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SELF-PROPELLED PLATFORM STAR 8

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1. Ref Code Qty Description 1 2420318260 1 Spare parts manual E 08 02 2 3078143420 1 Operator s manual E 08 02 2420505950 1 Warranty activation 3 3078147290 1 Read CE operation manual 4 2420319690 1 Repair manual E 05 03 5 3078148770 2 Haulotte logo 6 2421808660 1 Black yellow adhesive marking total length 7 ft 2 2 in 7 3078148900 110V plug label 8 3078147270 2 Do not stand on the hood decal 9 3078147930 4 Sling fastener 10 3078138820 1 Green arrow 11 3078149290 4 Fork lift truck fork location decal 12 3078149360 1 Mast emergency lowering 13 3078148760 1 Manufacturer s plate 14 3078147580 1 110 V socket position 15 3078148620 1 Battery charger socket position 16 3078147240 2 Danger hand finger crush hazard 17 3078149370 1 ON OFF 18 3078149340 2 Floor height load capacity 19 3078147220 2 Caution do not use as a welding ground 20 3078148300 1 Turntable control station 21 3078147890 1 Voltage chart 22 3078147050 1 Operating instructions 23 3078149280 1 Do not use the machine during charging 24 3078149300 2 Electrocution hazard the machine is not insulated 25 3078149390 2 Vertical body crush hazard 26 3078148630 1 Power supply on platform 27 307P201580 1 Vertical Star 22 J logo 29 3078149350 1 Danger travel direction 30 3078150870 1 Complementary safety instructions 31 307P203690 1 Platform control panel 32 307P201510 1 Permissible lo
2. No movement is made NO Check EM FU2 FUA and FU5 Y YES NO Replace any defective fuses YES END Check that the emergency stop and station selection buttons are operational NO Replace any See sheet Buttons ls defective buttons C004 Measure voltage at terminals 5 and 42 of the chopper END NO See sheet Replace the chopper C003 YES END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP082 NO MOVEMENT AVAILABLE FROM THE TURNTABLE Open the Turntable box and measure voltage at CNA 10 CNA 9 and CNA8 of the turntable board 8 0 idle CNA 8 0V at 4V CNA 10 5V and CNA 9 0V NO up CNA 10 0V and CNA 9 5 down See sheet C063 Replace the Serial board Follow the same wire colors and measure voltage at the terminals of manipulator SM1 OV lt cursor lt 4V FOR contact 5V or REV contact 5V YES Repair the wiring NO Folio 2 4 Replace manipulator SM1 See sheet C143 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP082 NO MOVEMENT AVAILABLE FROM THE TURNTABLE Folio 3 4 Measure voltage atthe terminals of contactor SB1 L3 NO p Check the wiring and See sheet the batteries C149 If necessary repair the wiring and or YES repl
3. Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP075 Folio 3 6 NO UP OR DOWN JIB MOVEMENT FROM THE PLATFORM No down movement No up movement Check battery charge Battery charge NO OK WES See sheet Charge the batteries C139 Put the key switch in the Platform position and activate jib movement No down movement Y No up movement The pump works SO Check pump wiring Measure voltage at termi nals 18 and 19 of the chopper Wiring is correc NO 18 24V 104 up 19 24V 104 up down S heet YES Replace the chopper ui See sheet Replace the chopper C003 Y Repair the wiring Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART NO UP OR DOWN JIB MOVEMENT Folio 4 6 FROM THE PLATFORM Measure voltage at the terminals of electrovalves YV3a and YV5 24 V u and YV5 24 V up down NO Repair the wiring between the chopper and the electrovalves See sheet C145 Replace the coil The problem persists Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheel Dre NO UP OR DOWN JIB MOVEMENT Folio 5 6 FROM THE PLATFORM Connect a pressure gauge to the pressure tapping at small pump output Make a jib up down movement
4. NE T tie Ir I EU END TY D 1 I I I m EI t LOOONOILVISNVAL INOLLOSMIQ NOLLVINSINO NOILIVAL SNIS331IS NOILVIN3INO Pinguely Haulotte Z 26 Repair manual Pinguely Haulotte 4 HYDRAULIC DIAGRAMS OGM 594 8 et 9 9 LA A14706 b 27 Repair manual Pinguely Haulotte Z suolleB 9 1 ANYL Sam SZ HIO ISI q 457919 OSLXPLW t l LSYN LYN ONIASALS NOILOSAIA NOILVLOU NOILVLNAIHO dir JAIVINAN AA For more information about both diagrams please refer to your spare parts manua
5. Replace electrovalve See sheet YV5 C067 NO Pressure zero See sheet Replace electrovalve 067 Test or replace the ibis 2320 PSI 160 bars 286 Sheet i C218 pressure limite Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DPO75 NO UP OR DOWN JIB MOVEMENT Folio 6 6 FROM THE PLATFORM Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART SIGSEDEUEB NO UP OR DOWN JIB MOVEMENT Folio 1 6 FROM THE TURNTABLE QUE up or down movement from ui turntable Put the key switch in the Platform position Activate jib movement he jib move up or down YES Put the key switch in the Turntable position Activate jib movement Open the Turntable box and measure voltage on CNA 10 CNA 8 and CNA 9 of the turntable board Di Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP076 Folio 2 6 NO UP OR DOWN JIB MOVEMENT FROM THE TURNTABLE 8 0 idle CNA 8 0V at 4V CNA 10 5V amp CNA 9 0V NO Follow the same wire colours and measure voltage at the terminals of manipulator SM1 Measure voltage at CNB A OV lt cursor lt 4V FOR contact 5V or NO CNBQ 24 V NO REV contact 5V YES Replace manipulator See sheet SM1 C1 Repair the wiring Replace the Serial
6. NO Follow the same wire colours and measure voltage at the terminals of manipulator SM2 Measure voltage at CNB4 OV lt cursor lt 4V FOR contact 5V or REV contact CNB4 24 V NO 5V Replace manipulator See sheet YES SM2 C142 Repair the wiring Replace the Serial See sheet board C063 END Y Measure voltage at pedal output oltage measured NO 24 V YES See sheet Repl th Repair the wiring ASERI REE C064 BREAKDOWN DETECTION FLOW CHART Pinguely Haulotte 4 Sheet DP079 Put the key switch in the Platform position and activate right left rotation movement NO The pump works Check pump wiring Measure voltage at terminals 7 and 8 of the chopper NO NO RIGHT OR LEFT ROTATIONAL MAST MOVEMENT FROM THE PLATFORM Folio 3 6 Wiring is correc YES 7 24V 104 left 8 24V 104 right Replace the chopper YES See sheet Replace the chopper See sheet C003 C003 Y Repair the wiring Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP079 vo RIGHT OR LEFT ROTATIONAL MAST MOVEMENT Folio 4 6 FROM THE PLATFORM Measure voltage at the terminals of electrovalves YV2a and YV2b 2a 24 V le and YV2b 24 V
7. Make several movement cycles using the hydraulic block in question to purge the hydraulic circuit Checkthe level in the hydraulic oil tank see relevant sheet Close the covers again NB Check the chopper software version when changing the block up to version 1 03 for blocks with two pressure limiters from version 1 05 for blocks with three pressure limiters For US machines version from 1 04 US Pinguely Haulotte Z Sheet C203 AN Caution Ensure that the oil is not too hot AN Caution Use a container to collect the oil to prevent pollution of the environment AN Caution It is essential to put the component into slings before dismantling reassembling it Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet 1 1 REPLACING THE MOTORPUMP UNIT 1 Preliminary operations Put the machine into the maintenance configuration see relevant sec tion Switch off the electric power supply see relevant section 2 Removing the motorpump unit 1 Mark and disconnect the electric connections of the motor pump unit 1 Mark and disconnect the four hoses 2 of the hydraulic pumps Put caps on the hoses Remove the fixing collar 3 of the motorpump unit and remove the unit Remove the suction and discharge flanges 4 of the large pump Reinstalling the motorpump unit Reinstall the suction and discharge flanges 4 equipped with new seals on the motorpump unit Put the mo
8. 546 ERI 35 102 PRESENCE OF LABELS 36 10 2 1 Labels Ee TEE 36 10 39 PRESENCE OFIMANUALS Jalad sus 39 11 PREVENTIVE MAINTENANCE SHEETS 41 Pinguely Haulotte 7 Repair Manual 12 OPERATING INCIDENTS 12 1 TROUBLE SHOOTING 13 CORRECTIVE MAINTENANCE PROCEDURE Repair manual Pinguely Haulotte Z 1 GENERAL RECOMMENDATIONS SAFETY 1 1 GENERAL WARNING 1 1 1 Manual This manual aims to help maintenance personnel service and repair the machine It cannot however replace the basic training required by any person working on the site equipment The site manager must inform operators of the recommendations in the instruction manual He is also responsible for application of current user regulations in the country of use Before operating on the machine it is essential to be familiar with all the recommendations in this manual and the user manual to ensure personnel and equipment safety 1 1 2 Labels Potential dangers and recommendations for the machine are indicated on labels and plates Read the instructions on them All labels conform to the following colour code Red indicates a potentially fatal danger Orange indicates a danger that may cause serious injury Yellow indicates a danger that may cause material damage or slight injury Maintenance pesrson
9. See sheet Replace electrovalve 067 YV4 Test or replace the 1450 PSI 100 bars See sheet and 2320 PSI 160 C218 bars pressure limiters No down movement Y Manually test electrovalve YV3 Replace electrovalve See Sheet Operation correct NO Y Manually test electrovalve Test or replace the eo sheet pressure Replace electrovalve See sheet YV3 067 Operation correct NO Replace electrovalve See sheet YV6 C067 Replace electrovalve See sheet 067 YV5 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP078 NO UP OR DOWN MAST MOVEMENT Folio 1 6 FROM THE TURNTABLE mast up or down movement from gt turntable Put the key switch in the Platform position Activate mast up down movement up or down YES Put the key switch in the Turntable position Activate mast up down movement Open the Turntable box and measure voltage at CNA 8 CNA 9 and CNA 10 of the turntable board Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP078 Folio 2 6 NO UP OR DOWN MAST MOVEMENT FROM THE TURNTABLE CNA 8 0V idle CNA 8 0V at 4V CNA 10 5V amp CNA 9 0V UP CNA 10 0V 8 CNA 9 5V down NO Follow the same wire colours and measure voltage at the te
10. Connect the plug 2 to the mains 110V for USA Safety precautions are Check the charge state on the light 3 on the bottom control panel required for battery Red zone machine charging servicing operations wear Yellow zone 8096 of charging complete gloves and protective Green zone batteries charged goggles 3 During charging Do not remove or close the element caps Ensure that element temperature does not exceed 45 C be careful in sum mer or in rooms with high ambient temperature 4 After charging Top up the electrolyte level if necessary 4 Additional operations Putthe machine back into the operational configuration Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C140 Sheet 1 1 REPLACING THE TILT SENSOR 1 Preliminary operations Putthe machine on a flat level surface Caution Putthe machine in the maintenance configuration see relevant section Switch off the electric power supply see relevant section Do not use the machine during maintenance 2 Removing the tilt sensor operations Markand disconnect the electric connections of the tilt sensor Remove the tilt sensor 2 by unscrewing the fixing bolts 1 3 Re installing the tilt sensor Puta new tilt sensor into place and secure with the fixing bolts 1 Reconnect the electric connections according to the marks made during dismantling Setthe adjusting s
11. See sheet and 2320 PSI 160 C218 bars pressure limiters Replace electrovalve See sheet YV1 C067 Repair manual Pinguely Haulotte 13 CORRECTIVE MAINTENANCE PROCEDURE List of corrective maintenance sheets Sheet no Description Replacing the chopper Replacing a component of the platform control station Replacing a hose Replacing the horn Replacing the hand pump Replacing the printed circuit Replacing an electrovalve Charging the traction batteries Replacing the tilt sensor Replacing the jib cylinder Replacing the top panel manipulator Replacing the bottom panel manipulator Replacing a steering wheel Replacing a coil Replacing the steering potentiometer Replacing the covers Replacing the hydraulic winder Replacing the batteries Dismantling reassembling the mast Replacing an end of travel contactor Replacing the hydraulic filter Replacing the hydraulic block Replacing the motor pump unit Replacing the hydraulic pump Replacing the rotation motor Replacing a drive wheel Replacing the hydraulic tank Replacing the turntable emergency stop button Replacing the battery charger Replacing the slew ring Replacing a steering pivot Replacing a steering cylinder Replacing the counterweights Replacing the electric plate Pinguely Haulotte 2 Repair manual Sheet no Description
12. during maintenance Mark and disconnect the electric connections of the component to be operations replaced Remove the component 3 Replacing a component on the platform control panel Puta new component and seal into place on the front of the platform con trol panel NB If itis a lever switch adjust the position of the fixing nut and counter nut so that the switch lever joint axle is on the same level as the seal to ensure tightness Reconnectthe electric connections according to the marks made when dismantling Fixthe closing plate with the four fixing screws Perform the function corresponding to the replaced component to check that it works properly Pinguely Haulotte Z Sheet C010 AN Caution Ensure that the oil is not too hot AN Caution Use a container to collect oil to prevent pollution of the environment Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 1 1 CHANGING A HOSE 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Close the shut off valve if any if not empty the hydraulic tank 2 Removing a hose NB Disconnect the hose from the equipment to which it is connected Unscrew the hose slowly to release residual hydraulic pressure Protect the holes of the equipment using caps 3 Installing a hose Reconnect a new hydraulic
13. 1 chopper 2 battery charger 3 tilt sensor 4 fuse holder 5 turntable box 6 collar and polypropylene tube 7 mast end of travel contactor support 8 on the plate Photo 5 Screw the stop collar of the spiral cable back into place Photo 7 ref 9 Screw the electric plate at its various fixing points Photo 6 Sa Photo 5 4 Additional operations Reconnect the charger to the socket Reconnect the hydraulic distribution block connections Reconnect the battery terminals Fix all the cables on the platform and jib Tighten all the cable clamps of all cables in the sleeve Tighten the cable sleeve with the fixing collars Reconnect the top panel plug Reconnect the travel motor cables Reconnect the steering cylinder hoses Reconnect the steering potentiometer plug Reconnect the plug of the electrovalve near the rotation motor Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C215 REPLACING THE JIB PLATFORM ASSEMBLY Sheet 1 1 AN Caution 1 Preliminary operations Ensure thatthe oll Is notice Ger machine into the maintenance configuration see relevant sec ll Switch off the electric power supply see relevant section Remove the jib end of travel contactor ref 1 Disconnect the hydraulic distributor ref 2 of the jib cylinder bg Caution Disconnect the hoses of the steering cylinder Use a container to collect the Putcaps on the hoses oil to prevent pollution of the
14. 3 fixing the board to the box and their sealing washers Remove the printed circuit and silent blocks equipping the fixing bolts STAR only disconnect the printed circuit s serial card 1 Installing the printed circuit Puta new printed circuit into place and fix using the bolts equipped with silent blocks sealing rings and new toothed washers STAR only Install the printed circuit s serial card Install the U1 electronic module except STAR see corresponding sheet Reconnect the electric connections according to the marks made during dismantling Close the turntable box Reconnectthe then terminals of the starter battery Putthe machine back into the operational configuration Test the printed circuit 4 Testing the printed circuit Perform the computer operating test see changing the U1 electronic module sheet Star 22J Star 8 Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C067 Sheet 1 2 CHANGING AN ELECTROVALVE 1 Preliminary operations AN Caution Putthe machine in the maintenance configuration see corresponding Ensure that the oil is not too paragraph hot Switch off electric power see corresponding paragraph 2 Removing an electrovalve Markand disconnect the electric connections 1 of the coils N Caution Mark the installation position of the electrovalve on the block Unscrew the four fix
15. environment 2 Removing the jib platform assembly Putthe jib platform assembly into slings Unscrew the 7 screws ref 3 of the top cover ref 4 of the jib platform N Caution assembly It is essential to put the component into slings before dismantling reassembling it AN Caution Check that the lifting means are in good condition and of sufficient capacity Remove the assembly using a hoist 3 Reinstalling the jib platform assembly Putthe jib platform assembly into slings Reinstall the assembly on the mast in order to secure the top cover ref 4 Screw the 7 screws of the jib platform top cover Reinstall the jib end of travel contactor Reconnect the hydraulic distributor of the jib cylinder ref 2 Reconnect the hoses to the jib cylinder ref 5 4 Additional operations Putthe machine back into the operational configuration Make several jib lifting movements to purge the hydraulic circuit Checkthe level of the hydraulic oil tank Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C216 REINSTALLING THE CABLE SLEEVE Sheet 1 2 1 Preliminary operations Putthe machine into the maintenance configuration see relevant sec tion AN Switch off the electric power supply see relevant section Check that the cable sleeve Disconnect the two electric cables of the brake control is properly positioned and Disconnect the 6 cab
16. Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C211 Sheet 2 2 REPLACING A STEERING PIVOT Place the wheel on the pivot Screw the fixing nuts 12 without tightening them too far to avoid blocking the bearings Fixthe stud 9 on the nut 10 Photo 6 Putthe cap on the wheel and secure 11 Photo 7 Grease generously NB The brake washer must be changed whenever the wheel is replaced 4 Additional operations Remove the slings Put the machine back into the operational configuration Make several travel movements to purge the hydraulic circuit Check the level of oil in the wheel reducer e Check the level of the hydraulic oil tank Sheet C212 AN Caution Ensure thatthe oil is not too hot AN Caution Use a container to collect the oil to prevent pollution of the environment AN Caution It is essential to put the component into slings before dismantling reassembling it Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET REPLACING A STEERING CYLINDER Sheet 1 1 1 Preliminary operations Putthe machine in the low configuration Switch off the electric power supply see relevant section 2 Removing the steering cylinder e Mark and disconnect the two hoses of the steering cylinder 1 NB Unscrew the hoses slowly to release residual hydraulic pressure Putcaps on the hoses Putthe cylinder into slings Unscrew the fixing screws of the steering c
17. Replacing the jib platform assembly Removing reinstalling the cable sleeve Replacing a wheel reducer or a hydraulic travel motor Adjusting a pressure limiter Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C003 Sheet 1 2 REPLACING THE SPEED VARIATOR 1 Preliminary operations Put the machine in the low position Cut off the electric power supply see 8 6 3 page 22 Disconnect the and terminals of the batteries to isolate the electric circuit Removing the speed variator Disconnect the speed variator s electric connections Remove the speed variator 1 Replacing the speed variator Put the speed variator back into place and secure with the fixing screws Reconnect the speed variator s electric connections Compact Reconnect the and terminals of the batteries Put the machine back in the operational configuration Optimum Optimum Compact Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET SHEET C003 Sheet 2 2 REPLACING THE SPEED VARIATOR Dn ce IN A Star 22 J Star 8 Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET SHEET C004 Sheet 1 1 REPLACING A COMPONENT ON THE PLATFORM CONTROL PANEL 1 Preliminary operations Cut off the electric power supply see 8 6 3 page 22 Caution A 2 Removing a component from the platform control panel Do not use the machine Remove the closing plate 1 by unscrewing the four fixing screws
18. SO Check pump wiring Measure voltage at terminals 9 12 17 18 of the chopper Wiring is correc NO 17 18 2 24V 104 down 9 12 24V 104 up down See sheet C003 See sheet Replace the chopper C003 Y YES Replace the chopper Repair the wiring Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DPO78 NO UP OR DOWN MAST MOVEMENT Folio 5 6 FROM THE TURNTABLE Measure voltage at the terminals of electrovalves YV3a YV3b YV4 8 YV6 V3a and YV4 24 V up and YV3b and YV6 24 V down Repair the wiring between the chopper and the electrovalves See sheet C145 Replace the coil The problem persists Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP078 Folio 6 6 NO UP OR DOWN MAST MOVEMENT FROM THE TURNTABLE Connect a pressure gauge to the pressure tapping at small pump output Make a mast up down movement Pressure 1450 PSI 100 bars No down movement YES Replace electrovalve YV4 See sheet C067 YES Test or replace the 1450 PSI 100 bars See sheet No down movement and 2320 PSI 160 C218 bars pressure limiters Y Manually test electrovalve YV3 Replace electroval
19. Sheet DP080 NO RIGHT OR LEFT ROTATIONAL MAST MOVEMENT CNA 8 0V idle CNA 8 0V at 4V down CNA 10 5V amp CNA 9 0V up CNA 10 0V amp CNA 9 5V Folio 2 6 FROM THE TURNTABLE NO Follow the same wire colours and measure voltage at the terminals of manipulator SM1 Measure voltage at CNB R CNB R 24 V YES OV lt cursor lt 4V FOR contact 5V or REV contact 5V Replace the Serial board NO Replace manipulator See sheet SM1 C143 Repair the wiring See sheet C063 END Y Measure voltage at SB7 output Ch NO YES 1 See sheet Replace the button Repair the wiring P C004 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP080 NO RIGHT OR LEFT ROTATIONAL MAST MOVEMENT Folio 3 6 FROM THE TURNTABLE Put the key switch in the Turntable position and activate mast movement NO The pump works Measure voltage at terminals 7 and 8 ofthe chopper 7 24V 104 left 8 24V 104 right YES See sheet Replace the chopper C003 Check pump wiring NO Wiring is correc See sheet Replace the chopper C003 Y Repair the wiring Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP080 RIGHT OR LEFT ROTATION
20. State of conservation 9 14 5 REPAIRS AND ADIUSIMEN Tr sa a cee 10 1 6 VERIFICATIONS WHEN RETURNING TO SERVICE 10 1 BEAUFORT SCALE lat 10 2 SPECIFICATIONS EE aaeanoa an iniaiaiai ranea aiina aiaia 11 2 1 TECHNICAL CHARACTERISTICS 11 2 1 1 STAR 22J technical characteristics 11 2 1 2 Size of the STAR 22 Jmeet 13 234 e TIGHTENING TORQUE 14 Pinguely Haulotte Repair Manual 2 2 1 Tightening torque values for large thread screws 14 2 2 2 Tightening torque values for small thread screws 14 2 2 3 Tightening torque values for hydraulic hoses 14 2 Ei SUIS tabl IN PS ccs Em 15 22 0 Table of adjustment meS anna u 15 3 SAFETY SYSTEMS Gala 17 Ads MACHINE ELEMENTS arena 17 D MO rai 17 3 1 2 Power supplies and fuses nen 7 7775 5 nan 17 3 1 3 rie TE 17 3 14 ika va vk aid Seed da 18 4 POSITIONS OF ELECTRIC 44 42 2 19 Ze CHASSIS EQUIPMENT racco 20 5 OPERATING EQUATIONS une u 21 SN RESI Pete opp 21 V MAA SHUTDOWN c 21 57 MAST ENE alice kiika al 21 Lol MDA eu uu 21 9 39 2 EE
21. characteristics see corresponding chapter and in compliance with the safety instructions specific to the equipment and places of use The main operation station is in the platform The operation station on the turntable is an emergency or standby station 2 1 TECHNICAL CHARACTERISTICS 2 1 1 STAR 22J technical characteristics STAR 22J Useful load interior exterior 440 Ib 2 pers 352 Ib 1 pers Maximum lateral force interior exterior 88 Ib 44 Ib Working height 28 ft 7 in Floor height 22 ft Maximum range 8 ft 6 in Turntable rotation 360 not continuous Max working slope and tilt 3 approx 5 296 Platform floor dimensions 2 ft 2 in x 3 ft Maximum slope in travel 25 Low travel speed 0 43 mph High travel speed 2 79 mph Traction batteries 24V in 2 trays Floor clearance under pothole system 3 4in mm max 172 in Tyres Solid tires Turning radius interior 1ft 5 in exterior 6 ft 1 in Mast telescoping travel 12 ft 1 in Maximum wind speed in operation inside outside 0 mph 27 96 mph Max pressure on the floor with a 440 Ib load 206 pound inch concrete Max force on one wheel 5467 Ibf Movement time with 1 person Turntable orientation approx 360 60s Mast telescoping out in approx 405 275 Jib lifting up down approx 265 365 Motor separate
22. console by a Pinguely Remove the covers see relevant sheet Haulotte technician 2 Removing the potentiometer Disconnect the electric connection 1 Slightly unscrew the screw 5 fixing the potentiometer support 3 Slacken the 2 BTR screws 2 Liftthe potentiometer support 3 to remove the potentiometer from the fix ing flat 4 of the wheel pivot Unscrew the nut 6 keeping the potentiometer on its support 3 Remove the potentiometer 7 3 Reinstalling the potentiometer before setting Connect the electric connection 1 Fixthe new potentiometer on its support 3 by screwing the fixing nut 6 Connect the calibrater 9 to the MDI socket 8 on the mother board 10 4 Adjusting and reinstalling the potentiometer Switch on the machine in the platform station Using the Roll buttons 11 find the Tester menu Press Enter 12 Find the Steer Angle parameter The angular value of the potentiometer is displayed on the console Adjust the potentiometer so that the value 0 is displayed on the console 13 From the platform station place the wheels perfectly straight Position the potentiometer leaving a gap of 0 07 to 0 19 in 2 to 5 mm 14 between the potentiometer fixing nut and the wheel pivot fixing flat and fix the potentiometer support so that the head of the fixing screw does not touch the support Fixthe potentiometer using the BTR screw
23. energizing Voltage 24V Power 1 2 kW Consumption 63A Hydraulic operation pump capacity 0 06 0 33 inch rev Sound level 75 db Vibrations at foot level 1 ft 7 in s Vibrations at hand level gt 1 ft 7 in s Hydraulic oil tank capacity 6 6 gallons Operating hydraulic pressure max steering pressure 2320 psi max rotation pressure 725 psi max mast out telescoping pressure 652 psi max jib lifting pressure 2320 psi Tightening torque for steering wheel nuts 213 ft Ib 11 Pinguely Haulotte Z Repair manual STAR 22J Tightening torgue for drive wheel nuts 213 ft Ib Tightening torque for slew ring screws 99 ft Ib Weight 390 stones Dimensions Figure Size page 13 All pressure values can be checked using a pressure inlet 2 drive wheels with brake reducing gears and electric motors controlled by choppers Jib lifting telescoping turning movements hydraulic electropump and speed controlled by choppers Steering by electro distributor 12 Repair manual Pinguely Haulotte Z 2 1 2 Size of the STAR 22 J mast Fig 1 Size Pinguely Haulotte Z 2 2 14 TIGHTENING TORQUE VALUES Repair manual 2 2 1 Tightening torque values for large thread screws Nominal diameter M 6 1 Tightening torque in ft Ib 6 63 to 8 11 10 9 9 6 to 10 3 11 6 to 12 5 M 7 1 11 06 to 14 15 5 to 17 7 19 2 to 20 6 M 8 1 25 16 2 to 19 9 22
24. hose Put the machine back into the operational configuration Make several movements using the hose to purge the hydraulic circuit Check the level in the hydraulic oil tank Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C040 Sheet 1 1 CHANGING THE HORN AN Caution 1 Preliminary operations Switch off electric power see corresponding paragraph Do not use the machine during maintenance 2 Removing the horn BPRTANORE Mark and disconnect the electric connections from the horn 1 Remove the horn by unscrewing the fixing bolts 2 3 Installing the horn o E e Put the horn back into place and fix with the fixing bolt Reconnect the electric connections according to the marks made during dismantling 4 Test Select the top control panel and switch on machine power Putthe machine back into the operational configuration Activate the horn switch from the platform control panel and check that the horn sounds Star 22J Star 8 AN Caution The horn should be audible from the basket Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C060 Sheet 1 1 CHANGING THE HAND PUMP 1 Preliminary operations AN Caution Put the machine the maintenance configuration see 6 3 page 32 Use a container to collect oil to prevent pollution of the 2 Removing the hand pump environment e Mark and disconnect the hyd
25. naked flames Contact with the hot parts of the motor Use of a machine generating hydraulic leakage 1 3 4 Risks of collision Risk of crushing people in the machine operation zone when travelling or manoeuvring equipment The operator must assess the risks above him before using the machine Pay attention to the position of the arms during turntable rotation Adapt movement speed to conditions related to the ground traffic slope and movement of people or any other factor that may cause a collision When driving down the ramp of a truck ensure sufficient space is available for safe unloading Check brake pad wear regularly to avoid all risk of collision Repair manual 1 4 INSPECTIONS Pinguely Haulotte Z Comply with the national regulations in force in the country of machine use For FRANCE Order dated 9 June 1993 circular DRT 93 dated 22 September 1993 which specify 1 4 1 Periodic inspections The machine must be inspected every 6 months in order to detect any defects liable to cause an accident These inspections are performed by an organisation or personnel specially designated by the site manager and under his responsibility whether or not they belong to the company Articles R 233 5 and R 233 11 of the French Labour Code The results of these inspections are recorded in a safety register kept by the site manager and constantly available to the labour inspector and the site safety co
26. operator if necessary 1 2 2 Environment Never use the machine On soft unstable or cluttered floors On a floor with a tilt greater than the allowed limit With a windspeed above the permitted level In case of outdoor use check that windspeed is lower or equal to the permitted level using an anemome ter Near electric lines find out about minimum distances according to current In temperatures of less than 15 C in particular in cold rooms consult our service department if work is required in conditions below 15 C In an explosive atmosphere In an incorrectly ventilated area as exhaust fumes are toxic During storms risk of being struck by lightning At night if the machine is not equipped with an optional light In the presence of intense electromagnetic fields radar mobile and high current DO NOT DRIVE ON THE PUBLIC HIGHWAY 1 2 3 Using the machine It is important to ensure that in normal use i e platform operation the platform station selection key remains in the the platform position to enable control of the machine from the platform If a problem occurs on the platform a person present and trained in emergency standby manoeuvres can help by putting the key in the ground control position Never use the machine with a load greater than the nominal load more people than the authorised number lateral force in the platform greater than the level permitted wind speed higher than the permi
27. right Repair the wiring between the chopper and the electrovalves See sheet C145 Replace the coil The problem persists Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP079 NO RIGHT OR LEFT ROTATIONAL MAST MOVEMENT Folio 5 6 FROM THE PLATFORM Connect a pressure gauge to the pressure tapping at small pump output Make a right left rotation movement Pressure 1450 PSI NO 100 bars YES Test or replace the 1450 PSI 100 bars See sheet See sheet and 2320 PSI 160 C218 or C067 bars pressure limiters sheet Replace the rotation C205 motor Replace electrovalve YV2 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP079 vo RIGHT OR LEFT ROTATIONAL MAST MOVEMENT Folio 6 6 FROM THE PLATFORM Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP080 vo RIGHT OR LEFT ROTATIONAL MAST MOVEMENT Folio 1 6 FROM THE TURNTABLE mast right or left rotation mu from the turntable Put the key switch in the Platform position Activate mast right left rotation movement Right left YES Put the key switch in the Turntable position Activate mast right left rotation movement Open the Turntable box and measure voltage at CNA 8 CNA 9 and CNA 10 ofthe turntable board Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART
28. stop and station selection buttons are operational NO Replace an See sheet Butt OK dd if P y ids defective buttons C004 YES Measure voltage at terminals 5 END and 42 of the chopper NO See sheet Replace the chopper C003 YES END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet 081 NO MOVEMENT AVAILABLE FROM THE Folio 2 4 PLATFORM Measure voltage at CNB4 CNB4 24 V SC YES See sheet C063 Replace the Serial board Y Measure voltage at pedal output Voltage measured NO 24 YES Repair the wiring See sheet C064 Replace the pedal Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DPO81 NO MOVEMENT AVAILABLE FROM THE Folio 3 4 PLATFORM Measure voltage at the terminals of contactor SB1 L3 NO Check the wiring and See sheet batteries C149 If necessary repair the wiring and or YES replace the batteries Replace contactor SB See sheet C200 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DEE NO MOVEMENT AVAILABLE FROM THE Folio 4 4 PLATFORM Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP082 Folio 1 4 NO MOVEMENT AVAILABLE FROM THE TURNTABLE No movement available from the turntable Put the key switch in the Turntable position Activate a movement
29. the chassis Photo 6 so that the trempe point Photo 4 is as close as possible to the mechanical stop of the chassis Photo 6 Tighten the screws in diagonally opposite pairs Prepare the screws to fix the ring to the chassis and apply loctite check ing that the thread is clean and totally grease free Insert two pins in two diagonally opposite screws threads of the chassis Tighten the screws one by one turning th mast from right to left Replace the pins with screws to fix to the ring to the chassis Photo 7 ref 1 Sheet C210 AN Caution After reinstalling the mast it is essential to have static and dynamic load tests performed by a certified organisation Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET NB Sheet 3 4 REPLACING THE SLEW RING Photo 7 Tighten to a torque of 99 Ibf ft 135Nm Tighten the screws in diago nally opposite pairs Check that the mast turns properly from stop to stop 4 Additional operations Remove the slings Check that the counterweights are properly secured to the machine Put the machine back into the operational configuration Make several rotation movements to test correct operation of the slew ring and to purge the hydraulic circuit Check the level of the hydraulic tank Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C210 Sheet 4 4 REPLACING THE SLEW RING Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C211 Sheet 1 2 REPLACING
30. torque values Fill the hydraulic oil tank use the oil recommended by Pinguely Haulotte Putthe machine back into the operational configuration Make several lifting cycles to purge the hydraulic circuit Checkthe level of the hydraulic circuit Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C208 Sheet1 1 REPLACING THE TURNTABLE EMERGENCY STOP BUTTON 1 Preliminary operations Putthe machine into the maintenance configuraiton see relevant sec tion Switch off the electric power supply see relevant section e Disconnect the then terminals of the batteries to isolate the electric circuit Caution Do not use the machine during maintenance operations 2 Removing the emergency stop button e Mark and disconnect the electric connections 1 of the emergency stop button Remove the head of the emergency stop button 2 by unscrewing it hav ing blocked its pin by inserting a rod into the hole 3 provided Remove the emergency stop button by unscrewing its two fixing screws 4 3 Reinstalling the emergency stop button Puta new emergency stop button into place Reconnect the electric connections according to the marks made during dismantling 4 Test Reconnect the then terminals of the batteries Put the machine back into the operational configuration Check that the emergency stop button works properly Pinguel
31. 2 RCH overload relay isolation relay internal charger relay 3 1 4 2 On off electrovalves YV1a YVib YV2a YV2b YV3a YV3b YV4 YV5 YV6 right steering left steering left rotation right rotation jib up or mast down mast up mast up jib down or jib up mast down 3 1 4 3 Buzzers H1 platform horn 3 1 4 4 Light indicators PV HA HPh hour meter battery indicator weighing or tilt alarm light indicator working light Repair manual Pinguely Haulotte 77 4 POSITIONS OF ELECTRIC COMPONENTS SA1 MDI Serial board JA 1B 2A 2B 3A 3B CUR ott anm Tu N TE 2 TR Grise assu i i i Pinguely Haulotte 77 Repair manual SB9 SA2 4 1 CHASSIS EQUIPMENT MD Right side travel motor MG Left side travel motor EDF Right travel motor electrobrake EFG Left travel electrobrake EG Left side travel motor inducer ED Right side travel motor inducer P1 Steering potentiometer EFG EFD 20 Repair manual Pinguely Haulotte 4 OPERATING EQUATIONS 5 1 START UP If SB1 1 and RCH 0 and SA1 turntable or SA1 platform and SB3 1 then chopper active 5 2 SHUTDOWN If SB1 0 or RCH 1 or SA1 0 or SA1 platform and SB3 0 then chopper inactive 5 3 MAST LIFTING 5 3 1 Turntable 5 3 1 1 Up If SA1 turntable and SB6 1 and SM1 1 and SQ1 1 or machine retracted and overload 0 then YV3b 1 and YV4 1 and M1 1 overload 1 if i
32. 21 pe db 21 pile Doble ea 21 ii PRI TT 22 pe RO 22 Pol 0 nsimi adain ian aa 22 Suo PIANO ainsi 22 qb TRAVEL 23 pal Pelia 23 O STEERNG soil 23 Sal 55 2 rennen 23 SES HORN WE 23 Repair Manual Pinguely Haulotte D zT AN Ac EE 23 5 9 1 Without option 23 5 9 2 With option on console 23 5 10 WORKING LIGHT OPTION LIGHT INDICATOR nnn 23 5 11 WEIGHING OR TILT ALARM UIGHTINDICATOR nan 23 5 12 HOUR METER AND BATTERY CHARGE 24 5 13 OTHER FUNCTIONS aas ee Eege 24 5 13 1 Platform movement validation button 24 6 WIRING OS nennen nna 25 7 HYDRAULIC 65 2 5 u 27 8 POSITIONS OF HYDRAULIC COMPONENT S 29 9 MAINTENANCE el 31 9 1 GENERAL RECOMMENDATIONS 2 nnne nnne nnn 91 9 2 SPECIFIC RECOMMENDATIONS 31 9 2 1 SPECIFIC TOOLS u u a Eee 31 922 Replacing an element EE EN 9 2 3 Ne E 32 9 3 MAINTENANCE SYSTEM E 32 9 4 ELECTRIC POWER SUPPLY E 32 10 1 MAINTENANCE PLAN a es ant 33 COnSumable Ber eret ie Nat ia 33 10 1 2 Maintenance 34 101 2
33. 5 8 1 and SA2 travel and SM3 1 and 501 1 or machine retracted and overload 0 then MD 1 and MG 1 full setpoint overload 1 if inputs 26 0 and 38 0 option not available at present Machine retracted gt SQ4 1 and 5012 1 5 7 1 Platform 5 7 1 1 Left If SA1 platform and SB8 1 and SA2 travel and SM2 1 and SQ1 1 or machine retracted and overload 0 then M1 1 and YV1b 1 overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and SQ12 1 5 7 1 2 Right If SA1 turntable and SB8 1 and SA2 travel and SM2 1 and SQ1 1 or machine retracted and overload 0 then M1 1 and YV1a 1 overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and SQ12 1 If SA1 platform and SB9 1 then H1 1 5 9 1 Without option If SQ1 0 and machine extended or overload 1 then buzzer 1 5 9 2 With option on console If travel_option 1 and Travel 1 or movement_option 1 and mast 1 or jib 1 or rotation 1 then buzzer 1 5 10 WORKING LIGHT OPTION LIGHT INDICATOR 5 11 The working light is electrically wired To use it activate the switch WEIGHING OR TILT ALARM LIGHT INDICATOR If overload 1 or SQ1 0 and machine extended then HA 1 option not available at present 23 Pinguely Haulotte Z Repair manual 5 12 HOUR METER AND BATTERY CHARGE LIGHT INDICATOR Shows the number of hours of use for the machine and remaining battery charge 5 13 OTHER FUNCTIONS 5 13 1 Platform movement validation button Pressi
34. 5V Measure voltage at CNB4 Replace manipulator See sheet SM2 C14 CNB4 24 V NO Repair the wiring YES END Measure voltage at pedal output Voltage measured NO 24 YES Repair the wiring Seesheet C064 Replace the pedal Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP085 NO LEFT OR RIGHT Folio 3 4 STEERING MOVEMENT NO The pump works Check pump wiring Measure voltage at terminals 6 12 and 20 of the chopper 24V 104 right 12 24V 104 left right 20 24V 104 left See sheet Replace the chopper C003 Y See sheet Replace the chopper C003 Repair the wiring Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP085 Folio 4 4 NO LEFT OR RIGHT STEERING MOVEMENT Measure voltage at the terminals of electrovalves YV1a YV1b and YB3b YV1a 24 right YV1b 24 left and YV3a 24 V left right Repair the wiring between the chopper and the electrovalves See sheet Replace the coil C145 The problem persists Connect a pressure gauge on the pressure tapping at small pump output Make a steering movement Pressure 1450 PSI 100 bars NO Test or replace the 1450 PSI 100 bars
35. 7 8 2350 to 2610 2 2 3 Tightening torque values for hydraulic hoses Description Drawing no A14706 Ref 7 Hose SP 5238 Lg 2060 Torque applied ft Ib min max 7 37 11 06 Ref 8 Hose SP 5008 Lg 530 7 37 11 06 Ref 9 Hose SP 5238 Lg 1640 7 37 11 06 Ref 10 Hose SP 2361 Lg 1450 44 25 59 Ref 11 Hose SP 449 Lg 670 59 73 75 Ref 12 Hose SP 5025 Lg 400 59 73 75 Repair manual Description Drawing no 414706 Ref 13 Hose SP 5008 Lg 1300 Pinguely Haulotte 4 Torque applied ft Ib min max 7 37 11 06 Ref 14 Hose SP 5008 Lg 550 7 37 11 06 Ref 47 Hose SP 5028 Lg 500 44 25 59 Ref 53 Hose SP 2361 Lg 700 44 25 59 Ref 54 Hose SP 1663 Lg 610 29 5 36 87 Ref 68 Hose SP 1786 Lg 500 18 44 25 81 Ref 69 Hose SP 1756 Lg 350 1844 25 81 2 2 4 Pressure table in psi Main Steering Rotation Lifting 2320 2320 725 652 2 2 5 Table of adjustment times Movement Microspeed Mast up Movement duration 50 s 2s for 32 ft 9 in High speed forward Mast and jib down 8 s 1s for 32 ft 9 in High speed reverse Mast and jib down 8 s 1s for 32 ft 9 in Braking distance High speed Mast and jib down 70cm 7 in Ring rotation from right to left Mast and jib down 60s 2s Right to left steering Ma
36. 877 HAULOT S Haulotte Netherlands BV T l Phone 31 162 670 707 Fax Fax 31 162 670 710 Haulotte Italia T l Phone Fax Fax 39 05 17 80 813 39 05 16 06 46 14 Haulotte Scandinavia AB u b T l Phone 46 31 744 32 90 Fax Fax 46 31 744 32 99 Haulotte Portugal T l Phone Fax Fax 351 21 955 98 10 351 21 995 98 19 Repair manual Pinguely Haulotte Z AN Caution The technical data in this manual is not binding and we reserve the right to make improvements or modifications without altering this manual GENERAL This manual gives the information required for you to perform servicing and repair operations on certain pieces of equipment yourself However we would like to bring your attention to the importance of respecting the safety instructions concerning the machine itself its use and its environment use within the limits of its performance correct servicing to ensure long service life During and after the guarantee period our After Sales service is available to perform any servicing operations you may require In this case contact our local agency or our Plant After Sales service specifying the exact type of machine and its serial number To order consumables or spare parts use the Instructions for use and maintenace manual and the Spare parts catalogue to order original parts the only guarantee of interchangability and perfect operation REMINDER We would like t
37. 9 to 25 1 27 3 to 30 2 M 10 1 5 31 7 to 33 1 45 to 49 4 53 9 to 59 7 M 12 1 75 55 3 to 69 3 81 1 to 88 5 95 9 to 103 2 M 14 2 88 5 to 110 6 125 4 to 140 147 5 to 162 2 M 16 2 140 1 to 169 6 191 8 to 213 8 236 to 258 M 18 2 5 191 7 to 236 265 5 to 295 324 5 to 354 M 20 2 5 272 9 to 331 9 383 6 to 420 4 457 3 to 501 5 M 22 2 5 368 8 to 457 2 516 3 to 567 9 619 6 to 685 9 M 24 3 3 464 7 to 582 6 656 4 to 730 1 789 2 to 870 3 M 27 3 685 9 to 848 1 958 8 to 1032 5 1150 6 to 1275 9 M 30 3 5 929 3 to 1157 9 1305 5 to 1445 6 1622 7 to 1733 2 2 2 2 Tightening torque values for small thread screws Nominal diameter M 8 1 Tightening torque in ft Ib 17 7 to 21 3 10 9 24 4 to 27 3 29 5 to 44 M 10 1 25 33 9 to 42 47 2 to 52 3 56 8 to 85 M 12 1 25 66 2 to 73 7 85 8 to 95 9 103 2 to 150 M 14 1 5 95 9 to 118 132 7 to 147 5 162 2 to 240 M 16 1 5 147 5 to 184 3 206 5 to 228 6 340 to 370 M 18 1 5 213 8 to 265 5 302 4 to 331 9 490 to 540 M 20 1 5 302 4410 to 376 420 4 to 464 6 690 to 760 M 22 1 5 405 7 to 501 5 575 3 to 641 6 920 to 1000 M 24 1 5 508 9 to 634 3 715 4 to 789 2 1160 to 1290 M 27 2 737 6 to 958 8 1032 5 to 1150 6 1690 to 1880 M 30 2 1032 5 to 1253 8 1445 6 to 160
38. A STEERING PIVOT AN Attention 1 Preliminary operations f Pl Putthe machine into the maintenance configuration see relevant sec Ensure that the oil is not too tion hot Disonnect the batteries Switch off the electric power supply see relevant section Remove the chassis covers see relevant sheet Attention Remove the wheel in question see relevant sheet Use a container to collect the Liftthe chassis with a jack or hoist oil to prevent pollution of the environment 2 Removing a steering pivot Remove the pin and washer Photo 1 Unscrew the steering pivot fixing plates Photo 2 AN Attention It is essential to put the E P component into slings before dismantling reassembling it N Attention Check that the lifting means are in good condition and of sufficient capacity Photo 1 Photo 2 Liftthe chassis The pivot comes down Hitthe pin near the stud on the pivot with a mallet Remove the pivot 3 Reinstalling a steering pivot Grease the steering pivot Grease the hub 1 NB Grease the parts added evenly and insert them using a mallet Place the bearing in the hub 2 e Push in completely 1 Insert seal 5 Pushin completely Position the hub after turning it on the pivot Photo 5 Lower the pivot e Install the conical roller bearing 6 Photo 4 Lower it Install a flat washer 8 on the bearing Photo 6 Pinguely
39. AINTENANCE SHEET Sheet P010 Folio 2 2 CHECKING SERVICING THE TRACTION BATTERIES Pinguely Haulotte 77 PREVENTIVE MAINTENANCE SHEET SHEET P011 Folio 1 1 LUBRICATING THE MAST 1 Lubricating the mast Extend the mast Switch off the electric power supply see relevant section Grease the slides at pad level using a spatula Grease the pads at the back of the machine NB Only use lubricants recommended by the manufacturer Putthe machine back into the operational configuration Pinguely Haulotte Z PREVENTIVE MAINTENANCE SHEET Repair manual Pinguely Haulotte 77 12 OPERATING INCIDENTS REMINDER Respecting the machine s operating and servicing instructions will enable you to avoid most incidents However certain incidents may arise and before any intervention it is essential to consult table 6 1 If the incident is listed simply follow the instructions Only common incidents whose solutions can be implemented by an operator are listed For all other incidents contact your PINGUELY HAULOTTE representative or the plant s After sales service Before diagnosing a failure check that the emergency stop palm buttons on the turntable and platform are unlocked the circuit breakers on the turntable panel are pushed in The speed chopper has a failure indication system on the timer display To diagnose a failure consult the table below note the alarm code and pass it onto the Aft
40. AL MAST MOVEMENT Folio 4 6 FROM THE TURNTABLE Measure voltage at the terminals of electrovalves YV2a and YV2b V2a 24 V left and YV2b 24 V right Repair the wiring between the chopper and the electrovalves See sheet C145 Replace the coil The problem persists Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP080 NO RIGHT OR LEFT ROTATIONAL MAST MOVEMENT Folio 5 6 FROM THE TURNTABLE Connect a pressure gauge to the pressure tapping at small pump output Make a left right rotation movement Pressure NO 1450 PSI 100 bars YES Test or replace the 1450 PSI 100 bars See sheet See sheet and 2320 PSI 160 C218 or C067 bars pressure limiters sheet Replace the rotation C205 motor Replace electrovalve YV2 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP080 RIGHT OR LEFT ROTATIONAL MAST MOVEMENT Folio 6 6 FROM THE TURNTABLE Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP081 Folio 1 4 NO MOVEMENT AVAILABLE FROM THE PLATFORM No movement available from the platform Put the key switch in the Platform position Activate a movement NO No movement is made YES Check fuses FU1 FU2 FUA and FU5 defective fuses YES END Make sure that the emergency
41. JIB MOVEMENT FROM THE PLATFORM No jib up or down movement from the platform Put the key switch in the Turntable position Activate jib movement he jib move up or down Put the key switch in the Platform position Activate jib movement YES Open the Platform box and measure voltage on CN23 and CNB6 of the platform board NO CN23 0 V CNB6 24 V Measure voltage at the terminals of selector switch SA2 SA2a 29A N Replace the See sheet selector C004 Repair wiring Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART NO UP OR DOWN JIB MOVEMENT Folio 2 6 FROM THE PLATFORM Measure voltage on CN1 9 CN1 10 and CN1 8 on the platform board CN1 8 0V idle CN1 8 0V at 4V CN1 10 5V amp CN1 9 0V up CN1 10 0V amp CN1 9 5V down NO Follow the same wire colours and measure voltage at the terminals of manipulator SM3 Measure voltage at CNB4 OV lt cursor lt 4V FOR contact 5V or NO NO REV contact CNB4 24V 5V Replace manipulator See sheet Mey YES SM3 142 Repair the wiring Replace the Serial See sheet board C063 Y Measure voltage at pedal output See sheet C064 Replace the pedal Repair the wiring
42. OWN DETECTION FLOW CHART Sheet DP084 Folio 2 2 TRAVEL MOVEMENT IN MICROSPEED ONLY Measure voltage atthe terminals of 504 wire 106 5 Visually check that SQ4 Repair the Se SQ4 is closed an NO END SQA is closed YES Adjust or replace the See sheet sensor C200 Repair the wiring between 504 and 42A Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP085 Folio 1 4 NO LEFT OR RIGHT STEERING MOVEMENT No left or right steering movement from the platform Put the key switch in the Platform position Activate left or right steering Open the Platform box and measure voltage at CN23 and CNB6 of the platform board CN23 24V bas CNB6 OV Measure voltage at the terminals of selector switch SA2 SA2a 29A 24V SA2b OV Replace See sheet selector C004 Repair the wiring Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP085 Folio 2 4 NO LEFT OR RIGHT STEERING MOVEMENT Measure voltage at CN1 3 CN1 4 and CN1 5 ofthe platform board NO CN1 3 0V idle CN1 3 0V at 4V CN1 5 5V amp CN1 4 0V up CN1 5 0V amp CN1 4 5V down Follow the same wire colors and measure voltage at the terminals of manipulator SM2 OV lt cursor lt 4V FOR contact 5V or REV contact
43. Pinguely Haulotte Z CE REPAIR MANUAL SELF PROPELLED PLATFORM STAR 8 10P 242 031 9680 E 06 03 GB SS VA 7 150 9001 GROUPE 4 Z TELESCOPIQUES GSEAUX TRACTEES Supiy ARTICULEES MATS PINGUELY HAULOTTE LA PERONNIERE BP 9 42152 L HORME T l 33 0 4 77 29 24 24 Fax SAV 33 0 4 77 3128 11 email haulotte haulotte com Web www haulotte com Distribu par Distributed by Haulotte France T l Phone Fax Fax 33 0 4 72 88 05 70 33 0 4 72 88 01 43 Haulotte Hubarbeitsb hnen T l Phone 49 76 33 806 920 Fax Fax 49 76 33 806 82 18 Haulotte UK T l Phone 44 0 1952 292753 Fax Fax 44 0 1952 292758 Haulotte Asia T l Phone Fax Fax 65 6251 5592 65 6251 4492 Haulotte Australia PTY Ltd T l Phone 61 39706 6787 Fax Fax 613 9706 6797 Haulotte Do Brazil T l Phone Fax Fax 55 11 3026 9177 55 3026 9178 Haulotte Iberica Madril T l Phone 34 91 656 97 77 Fax Fax 34 91 656 97 81 Haulotte Iberica Sevilla T l Phone 34 95 493 44 75 Fax Fax 34 95 463 69 44 Centre Mondial Pieces de Rechange Spare Parts International Centre T l Phone 33 0 4 77 29 24 51 Fax Fax 33 0 4 77 29 98 88 Haulotte Portugal T l Phone Fax Fax 351 21 955 98 10 351 21 995 98 19 Haulotte U S Inc Main tool free Service tool free 1 877 HAULOTTE 1
44. See sheet board C063 END Y Measure voltage at SB5 output NO ension measured 24 V YES See sheet Replace the butt Repair the wiring C004 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP076 Folio 3 6 NO UP OR DOWN JIB MOVEMENT FROM THE TURNTABLE No down movement No up movement Check battery charge Battery charge NO OK WES See sheet Charge the batteries C139 Put the key switch in the Turntable position and activate jib movement No down movement Y No up movement The pump works SO Check pump wiring Measure voltage at terminals 18 and 19 of the chopper Wiring is correc NO 18 24V 104 up 19 24V 104 up down S heet Replace the chopper ui See sheet Replace the chopper C003 Y Repair the wiring Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART NO UP OR DOWN JIB MOVEMENT Folio 4 6 FROM THE TURNTABLE Measure voltage at the terminals of electrovalves YV3a and YV5 24 V u and YV5 24 V up down NO Repair the wiring be tween the chopper and the electrovalves See sheet C145 Replace the coil The problem persists Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART nee Dar
45. THE PLATFORM Measure voltage at CN1 9 CN1 10 and CN1 8 on the platform board CN1 8 0V idle CN1 8 OV at 4V CN1 10 5V amp CN 1 9 0V UP CN1 10 0V amp CN1 9 5 NO Follow the same wire colours and measure voltage at the terminals of manipulator SM3 Measure voltage at CNB4 OV lt cursor lt 4V FOR contact 5V or NO CNB4 24 V NO REV contact 5V Replace manipulator See sheet YES SM3 142 Repair the wiring Replace the Serial See sheet board C063 END Y Measure voltage at pedal output oltage measured NO See sheet Replace the pedal Repair the wiring p p C064 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet 077 NO UP OR DOWN MAST MOVEMENT Folio 3 6 FROM THE PLATFORM No down movement No up movement Measure voltage at terminal 24 of the chopper Voltage measured NO 24 V Check if the mast is at its max height gt I ax height reached YES Lower the mast Measure voltage at 5010 NO Replace the sensor See sheet C200 Repair the wiring END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP077 Folio 4 6 NO UP OR DOWN MAST MOVEMENT FROM THE PLATFORM No down movement No up movement C
46. ace the batteries Replace contactor SB See sheet C200 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP082 vo MOVEMENT AVAILABLE FROM THE TURNTABLE Folio 4 4 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP083 Folio 1 4 NO FORWARD OR REVERSE TRAVEL MOVEMENT No forward or reverse travel movement from the platform Put the key switch in the Platform position Activate FOR and REV travel Open the Platform box and measure voltage at CN23 and CNB6 of the platform board CN23 24V NO CNB6 OV Measure voltage at the YES terminals of selector switch SA2 SA2a 29A 24V SA2b OV Replace See sheet selector C143 Repair the wiring Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP083 Folio 2 4 NO FORWARD OR REVERSE TRAVEL MOVEMENT Measure voltage at CN1 8 CN1 9 CN1 10 on the platform board CN1 8 OV idle CN1 8 OV at 4V CN1 10 5V 8 CN1 9 0V UP CN1 10 0V 8 CN1 9 5 down NO Follow the same wire colors and measure voltage atthe terminals of manipulator SM3 Measure voltage at CNB4 OV lt cursor lt 4V FOR contact 5V or REV contact 5V NO CNB4 24 V SC YES Replace manipulator See sheet C143 Repair the wiring SMS Y Measure volt
47. ad 33 3078147950 2 Safety harness 34 3078147260 2 Horizontal body crush hazard 35 3078149380 1 Jib emergency lowering 36 307P201500 1 Symbols summary 37 3078149310 1 Do not stand in the working area 38 3078148330 1 Red arrow 36 Repair manual Pinguely Haulotte Z Ref Code Qty Description 39 3078147140 1 Hydraulic oil 39 3078148920 1 Organic hydraulic oil 40 3078147210 1 Oil level 41 3078147350 1 Wear protective clothing 42 3078147330 1 Servicing of batteries 43 3078148810 1 Emergency movements 44 3078148030 1 Danger explosion hazard 45 2420316420 1 Safety manual 46 2420316430 1 Manual of responsibilities 47 2420313920 1 Owner s manual 37 Pinguely Haulotte 4 Md O OO SAN Gi DS DO DA Sr E EN y i 16558 Repair manual Pinguely Haulotte 4 10 3 PRESENCE OF MANUALS It is important to ensure that the manuals supplied with the machine are in good condition and stored in the document holder provided on the platform An illegible manual may lead to incorrect or dangerous use of the machine Operating instructions Check presence of manuals Check that the manuals are legible complete and stored in the document holder provided on the platform Replace if necessary extra copies can be supplied on request by the manufacturer 39 Repair manual Pinguely Haulotte A 11 PREVENTIVE MAINTENANCE SHEETS Lis
48. age at pedal output Measured voltage 24V e Replace the pedal See sheet 064 Repair the wiring Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DF065 NO FORWARD OR REVERSE TRAVEL MOVEMENT Todo s Measure voltage at terminals 1 and 15 of the chopper NO 1 24 V and 15 24 V Replace the Serial board Seesheet C063 Measure voltage directly on the brakes Repair the wiring between the brakes and the chopper Y Replace the chopper See sheet C003 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART elle DPOOS NO FORWARD OR REVERSE TRAVEL MOVEMENT Folio 4 4 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP084 Folio 1 2 TRAVEL MOVEMENT IN MICROSPEED ONLY Travel movement microspeed Put the key switch in the Platform position Retract the mast and jib completely Measure voltage at terminal 36 of the chopper NO Measure voltage atthe terminals of SQ12 wire 36A YES Replace the Seesheet chopper C003 YES NO Repair wiring between 5012 and chopper Visually check that 5012 is closed END NO SQ12 is closed 5 Adjust or replace the See sheet C200 e sensor Pinguely Haulotte Z BREAKD
49. ant sheet Reinstall the hydraulic plate see relevant sheet Reinstall the electric plate see relevant sheet Reinstall the end of travel contactor 5010 see relevant sheet Reinstall the charger see relevant sheet Reinstall the circuit breaker see relevant sheet Reinstall the jib see relevant sheet Reinstall the end of travel contactor 5012 see relevant sheet Reinstall the hydraulic supply hose at the top of the mast Reinstall the hydraulic winder see relevant sheet Reinstall the end of travel contactors SQ3 and SA4 and the sheet covering them see relevant sheet Reconnect pump supply Reinstall and reconnect the batteries see relevant sheets Reinstall the bottom right and left covers see relevant sheet Reinstall the motor cover see relevant sheet Reinstall the right and left side covers see relevant sheet Putthe machine back into the operational configuration Make several movements to check correct machine operation and safety Systems Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C200 Sheet 1 1 REPLACING AN END OF TRAVEL CONTACTOR 1 Preliminary operations AN Caution e Put the machine into the maintenance configuration see relevant sec Do notuse the machine tion during maintenance Switch off the electric power supply see relevant section operations 2 Removing an end of travel contactor Mark the position of the en
50. b PI dodo ge BR e I I IN d Ans vd eZ P MEN I gt P Z ESSIB t T P rd jew oq CH 17 f v r I L 1 trom 12107 fa 12 ni I 5 156 ed sl 7 Tag ld WUOMSZ 4 Ec 145 4 d uH DE 4 b oq op io d ims por la 9 I I lo u real IN I 7 4 2 zl I I B nde Tal 1 gt I I lo ovt LEI 4 dol IN bi ver St d eee 1 Seems il At 4 GC por SSS ee wir 4 2 gad ent 4 24 4 I eo SOL a Im r Zov r 179 oi I I ws P DU P M 2 oV I Da en I i d ENT pog mi mj 34 33 b Ecc r E z 16m lo I 201 91 10 I Go E vi a s o od II La i LONO ONO ZIONO Arno sanot e ire LA I en wanol 2 co a 986 r 8 VNO ejgejuini mo La x 2 919 101 sjgNoL are ees JED Jela ANI Bris oue De i ed o VO SINO t pon d LO 9994 25 cO 9999 Repair manual 9j 998N pie9 jenas 21198 24180 6 LND ino ono I 4 um I
51. crew 4 so that the tilt sensor level is set Putthe machine back into the operational configuration 4 Tilt sensor operating test e Extend the machine Tilt the tilt sensor and check that an audible alarm is sounded Make mast up and jib lifting movements to the safety contacts Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C141 Sheet 1 1 CHANGING THE JIB CYLINDER 1 Preliminary operations Putthe machine in the maintenance configuration see relevant section AN Caution Switch off the electric power supply Putthe basket in slings to ensure it does not fall Photo 1 and secure it Slightly lift the drum to facilitate access to the cylinder Ensure that the oil is not too hot 2 Removing the jib cylinder Putthe cylinder 1 and the vertical parts 2 and 3 of the jib into slings e Mark disconnect the 2 hydraulic hoses of the jib cylinder NB Unscrew the hoses slowly to release residual hydraulic pressure Putcaps on the hoses Remove the 2 bolts of the cylinder pin 4 on the cylinder body side Remove the pin 4 Remove the 2 bolts of the cylinder pin 5 on the rod side Remove the pin 5 Remove jib cylinder 1 3 Reinstalling the jib cylinder NB Before reassembly check the condition of all articulated pin rings and replace if necessary Lubricate all bores before reinstalling the pins Only use lubricants recomm
52. d of travel contactor 1 Remove the end of travel contactor Open the end of travel contactor mark and disconnect the electric con nections 3 Reinstalling an end of travel contactor Open the new end of travel contactor reconnect the electric connections and close the contactor again Putthe end of travel contactor into place according to the position marked during dismantling and fix onto its support Donottighten the bolts before adjusting 4 Adjustment and test Putthe machine back into the operational configuration Make the movement using the contactor in question and check that it works properly Adjust the position of the contactor if necessary and tighten the fixing bolts SQA mast down SQ10 high position caisson SQ12 jib up 504 5012 Pinguely Haulotte Z Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C201 Sheet 1 1 REPLACING THE HYDRAULIC FILTER AN Attention 4 1 Preliminary operations Ensure that the oil is not too Put the machine into the maintenance configuration see relevant sec hot tion Switch off the electric power supply see relevant section A d 2 Removing the hydraulic filter Attention Unscrew the bowl 1 of the hydraulic filter Use a container to collect the Place a bowl under the hydraulic filter to collect the oil oil to prevent pollution of the Take the filtration element out of the base environment 3 Reinstalling the hydraul
53. d power unit a its coil is in short circuit b anomaly in the switch 9 DRIVER This alarm is indicated in the case of an error on Rio SHORTED the open mains switch Sues ing SOI d fault in the safety system circuit often related to POWER FAILURE SERIAL ERROR Incorrect reception or reception of an incoherent A 10 Check station connectors 1 message from the selected serial card driver short circuit 41 BRAKE DRIVER This alarm appears when there is a problem on 22 D E M KO the electrobrake driver E e M command circuit on the electrobrake 12 MICRO en The logic micro controller or its links are defective a Defecti ling test is performed continuously giving the de nidi 13 FORW BACK alarm if two operation directions are given at the 525 same time i c Erroneous movement Repair manual Pinguely Haulotte 77 CODE ALARM PROBABLE CAUSES REMEDIES en rar Humidity in ihe upper START P station blow the card seat operation 15 POWER FAILURE Short circuit on the valve on the mains or on the brakes 16 RIGHT 0 EVER test is performed during operation it checks that during operation current is greater than a a See RIGHT STBY 17 LEFTI 0 EVER minimum value Otherwise this alarm appears and HIGH the machine is blocked a Check that motor The test is performed durin
54. draulic filter cartridge See chap 5 3 1 see 250 hours periodicity Check tightness of slew ring screws see 500 hour periodicity drawing ref 4 drawing ref 5 drawing ref 6 drawing ref 3 drawing ref 7 Every 250 hours Change the hydraulic filter cartridge See chap 5 3 1 Grease the friction parts of the mast check pad wear Check the tightness of wheel nuts Upper clevis screws drawing ref 10 drawing ref 8 drawing ref 9 drawing ref 11 Every 500 hours Check the tightness of the ring Screws If using organic oil empty the hydrau lic oil tank drawing ref 12 Every 1000 hours Empty the hydraulic oil tank capacity 25 1 See chap 5 3 3 drawing ref 13 Every 2000 hours Empty the hydraulic oil tank and the whole circuit See chap 5 3 3 drawing ref 14 35 Pinguely Haulotte Z Repair manual 10 2 PRESENCE OF LABELS Make sure that the labels and plates informing personnel of the various dangers related to machine use are in good condition The labels also inform operators on the use and maintenance of the machine An illegible label may result in incorrect or dangerous use of the machine Instructions Check that the labels are present Check that all the labels described below are legible and in place Replace if necessary additional copies can be supplied on request 10 2 1 Labels positions
55. e NO UP OR DOWN JIB MOVEMENT Folio 5 6 FROM THE TURNTABLE Connect a pressure gauge on the pressure tapping at small pump output Make a jib up down movement Pressure 2320 PSI 160 bars YES NO See sheet Replace electrovalve C067 YV5 NO Pressure zero Replace electrovalve See sheet YV3 067 Test or replace the 2320 PSI 160 bars pressure limiters See sheet C218 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART DEOTG NO UP OR DOWN JIB MOVEMENT Folio 6 6 FROM THE TURNTABLE Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP077 Folio 1 6 NO UP OR DOWN MAST MOVEMENT FROM THE PLATFORM No mast up or down movement from the platform Put the key switch in the Turntable position Activate mast up down movement up or down Put the key switch in Platform position Activate mast up down movement YES Open the Platform box and mea sure voltage on CN23 and CNB6 of the platform board CN23 OV NO CNB6 OV Measure voltage at the terminals of selector switch SA2 SA2a 29A OV NO SA2b OV Replace See sheet selector C004 Repair the wiring Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP077 Folio 2 6 NO UP OR DOWN MAST MOVEMENT FROM
56. e area based on the periodicity The symbol represents the consumable to be used 10 1 1 Consumable Lubricants CONSUMABLE SPECIFICATION SYMBOL used by ELF TOTAL HAULOTTE AFNOR 48 602180 V HYDRELFDS EQUIV Hydraulic oil G 46 BPSHF ZS 46 46 ISZS 46 Extreme pressure CARDREXA lithium grease RO SAME DC 1 55 MULTIMOTIVE MULTIS Lead free grease Grade 2 or 3 O GREASE 2 EP 2 Exchange or specific operation Loctite 8021 LS 60 cat 26470 D Organic oil SHELL Naturel ISO 46 gt le HF E see page 35 ui a E AFNOR 48 602150 V SHELL G 32 TELLUS T 32 see page 35 33 Pinguely Haulotte 77 Repair manual 10 1 2 Maintenance plan 2000 h mra Sun ji E Mu IT ef 6 D E ce vee 8 he sell D I uc s a gt 5295 1 49 34 Repair manual Pinguely Haulotte Z 10 1 3 OPERATIONS IMPORTANT IF ORGANIC OR EXTREME COLD OILS ARE USED THE PERIODICITIES IN THE TABLE BELOW ARE REDUCED BY HALF PERIODICITY OPERATION REFERENCE Every day or before each start of opera tions Check hydraulic tank level See chap 4 3 3 electrolyte level in the batteries See chap 4 3 3 drawing ref 1 drawing ref 2 Every 50 hours Grease wheel pivot pins ring bearing ring teeth CAUTION after first 50 hours Change the hy
57. electric power supply see relevant section Raise the machine with a jack or hoist 2 Removing a drive wheel Push back the tab 1 of the toothed washer 2 Unscrew the wheel s fixing nut 3 Remove the toothed washer 2 then the flat washer 4 Remove the wheel d N N 3 Reinstalling a drive wheel Replace the key 5 if necessary Puta new wheel into place and secure with the fixing nut 6 After tightening block the nut with the KM washer Putthe machine back into the operational configuration Pinguely Haulotte Z Sheet C207 AN Caution Ensure that the oil is not too hot AN Caution Use a container to collect the oil to prevent pollution of the environment Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet 1 1 REPLACING THE HYDRAULIC TANK 1 Preliminary operations Putthe machine into the maintenance configuration see relevant sec tion Switch off the electric power supply see relevant section 2 Removing the hydraulic tank 1 Empty the tank by removing the plug 2 Disconnect the hydraulic hoses 3 and remove the hydraulic connectors Putcaps on the hoses Remove the tank 1 by removing its fixing nuts 4 3 Reinstalling the hydraulic tank Reinstall the tank and secure with its nuts NB Take care with hydraulic hoses passing behind the tank Putthe connectors back into place and connect the hoses see table of tightening
58. ended by the manufacturer Photo 1 Putthe jib cylinder into place and reinstall the 2 articulation pins on the cylinder rod and body sides Secure the pins with their bolts Remove the slings 4 Additional operations Putthe machine back into the operational configuration Make several jib movements to test operation and purge the hydraulic cir cuit e Check the hydraulic circuit level Pinguely Haulotte Z Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C142 Sheet 1 1 REPLACING THE TOP PANEL MANIPULATOR 1 Preliminary operations Putthe machine into the maintenance configuration see relevant sec Caution tion Do not use the machine Switch off the electric power supply see relevant section during maintenance opera tions 2 Removing the manipulator 2 Remove the closing plate 1 by taking out the four fixing screws e Mark and disconnect the electric connections of the manipulator Remove the manipulator by taking out the fixing screws 3 Reinstalling the manipulator Fixa new manipulator equipped with new seals on the platform control panel Reconnect the electric connections according to the marks made during dismantling Putback the closing place and secure with the four fixing screws Putthe machine back into the operational configuration Make several up and down movements from the platform control panel to test manip
59. er sales service who will given you the instructions to follow Pinguely Haulotte 4 Repair manual 12 1 TROUBLE SHOOTING CODE ALARM PROBABLE CAUSES REMEDIES The battery is discharged The alarm is only indicated if the BATTERY CHECK option has been selected i LON BATTET e Reduces the traction current and disables lifting EE movements at approximately 10 of residual charge The alarm is given if the capacitors take more 2 CAPACITOR than 500 ms to charge in the KEY ON position Me ian CHARGE The most likely cause is a fault on the unit or 9 PP power supply 3 NO ISOLATION Indicates a or current leak to the machine Search for an insulation chassis fault on the machine 4 PRESSURE NOT overload pressure switch has detected an Unload the platform OK overload in the basket p STEER SENSOR The microprocessor indicates that the steering a program error 5 KO potentiometer signal is not in the range defined in b broken steering the program potentiometer 6 RISERVATO AD serial line reception Check display panel MDI connection CONTACTOR This alarm is indicated if there is an error on the 1 Ever ii DRIVER closed mains switch aeu E LS control circuit a mains switch stuck 8 CONTACTOR Test performed on switching on checking that the b this alarm may be CLOSED mains switch is actually open caused by a malfunction of the fiel
60. erously Photo 3 ref 2 Putthe assembled slew ring and its support into slings Position the assembly opposite the mast cylinder Screw the fixing plate to the centre of the slew ring Photo 3 ref 3 Make sure there is no grease on the threads Re secure the support ring assembly to the mast with 12 screws class 8 8 HM16x100 38 and loctite Photo 2 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C210 Sheet 2 4 REPLACING THE SLEW RING NB Photo 4 Caution Before reassembling the mast rotation motor check that the cable sleeve is free to move around the whole rotation Caution If safety parts are replaced they must be validated with NB static tests CE 1 25 x nominal USA 1 5 x nominal Start by putting in the screws on one side and adjust the mast posi tion with the sling to adjust the position of the ring assembly Tighten to a torque of 143 Ibf ft 195Nm for the ring mast fixture and 99 ft lb 135Nm for the ring support fixture using a torque wrench Turn the ring to the Trempe point marked by a red spot on the ring Photo 4 Put the mast into slings 2 m slings to put it in the vertical position Photo 5 Photo 5 Prepare planks where the mast will be placed to protect the slew ring Position the mast in the vertical position Move the whole assembly forwards by lifting the mast with the hoist control Position the mast using the guides fixed on
61. evel of the hydraulic oil tank Pinguely Haulotte Z Sheet C205 AN Caution Ensure that the oil is not too hot AN Caution Use a container to collect the oil to prevent pollution of the environment AN Caution It is essential to put the component into slings before dismantling reassembling it Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet 1 1 REPLACING THE ROTATION MOTOR 1 Preliminary operations Putthe machine into the maintenance configuration see relevant sec tion Switch off the electric power supply see relevant section Close the shut off valve or empty the hydraulic tank 2 Removing the rotation motor Mark and disconnect the hoses 1 of the rotation motor Puta cap on the hose Unscrew the four fixing screws 2 of the rotation motor Remove the rotation motor 3 Reinstalling the rotation motor Puta new motor filled with oil into place Reinstall the screws with loctite Reconnect the hydraulic hoses equipped with new seals Put the machine back into the operational configuration Make several operating cycles to purge the hydraulic circuit Check the level of the hydraulic oil tank Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C206 Sheet 1 1 REPLACING A DRIVE WHEEL 1 Preliminary operations Putthe machine into the maintenance configuration see relevant sec tion Switch off the
62. g active and inactive cabling is correct 18 R VMN NOT OK periods It checks coherence of the VMN in relation b Check that the motor is to the command insulated from the chassis c Power fault a Check that motor The test is performed during active and inactive cabling is correct 19 L VMN NOT OK periods It checks coherence of the VMN in relation b Check that the motor is to the command insulated from the chassis Power fault LEFT STBY I 20 HIGH The test is performed during inactive periods and S current sensor Js checks that the current is zero If it is not the alarm b Fault th t t 24 RIGHT STBY I is given The alarm disables the machine Do Faull enne TE HIGH circuit or logic or power unit a anomaly on the current 22 HIGH FIELD Anomaly in the field current Field current is not receiver CURRENT zero during inactive periods b fault on the field power unit a Check that the motor is Test performed during inactive periods In such insulated from the chassis conditions field input voltage should correspond to b The motor field is not 29 YEIELDINDOTEOR Vbatt The alarm is given if voltage is different connected to the chopper from this value c Fault on the power section concerning the field NO FIELD Anomaly in the field current The field current is TRI anomaly HS AE a CURRENT zero during operation g op b field cable disconnected Fault in the memory zone containing configu
63. hazardous situations concerning safety devices load limiters tilt sensor cylinder leaks deformation welds bolt tightness hoses electrical connections tyre state excessive mechanical gaps NOTE If the machine is rented leased the user responsible for the machine must examine its state of conservation and suitability He must ob tain assurance from the leaser that general periodic inspections and pre operation inspections have been performed Pinguely Haulotte 2 Repair manual 1 5 REPAIRS AND ADJUSTMENTS These cover major repairs and work on or adjustments to safety systems or devices of a mechanical hydraulic or electrical nature These must be performed by personnel from or working for PINGUELY HAULOTTE who will use only original parts Any modification not controlled by PINGUELY HAULOTTE is unauthorised The manufacturer cannot be held responsible if non original parts are used or if the work specified above is not performed by PINGUELY HAULOTTE approved personnel 1 6 VERIFICATIONS WHEN RETURNING TO SERVICE To be performed after extensive disassembly reassembly operation repair affecting the essential components of the machine any accident caused by the failure of an essential component It is necessary to perform a suitability examination a state of conservation examination a static test a dynamic test see coefficient in paragraph see Chap 1 4 2 page 9 AN Caution These test must be perfo
64. heck battery charge Battery charge NO i YES See sheet C139 Charge the batteries Put the key switch in the Platform position and activate mast movement No down movement Y No up movement The pump works SO Check pump cabling Measure voltage at terminals 9 12 17 and 18 of the chopper NO 17 18 24V 104 down 9 12 24V 104 up down s heet YES Replace the chopper C003 See sheet Replace the chopper C003 Y Repair the wiring Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet 077 NO UP OR DOWN MAST MOVEMENT Folio 5 6 FROM THE PLATFORM Measure voltage at the terminals of electrovalves YV3a YV3b YV4 8 YV6 V3a and YV4 24 V up and YV3b and YV6 24 V down Repair the wiring between the and the electrovalves See sheet C145 Replace the coil The problem persists Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP077 Folio 6 6 NO UP OR DOWN MAST MOVEMENT FROM THE PLATFORM Connect a pressure gauge to the pressure tapping at small pump output Make a mast up down movement Pressur 1450 PSI NO 100 bars No down movement YES Pressure Zero NO
65. ic filter Clean the filtration element support Replace the filter Screw the base back onto the fixed part of the hydraulic filter 2 Putthe machine back into the operational configuration Make several lifting cycles to purge the hydraulic circuit Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C202 Sheet 1 1 REPLACING A HYDRAULIC BLOCK 1 Preliminary operations AN Caution Putthe machine into the maintenance configuration see relevant sec Ensure that the oil is not too tion hot Switch off the electric power supply see relevant section 2 Removing the hydraulic block Open the covers to access the components Markand disconnect the electrovalves 2 of the hydraulic block 1 Mark and disconnect the hoses 3 of the hydraulic block NB Unscrew the hoses slowly to release residual hydraulic pressure Putcaps on the hoses Remove the union connectors from the hydraulic block Remove the hydraulic block by removing the fixing screws and washers 1 Reinstalling the hydraulic block Putthe hydraulic block into place and fix with screws equipped with new toothed washers Putback the union connectors Reconnect the hydraulic hoses according to the marks made during dis mantling Reconnectthe electrovalves of the hydraulic block according to the marks made during dismantling Putthe machine back into the operational configuration
66. ing screws 3 of the electrovalve 2 and remove Use a container to collect oil to prevent pollution of the 3 Installing an electrovalve environment Puta new electrovalve equipped with its seals into place and fix using the 4 screws in the position of the electrovalve on the block Tighten to the recommended torque see corresponding paragraph Reconnect the electrovalve s electric connections according to the marks made during dismantling Putthe machine back into the operational configuration Make several movement cycles using the replaced electrovalve to purge the hydraulic circuit Checkthe level of the hydraulic oil tank Star 22 J Star 8 Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C139 CHARGING THE TRACTION BATTERIES Sheet 1 1 1 Preliminary operations AN Caution Ensure that the mains supply is suitable for the charger s consumption and Do not use the machine voltage during the charging process Fillto the minimum electrolyte level if an element s level is below this mini mum E Work in a clean ventilated area away from naked flames AN Caution Use the machine s on board charger Its charge output is suited to the machine 2 Charging the batteries NB Charging starts automatically as soons as the mains supply is connect ed For information charging time for a battery discharged by 8096 is approximately 15 hours AN Caution
67. irection of the red arrow on the control panel will move the machine in the direction of the red arrow on the chassis AN Caution If the machine has a 220 V 16A max plug the extension must be connected to a mains socket protected by a 30 mA differential circuit breaker Repair manual 1 3 1 Risks of jerky movements and tipping over Risks of jerky movement and tipping over are high in the following situations Sudden action on the controls Overloading of the platform Uneven ground Be careful during thaw periods in winter Gusts of wind Contact with an obstacle on the ground or at a height Working on platforms pavements etc Allow sufficient stopping distances 3 meters at high speed 1 meter at low speed Allow sufficient stopping distances 3 metres at high speed and 1 metre at low speed Do not alter or neutralise any components connected in any way to the machine s safety or stability Do not place or fasten a load so that it overhangs the machine s parts Do not touch adjacent structures with the elevator arm 1 3 2 Electrical risk Electrical risks are high in the following situations Contact with a live line check safety distances before operation near electricity lines Use during storms 1 3 3 Risk of explosion or burning The risks of explosion or burning are high in the following situations Working in explosive or inflammable atmosphere Filling the fuel tank near
68. jack or hoist Remove the 5 wheel nuts 1 and remove the wheel 3 Reinstalling a wheel Puta new wheel into place and put back the nuts 1 Lower the machine back to the ground Tighten the nuts Tightening torque for wheel nuts 213 ft lb 29 m dNm Putthe machine back into the operational configuration Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C145 Sheet 1 1 REPLACING A COIL 1 Preliminary operations e o Put the machine into the maintenance configuration see relevant sec tion Switch off the electric power supply see relevant section 2 Removing a coil Disconnect the electric connector 1 of the coil in question Unscrew the nut 2 and remove the coil 3 3 Reinstalling a coil Puta new coil into place 3 and secure with the nut 2 Reconnect the electric connector 1 on the coil Putthe machine back into the operational configuration Check correct operation by making the movement corresponding to the replaced coil Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C146 Sheet 1 1 REPLACING AND SETTING THE STEERING POTENTIOMETER Caution 1 Preliminary operations Before final reinstallation of Putthe machine into the maintenance configuration see relevant sec the steering potentiometer it tion must be set with a zapi Switch off the electric power supply see relevant section
69. l 28 Repair manual Pinguely Haulotte 4 8 POSITIONS OF HYDRAULIC COMPONENTS 1 YV1 Steering electrovalve 2 YV2 Turntable rotation motor control electrovalve 3 YV3 Jib up down electrovalve 4 YVA Up down control electrovalve When idle down if YV6 1 5 YV5 Power supply selection electrovalve When idle supply of the small chamber of the mast lifting telescopic cylinder In work supply of the jib 6 Distributor 7 YV6 Telescopic lifting cylinder down control electrovalve 8 Main pressure regulator set at 160 bars 9 Lifting pressure regulator set at 45 bars 10 Emergency lowering manual valve 11 YV6 Emergency lowering electrovalve 12 Emergency pump 13 Steering pressure regulator set at 100 bars 29 Pinguely Haulotte 4 Repair manual 30 Repair manual Pinguely Haulotte Z 9 MAINTENANCE 9 1 GENERAL RECOMMENDATIONS AN Caution Do not use the machine as a welding ground Do not weld without disconnecting the and terminals of the batteries Do not use the battery to jumpstart other vehicles The servicing operations described in this manual are given for normal operating conditions In difficult conditions extreme temperatures high humidity polluted atmosphere high altitude etc some operations may need to be performed more often and specific precautions may be necessary consult the HAULOTTE after sales service for more informa
70. les see relevant sheet Disconnect the mast lowering electrovalve plug near the rotation motor see relevant sheet Mark the position of the cables on the electric onnections of the hydraulic distribution block Unscrew the connections and remove the wires see relevant sheet Disconnect the electric connections of the pump see relevant sheet Disconnect the mast end of travel contactor see relevant sheet Disconnect the jib cylinder distribution block see relevant sheet Disconnect the jib end of travel contactor see relevant sheet Disconnect the top panel plug see relevant sheet Unscrew all the cable clamps on the platform Unscrew the collars on the jib Dismount the two bolts above the electric plate Unscrew the spiral cable stop collar Photo 7 ref 9 2 Removing the electric plate Unscrew the two fixing screws of the push button Photo 1 ref 1 with a BTR key Photo 1 Photo 2 Pull the wire of the charger s 220V plug Photo 2 ref 2 Unscrew the horn screw Photo 3 ref 2 Unscrew and remove the 4 nuts from the electric plate closing plate Photo 3 ref 3 Unscrew the other screws on the edge ofthe electric plate Photo 4 Pinguely Haulotte Z Sheet C214 Photo 6 Photo 7 CORRECTIVE MAINTENANCE SHEET REPLACING THE ELECTRIC PLATE Sheet 2 2 3 Reinstalling the electric plate Put back the electric plate checking the cable routes via the plate Fix the various elements horn
71. les of the electric motor secured each time the Disconnect the 2 hoses of the steering cylinder machine s systems are Disconnect the steering potentiometer connectors removed 2 Removing the cable sleeve Unscrew the collars around the support 3 near the rotation motor 5 and the steering cylinder 6 Unscrew the rizlans 2 and the collar 4 fixing the cables to the cable sleeve support Remove the cable sleeve from its support 3 Remove the cable sleeve 3 Installing the cable sleeve The cables inserted into the cable sleeve include 2 hydraulic hoses on the second row from the top 1 2 brake cables 2 travel motor inducer circuits 2 travel motor induced circuits 3 steering potentiometer cables Tape the cables and tighten with a rizlan 2 Fixthese cables on the cable sleeve support guide 3 Putthe cable sleeve back around the cables and at the top of the support guide Fixthe cable sleeve with a fixing collar near the rotation motor on the rod guide 5 near the steering cylinder 6 Operate the machine to stretch the cable sleeve and check its escape limit
72. m the cylinder plate at the bottom of the mast and remove the plate Unscrew the two elbow unions at the bottom of the mast Photo 4 amp Photo 5 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C198 Sheet 2 6 DISMANTLING REASSEMBLING THE MAST Photo 4 amp Photo 5 Putthe ring support Photo 6 into slings Unscrew the 12 bolts class 8 8 HM16x100 38 of the ring support Photo 7 and remove the ring with an overhead crane Take the circlips off the upper part of the cylinder Photo 8 Putthe cylinder into slings and remove it with an overhead crane Putthe smallest caisson into slings and remove it with an overhead crane Unscrew the 6 fixing screws on each stop of the 1st elevation caisson and remove the stops Unscrew the 6 screws of the next stop and remove it Putthe 3rd caisson into slings and remove it with an overhead crane Putthe 2nd caisson into slings and remove it with an overhead crane Putthe 1st caisson into slings and remove it with an overhead crane Photo 7 Photo 8 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C198 Sheet 3 6 DISMANTLING REASSEMBLING THE MAST 3 Reinstalling the mast Place the caissons on trestles Insert the 1st caisson in the bottom of the mast Checkthe clearance between the 1st caisson and the bottom of the mast the gap should be between 1 and 2 mm at each end of the mast Adjust the gap with a set
73. maintenance configuration see relevant section hot Switch off the electric power supply see relevant section NB Unscrew the hoses slowly to release residual hydraulic pressure ion AN 2 Removing the hydraulic winder 1 Use a container to collect the oil to prevent pollution of the environment Disconnect the hydraulic hoses 2 and 3 Putcaps on the hoses Unscrew the two fixing nuts 4 to free the hose 5 Remove the winder by taking the fixing nuts 6 off the support 3 Reinstalling the hydraulic winder Perform dismantling operations in reverse order to reassemble 4 Additional operations Putthe machine back into the operational configuration Make several movements using the replaced hydraulic winder to purge the hydraulic circuit e Check the hydraulic oil tank level Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C149 Sheet 1 1 REMOVING REPLACING THE BATTERIES 1 Preliminary operations AN Caution Putthe machine into the maintenance configuration see relevant section Battery servicing operations Switch off the electric power supply see relevant section require safety precautions Remove the standby pump 1 by removing the 3 fixing nuts 2 We also rec wear gloves and protective ommend removing the hoses goggles Disconnect the and then terminals of the batteries 2 Removing the upper batter
74. mmittee if one exists and the list of specially designated personnel Article R 233 5 of the French Labour Code Moreover before each use check the following the operator s manual is in the storage compartment on the platform the stickers are placed according to the section concerning Labels and their positions oil level and any elements in the mainteance operation table look out for any danaged incorrectly installed modified or missing parts NOTE This register can be obtained from trade organisations and in some cases from the OPPBTP or private prevention agencies The designated persons must be experienced in risk prevention Articles R 233 11 or order n 93 41 No member of personnel is allowed to perform any check whatsoever during machine operation Article R 233 11 of the French Labour Code 1 4 2 Examination of machine suitability The manager of the site where the machine is operated must ensure the machine is suitable i e capable of performing the work in complete safety and in compliance with the operating manual Furthermore the French order of 9 June 1993 addresses problems relative to leasing examination of the state of conservation checking upon operation after repairs and test conditions static test coefficient 1 25 dynamic test coefficient 1 1 All users must consult this order s requirements and comply with them 1 4 3 State of conservation Detect any deterioration liable to cause
75. nd SM3 1 and overload 0 then YV5z1 overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and SQ12 1 5 5 ROTATION 5 5 1 Turntable 5 5 1 1 Left If SA1 turntable and SB7 1 and SM1 1 and SQ1 1 or machine retracted and overload 0 then YV2a 1 and M1 1 overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and SQ12 1 5 5 1 2 Right If SA1 turntable and SB5 1 and SM1 1 and SQ1 1 or machine retracted and overload 0 then YV2b 1 and M1 1 overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and SQ12 1 5 5 2 Platform 5 5 2 1 Left If SA1 platform and SB8 1 and SA2 rotation andSM2 1 and SQ1 1 or machine retracted and overload 0 then YV2a 1 and M1 1 overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and SQ12 1 5 5 2 2 Right If SA1 turntable and SB8 1 and SA2 rotation and SM2 1 and SQ1 1 or machine retracted and overload 0 then YV2b 1 and M1 1 overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and SQ12 1 22 Repair manual 5 6 5 7 5 8 5 9 TRAVEL STEERING HORN BUZZER Pinguely Haulotte 77 5 6 1 Platform If SQ4 0 or SQ12 0 then Microspeed 1 5 6 1 1 Forward If SA1 platform and SB8 1 and SA2 travel and SM3 1 and SQ1 1 or machine retracted and overload 0 then MD 1 and MG 1 full setpoint overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and 5012 1 5 6 1 2 Reverse If SA1 turntable and
76. nel must ensure that these labels and plates are in good conditions and keep them legible Spare labels and plates can be supplied by the manufacturer on request 1 1 3 Safety Ensure that any person entrusted with the machine is take the safety measures implied by its use Avoid any working mode that may affect safety Any use that does not comply with the recommendations may generate risks and damage to people and equipment After intervention maintenance personnel must check that the operator manual is present This must be kept by the user throughout the machine s service life even if it is loaned rented or sold Ensure that all the plates or labels related to safety and danger are complete and legible AN Caution To attract the reader s attention instructions are indicated by this standardised sign Pinguely Haulotte 2 Repair manual 1 2 GENERAL SAFETY RECOMMENDATIONS AN Caution Only trained operators may use Haulotte self propelled platforms 1 2 1 Operators Operators must be aged 18 or over and hold an operating permit issued by the employer after verification of medical aptitude and the practical platform operation test There must be at least two operators present so that one of them can intervene rapidly if necessary take over the controls in the case of accident or breakdown monitor and prevent machines or people from circulating around the plat form guide the platform
77. ng the button validates platform movements for 5 seconds This duration is renewed as soon as a movement is made 24 Pinguely Haulotte 4 Repair manual 6 WIRING DIAGRAMS Re gto g SSS Se 7 ge 4 EX Tis Tos Tas MK MS Te ic ve E POE 1 SES lt lt n 77271 lo DE SEI RITA III RO ZII lt Tem Tina ae ees aw Jena Jan SAC T 1 Poa hk J la la lo I l ly Ii lo In lo 1 ro N n A IL vive IN give lo eve 10 give 20 IS eck ewe ly zivelo ow D p __ KA ver Li 3 I te 12 62 220 21 9 02 S i kde s SR E qoem mm 2 ao a 18 EP 55 zn BE S52 ve Be she B2 20 S S 3558 1 1 A ir 15 55 35 lt Eo ofze ES oS lt 8 85 IU 12 200 88 9 590 59 st 55 33 to 22 1 la 10 ys CE 28 ess 55 25 Ses 98 85 35 35 O38 SI p d 3 L D a ss e25 2 2 288 s de tee Pod og Bis lt E S 579 sc 200755 T core d o 8 5 Le I l A v TEIL ii EI 5528 f L xS o Sp 4 4 IQ 1012orpul 5955 22 au EK Ss Ss ito 4 4nejeoipu 32 25 cS N 7 oo oo pa Th E I Lona im DO four 5 r IN 0 wn E EE EE go ii di dr de al Y 9 10 m LI EN bl Bow h
78. nputs 26 0 and 38 0 26 and 38 ZAPI chopper inputs 26 jib up blocking 38 jib down blocking Machine retracted gt SQ4 1 and SQ12 1 5 3 1 2 Down If SA1 turntable and SB6 1 and SM1 1 and overload 0 then YV3a 1 YV6 1 and M1 1 overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and SQ12 1 5 3 2 Platform 5 3 2 1 Up If SA1 platform and SB3 1 and SB8 1 and SA2 Mast and SM3 1 and SQ1 1 or machine retracted and overload 0 then YV3b 1 and YV4 1 and M1 1 overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and SQ12 1 5 3 2 2 Down Overload 0 then YV3a 1 and YV6 1 and M1 1 Overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and SQ12 1 5 4 JIB 5 4 1 Turntable 5 4 1 1 Up If SA1 turntable and SB5 1 and SM1 1 and SQ1 1 or machine retracted and overload 0 then YV3a 1 and YV5 1 and M1 1 Overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and SQ12 1 21 Pinguely Haulotte Z Repair manual 5 4 1 2 Down If SA1 turntable and SB5 1 and SM1 1 and overload 0 then YV5 1 overload 1 ifinputs 26 0 and 38 0 Machine retracted gt SQ4 1 and SQ12 1 5 4 2 Platform 5 4 2 1 Up If SA1 platform and 5 8 1 and SA2 jib and SM3 1 and 501 1 or machine retracted and overload 0 then 1 and YV5 1 and M1 1 overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and 5012 1 5 4 2 2 Down If SA1 turntable and 5 8 1 and SA2 jib a
79. nt sheet Disconnect and remove the batteries see relevant sheet Disconnect the pump power supply after marking the supply wires see relevant sheet Remove the plate covering the end of travel contactors SQ3 and SQ4 and remove them see relevant sheet Remove the hydraulic winder see relevant sheet Remove the end of travel contactor 5012 see relevant sheet Remove the hydraulic supply hose at the top of the mast Remove the jib see relevant sheet Remove the circuit breaker see relevant sheet Remove the charger see relevant sheet Remove the end of travel contactor 5010 see relevant sheet Remove the electric plate see relevant sheet Remove the hydraulic plate see relevant sheet Remove the hydraulic filter see relevant sheet Remove the pump see relevant sheet Remove the hydraulic tank see relevant sheet Remove the hydraulic block assembly see relevant sheet Remove the rotation motor see relevant sheet Remove the counterweight see relevant sheet Remove the cable sleeve support see relevant sheet 2 Removing the mast Remove the trapdoor in the middle of the mast ref 1 Photo 1 Unscrew the 12 screws on the ring replace the screws systematically to reassemble 8 8c class screws HM14 x 65 34 then tighten to a torque of 99 ft lb 135 Nm Put the mast into slings approx 94 stones 600 kg Photo 2 Place the mast on trestles Photo 3 Photo 3 Unscrew the 3 screws fro
80. o remind you that our machines comply with the clauses of the Machines Directive 89 392 CEE dated June 14th 1989 modified by directives 91 368 CEE dated June 21st 1991 93 44 CEE dated June 14th 1993 93 68 CEE 98 37 CE dated July 22nd 1993 and 89 336 CEE dated May 3rd 1989 to directive 2000 14 CE and directive EMC 89 336 CE Pinguely Haulotte 7 Repair manual Repair Manual Pinguely Haulotte A SUMMARY 612 257 1 1 GENERAL RECOMMENDATIONS SAFETY 5 11 GENERAL E HE 5 li Manual conic tret DS sus D DE 5 1 12 EE 5 lol GE 5 1 2 GENERAL SAFETY 6 6 1 2 1 Operators 4 8 aska ds Tapa aaa 6 1 2 2 Emironment 6 1 2 3 Using the machine era 6 To RESIDUALRISRS ann 8 1 3 1 Risks of jerky movements and tipping over sien 8 1 3 2 Electrical riskieren ian 8 1 3 3 Risk of explosion or UTI en ae ee 8 1 3 4 Risks of collision 2 8 WA LU u01 8 9 1 4 1 Periodic inspections 9 1 4 2 Examination or machine suitability eed Sent aita idikas 9 1 4 3
81. of adjustment wedges Check that the caisson works properly by sliding it manually Insert the 2nd caisson into the st Checkthe gap and adjust if necessary Check that the caisson works properly by sliding it manually Putthe stops back on the 1st caisson making it protrude by approxi mately 5 cm Insert the 3rd caisson in the 2nd Checkthe gap and adjust if necessary Check that the caisson works properly by sliding it manually Putthe stop back on the 2nd caisson making it protrude by approximately 5 cm e Check the gap between the 4th and 3rd caissons the gap should be between 1 and 2 mm at each end of the mast Adjust the gap with a set of adjustment wedges Check that the caisson works properly by sliding it manually Gap adjustment at reassembly Photo 10 Bottom of the mast 1st elevation 2nd elevation a Gap adjustment at reassembly Gap adjustment at reassembly 3rd elevation Photo 9 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C198 Sheet 4 6 DISMANTLING REASSEMBLING THE MAST AN Caution THEN PERFORM THE DISMANTLING OPERATIONS SECTION 2 IN REVERSE After assembling the mast it ORDER TO REASSEMBLE is essential to have static and dynamic load tests facilitate caisson sliding use a synthetic lubricant spray see section listing carried out by a certified Consumables recommended by Pinguely Haulotte organisation 4 Adjustment of pad
82. ration parameter data The alarm disables the machine If 25 EEPROM KO the fault does not disappear after switching the ignition key on and off again change the Eeprom Parameters recorded previously may have been lost and replaced with default values 26 CHOPPER NOT The chopper is not programmed or incorrectly CONFIGURATED programmed THERMAL This lan shows that chopper temperature is 27 over 75 C Minimum current is gradually reduced PROTECTION 3 until zero when temperature reaches 90 C 28 EVP NOT OK Proportional electrovalve command values incoherent Pinguely Haulotte Z Repair manual CODE ALARM PROBABLE CAUSES REMEDIES Alarm informing that machine maintenance is 29 CHECK UP due Time 2300 hours Does not disable the NEEDED machine but continues to show the fault until the message is eliminated CHECK UP DONE on ON The control microprocessor is defective A 30 CONTACTAR dangerous situation not detected by the main OPEN 25 microprocessor has been identified a Potentiometer wire broken The test is performed during inactive periods The mi dn caning 31 VACC NOT OK alarm indicates that accelerator voltage is greater B than 1 V compared with the minimum value Potentiometer defective recorded interrupted d Serial command programming is incorrect SERIAL TILLER Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP075 Folio 1 6 NO UP OR DOWN
83. raulic hoses 2 from the hand pump 1 NB Unscrew the hoses slowly to release residual hydraulic pressure Fitcaps to the hoses Remove the union pieces 3 from the hand pump Remove the hand pump by removing its fixing bolts 5 3 Installing the hand pump Puta new hand pump into place and fix using the fixing bolts Replace the non return valve 6 if necessary Install the union pieces on the pump Reconnect the hydraulic hoses according to the marks made during dis mantling Putthe machine back into the operational configuration Close the decompression valve 4 Perform an emergency operation to check that the hand pump works pro perly see Operation and Maintenance Instructions manual Open the decompression valve HA16 PX HA18 PX HA 465 RT Star 22 J Star 8 Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C063 Sheet 1 1 CHANGING THE PRINTED CIRCUIT 1 Preliminary operations Putthe machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Disconnect the then terminals of the starter battery 2 Removing the printed circuit Open the turntable electric box Carefully mark and disconnect all the electric connections 1 of the prin ted circuit 2 Remove the U1 electronic module 4 see corresponding sheet Remove the bolts
84. res described in the maintenance sheets are respected unscrew hydraulic connectors slowly to release residual pressure To preserve the integrity of the safety systems and the technical characteristics of the platform it is essential to use original parts and to respect the initial setting and tightening torque values see relevant chapter 31 Pinguely Haulotte A Repair manual 9 2 3 Locating the breakdown Certain checks reguire the elevating platform to be switched on In this case personnel must ensure that the measurement devices used are properly insulated that they do not touch the live parts that they are not wearing or carrying metal objects that may damage the live components e g dropping a wench when servicing the batteries 9 3 MAINTENANCE SYSTEM Maintenance configuration Position the elevating platform on a firm horizontal surface Fold the machine completely 9 4 ELECTRIC POWER SUPPLY Instructions Cutting off the electric power supply Press the turntable emergency stop near the control panel Photo 10 page 32 Photo 10 Turntable control panel Restoring the electric power supply Reset the emergency stop Photo 10 page 32 aaa 32 Repair manual Pinguely Haulotte Z 10 1 MAINTENANCE PLAN The plan on the next page shows the periodicity point of maintenance device and consumables to be used The reference in the symbol indicates the maintenanc
85. rmed by a competent person 1 7 BEAUFORT SCALE The Beaufort Scale of wind force is accepted internationally and is used when communicating weather conditions It consists of number 0 17 each representing a certain strength or velocity of wind at 10m 33 ft above ground level in the open Description of Wind Specifications for use on land MPH m s 0 Calm Calm smoke rises vertically 0 1 0 0 2 1 Light Air Direction of wind shown by smoke 1 5 0 3 1 5 2 Light Breeze Wind felt on face leaves rustle ordinary vanes moved by 6 11 1 6 3 3 wind 3 Gentle Breeze Leaves and small twigs in constant motion wind extends 12 19 3 4 5 4 light flag 4 Moderate Breeze Raises dust and loose paper small Branches are moved 20 28 5 5 7 9 5 Fresh Breeze Small trees in leaf begin to sway crested wavelets form 29 38 8 0 10 7 on inland waterways 6 Strong Breeze Large branches in motion whistling heard in telephone 39 49 10 8 wires umbrellas used with difficulty 13 8 7 Near Gale Whole trees in motion inconvenience felt when walking 50 61 13 9 against wind 17 1 8 Gale Breaks twigs off trees generally impedes progress 62 74 17 2 20 7 9 Strong Gale Slight structural damage occurs chimney pots and slates 75 88 20 8 removed 24 4 10 Repair manual Pinguely Haulotte Z 2 SPECIFICATIONS Self propelled platforms models STAR 22J are designed for all overhead work within the limits of their
86. rminals of manipulator SM1 Measure voltage at CNB S OV lt cursor lt 4V FOR contact 5V or NO NO REV contact 5V Replace manipulator See sheet YES SM1 C143 Repair the wiring Replace the Serial See sheet board C063 END Y Measure voltage at SB6 output SB6 24 V NO YES 1 See sheet Replace the button Repair the wiring P C004 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DPO78 NO UP OR DOWN MAST MOVEMENT Folio 3 6 FROM THE TURNTABLE No down movement No up movement Measure voltage at terminal 24 of the chopper oltage measured NO 24 V Check if the mast has reached its max height gt ax height reached YES Lower the mast Measure voltage at 5010 NO Replace the sensor See sheet C200 Repair the wiring END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP078 Folio 4 6 NO UP OR DOWN MAST MOVEMENT FROM THE TURNTABLE No down movement No up movement Check battery charge Battery charge NO i YES See sheet C139 Charge the batteries Put the key swith in the Turntable position and activate mast movement No down movement Y No up movement The pump works
87. s 2 Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C147 Sheet 1 1 REMOVING REPLACING THE COVERS 1 Preliminary operations Putthe machine into the maintenance configuration see relevant sec tion Switch off the electric power supply see relevant section 2 Removing the motor cover 2 Unscrew the fixing screws 1 Remove the cover 2 3 Reinstalling the motor cover 2 Reinstall a cover 2 Tighten the fixing screws 1 4 Removing a side cover 3 First remove the motor cover 2 Manually unscrew the fins 4 Unscrew the screws 5 Remove the cover 3 5 Reinstalling a side cover 3 Puta new side cover into place 3 Screw the screws 5 and fins 4 back into place Reinstall the motor cover 2 6 Removing a pivoting turntable cover 6 Open the cover 6 and put it into slings Take the cover off its hinges 8 and remove 7 Reinstalling a pivoting turntable cover 6 Puta new cover into place 6 Remove the slings 5 8 Additional operations e Check that the cover is properly anchored on the machine Putthe machine back into the operational configuration Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET aneor CES REMOVING REPLACING THE SuSE HYDRAULIC WINDER AN Caution 1 Preliminary operations Ensure that the oil is not too Put the machine into the
88. s after assembling the mast Raise the mast to the start of the 3rd caisson Check the gap between the 4th and 3rd caissons between 1 and 2 mm using thickness wedges on the front side and right and left sides of the mast Photo 11 4th caisson 3rd caisson Gap check be tween 1 and 2 mm REAR Bottom of the mast Adjusting screws Side gap right and left between 1 and 2 mm Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C198 Sheet 5 6 DISMANTLING REASSEMBLING THE MAST fnecessary adjust this gap using the two adjusting screws on the side NB Repeat this operation between the 3rd and 2nd caisson between the 2nd and 1st caisson and finally between the 1st caisson and the bottom of the mast NB If the side gap is less than 1 mm there must be a blockage The mast must be dismantled and reassembled Adjusting screws Photo 12 Gap adjusting screw for assembled mast Photo 13 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C198 Sheet 6 6 DISMANTLING REASSEMBLING THE MAST 5 Additional operations Reinstall the cable sleeve support see relevant sheet Reinstall the counterweight see relevant sheet Reinstall the rotation motor see relevant sheet Reinstall the hydraulic block assembly see relevant sheet Reinstall the hydraulic tank see relevant sheet Reinstall the pump see relevant sheet Reinstall the hydraulic filter see relev
89. st and jib down 4s 1s Mast up with nominal load in the basket STAR 22 J 425 Jib up with nominal load in the basket 26s 25 3s 15 Pinguely Haulotte 4 Repair manual Repair manual Pinguely Haulotte Z 3 1 MACHINE ELEMENTS 3 SAFETY SYSTEMS 3 1 1 Motors M1 electropump MD right traction motor MG left traction motor EFG left electrobrake EG left energizing EFD right electrobrake ED right energizing 3 1 2 Power supplies and fuses FU1 1A overload protection being phased out FU2 10A control protection FU3 10A electrovalve protection FUA 250A power protection FU5 5A working light 3 1 3 Inputs 3 1 3 1 Control inputs SB1 emergency stop line contactor SA1 turntable platform station selection SA2 platform panel movement selection SB3 platform emergency stop SB5 turntable jib control SB6 turntable mast control SB7 turntable rotation control SB8 platform movement validation button SB9 platform buzzer SM1 turntable manipulator SM2 platform rotation steering manipulator SM3 platform travel mast jib manipulator Brake release control option 3 1 3 2 Safety system inputs 501 tilt 504 mast bottom end of travel SQ10 mast top end of travel SQ12 jib 0 B1 weighing pressure sensor P1 steering potentiometer P2 weighing angle sensor RL2 isolation relay 17 Pinguely Haulotte 4 18 Repair manual 3 1 4 Outputs 3 1 4 1 Relays RL1 RL
90. t of preventive maintenance sheets Sheet no Description Lubricating the steering wheel pivots Checking filling the hydraulic oil tank Changing the hydraulic filter cartridge Checking servicing the traction batteries Lubricating the mast 41 Pinguely Haulotte 2 Repair manual 42 Pinguely Haulotte 77 PREVENTIVE MAINTENANCE SHEET Sheet 1 1 SHEET P003 GREASING THE STEERING WHEEL PIVOTS 1 Greasing the steering wheel pivots Cut off the electric power supply see S 6 3 page 22 Grease the pivots NOTA Only use the grease recommended by the manufacturer O KI Compact optimum previous design Put the machine back into the operational configuration Compact optimum current design Star 22J Star 8 Pinguely Haulotte 4 PREVENTIVE MAINTENANCE SHEET Pinguely Haulotte 77 PREVENTIVE MAINTENANCE SHEET Sheet P005 CHECKING FILLING Folio 1 1 THE HYDRAULIC OIL TANK 1 Preliminary operations Putthe machine in the maintenance configuration see corresponding para graph Switch off electric power see corresponding paragraph 2 Checking filling the hydraulic oil tank NB This operation must be carried out when the oil is cold i e before star ting the machine Check that the level of oil 1 in the tank is between the high and low levels when cold Top up if necessary by filling via the cap 2 NB Only use the oil recommended b
91. teries see relevant sheet Remove the covers see relevant sheet Remove the hand pump see relevant sheet Remove the end of travel contactors see relevant sheet Remove the hydraulic winder see relevant sheet Remove the hydraulic supply hose from the top of the mast Remove the jib plus basket assembly see relevant sheet Remove the circuit breaker see relevant sheet Remove the charger see relevant sheet Remove the electric plate see relevant sheet Remove the hydraulic filter see relevant sheet Remove the pump see relevant sheet Remove the hydraulic tank see relevant sheet Remove the hydraulic unit see relevant sheet Remove the rotation motor see relevant sheet Remove the counterweights see relevant sheet Remove the cable sleeve support see relevant sheet Remove the mast see sheet 198 and place on trestles Photo 1 NB Unscrew the hydraulic hoses slowly to release residual pressure NB Put caps on the hoses NB Only use greases and lubricants recommended by the manufacturer see relevant section 2 Removing the slew ring Unscrew the 12 screws fixing the ring to the mast Photo 2 Separate the ring assembly from the main mast caisson 3 Reinstalling a new slew ring Screw the slew ring onto its support using new screws class 8 8 HM14x65 34 and loctite to a torque of 99 ft lb 135Nm photo 3 ref 1 Photo 3 Grease gen
92. tion Only authorized and skilled personnel may work on the machine and safety instructions related to personnel and environment protection must be respected Regularly check that the safety systems work properly IMPORTANT REMOVE ALL COVERS BEFORE WORKING ON THE TURNTABLE COMPONENTS 9 2 SPECIFIC RECOMMENDATIONS Before any maintenance intervention on the overhead platform indicate on the turntable and platform control stations that the machine is being serviced If possible restrict access to the platform to maintenance personnel only 9 2 1 SPECIFIC TOOLS Personnel should therefore be familiar with the use of the specific tools required measurement devices torque tightening devices lifting apparatus etc and respect the operating limits specified in the documentation supplied with the tools Incorrect use of a tool incorrect adjustment after a reading error may cause premature deterioration of the platform or more seriously an accident for which HAULOTTE cannot be held responsible 9 2 2 Replacing an element Before replacing an element the machine must be put in the maintenance configuration see relevant chapter and the electric power supply cut off see relevant chapter All distributing valves are with open center breaking the electric circuit therefore decreases pressure in the hydraulic circuits up to the non return valves flanged on the cylinders An element can be replaced safely if the procedu
93. torpump unit into place and secure with the fixing collar 3 Reconnect the hydraulic hoses 2 on the pumps according to the marks made during dismantling Reconnect the electric connections 1 on the motor according to the marks made during dismantling Put the machine back into the operational configuration Check motor rotation direction Make several lifting cycles to purge the hydraulic circuit Check the level of the hydraulic oil tank Pinguely Haulotte Z Sheet C204 AN Caution Ensure that the oil is not too hot AN Caution Use a container to collect the oil AN Caution It is essential to put the component into slings before dismantling and reassembling it Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 1 1 REPLACING THE HYDRAULIC PUMP 1 Preliminary operations Putthe machine into maintenance configuration see relevant section Switch off the electric power supply see relevant section 2 Removing the hydraulic pump Remove the motorpump unit see relevant sheet Remove the screws fixing the pumps 2 to the motor and remove the pumps 1 3 Reinstalling the hydraulic pump Put new pumps equipped with new seals into place on the electric motor and secure with fixing screws Putback the motorpump unit see relevant sheet Putthe machine back into the operational configuration Make several lifting cycles to purge the hydraulic circuit Checkthe l
94. tric arc weld on the machine without first disconnecting the batteries AN Caution Do notuse the batteries to jump start another vehicle 1 2 NB Preliminary operations Putthe machine into the maintenance configuration see relevant section Battery servicing Checkthe electrolyte levels before charging once a week in normal use If necessary top up with distilled or de mineralised water after charging No not add acid in the event of spillage contact our After sales department Do not leave discharged batteries idle Avoid overflow Clean the batteries to avoid salt formation and current deviation e Wash the top without removing the caps Dry with compressed air or clean cloths Grease the lugs To enable rapid diagnosis of the state of your batteries note the density of each element once a month using a battery hydrometer as a func tion of temperature using the graph below do not measure directly af ter filling Pinguely Haulotte Z PREVENTIVE MAINTENANCE SHEET Sheet P010 Folio 2 2 CHECKING SERVICING THE TRACTION BATTERIES STOP Do not recharge Recharge RECHARGE IMMEDIATELY Fahrenheit Burr ER Electrolyte freezing point in Fahrenheit C for densities noted at 86 Fahrenheit 30 State of charge of a battery as a function of density and temperature Pinguely Haulotte Z PREVENTIVE M
95. tted level Repair manual Caution Never use the platform as a crane goods lift or elevator Never use the platform or tow or haul Pinguely Haulotte 2 To avoid all risk of serious fall operators must respect the following instructions Hold the hand rails firmly when climbing onto or operating the platform Wipe any traces of oil or grease off the steps floor and hand rails Wear protective clothing suited to working conditions and current local legis lation in particular when working in hazardous areas Do not disable the safety system end of stroke contactors Avoid contact with fixed or mobile obstacles Do not increase working height by using ladders or other accessories Never use the hand rails as a means of access for getting onto and off the platform use the steps provided on the machine Never climb on the hand rails when the platform is raised Never drive the platform at high speed in narrow or cluttered areas Never use the machine without installing the platform protective bar or clo sing the safety barrier Never climb on the covers To avoid risks of tipping over operators must respect the following instructions NB Do not disable the safety system end of stroke contactors Avoid moving the steering control levers in the opposite direction without stopping in the O position to stop during a travel manoeuvre move the manipulator lever gradually Respect maximum load and ma
96. ulator operation Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C143 Sheet 1 1 REPLACING THE BOTTOM PANEL MANIPULATOR 1 Preliminary operations Putthe machine in the maintenance configuration see relevant section Caution Switch off the electric power supply see relevant section Do not use the machine during maintenance opera 2 Removing the manipulator 2 tions Remove the closing plate 1 by taking out the four fixing screws e Mark and disconnect the electric connections of the manipulator Remove the manipulator by taking out its fixing screws 3 Reinstalling the manipulator Fixa manipulator equipped with new seals on the turntable control panel Reconnect the electric connections according to the marks made during dismantling Putthe closing plate back into place and secure with the four fixing Screws Putthe machine back into the operational configuration Make several up and down movements from the turntable control panel to test manipulator operation Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C144 Sheet 1 1 REPLACING A STEERING WHEEL 1 Preliminary operations Putthe machine in the low configuration Switch off the electric power supply see relevant section 2 Removing a wheel Slacken without completely unscrewing the nuts of the wheel to be removed Raise the machine using a
97. unter weight Put each counterweight into slings Tighten the screws and grower washers at the back of the main counter weight Screw the closing plate for the electric part back onto the electric plate e Position the 68 Ib 31kg counterweight opposite each battery tray Insert the battery tray pilot points into the counterbores Fix the counterweights with the fixing screws Pinguely Haulotte Z Sheet C214 AN Caution Ensure thatthe oil is not too hot AN Caution Use a container to collect the oil to prevent pollution of the environment AN Caution It is essential to put the component into slings before dismantling reassembling it AN Caution Make sure that the lifting means are in good condition and of sufficient capacity Photo 3 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET REPLACING THE ELECTRIC PLATE 1 1 Sheet 1 2 Preliminary operations Put the machine into the maintenance configuration see relevant sec tion Disconnect the battery terminals top and bottom trays Switch off the electric power supply see relevant section Disconnect the two hoses of the steering cylinder see relevant sheet Disconnect the plug of the steering potentiometer see corresponding sheet Disconnect the travel motor connections see relevant sheet Unscrew the cable clamp of the cables inside the sleeve see relevant sheet Unscrew the cable sleeve fixing cab
98. ve See Sheet Operation correct NO Y Manually test electrovalve Test or replace the eo sheet pressure limiters Replace electrovalve See sheet YV3 067 Operation correct NO Replace electrovalve See sheet YV6 C067 Replace electrovalve See sheet 067 YV5 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP079 Folio 1 6 NO RIGHT OR LEFT ROTATIONAL MAST MOVEMENT FROM THE PLATFORM No mast right or left rotation movement from the platform Put the key switch in the Turntable position Activate the right left rotation movement Right left rotation ovement O gt 5 Put the key switch in the Platform position Activate mast right left rotation movement Open the Platform box and measure voltage at CN23 and CNB6 of the platform board CN23 OV NO CNB6 OV Measure voltage at the terminals of selector Switch SA2 SA2a 29A OV NO SA2b OV Replace the See sheet selector 004 Repair the wiring Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP079 Folio 2 6 NO RIGHT OR LEFT ROTATIONAL MAST MOVEMENT FROM THE PLATFORM Measure voltage at CN1 4 CN1 5 and CN1 3 on the platform board CN1 3 0V idle CN1 3 0V at 4V CN1 5 5V amp CN1 4 0V up CN1 5 0V amp CN1 4 5V down
99. ximum number of people authorised on the platform Distribute the load evenly and place in the centre of the platform if possible Check that the floor resists the pressure and load per wheel Avoid contact with fixed or mobile obstacles Do not drive the platform at high speed in narrow or cluttered areas Do not drive the platform in reverse inadequate visibility Do not use the machine if the platform is cluttered Do not use the machine with equipment or objects hanging from the hand rails Do not use the machine with elements that may increase the wind load e g panels Do not perform machine maintenance operations when the machine is raised without setting up the required safety means gantry crane crane Make daily checks and monitor proper operation during periods of use Preserve the machine from any uncontrolled operation when it is not in ser vice Do not tow the platform it is not designed to be towed and must be transported on a trailer Pinguely Haulotte 2 1 3 RESIDUAL RISKS AN Caution The direction of travel can be reversed after a 180 turntable rotation Take account of the colour of the arrows on the chassis compared with the direction of travel green forward red 7 reverse Thus moving the manipulator in the direction of the green arrow on the control panel will move the machine according to the direction indicated by the green arrow on the chassis Similarly moving a manipulator in the d
100. y 3 Release the lock 4 of the battery support Putthe battery support into slings using the lifting rings 5 Pivot the support around its axis Using an overhead crane remove the battery 3 Removing the lower battery 6 Unscrew the 2 nuts 7 Putthe battery support into slings using the lifting rings 8 Using an overhead crane remove the battery 4 Re installing the batteries Perform the dismantling operations in reverse order to reassembly starting with re installation of the lower battery 6 Additional operations Reconnect the then terminals of the batteries e Put the standby pump back into place Putthe machine back into the operational configuration Pinguely Haulotte Z Sheet C198 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet 1 6 DISMANTLING REASSEMBLING THE MAST AN Caution Ensure that the oil is not too hot AN Caution Use a container to collect the oil to prevent pollution of the environment AN Caution Make sure the lifting means are in good condition and of sufficient capacity Photo 1 Photo 2 1 Preliminary operations Put the machine in the maintenance configuration see relevant section Switch off the electric power supply see relevant section Remove the right and left side covers see relevant sheet Remove the motor cover see relevant sheet Remove the lower right and left covers see releva
101. y Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C209 Sheet 1 1 REPLACING THE BATTERY CHARGER 1 Preliminary operations AN Caution e Put the machine into the maintenance configuration see relevant section Battery servicing operations Switch off the electric power supply see relevant section require safety precautions wear gloves and protective 2 Removing the charger 1 goggles Mark and disconnect the electric connections 2 Remove the charger by removing its fixing screws and nuts 3 3 Reinstalling the charger 1 Perform the dismantling operations in reverse order to reassemble 4 Additional operations Putthe machine back into the operational configuration Pinguely Haulotte Z Sheet C210 AN Caution It is essential to put the component into slings before dismantling reassembling it Caution Ensure that the lifting means are in good condition and of sufficient capacity AN Caution Ensure that the oil is not too hot AN Caution Use a container to collect the oil to prevent pollution of the environment Photo 1 Photo 2 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet 1 4 REPLACING THE SLEW RING 1 Preliminary operations Putthe machine into the maintenance configuration see relevant sec tion Switch off the electric power supply see relevant section Disconnect and remove the bat
102. y the manufacturer Putthe machine back into the operational configuration Star 22 J Star 8 HA16 18PX New Design HA46 51JRT New Design Pinguely Haulotte Z PREVENTIVE MAINTENANCE SHEET Pinguely Haulotte 77 PREVENTIVE MAINTENANCE SHEET Sheet P006 CHANGING THE HYDRAULIC FILTER Folio 1 1 CARTRIDGE 2 Preliminary operations Putthe machine in the maintenance configuration see corresponding para AN Caution graph Usea container to collect oil Switch off electric power see corresponding paragraph to prevent pollution of the environment 2 Replacing the hydraulic filter cartridge NB The filter has a clogging indicator Clogging should be checked when the machine is hot otherwise the indicator may be visible due to the viscosity of the cold oil Change the cartridge 1 if the clogging indicator appears 2 Unscrew the base nut 3 and remove the cartridge from the hydraulic filter Screw a new cartridge into place Putthe machine back into the operational configuration HA16 18 PX HA46 51JRT HA20 26 PX HA61 80JRT STAR 22 J Star 8 H14P H16TP HB40 44J Pinguely Haulotte Z PREVENTIVE MAINTENANCE SHEET Sheet P010 Pinguely Haulotte 77 PREVENTIVE MAINTENANCE SHEET Folio 1 2 CHECKING SERVICING THE TRACTION BATTERIES AN Caution These operations reguire safety precautions wear gloves and protective goggles AN Caution Do not elec
103. ylinder 2 Remove the steering cylinder 1 Reinstalling the steering cylinder Puta new steering cylinder into place with the fixing screws 4 Reconnect the hydraulic hoses according to the marks made during dis mantling 1 Putthe machine back into the operational configuration Make several steering movements to purge the hydraulic circuit Check the level of the hydraulic oil tank Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C213 1 2 1 REPLACING THE COUNTERWEIGHTS Sheet 1 1 Preliminary operations Putthe machine into the maintenance configuration see relevant sec tion Switch off the electric power supply see relevant section Removing the counterweights Putthe counterweights 1 fixed on the battery trays into slings Unscrew their fixing screws 2 Remove the counterweights Remove the bottom battery tray by unscrewing the fixing plates on either side of the tray see relevant sheet Slacken all the fixing screws 4 of the hydraulic tank 3 Unscrew the closing plate fixed to the electric plate to access the fixing screws at the back of the main counterweight Putthe main counterweight into slings Unscrew the screws at the back of the 86 stone 550 kg counterweight Remove the counterweight Reinstalling the counterweights Vacuum clean the holes drilled on the fixing plate of the main co

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