 / B4 4D3 7 8
C3.2 / 19.9
4D4
11.9 / C2.5 C2.5 / 24.8
A1 A1 11 21
1K38 1K40 12K2 12K2

/4.6 /4.6 22 24
A2 A2 12 14
21.9 / 0V 0V / 24.8
19.9 / TG
X40 GND 38 X30 32 34 X40 8 GND X20 17 18
=90 W30
41x
2 34 =110 W20
41x1²
17 18
A31 15.4 / 0V_3 0V_3 / 27.6 A21 21.9 / 0V_2 0V_2 / 31.8
X31 2 GND 34 X21 GND 17 18 GND
13 21
WY69 WKH WMPR WY52 WY53
Truck Truck Truck Truck Truck
SZO1 2x wh bn 2x wh 2x wh bn 2x bn wh 2x wh bn
14 22
+ -
1 1 1
Y69 KH1 / 29.0 MPR
M Y52 Y53
2 2 2
OPTION OPTION OPTION

BOOM SENSOR OPTION HYDRAULIC OIL CABINE
BLOCKING TRAMMING THREAD GREASING FILTERING PRESSURIZER
14 14
12 11 /7.4 12 11 /11.4
Date Page
ETHER INJECTION DI 500
Draw. chseere SUCTION HOOD 22
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
WIPER PANE FRONT PANE WASHING DEVICE FOR FRONT WIPER WIPER PANE TOP PANE WASHING DEVICE FOR TOP WIPPER
BL/RE
3.1 / A1 A1 / 24.0
GND
YE-GN
4S1 4
4S2
5 3 1 6 2 3 7 10
4S1.1
7 3 5 9
GND
WH
GND
GND GND
VIYE OR BK BL/RE BL/BK BK BL-BK BN

GN
ST1.1 1 2 3 4 5 6 7 ST1 1 4 3 2 5 6
=20
RE BN WH GN WH BK
BK BK BN BL YE/GN
53 53b 31 53a 31b + . 53 31 53a 31b + .

4M1 4M1.1 4M2 4M2.1
M M
R1 R2
M M
Date Page
PANE WASHING DEVICE DI 500
Draw. chseere 23
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
CABIN CIGARETTE LIGHTER WORKING LIGHTS 4H1.1, 4H2.1 OPTION

LIGHTS OPTION STAIR LIGHT
3.7 / C6
5.6 / STL1
5.6 / STL2
BL/RE
23.9 / A1
3.2 / A2
GND
4R1 +
=30 6K2
A1 11
4S5 5 10 .6
6K2
A2 12 14
1 9 -
BK
GND
GND
22.9 / 0V 0V / 25.0
GND GND GND GND 22.9 / C2.5
BL-GN
GR-BK BK
BK BK
ST1 7 8 ST2 1 2 6 5
=20 =10 X11 25 GND
=70 BL BN =80
BL BL BL BL BN BN WH3
Truck
2x bn wh
X1 X1 X1 X1
S1 4H1 4H1.1 4H2 4H2.1 X1 1
X2 X2 X2 X2 H3 H2
X2 2
14
12 11 .6
Date Page
LIGHTS, DI 500
Draw. chseere CIGARETTE LIGHTER 24
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
REVERSING REVERSING TRAMMING TRAMMING HORN

LIGHT LIGHT LIGHTS LIGHTS
=20
3.3 / A5
3.2 / A3
hbl/re OR-BL OR-BL
GND
ST18 1
1 3 2 6 10 4S6 re
- - 9
ye
4H6 4H7 4S4
+ +
ST18 2
WH-BK
ST13 1 5 2 6 GND GND

YE-GN
BK
BK
ST2 8 BL-GN
BN SX4 3 ST2 3 7
A2
H1
A1
GND
SX4 4 6
ST2
BL BN BL BN 4
GR-BL
+ +
4H4 4H5
- - ST2
13
W40 blgn W11 14ye-gn 21gr-bl 19or-bl 22bl-gn
=120
X40 33 X11 14 21 19 22
=10
11 A1
1K41 1K41
.8 12 14 A2
24.9 / 0V 0V / 28.0
14
12 11 .7
Date Page
Draw. chseere
DI 500 25
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
AIR CONDITIONER AIR CONDITIONER ON MAGNETIC CLUTCH

AIR COMPRESSOR
3.4 / B2
3.4 / B1
GND
6R1 6S2
5 10
0 + 3 4 1
1
2
3 2 1 9
6S1
BN-WH
BN-WH
BK-WH
BK-RE
BK-YE
RE
BK
RE VI VI-BK VI-BK RE
=20 =10 X10 8 X40 34
ST3 5 2 3 4 1 7 8
=60 =120
BN-YE
BN-YE
A1 11
W10 7gn-bk W40 bl
6K1 6K1
A2 .5 12 14
102 516 517 518 521
102
ST4 1
GND
ST4 6
e 521
D
523
ST4 7 SX2 1
6Y1
2xsw
ST4 2 BK BL
M
522
ST4 5 YE-BK GN-BK
ST5 3 4 1 2 GND
B31
W6 3 4 1 2
ST5.2 1 2 ST5.1 1 2
W7 BK BK-YE
Truck bn wh
2x
ST5.3 1 2 6B1 P
bk re
6B2 P
14 6M1
M
12 11 .6
Date Page
AIR CONDITIONER DI 500
Draw. chseere 26
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
RADIO TRAMMING 2.GEAR CONTROL OIL PRESSURE

24V
=10
BL BL BL BL BL
11 11
1K10 1K3
/11.4 12 14 /5.7 12 14
BL BL
X10 14 X100 1 2 3 4
XT 2 X30 27 28
3 4 =20 =90
W30
FT12 W11 25ye-re 41x 27 28
T12 6,3A
X10 13
1 2
SX4 7
A31
XT 1 GND
22.4 / 0V_3
GND 0V_3 / 28.1
X31 27 GND 28 GND
GND YE-RE BK
WY21 WY4
Truck Truck
2x wh bn 2x wh bn
RC / 33.0
ST16 1 2 ST17 1 2
=70
1 1
C8 Y21 Y4
14.9
ST19 1 2 3
3 3
B22
12V +V GND
Date Page
12V DI 500
Draw. chseere 27
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
RESERVE OPTION FOAM INJECTION ON/OFF OPTION FOAM INJECTION OPTION ANTI JAMMING SYSTEM
14.3 / C7.3
13.9 / C2.2
22.8 /AFA/AJS
GND gr/re GND
3S7 Z1 3S8
5 10 x1 5 10
H4 1R4
1 9 x2 1 9
Z2 ->
VI-BK
21
W70
W11 13vi-bk W90 gr/blRES dvl/ye ye/re bl/ye 25x 14
=20 =30 =40

=10 X11 13 X90 50 51 52 X70 14
15.9 / 10V
18.4 / C2.7
21
1K39
/20.8 22 24
21 A1 15
1K43 KT5 M KT5
/18.6 22 24 A2 .6 16 18
21
13.9 / VDU
1K12
/12.4 22 24
25.9 / 0V 0V / 30.0
X30 36 X90 54 GND X40 35 36 GND GND X30 29 30
=90 W30
41x 29 30
27.8 / 0V_3 0V_3 / 28.6 WB71 KT5

Truck
X30 GND 36 2x wh bn W42 3 2 1 4
A31 4x 28.2 / 0V_3
W91 X31 29 GND GND 30

Truck A31
2x bn wh
W4B1 wh bn
WY66 bn wh
Truck Truck
2x 2x
1 1
Y71 3 2 1 4
Y303 B71
2 3
4B1 P 1
Y66
2
18
2
16 15 .7
Date Page
OPTION DI 500
Draw. chseere 28
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
=120
3.5 / 2F4
3.5 / 2F3
30 13 30 13
100K1 100S1 200K1 200S1
.3 87 14 .7 87 14
22.4 / KH1
85 - 85 -
100K1 200K1
50 86 + 50 86 +
BN BN
GND GND
RE GND GND
RE
+ - + -
100M1
M 200M1
M
30 87 .2 30 87 .6
Date Page
OPTION DI 500
Draw. chseere 29
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
BL-YE
3.2 / A4
SX4 1
=20
W11 15bl-ye
12 14 A1
X11 15
1K23 1K28
/17.1 11 A2
28.9 / 0V
=10 X90 29 28 30 31 53
29bn-wh
=30
30bn-gn
28bn-bk
31wh-re
W90
X17 X18 X30 X31 X20 BKVI

34
ST21 1
A28 W28
gn
AIMING DEVICE 2 X16 Y410
bn
1 X15 Z4
3
wh
X14 LEFT
GND
BKWH
37
W27 ST21 2
wh
A27 3 X9
1
bn
X10
Y411
gn Z4
2 X12 RIGHT
GND
B21
BKGR
35
ST21 3
W29
bn
A29 17 X4 Y412
FEED SENSOR wh
20 X5 Z3
19
gn
X6 FORWARD
GND
ye
18 X7
BLRE
36
ST21 4
W25
bl
W35 7 7 X32 Y413
wh wh
2 6 6 X27 Z3
A35 6
pi
5 5
pi
X26 REV
ROPE TRACTION DECODER
4
ye
4 A25 4
ye
X25
GND
gn gn
3 3 3 X24
gr gr
5 2 2 X23
bn bn
1 1 1 X22
14
12 11 /13.4
Date Page
Draw. chseere
DI 500 30
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
SWITCH PANEL WINCH WINCH DRILLBIT BIT BREAKING

FORWARD REVERSE UNCOUPLING DEVICE DEVICE
OPEN CLOSE
12.9 / C2.3
11.9 / C2.6
X20 39 40
W20 39 40
41x1²
A21 22.9 / 0V_2 0V_2 / 31.3

X21 39 40 GND
W26 1 2 PE
7x
A26
X26 1 2 2 2 2 GND
GND
26D1 26D2 26D3 26D4

1 2 3 4 5 6 7 8
ST26 1 2 3 4 5 6 7 8
X26 3 4 5 6
W26.3 W26 3 4 5 6
Oelflex
12x 1 2 3 4 5 6 7 8
A21
31.9 / 0V_2
X21 GND 41 42 GND GND 43 44 GND
3 3 3 3
WY80 bn wh WY81 wh bn WY67 bn wh WY68 wh bn
S72 S73 S56 S57 Truck Truck Truck Truck
2x 2x 2x 2x
4 4 4 4
1 1 1 1
Y80 Y81 Y67 Y68
2 2 2 2
Date Page
OPTION BIT BREAKING DEVICE DI 500
Draw. chseere 31
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
CONTROL DEVICE CONTROL UNIT
=30 3.7 / C4
RE
=120
RE
3.7 / C5
DIA
DIAGNOSTIC
1 2
GND
NC NC
BN YE/RE GR VI GN/WH
RE RE
1 10 11 X12/ST2 12 1 8 6 7 5 2
ST25
bk 2
2 3
KE
CONTROL SYSTEM
P2 ST25
wh 3
8 4
X11/ST1 X13/ST3
12 7 4 11 9 10 1 5 8 4 12 9 2 3 11 7 10 6 1 2
X3
BN BN
BN YE RE BN BK BL WH/BL VI VI/BL GR OR OR GN BL BN
ST25 4
1 12 8 5 6 7 2 11 3 10 9 4
X1 X5
T 90 S Y1
GND GND
Date Page
OPTION COOLANT HEATER DI 500
Draw. chseere 32
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
DISPLAY CAMERA
=70 =120
27.4 / RC
GND
CB
ST ST
DP GND L L SWITCH BOX
CA L
CAMERA
Date Page
Draw. chseere
DI 500 33
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
1H4 1H6 1H7 A11

/14.1 Oiler function Oiler level 2H1 2H2 2H3 2H4 2H5 2H6 1S3
Centering /8.1 /8.1 /8.2 /8.6 /8.4 /8.5 /11.3 4S1
1H3 position 2S19 Drilling /23.1
/14.0 /7.0 Tramming 1S4 Pane washing device
Magacine position Reset service lamp 1S0 /13.8
1H5 /5.1 2H21 Dust collector
/14.2 EMERGENCY STOP /9.6 Engine On 1S5
4S2
Service /23.5
/11.7 Pane washing device
B21 1R4 2H22 2H20 Oszillation
/30.4 Option foam unlocked
Driving /9.7 /9.4
Angle measurement injection
control 1P1
lever /13.0
1R2 2H23 BLIND Hourmeter
/9.8
/15.7
Rotation
3S7
1R1 4S6 2H7 2H8 2H9 2H10 2H11 2H12 /28.1
/15.5 /25.8 Option foam
/6.6 /8.6 /8.7 /8.9 /6.5 /9.3 injektion ON-OFF
Vorschub HORN
Lafette
2H13 2H14 2H15 2H16 2H17 2H18 4R1
/8.3 /9.0 /9.1 /8.8 /9.2 /9.3 /24.4
Cigarette lighter
1S1 1S2
1S1 Pushed hold 1S2 Pushed hold 4S3
Drill boom lift sag Track assembly lift sag /12.0
left right 24bar
Option Rollover
1R3
/7.7
Drehzahl - ECM
2S2
/6.1
A11 Kompressor
.3 Ein - Aus
2S1
/4.2
Ingnition key
2H1-Charging control
2H2-Engine oil pressure
H3-Empty
2H4-Empty 4S4
2H5-Hydraulic oil level /25.3
Tramming lights
2H6-Temperature Compressor oil
2H7-Compressor On F1 =7,5A F6 F1
F2 =7,5A /3.5 F11 /3.1 4S5
2H8-Engine Air filter /3.6 /24.2
F3 =10A
2H9-Hydraulic Oiler filter Working lights
F4 =7,5A F7 F2
2H10-EMERGENCY STOP F5 =15A /3.2
/3.5 F12
2H11-Ether overwrite amount F6 =7,5A
/3.7 6S2
F7 =15A /26.5
2H12-Tramming Fast
2H13-Compressor Between position
F8 =25A F8 F3 Klimaanlage Ein
F9 =15A /3.8 F13 /3.2
2H14-Compressor Air filter F10=15A /3.3
2H15-Compressor Oiler filter F11=15A
F12=15A F9 F4
2H16-Engine warning /3.2
2H17-Diagnostic lamp F13=7,5A /3.7 F14
F14=15A /3.4
2H18-Tramming Slow
F10 F5
2H21-Coolant temperature /3.7 /3.4
2H22-Fuel tank level
Date Page
CIAM DI 500
Draw. chseere Dashboard 34
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
3H1 1S6 1S6.1

2S3.1 Flushing Flushing and Suction
Clamping circlip open /17.2
2S3.2 Centering closed
Clamping circlip close yellow 1S9
/12.6
Rotation left - right
Feed and Fast feed
1S7
2S3 Flushing and Suction stop
Magacine indexing left right
Clamping circlip on- swing
55.2
3S5
3S9 /22.7
/18.6 Suction hood displace
Hammer centralizer
3S8
/28.6
Option
3H2 AJS
/17.3
2. Centering closed
blue 1S8
/12.4
Compressor lower
3S1 Delivery
/17.4
Centering open - close
Uncoupling device open - close
6S1
/26.1
3S1.1 Blow switch
With Button pushed
2. Centering open - close
6R1
/26.2
Temperature switch Air conditioner
Date Page
Seat DI 500
Draw. chseere 35
Insp. 22.02.2008 of
e500-006
0 1 2 3 4 5 6 7 8 9
1B7
/21.3
W20
1B4
/21.2
1B6 A26
/21.0 /31.0
W22
1B5 JAW
/21.1
OPEN
1B3 A21
A25
1B2 A22 1B1 Y39 Y40 /21.7 /5.7
.7
/20.4 /20.5
/21.6 /21.5
X21 W24
SWING ARM
TERMINAL ELECTRIC BOXABOUT MAGACINE
Y43 Y73 Y83
/19.5 /17.7
Y81 Y45 Y47
Y75 /31.5 /19.2 /19.6 Y58 Y53 Y66
/18.2 Option /18.4 /22.8 /28.7
Y74
/18.1
3B1
/17.1
Y76
/17.4 A21
/5.7
.6
Y44 Y59 Y52

/19.5 /18.4 /22.7 Y67
/31.7
Y80 Y41 Y46
Y70 /31.4 /20.7 /19.2 3B6 Y72 Y82
Option /17.3 /17.7
Date Page
FEED DI 500
Draw. chseere 36
Insp. 22.02.2008 of
e500-006

Sandvik Di - 400

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Sandvik Di - 400

Uploaded by

Copyright:

Available Formats

DI 400 / 500

T1 KT1 KT2 KT3 KT4 KT5 1

1K39 1K40 1K41 1K42 1K43

Risk of electric shock. Electric shock may cause death of severe

3. LOCATION OF THE MAIN SWITCH

4. FUSES, LOCATION AND DESCRIPTION

Always switch the main power off before changing a fuse.

Replace a blown fuse only with identical fuse.

4.1. Main fuses

2F1= 50A Main supply

2F3= 50A Option Hydraulic oil filter

4.2. Fuses inside the main electric box

T1 KT1 KT2 KT3 KT4 KT5 1

1K39 1K40 1K41 1K42 1K43

Main electric box

Fuse Size (A) Function

4.3. Fuses in the cabin

Fuse Size (A) Function

5. COMPONENTS IN THE MAIN ELECTRIC BOX

T1 KT1 KT2 KT3 KT4 KT5 1

1K39 1K40 1K41 1K42 1K43

Pos. Components Pos. Components

5.1. Function of the components

5.2. Time relays

T1 KT1 KT2 KT3 KT4 KT5 1

1K39 1K40 1K41 1K42 1K43

R2 Delay R2 Delay R2 Inst. R2 Left R2 Inst.

KT1, KT2, KT3, KT4, KT5

Example of time settings:

On-delay time delay

On-delay flasher function

Off-delay time delay opening, low-level control

Star-delta function with double delay at energisation

5.2.3. How to connect

KT1, KT2, KT3, KT4, KT5

If an indicator lamp for the air filter

1H6 = Function = 2B10

The function of the lubricator is shown

7.3. Engine oil pressure and coolant temperature

2H2 2H2 = Engine air filter = 2B2

After the lamp test the engine

7.4. Engine speed and coolant level

2H16 = Engine warning lamp

If the RPM - sensor is changed

2H16 2H17 2H20

7.5. Hydraulic oil

2B9.1 2B9 2B5

2H5 = Hydraulic oil level = 2B5

If the lamp for the hydraulic oil level is lit,

If the lamp for the hydraulic oil filter is lit,

7.6. Compressor oil and filter

2H15 = Compressor oil filter = 2B15

If the lamp for the compressor oil fiter is lit

7.7. Compressor temperature and pressure

2B6 2B1 2B4 2R13 2B6 2B1

2H6 = Compressor temperature first stage = 2B6

8. DRILLING STOP DEVICE (SAFETY WIRE)

9. THROTTLE POSITION SENSOR

Risk of damaging the electronic engine controller. If TPS is damaged,

10. ECM FLASH CODES

Flash codes represent diagnostic codes

Engine warning lamp Engine flash code

Possible Performance Effect of Active Diagnostic Codes