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H14-16 GB.book

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1. YILSVIN YNILLINI 3AVIS A 3 3197109 NMOJLYIG 83INYd NOILVLON 31 el NOISN31X3 WOO8 S 310W 031593 Dx MILLS 39vdOOS313l 31W1OY ITAVINUNL 8303193810 31553 138001 NOI1VIN3INO NOILVASNVHL NOIIVAISNVML 42 Repair manual Pinguely Haulotte Z 8 MAINTENANCE 8 1 GENERAL RECOMMENDATIONS Attention Do not use the machine as a welding earth Do not weld without disconnecting the and terminals of the batteries Do not startother vehicles with the batteries connected Servicing operation described in this manual are given for normal conditions of use In difficult conditions extreme temperatures high hygrometry polluted atmosphere high altitude etc certains operations must be carried out more frequently and specific precautions must be taken consult PINGUELY HAULOTTE After Sales Service for information Only authorised and competent personel may operate on the machine and must comply with the safety instructions related to Personnel and Environment protection As far as the motor is concerned refer to the m
2. juawajddns K C 6 uondo 9 9591 En 9096 5 me OL 57 Pinguely Haulotte 2 Repair manual 58 Repair manual Pinguely Haulotte 7 9 PREVENTIVE MAINTENANCE SHEETS List of preventive maintenance sheet Sheet no Description Checking filling the hydraulic oil tank Replacing the hydraulic filter cartridge Checking changing the oilof a wheel reducing gear 59 Pinguely Haulotte 2 Repair manual 60 Pinguely Haulotte Z PREVENTIVE MAINTENANCE SHEET Sheet P005 CHECKING FILLING Folio 1 1 THE HYDRAULIC OIL TANK 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 page 32 Switch off electric power see 6 4 page 32 2 Checking filling the hydraulic oil tank NB This operation must be carried out when the is cold 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 up if necessary by filling via the cap 2 NB Only use the oil recommended by the manufacturer e Put the machine back into the operational configuration HA16 18PX New Design HA46 51JRT Pinguely Haulotte Z PREVENTIVE MAINTENANCE SHEET
3. NO 12V OK YES Replace the U1 module See Fiche Replace the wiring harness between C058 or the turntable control panel and the electrovalve in question YV10 END The fault persists Replace the printed circuit See Fiche 063 END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP034 Folio 4 4 MACHINE TRAVEL SPEED DOES NOT CORRESPOND TO THE SELECTOR SPEED Q Y Open the platform control panel Y Place the speed selector SA11 on low speed Place the speed selector SA11 on medium speed Check the setpoints at the terminals of selector SA11 Check the setpoints at the terminals of selector SA11 SA11a OV 804 SA11b 12V 805 SA11a OV 804 SA11b OV 805 Y Place the speed selector SA11 on high speed Check the setpoints at the terminals of selector SA11 SA11a 12V 804 SA11b 805 YES Replace the See Fiche YES speed selector 044 SA11 END Y Open the turntable control Replace the 01 See Fiche panel module C058 or C107 Check for 12V voltage on terminal 805 harness 805 Replace wiring Open the turntable control panel Check for 12V voltage on terminal 804 The fault M persists YES Replac
4. Pinguely Haulotte Z Sheet DP072 BREAKDOWN DETECTION FLOW CHART NO TELESCOPING MOVEMENT IN AND OR OUT FROM THE PLATFORM OR TURNTABLE CONTROL PANEL 2 Activate the rotation movement in manual Put the emergency lever into place on the manual control of the rotation distributor YV5 Activate the lever right left while pressing the emergency control of the safety valve YV1 or activate the emergency unit Movement OK Folio 4 4 _NO See Fiche DP047 Replace the PVG YV4 distribution element See Fiche C108 Repair manual Pinguely Haulotte D 11 CORRECTIVE MAINTENANCE PROCEDURE List of corrective maintenance sheets Sheet no Description Changing a hose Changing a wheel Changing a wheel reducing hear or a travel hysraulic motor Changing a cylinder Changing the tilt sensor Changing the horn Changing the tilt sensor buzzer Changing the hydraulic pump Changing an electric component of the top control panel Changing an electric component of the bottom control panel Changing a manipulator Changing the starter battery Changing a cover gas spring Changing the turntable rotation hydraulic motor Changing the swing joint Changing the basket rotation hydraulic motor Changing the basket Changing the weighing rolling bearing Changing the turntable rotation gearing Changing the hydraulic filter Changing the U1 ele
5. AT 52 4 2 E 3 0 8 i HAYTS 2 2 ES E FX E e 624 KA pe pa SL gt 479 NOILYLOM ZA NOISNSLLXS Wood SIN OUO HUP SNHLON MATISSE NAISSA NOT LW ISNVWHL NOILWISNWYUL 41 Repair manua Pinguely Haulotte Z DIAGRAM 16 REFERENCE 16009 7 2 P600914 T1 SCT y EEN 7 E 1 59 1 69 169 10045 7159 SL 101 47 9 70046 lt 11 69 10045 Ja 1 RK 8 Di 1 4 radar ERA onu LA wood air 3j amp 8lIVv IndN3d
6. YES cc co See Fiche Replace coil YV16A C059 or YV16B Y YES The fault persists Repair the connection or END replace the wiring harness between the turntable control panel and electrovalve YV16 See Fiche C063 Replace the printed circuit END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP060 Folio 4 4 NO STEERING MOVEMENT RIGHT OR LEFT G Maintain the control activated and check for 12V voltage at terminals 703 and 705 ofthe printed circuit Open the platform or turntable control panel and NO check the wiring of the manipulator SM4 YES NO a Replace the U1 module See Fiche Repair wiring C107 YES END Check the electric continuity of the switch contacts when closed NO The fault 211A 703 and 211A 705 persists END Replace the See Fiche NO printed circuit 063 5 Replace the See Sheet END manipulator 5 4 45 Repair the connection or replace the wiring END harness between the manipulator SM4 and the printed circuit of the turntable control panel Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP072 Folio 1 4 NO TELESCOPING MOVEMENT IN AND OR OUT FROM THE PLATFORM OR TURNTABLE CONTROL PANEL No telescoping movement out and or in from the platform or turntable contr
7. 2528 mm 2214 mm 7ft 1ft in 2300mm x 800mm Gin x 2ft 7ft 6in 2278mm 7ft 5in E 2249mm 7ft din sd 2300mm 7ft Gin 17 Pinguely Haulotte 2 2 3 18 TIGHTENING TORQUE Nominal diameter M 6 1 Repair manual 2 3 1 Tightening torque for large thread 9 11 Tightening torque in N M 10 9 13 14 15 17 M 7 1 15 19 21 24 26 28 M 8 1 25 22 27 31 34 37 41 10 1 5 43 45 61 67 73 81 12 1 75 75 94 110 120 130 140 M 14 2 120 150 170 190 200 220 M 16 2 190 230 260 290 320 350 M 18 2 5 260 320 360 400 440 480 M 20 2 5 370 450 520 570 620 680 M 22 2 5 500 620 700 770 840 930 24 3 3 630 790 890 990 1070 1180 27 3 930 1150 1300 1400 1560 1730 30 3 5 Nominal diameter 1260 1570 1770 1960 2200 2350 2 3 2 Tightening torque for fine thread Tightening torque in N M 10 9 M 8 1 24 29 33 37 40 44 M 10 1 25 46 57 64 71 77 85 M 12 1 25 83 100 120 130 140 150 14 1 5 130 160 180 200 220 240 16 1 5 200 250 280 310 340 370 M 18 1 5 290 360 410 450 490 540 20 1
8. Caution Remove the fixing nuts and the 3 tie rods 2 then separate the elements Use a container to collect oil to prevent pollution of the environment 3 Re assembling the hydraulic distribution block Replace the O rings seals If necessary put back the control units see corresponding sheet e Install the input plate input module distribution elements and closing plate e Install the fixing nuts and tie rods 2 Tighten to 2 2 daN m 1 4 Ib ft Install the hydraulic distribution block see corresponding sheet Putthe machine back in the operational configuration Make several lifting travel steering and turntable rotation movements to purge the hydraulic circuit Checkthe level of the hydraulic oil tank Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C077 CHANGING CONTROL UNIT Folio 1 1 ON THE DISTRIBUTION BLOCK 1 Ensure that the oil is not too hot HA16 18PX HA46 51JRT 2 HA46 51JRT New Design NB Preliminary operations Putthe machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Removing the control unit e Remove 4 fixing bolts and silent blocks 1 from the turntable box One of the bolts also holds the horn Place the turntable box and the on the wheel e Mark disconnect the electric connection
9. HES uoneiog e d VOLE 5 I 2 X i o uonesua msi gt m Dees z z vopesuadwog lr o uonesuadwon vor ES 3 S uy I _ a v or 5 amp 3 N Anueg pu N SEN t E Jalued 10 Vote SS 8 m x 2 Jeor a 1 ven I T vL0t 5 a 2 u 3 seng X 4 Jojelejeoov hd 0 Jnejejgigoov a l 2 4 2 i d 1 N S gt 8 8 2 e 0 5 a Zi lt D I 2 Y gt amp 55 27 Pinguely Haulotte 2 Repair manual 4 4 DIAGRAM 523 FOLIO 04 05 T zez g 3 Sor 5 2 un I dn peg a 5 A suda 2 e 2 EU je 9 I gt S I i ah 4 Jy Joje1gigoov a DEEN T i i 5 i 5 T duel dusel IO doe auf 3 D GEE S I doe amp 1 2 anssasd IO 5 v 2 B au 2 S Je en i Gi almesadwe di e eju due 1 duel 10 z I am due VLLL LO 3 E 9 2175584 10 l any 1056814 69 9 I 1 y De D i CN 2 Jazzng I Le E
10. Go 16 17 3 ey Em aa CCC E aaa aa e E E ML SO o 7 TEE ES een Q I EM sai A14456a gt oh Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C129 Folio 6 6 DISMANTLING RE ASSEMBLING THE BOOM Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C130 Folio 1 2 CHANGING THE DEUTZ DIESEL THERMAL MOTOR Caution 1 Preliminary operations Leave the motor and exhaust Putthe machine in the maintenance configuration see see corresponding pipe to cool sufficiently paragraph before performing any e Switch off electric power see see corresponding paragraph maintenance operation on Close the hydraulic tank suction valve these elements 2 Removing the connections Remove the cover on the motor side see corresponding sheet Disconnect the starter battery terminals see corresponding sheet Onthe motor disconnect the electric connectors 1 oil temperature oil pressure generator Disconnect the fuel incoming 2 and outgoing pipes Disconnect the electric c
11. lt I 1 2 Jnessiuany 1 E 2 AJA SA l E I 51 N b E M Es z j S S amp NT I 9 Die I 8 o t z I I 1 I 9 I S I I 0 5 1 1 adoosajay _ 3 edooso L m 3 SIE 5818 28 lis gt ue woog S 1 gt al i 2 8 1 Pen 9 2 20 2 a 9 S E Jempuag la le 2907 musst 20 22 i 1 LI I qu THE 7 I Si ta I 9 S maen I m CN I 5 1 ES 5 5 2 8 nes Ja 5 a 1 N lt E I o 1 N gt N y i H Ines eurjz 4 I amp E 8 9 S 3 SA hj e Ss sy y 9 2 Or i zi m 202 358 Si Sag lt L O I gt Y a 28 Repair manual 4 5 DIAGRAM 523 FOLIO 05 05 20 19 18 15 14 11 10 woog abenajay adoasaja uonejueuo vonejueuo uoppalig UORISOd uonejsuei ue INN edo9sa g1 adogsaja
12. BEWARE OVERHEAD ELECTRICAL HAZARDS REGULATION 133 of the CONSTRUCTION SAFETY ACT 1912 REQUIRES a Minimum approach of an appliance 3 m for voltages up to 132 000 to live electrical apparatus 6 m for voltages above 132 000 and up to 330 000 b Inspection of the work site for 8 m for voltages above 330 000 electrical hazards before commencing to use the appliance c Constant vigilance and an observer required whilst working or travelling the appliance in the vicinity of live electrical apparatus 54 USE OF STANDBY UNIT Turn the key operated selector to turntable position Be carefull that the emergency stop button is released Activate the switch in the triangle FUEL and activate the lever or the switch corresponding to the movment required in the same time FUELLING WITH A FILLER ONLY 7814 521 7814 522 RECOMMENDATIONS FOR USE BEFORE USING THIS MACHINE THE OPERATOR MUST 1 Read and understand the information in the Operators Manual and the information marked on the machine and become familiar with the controls 2 Receive training and practical experience in operating the machine under the employer s supervision 3 Ensure that maintenance is performed in accordance with the manufacturer s instructions contained in the Operators Manual 4 Refrain from using the machine in the event of any malfunction 5 Avoid contact with electrical components
13. END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet NO BOOM LIFTING MOVEMENT Folio 2 3 UP AND OR DOWN FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Activate the boom lifting movement in the emergency mode Put the emergency lever into place on the platform control of the boom lifting distributor YV3 Activate the lever up down while pressing the emergency control of the safety valve YV1 Movement OK Activate the lifting switch 5 13 of the turntable control panel and check for 3V or 9V voltage depending on the movement direction on the electrovalve connector YV3 Maintain the control activated and check for 3V or 9V voltage depen ding on the movement direction on terminal 403A of the printed circuit Voltage OK See Fiche 077 electrovalve Voltage y OK Replace the U1 See Fiche module 058 YES Repair the connection or replace the wiring harness between the turntable control panel and electrovalve YV3 Voltage OK Replace the See Fiche printed circuit 063 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet NO BOOM LIFTING MOVEMENT Folio 3 3 UP AND OR DOWN FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Activate the rotation movement in the emergency mode Put th
14. Put a new cover into place and position on the supports 4 Put the washers 2 gas spring ball pivots 3 and locking pins into place on the pins Re mount the support 1 Put the machine back in the operational configuration Check that the cover opens and closes properly When re installing a cover adjustment may be necessary For this purpose supports 1 and 4 are equipped with adjustment lights Pinguely Haulotte Z Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C123 Folio 1 1 CHANGING CONTROL PANEL COVER 1 Preliminary operations Attention Do not use the machine during maintenance operations Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph 2 Removing a cover Open the control panel cover Remove the cover s two support washers 1 on the right and left side of the support Remove the locking pins from the upper ball pivots on the 2 gas springs 2 Free the ball pivots from the 2 pin gas springs Close the cover and raise to free it from the two supports 3 Remove the cover 3 Installing a cover Position the cover on the supports 3 Put into place on the pins the washers 1 ball pivots 2 on the gas springs and locking pins Check that the cover opens and closes properly Put the machine back in the operational configuration When installing a new co
15. Sheet DP018 NO TURNTABLE ROTATION MOVEMENT Folio 3 3 RIGHT AND OR LEFT FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Activate the arm lifting movement in the emergency mode Put the emergency lever on the manual control of the rotation distributor YV4 Activate the lever to the right and left while pressing the emergency control of the safety valve YV1 NO Movement Fiche DP023 OK Replace electrovalve YV5 See Fiche 077 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP019 THE MOTOR DOES NOT START Folio 1 2 FROM THE PLATFORM PANEL BUT DOES START FROM THE TURNTABLE PANEL The motor does not start from the platform but does start from the turntable Place the key switch in the platform position Check that the platform panel power light indicator is on NO Open the turntable control panel and check the state of fuse FU6 YES NO Open the platform control panel and E check the connection continuity and connector of switch SB4 YES Replace fuse FU6 Connection OK END In the turntable control panel Repair the 5 check for 12V voltage on lines connection of 211 and 242 of the wiring switch SB4 Activate switch SB4 harness connection terminal and check continuity block between the platform between the tw
16. Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP026 Folio 2 5 NO COMPENSATION MOVEMENT UP AND OR DOWN Press the pedal and activate the compensation switch and check for 12V vol tage on the terminals of the PVG connector YV2a YV2b for H14 16 HB40 44J Open the turntable control panel Press the pedal and activate the compensation switch Check for 12V voltage on terminal 305 415 for H14 16 HB40 44J of the printed circuit See Fiche Replace the PVG 077 YV2 control head NO Replace the See Fiche 2 module C058 YES Repair the connection or The fault NO replace the electric wiring persists harness between the turntable control panel and PVG YV2 END Replace the See Fiche printed circuit C063 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP026 Folio 3 5 Invert the coils of the compensation electrovalve YV15A and YV15B Press the pedal and activate the compensation switch NO COMPENSATION MOVEMENT UP AND OR DOWN The defective ovement up 1 or down is made when an opposite movement is activated down 1 or up 2 Put coils YV15A and YV15B back in their original position Press the pedal and activate the compensation switch Check for 12V voltage at the terminals of the YV15A up or YV15B down connector Open the turnta
17. Replace the starter Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP018 NO TURNTABLE ROTATION MOVEMENT Folio 1 3 RIGHT AND OR LEFT FROM THE PLATFORM OR TURNTABLE CONTROL PANEL No turntable rotation movement right and or left from the platform or turntable control panel Place the key switch in the turntable or platform position Activate the lifting switch from the turntable control panel SA15 or the rotation manipulator SM2 from the platform control panel with the activated Lifting movement OK i YES Open the platform or turntable control panel and check the wiring of the rotation manipulator SM31 or rotation switch SA15 NO Repair wiring 5 Turntable panel Platform panel END y rotation fault rotation fault Place the key switch in the turntable Place the key switch in the platform position position Open the platform control panel Open the turntable control panel Press the pedal and tilt the rotation manipulator as far as Activate the rotation switch SA15 and possible check for 12V on terminals 517 or 516 of Check for 0 5V or 4 5V voltage depending on the the printed circuit direction of movement on terminal 512 of the printed circuit Replace the rotation See Fiche NO manipulator SM31 or lifting C045 Fiche switch SA15 044 5 Re
18. Sheet C126 Folio 2 2 CHANGING STEERING PIVOT LOVE V USO A14507c Sheet 127 Caution Use container to collect oil to prevent pollution of the environment Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Folio 1 1 CHANGING THE EMERGENCY UNIT 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Close the hydraulic tank suction valve 2 Removing the emergency unit Remove the cover on the reducing gear side see corresponding sheet Disconnect the battery terminals see corresponding sheet Disconnect the unit s supply terminals 1 after marking them NB Unscrew the hoses slowly to release residual hydraulic pressure Markthen disconnect the hoses 2 at the emergency pump Putcaps on the hoses Unscrew the tightening flange 3 of the emergency unit Remove the emergency unit by pulling it upwards 3 Installing the emergency unit Putthe emergency unit into place making sure it is the right way round Screw the tightening flange 3 back onto the emergency unit e Reconnect the hydraulic hoses according to the marks made during dis mantling e Reconnect the supply terminals according to the marks made during dis
19. Spare parts catalogue to order original parts the only guarantee of interchangability and perfect operation REMINDER We would like to 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 directive EMC 89 336 CE Pinguely Haulotte Z Repair manual Repair Manual Pinguely Haulotte 7 SUMARY GENERAL siae de ee cas 1 1 GENERAL RECOMMENDATIONS SAFETY 7 Ms GENERAL WARNING cca 7 ili Malal a 7 e WT 7 bi 7 1 2 GENERAL SAFETY 65 8 1 2 1 Ic PP 8 1 2 2 EMVirOnment 8 1 2 3 Using the machine eccidi 8 Tos RESIDVAERBDS to 10 1 3 1 Risks of jerky movements tipping over ss 10 1 3 2 Electrical risks keinen 10 1 3 3 Risk of explosion or DONTE o ee 10 1 3 4 Risks of collision 10 14 INSPEC TONS ocen an en 11 1 4 1 Periodic 11 1 4 2 Examination or machine SUA seen se tra entr radiale then air 11 1 4 3 State of conservation sise 11 14 5
20. are free of the bosses fixed to the side plate 3 Installing a cover Put a new cover into place and position so that the support pins are facing the bosses 2 Lockthe spring clip 1 Putthe machine back in the operational configuration e Check that the cover opens and closes properly Sheet 126 Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Folio 1 2 CHANGING STEERING PIVOT Ensure that the is not too hot Caution Use a container to collect oil to prevent pollution of the environment Caution It is essential to put the component in slings before dismantling re assembling it 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Remove the wheel corresponding to the element to be removed see cor responding sheet Remove the motor and reducing gear corresponding to the pivot to be removed see corresponding sheet 2 Removing a pivot see figure 1 Place wedge under the steering pivot 1 Remove the fixing screw 23 from the steering clevis pin Remove the pin 11 from the clevis Disconnect the hoses from the hydraulic motor 35 and remove them Remove the two screws 19 from the cap 17 on the pivot pin 14 Remove the cap unscrew the lubricator 18 Do the same on both pins Put
21. aubisuo INN al uonejueuo vonejueuo YOL 9Ad woog abenajay adoosaja adoosa gii uonejueuo vonejueto uonejsuei uonejsuei Pinguely Haulotte 2 NBRE TOTAL DE FOLIOS 5 MODIFICATION DATE DE CREATION 20 04 1999 DESSINE PAR Laurent DI FLORIO PINGUELY HAULOTT E523 H14T H16TP DATE DE VERIFICATION VERIFIE PAR Fr d ric DENEZE TEL 04 77 29 24 24 La P ronnitre BP9 30 04 1999 42152 L HORME 29 Pinguely Haulotte 2 Repair manual 30 Repair manual 5 1 5 2 5 3 5 4 9 9 START STOP MOTOR ACCELERATOR COMPENSATION ROTATION Pinguely Haulotte Z 5 OPERATING INSTRUCTIONS If SB3 1 or SB4 1 W 0 D 0 YV1 0 then KA2 1 By selecting turntable platform is impossible If KA2 1 or mo motor fault for more 6 seconds then KP1 1 No motor fault gt D 1 and B2 1 and B3 1 If HM4 1 or HM31 1 or HM2 1 or SA2 1 and SQ6 1 then KT2 1 5 4 1 Up If SA5a 1 and SQ6 1 SM31ab 0 and SM2ab 0 then YV15a 1 and Yet YV1 1 YV1 is time delayed for 2 seconds If SQ6 passes to O during a movement this one is not cut 5 4 2 Down If SA5b 1 and SQ6 1 and SM31ab 0 and SM2ab 0 then YV15b 1 and YV2b 1 and YV1 1 YV1 is time delayed for 2 seconds If SQ6 passes to O during a movement t
22. container to collect oil to prevent pollution of the environment Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Folio 1 1 CHANGING 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 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 77 CORRECTIVE MAINTENANCE SHEET Sheet C034 Folio 1 1 CHANGING WHEEL 4 Preliminary operations machine in the maintenance configuration see corresponding para graph Switch off electric power see corresponding paragraph 5 Removing a wheel Unblock without completely unscrewing the fixing screws 1 of the wheel to be removed Raise the machine using a jack or hoist Remove the fixing screws 1 from the wheel and remove the wheel 2 Puta new wheel into place and put back the fixing screws Putthe machine on the ground e Tighten the fixing screws to the re
23. damanging the pins rings and bores Replace the pins and lubricators if necessary Put the steering bar into place Put back the central steering pin 12 Put back the smooth male clevis 31 and fix using its fixing screw 16 equipped with a new washer 25 Put the steering cylinder clevis into place Put back the pin 27 Put the washer 22 into place and screw the nut 21 Position the clevises of the two steering bars on the lever and put back the pins 11 Fix with screws 23 and washers 24 Lubricate the central pivot pin and the steering bar clevis pins 5 Installing a steering bar Replace the pins and lubricators if necessary Put the steering bar into place Adjust wheel alignment if necessary slacken the counter nut 9 on the steering bar screw or unscrew the clevis 8 to adjust the length of the steering bar tighten the counter nut 9 Put back the two pins 11 and block with screws 23 and washers 24 Lubricate the pins 6 Additional operations Put the machine back in the operational configuration Lubricate the pins using the lubricators Pinguely Haulotte MAINTENANCE SHEET 2 2 18 2324 A14507c Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sh
24. 2 NO MOVEMENT AVAILABLE FROM THE PLATFORM CONTROL PANEL No movement available from the platform control panel Open the turntable control panel Check the state of fuse FU6 NO Replace the fuse YES Place the key switch in the platform position Open the platform control panel Press the pedal and check for 12V voltage on terminal 2110 or 211A NO Hold down the pedal and check for 12V voltage on terminal 211 of the platform YES control panel Internal wiring of the platform control panel is defective Repair cabling or replace the NO platform control panel a YES END See Fiche 064 Replace the Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART AVAILABLE 22 FROM THE PLATFORM CONTROL PANEL Open the turntable control panel Check for 12V voltage on terminal 211 NO YES Check wiring of wire 211 inside the platform control panel Replace the wiring harness between the turntable control panel and the platform control panel Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet 25 Folio 1 2 NOISY HYDRAULIC PUMP The hydraulic pump makes a noise Check the oil level in the circuit Oil level Top up with oil Se
25. 3 Unscrew the screws 4 fixing the hydraulic motor to the wheel reducing gear Replace the defective hydraulic motor or reducing gear Installing wheel reducing gear or a hydraulic motor e Assemble the hydraulic motor to the reducing gear using fixing screws equipped with new grower washers Fix the hydraulic motor using the four fixing bolts equipped with new elas tic washers e Re install the reducing gear motor assembly and secure with fixing screws Tighten to the torque recommended see tightening torque value table nthe case of a steering axle couple the steering connecting rod to the pivot Reconnect the hydraulic hoses to the hydraulic motor and the reducing gear hose equipped with a new seal according to the marks made when dismantling 4 Additional operations Checkthe level of oil in the wheel reducing gear see corresponding sheet Putthe wheel back see corresponding sheet Putthe machine back into the operational configuration Make several travel movements to purge the hydraulic circuit Checkthe level of the hydraulic oil tank Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C035 CHANGING A WHEEL REDUCING GEAR Folio 2 2 OR A TRAVEL HYDRAULIC MOTOR HA NV Figure 1 Figure 2 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C038 Folio 1 1 CHANGING THE STEERING CYLINDER 7 Preliminary operati
26. 5 410 510 570 630 690 760 22 1 5 550 680 780 870 920 1000 M 24 1 5 690 860 970 1070 1160 1290 M 27 2 1000 1300 1400 1560 1690 1880 M 30 2 1400 1700 1960 2180 2350 2610 Pinguely Haulotte 2 Repair manual 2 3 3 Pressure table in bar Generator Peas Main Steerin Prole Rotation Up Down sensing release H14 16 23 30 240 240 240 100 240 240 Telescope Telesope Travel compensation Jib ip Jib down out y unit H14 16 110 240 240 240 240 240 130 2 3 4 Table of adjustment times Movement HS deceleration Control From the basket Movement duration 1 20 m 20cm HS travel forward and reverse From the basket 12s 2s 20m Micro speed travel From the basket 455 25 10m Boom lifting 14 From the basket 485 25 Boom lifting 16 From the basket 40s 25 lowering H14 From the basket 38s 25 lowering 16 From the basket 30s 2s Telescope out From the basket 30s 2s Telescope in From the basket 25s 2s Rotation From the basket 30s 1s per 1 4 turn Jib up From the basket 30s 2s Jib down From the basket 23s 2s Right left basket rotation speed From the basket 15s 2s Compensation speed up From the ba
27. 8 7 3 Common yellow labels Repair manual Repair manual Pinguely Haulotte 7 8 7 4 Various labels CONSIGNE D UTILISATION POUR UTILISER CET APPAREIL L OPERATEUR DOIT 1 Lire et comprendre les informations contenues dans le manuel de conduite et les inscriptions appos es sur la machine se familiariser avec les commandes 2 Etre form et entra n pour la conduite de celui ci sous la responsabilit de son employeur 3 Assurer correctement l entretien suivant le catalogue constructeur 4 Ne pas utiliser l appareil en cas de disfonctionnement 5 Ne pas laver sous pression les composants lectriques 6 Ne rien d monter la stabilit serait modifi e 7 Ne pas modifier l appareil sans accord du constructeur 8 Ne pas utiliser la machine comme masse de soudure 9 Ne pas souder sur la machine sans d connecter les cosses des batteries se r f rer la notice de conduite et d entretien INSPECTION JOURNALIERE 1 V rifier le niveau d huile hydraulique et le liquide des batteries 2 V rifier s il n y a pas de signe apparent de d fectuosit fuite hydraulique boulonnerie liaisons lectriques 3 V rifier le fonctionnement de l indicateur de devers en faisant fonctionner l alarme sonore INSTRUCTION AVANT UTILISATION 1 Enlever la broche de blocage d orientatio
28. Check the tightness of the wheel nuts torque 32 daN m Change the hydraulic filter cartridge Every 500 hours 24 Motor see manufacturer s manual 25 Change the wheel reducer oil Fill up capacity 4 x 1 4 litres for 4 4 and capacity 2x14 litres for 4 2 26 Ring screws check the tightness and tighten if necessary torque 10 daN m Every 1000 hours 11 Motor see manufacturer s manual or every year 27 Empty the hydraulic oil tank Every 2000 hours 28 Empty the tank and the whole hydraulic oil circuit 29 Empty and clean the diesel tank 30 Grease the rotation reducer 1 point Every 3000 hours 48 Check the condition of the telescope friction pads the electric cables and hydraulic hoses REMINDER The frequencies given above to be reduced in the case of work in difficult conditions consult the After Sales department if necessary Repair manual Pinguely Haulotte Z 8 7 PRESENCE OF LABELS It is important to check that the labels and plates warning personnel of the various dangers associated with using the machine are in good condition The labels providing operators with information on machine use and maintenance must also be checked An illegible label may lead to incorrect or dangerous use of the machine Operating instructions Check the presence of the labels Check that all the labels described be
29. Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP026 Folio 5 5 NO COMPENSATION MOVEMENT UP AND OR DOWN Replace the double flow See Fiche limiter 083 The fault persists Replace the balancing See Fiche valve 082 The fault persists YES Replace the electrovalve See Fiche YV15 C067 Sheet DP027 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Folio 1 5 NO PLATFORM ROTATION MOVEMENT RIGHT AND OR LEFT No platform rotation movement right and or left Place the key switch in the platform position Press the pedal and activate the compensation switch on the platform control panel Compensation movement OK Stop the movement and release the pedal Open the turntable control panel and check that the LED associated with the electrovalve YV19A left or YV19B right is off 70 Press the pedal and activate the platform rotation switch Check that the LED associated with the electrovalve YV19A left or YV19B right is on YES YES Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP027 Folio 2 5 NO PLATFORM ROTATION MOVEMENT RIGHT LEFT Press the activate the platform rotation switch Check for 12V vol tage at the terminals of the PVG connector YV2a YV2b for H14 16 HB40 44J Open the turnta
30. IN AND OR OUT FROM THE PLATFORM OR TURNTABLE CONTROL PANEL o Activate the telescoping movement in manual Put the emergency lever into place on the manual control of the telescoping distributor YV4 Activate the lever up down while pressing the emergency control of the safety valve YV1 or activate the emergency unit Movement OK Place the key switch in the turntable position Activate the turntable control panel rotation switch SA15 Rotation movement OK See Fiche DP023 YES Activate the telescoping switch SA8 of the turntable control panel and check for 3V or 9V voltage depending on movement direction at the terminals of the PVG YV4 control head Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP072 NO TELESCOPING MOVEMENT Folio 3 4 IN AND OR OUT FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Maintain the control activated and check for 3V or 9V depending on movement direction on terminal 506A of the printed circuit Voltage OK Replace the 4 control See Fiche DE Voltage head C108 y Replace the 01 SeeFiche module C107 YES END Repair the connection or replace the wiring harness NO between the turntable control panel and the YV4 control head Replace the See Fiche printed circuit 063 The fault persists
31. Removing the jib Mark the position of the cam 6 of sensor SQ2 7 Remove the two pins 8 fixing the jib to the jib link part as described above then remove the vertical parts of the jib 2 and 3 and the cylinder 1 4 Removing the jib link part 9 Put the jib link part into slings 9 Put the receiver compensation cylinder into slings 10 Remove the M canindus pin blocking the pin then remove the pin 11 of the receiver compensation cylinder 10 Remove the male clevis blocking the link part rotation pin 12 by remo ving its fixing screw Remove the rotation pin 12 then remove the jib link part 9 5 Installing the jib link part NB Lubricate all bores before re installing the pins Only use lubricants recommended by the manufacturer Check the condition of the rings of the different jib pins and replace if necessary Put the jib link part back into place Install the link part rotation pin Install the clevis and block using the screw previously coated with normal blue loctite 243 Install the receiver compensation cylinder pin and block with a new M ca nindus pin Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet 069 Folio 2 2 DISMANTLING RE ASSEMBLING THE JIB 6 Installing the jib Put the jib and its cylinder into place and install the articulation pins Fix the pins with M canindus pins Install the 3 stop rings and the contactor SQ2 cam in the positions
32. SAT Platform jib SA8 Turntable telescope SA9 SA11 LS MS HS SB3 Turntable start SB4 Platform start SB5 Buzzer SA13 Turntable lifting SA15 Turntable rotation SM31 Rotation and lifting SM2 Telescoping SM4 Travel 21 Pinguely Haulotte 2 Repair manual 3 1 4 Safety inputs SQ6 Weight 2nd threshold 505 Weight 164 threshold 501 Tilt SQ2 Jib from 0 to 90 503 lifted 509 Telescope out SQ12 8M break SQ13 8M break 4 Oil tank temperature B3 Motor oil pressure B1 Filter clogged D Generator 3 1 5 Relay outputs KP1 Motor stop KT2 Accelerator KA2 Starter 3 1 6 On off electrovalve outputs YV1 LS YV2a PVG TOR YV2b PVG TOR 9 Differential blocking YV13 Differential blocking YV8 HS 10 5 5 YV12 MS HS YV15a Compensation up YV15b Compensation down YV18a Jib down YV18b Jib up YV19a Left basket rotation YV19b Right basket rotation YV16a Rear left steering in 4 4 YV16b Rear right steering in 4 4 YV24 Basket rotation compensation 3 1 7 Proportional electrovalve outputs YV3 Lifting YV4 Telescoping YV5 Rotation YV6 Travel YV7 Travel 22 Repair manual Pinguely Haulotte Z 3 1 8 Buzzers HA1 Horn HA4 Tilt overload temperature buzzer HA2 Overload 1st threshold buzzer 3 1 9 Light indicators HL1
33. 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 1 4 2 11 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 12 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 t
34. block and connect a pressure gauge of at least 0 300 bars 0 4351 PSI Switch electric power on again see corresponding paragraph and start the motor Without activating a movement measure pressure on the gauge Adjust the hexagonal socket head screw on the pressure limiter 4 until the pressure indicated in the table below is shown on the pressure gauge Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Unscrew the pressure gauge and put the hydraulic pressure tapping cap back into place Put the machine back in the operational configuration Extend the machine several times to check operation 2 Adjusting the main pressure limiter 3 Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Unscrew the cap of the minimess hydraulic pressure tapping 2 on the distribution block and connect a pressure gauge of at least 0 300 bars 0 4351 PSI Switch electric power on again see corresponding paragraph Extend the boom lifting cylinder fully to its stop to block the movement Activate a boom lifting movement and measure pressure on the gauge Adjust the hexagonal socket head screw on the main pressure limiter 3 so that movements are disabled at the pressure indicated in the table below Put the machine in the maintenance configuration see corresponding
35. connectors Use a container to collect oil Unscrew the hoses slowly to release residual hydraulic pressure to prevent pollution of the environment Photo 2 Caution It is essential to put the component in slings before dismantling re assembling it Photo 21 Slinging 5 al On the travel block mark then disconnect the hoses ref 1 2 3 4 and 5 Photo 3 coming from the hydraulic swing joint Put caps on the connectors Photo 3 Pinguely Haulotte Z Sheet C128 Photo 5 Photo 8 CORRECTIVE MAINTENANCE SHEET Folio 2 6 CHANGING THE SLEW RING In the chassis box mark and disconnect the electric wires coming from the swing joint Photo 4 Remove the screw that blocks rotation on the lower part of the swing joint by slackening the counter nut ref 1 Photo 5 and unscrew the screw ref 2 Photo 5 Bring the electric wiring harness and hoses under the hydraulic swing joint Put the turntable assembly into slings see Photo 6 and Photo 7 Photo 6 Unscrew the 28 screws and remove the flat washers fixing the ring onto the chassis see Photo 8 Place the turntable assembly onto suitable safety stands see Photo 9 and Photo 10 Photo 9 Photo 10 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C128 Folio 3 6 CHANGING THE SLEW RING 2 Removing the ring Mark then disconnect the hoses ref 1 and 2 Photo 11 of the rotation red
36. cylinder NB Put the cylinder 1 and the vertical elements 2 and 3 of the jib into slings Mark and disconnect the 2 hydraulic hoses of the jib cylinder Unscrew the hoses slowly to release residual hydraulic pressure Fit the hoses with caps Remove the 2 bolts and stop rings from the cylinder pin s pin 4 on the cylinder body side Remove the M canindus pin blocking the pin and remove the pin 4 Remove the two and stop rings from the cylinder pin s pin 5 on the cylinder rod side Remove the M canindus pin blocking the pin then remove the pin 5 Remove the jib cylinder 1 3 Installing the jib cylinder NB Before re assembly check the condition of all the articulation pin rings and replace if necessary Lubricate all bores before re instal ling the pins Only use lubricants recommended by the manufactu rer Put the jib cylinder back into place and put back the two articulation pins on the cylinder rod and body side Fix the pins with M canindus pins Install the 4 stop rings and fix with their bolts Remove the slings 4 Additional operations Unfasten the platform Put the machine back into the operational configuration Make several jib movements to check operation and purge the hydraulic circuit Check the level of the hydraulic circuit Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet 074 Folio 2 2 CHANGING THE JIB CYLINDER Pinguely Hau
37. head C077 or C108 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART NO MACHINE TRAVEL OISE Setpoints 29 2 exc neutral 29 3 12V 29 4 forward 2 5 to 4 5V Reverse 2 5 to 0 5V Replace defective wiring har nesses no 612 606 and 611A See Fiche C058 or C107 Replace the U1 module The fault NO persists YES Replace the printed circuit See Fiche C063 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP034 Folio 1 4 MACHINE TRAVEL SPEED DOES CORRESPOND TO THE SELECTOR SPEED Machine travel speed does not correspond to the selector Do not press the pedal Open the turntable control panel and check that the LEDs associated with electovalves YV8 YV10 and 12 are off All the LEDs are off Note the LED that is on Put the machine on wedges so that the wheels are not touching the ground Place the key switch in the platform position Place the speed selector in the High speed position Press the pedal and make a forward travel movement Check that the LEDs associated with electrovalves YV8 YV10 and YV12 are on All the LEDs are NO All the LEDs are off Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP034 Folio 2 4 MACHINE TRAVEL SPEED DOES NOT CORRESPOND TO THE SELECTOR SPEED Pl
38. lifting Start the platform start the thermal motor manipulator SM31 while pressing the emergency without making a movement control of the safety valve YV1 Check the load sensing pressure reading tap M 25 to 30 bars Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet 23 i Folio 2 5 NO MOVEMENT AVAILABLE FROM TURNTABLE OR PLATFORM CONTROL PANELS Movement NO OK Open the turntable control panel Press the pedal and activate the boom lifting manipulator SM31 Check that the LED associated with electrovalve YV1 is on NO YES Maintain activation of the controls and check connector YV1 for 12V voltage 1A to 1 6A current Replace the electric wiring YES harness between electrovalve YV1 and the turntable control panel 1A to 1 6A dis END 9 K YES Replace electrovalve Replace the coil of See Fiche YV1 electrovalve YV1 C077 or C108 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART AVAILABLE PS FROM TURNTABLE OR PLATFORM CONTROL PANELS Pressure NO 25 to 32 bars YES Adjust the load See Sheet sensing pressure 073 or C111 NO Pressure OK YES Check the coupling See Fiche between the hydraulic 042 or END pump and the thermal 091 motor Coupling NO OK Y Replace
39. lifting travel steering and turntable rotation movements to purge the hydraulic circuit and test block operation Checkthe level of the hydraulic oil tank H14 16 HB40 44J HA46 51JRT New Design Pinguely Haulotte Z Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C067 Folio 1 1 CHANGING AN ELECTROVALVE 1 Preliminary operations Caution Put the 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 electrovalve e Mark and disconnect the electric connections 1 of the coils N Caution Mark the installation position of the electrovalve the block e Unscrew the four fixing 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 Pinguely Haulotte Z CORRECTIVE MAIN
40. manufacturer s manual YES Check the state of the motor safety systems END motor oil pressure battery charge and replace the defective component See motor manufacturer s manual Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet 56 ONLY TRAVEL MICRO SPEED IS AVAILABLE Folio 1 2 ON THE MACHINE REGARDLESS OF THE SPEED SELECTED Only travel micro speed remains available on the machine regardless of the selected speed Check that the machine is folded 502 1 SQ3 1 SQ9 1 Machine folded Fold the machine Check the setpoint at the output of sensors 502 SQ3 and 509 Adjust the sensor s or replace See Fiche Setpoint the defective sensor s C110 YES END Check the continuity of wiring harnesses no 206 207 and 204 NO Replace the defective wiring harness es no 206 207 or 204 YES END Replace the U1 module See Fiche C107 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP056 ONLY TRAVEL MICRO SPEED IS AVAILABLE Folio 2 2 ON THE MACHINE REGARDLESS OF THE SPEED SELECTED The fault NO persists Replace the printed circuit See Fiche C063 END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP058 Folio 1 1 SUDDEN STOP OF TRAVEL MOVEMENT DURING A PLATFORM LIFTING OPERATION Sudden stop of t
41. of steering wheels 2 Differential blocking Hydraulic brakes 2 Freewheel oui Tightening torque Wheel nuts 320 m N Slew ring 1000 DEUTZ diesel motor F3L1011F Power 38 28 Kw 28 33 hp 2400 min 1 Idling power 20 4 15KW 15 21 hp 1250 min 1 Consumption 2309 kwh Idling consumption 2309 kwh Hydraulic pump 45 3 yes 85 l min 13 Pinguely Haulotte 2 Repair manual 2 1 2 Technical characteristics H16TP X DESCRIPTION H14T X Unit Hydraulic pressure General 24 Travel 24 MPa Steering 24 Slew 10 Travel speed Low speed 1 6 Medium speed 3 0 Sun High speed 6 0 Max force on one wheel 3100 Kg Max pressure on the floor hard floor concrete 9500 Kg m soft floor beaten earth 3100 Ignition battery 12V 95Ah 450A Supply voltage 104 dB Acoustic power 71 5 dB 14 DESCRIPTION H16TP X Unit Stat pasket Option basket 2300 800 Load 230 2 peoples 230 2 peoples Kg Max lateral manual force 400 N Max wind speed 45 Km h Floor height 13 44 m Working height 15 44 m Overall length 8 47 m Overall width 2 30 m Overall height 2 21 m Wheel base 2 00 m Floor clearance 0 34 m Max bearing distance 12 30 m Boom range 1 75 Turntable rotation 360 continu travel slope 4 4 50 Tyre dimensions 14 17 5 SKS HAULER Interior tur
42. paragraph Switch off electric power see corresponding paragraph Unscrew the pressure gauge and put the hydraulic pressure tapping cap back into place Put the machine back in the operational configuration Make several boom lifting movements to check operation 3 Adjusting the telescope extension pressure limiter 1 Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Unscrew the cap of the minimess hydraulic pressure tapping 2 on the distribution block and connect a pressure gauge of at least 0 300 bars 0 4351PSI Switch electric power on again see corresponding paragraph Extend the telescope cylinder fully to its stop to block the movement Activate a telescoping movement and measure telescoping pressure on the gauge Adjust the hexagonal socket head screw on the telescoping pressure limi ter 1 so that movements are disabled at the pressure indicated in the table below Pinguely Haulotte Z Sheet C073 CORRECTIVE MAINTENANCE SHEET Folio 2 4 ADJUSTING PRESSURE LIMITER NB NB Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Unscrew the pressure gauge and put the hydraulic pressure tapping cap back into place Put the machine back in the operational configuration Make several telescoping movements to check operat
43. replaced pressure limiter to purge the circuit Adjust the limiter to the required pressure see corresponding sheet Check that the corresponding movement is made correctly Caution Use a container to collect oil to prevent pollution of the environment Sheet 082 Ensure that the oil is not too hot Caution Use a container to collect oil to prevent pollution of the environment Caution Balancing valves are safety elements They are calibrated in the plant and must not be re adjusted Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET CHANGING A BALANCING VALVE Folio 1 1 FOR THE COMPENSATION FUNCTION 1 Preliminary operations e machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph 2 Removing a balancing valve Remove the balancing valve 1 by unscrewing it 3 Installing a balancing valve Screw a new balancing valve whose characteristics correspond to the machine in question into the hydraulic block Tighten to a torque of 45 to 50 Nm 33 to 36 7 Ib ft Putthe machine back into the operational configuration Make several movements using the replaced balancing valve to purge the circuit Check that the corresponding movement is made correctly Pinguely Haulotte Z CORRECTIVE MAINTEANCE SHEET Sheet 083 CHANGING DOUBLE FLOW LIMITER Folio 1 1 FO
44. the hydraulic See Fiche Replace the See Fiche pump C042 or C091 coupling C042 or C091 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet 23 Folio 4 5 NO MOVEMENT AVAILABLE FROM TURNTABLE OR PLATFORM CONTROL PANELS Replace the pressure limiter of the PVG input module Clean the protective filter Screen The fault NO persists YES END Replace the PVG input See Fiche module C076 or C094 The fault NO persists YES END Adjust or replace the pump See Fiche regulation valve pressure C073 or C111 limiter 240 bars The fault NO persists YES END Replace the hydraulic See Fiche pump C042 or C091 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART MOVEMENT AVAILABLE FROM TURNTABLE OR PLATFORM CONTROL PANELS Place the key switch in the turntable position Check for 12V voltage between points 0 and 240 of the turntable panel printed circuit NO YES Replace relay KMG See Fiche Replace the U1 module See Fiche C062 C058 or C107 The fault NO The fault NO persists persists YES END YES END Repair the wiring of the key See Fiche Replace the printed circuit See Fiche switch SA1 or C044 C063 replace the switch Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP024 Folio 1
45. tilt buzzer sounads and the fault light on the platform control panel comes on 6 Removing an SQ3 end of stroke contactor boom lifting SQ9 Remove the protective plate ref 1 Photo 14 Unscrew the fixing screws ref 2 Photo 15 of the contactor support Remove the end of stroke contactor Photo 14 Open the end of stroke contactor mark and disconnect the electric con nections 7 Installing an SQ3 end of stroke contactor boom lifting Open the new end of stroke contactor reconnect the electric connections and close the end of stroke contactor Put the end of stroke contactor back into place in the position marked during dismantling and fix on its support using screws ref 2 Photo 15 8 Adjustment and testing the machine back into the operational configuration Make a boom lifting movement NB Ensure that the end of stroke contactor roller is not at its limit against the welded cam ref 3 Photo 15 A slight gap should be left in the plunger Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C121 Folio 2 4 CHANGING AN END OF STROKE CONTACTOR Photo 15 9 Checking break actions 503 e When boom is above the horizontal travel should switch to micro speed and if the machine is tilted all movements are disabled except telescope in boom lifting rotation basket rotation and compensation For the USA if the machine is tilted the tilt buzzer sounads and the fault light
46. weighing contactors see corresponding sheet NI 2222422222774 C 172 jl N SO OV E PSI Sa Ver rer CA 2 9 A 09 Figure 1 Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C053 Folio 3 3 CHANGING THE BASKET 27 cote a vide 72 MU ER RXR MGW Sssessss jj NSNNSSSNNNNNNSNNNNNNNNNNSNNSNNS SS KS ii X C Figure 3 HA16 18PX HA46 51JRT 108 4 25 H21T 62 103 mm 4 055 H23T TP H25TP HB68J HB76J 108 mm 4 25 in Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet 054 Folio 1 1 CHANGING WEIGHING SYSTEM ROLLING BEARING 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph e Remove the basket see corresponding sheet 2 Removing the rolling bearing Remove the screws 1 from the rolling bearing track Remove the rolling bearing track 2 Remove the circlips 4 then the ball bearings 3 3 Installing the rolling bearing Putnew rolling elements on the bearing track Block in travel using the cir clips Lubricate the rolling bearings NB Only use lubricants recommended by the manufac
47. with the articulation pin e Install the male clevis to block the cylinder pin and fix with its fixing screw equipped with a new grower washer Fixthe boom lifting cylinder on the body side of the cylinder using the pin Install the male clevis to block the pin and fix with its fixing screw equipped with a new grower washer Reconnect the 2 hydraulic hoses of the boom lifting cylinder 4 Additional operations Lowerthe boom Remove the sling from the boom Putthe machine back into the operational configuration Make several boom lifting movements to check operation and purge the hydraulic circuit Checkthe level of the hydraulic circuit Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet 075 Folio 2 2 CHANGING THE BOOM LIFTING CYLINDER Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C076 Folio 1 1 DISMANTLING RE ASSEMBLING THE HYDRAULIC DISTRIBUTION BLOCK 1 Preliminary operations Caution Remove the hydraulic distribution block see corresponding sheet Ensure that the oil is not too hot 2 Dismantling the hydraulic distribution block 1 Mark the positions of the input plate input module distribution elements and the closing plate If necessary remove the control units see corresponding sheet
48. 180 rotation Bear in mind the colour of the arrows on the chassis in relation to the colour shown on the platform control panel green and red 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 direction of the red arrow the control panel will move the machine in the direction of the red arrow on the chassis Caution If the machine has 220 V 16 max plug the extension must be connected to a mains socket protected by a 30 mA differential circuit breaker 10 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 5 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 a
49. 3 UP AND OR DOWN FROM THE PLATFORM OR TURNTABLE CONTROL PANEL No boom lifting movement up and or down from the platform or turntable control panel Place the key switch in the turntable or platform position Activate the lifting switch on the turntable control panel 5 14 or the lifting manipulator SM31 on the platform control panel Lifting movement OK Open the platform or turntable control panel and check the wiring of the boom lifting manipulator SM31 or boom lifting switch SA13 NO Repair wiring 5 Turntable panel boom Platform panel boom END y lifting fault lifting fault Place the key switch in the turntable Place the key switch in the platform position position Open the platform control panel Open the turntable control panel Tilt the boom lifting manipulator SM31 as far as possible Activate the boom lifting switch SA 13 Check for 0 5V or 4 5V voltage depending on the move and check for 12V voltage on terminals ment direction on terminal 403 of the printed circuit 505 or 504 of the printed circuit Replace the boom lifting See Fiche manipulator SM31 or the lifting C045 Fiche switch SA13 C044 Repair the connection or replace the electric wiring END harness between the boom lifting manipulator SM31 or boom lifting switch SA13 and the printed circuit of the turntable control panel
50. 51 3078148700 1 Acoustic power 11 3078148890 1 Biodegradable oil in option 49 Pinguely Haulotte 2 Repair manual 50 Ref Code Qty Description 57 307P202360 1 Motor support rotation 29 3078145730 1 220 V socket for Holland only 24 3078145580 1 Platform control panel label 23 3078145570 1 Turntable control panel label 27 1 Operating and servicing manual 28 1 Parts manual 7 3078144560 1 Diesel operating instructions for Australia 10 3078144430 1 Danger of electrocution for Australia 60 3078149240 2 Do not spray water near the built in generator 61 3078150500 1 Built in generator ON button 48 3078145210 1 White arrow Australia 49 3078145220 1 Black arrow Australia 12 3078145230 1 Danger Direction of movement Australia 59 3078145200 1 Pressurised fluid for Australia 24 307 203630 1 Platform control panel 23 307 203640 1 Ground control panel Repair manual Pinguely Haulotte 7 8 7 2 labels Composant sp cifique cette machine NE PAS INTERCHANGER Component specific to this machine DO NOT INTERCHANGE Komponenten nurf r diese maschine geeignet BITTE AUF EINE ANDERE MASCHINE NIGHT MONTIEREN MACHINE MASCHINE N 7814 414 E 7814 507 7814 363 7814 362 7814 921a 7814 60 51 Pinguely Haulotte 2 52 Fes mn
51. Battery charge HL2 Air filter HL4 Motor oil pressure HL9 Fault light indicator 23 Pinguely Haulotte 2 Repair manual 24 Pinguely Haulotte Repair manual WIRING DIAGRAM 4 DIAGRAM E 523 FOLIO 01 05 4 1 di9LH LPLH 6661 70 06 NOILVOIAIH3A 31val 3zaNaa ugpoi4 Hd ve ve 62 LL VO MAL INWOHA 2912 648 Sue ET 6661 70 80 pl em m 299 masse UL LO TIN VH A TAN ONId dois Joyesaja00y 6 20 J911e 9 Ausbau 905 INAJLIDIDIMY Inajeulayy Jnejjeuigiq sJnooes ap 2 20 12 10 paises sees li 1 1 I 1 I WA sa ta a y mu 9 qd 1 y LI 2 0 8 I i I 3 FEIE ER gt eto 81 10 61 10 02 0 6 20 idi Av du KO SEH 189 1 20 cre N 0 3 4 o ozL VOL 5 08 vosc ll Ind ll ena una e LOL 0 6L 8L ZL OL GL vL EL 21 LL OL 6 8 9 L 25 Repair manual Pinguely Haulotte 2 FOLIO 02 05 DIAGRAM E 523 4 2 20 mos 1 1 ici neon o m LLOINVH A14NONId om 6661 70 80 Id wane B 501104 1VLOL VSIA NOIL
52. HIBITED 1 2 3 Using the machine Do not use the machine with a load greater than allowed load if wind speed exceeds the maximum with more than maximum authorised number of occupants in platform with a side load in the platform greater than permissible limit Repair manual Caution Never use the platform as a crane hoist or lift Never use the machine to pull or tow Never use the boom as ram or thruster or to lift the wheels Pinguely Haulotte Z To reduce the risks of serious falls operators must respect the following instructions Hold the guardrail firmly when lifting or driving the platform Remove any traces of oil or grease from the platform steps floor or guardrails Wear personal protective equipment suited to working conditions and conform to local regulations particularly when working in hazardous areas Never disable the limit switches of the safety devices Avoid contact with stationary or moving obstacles Do not increase the platform operating height by means of ladders or other accessories Never use the guardrails to climb into or out of the platform use the steps provided Never climb on the guardrails when the platform is up Avoid driving the machine at high speed in narrow or congested are as Never use the machine without putting in place the platform safety bar or closing the safety gate Never climb on the covers To reduce the risks of tipping ov
53. HM4 defective Wiring harness defective Electronic module U1 defective Coils of electrovalve YV6 or YV7 defective Electrovalves YV6 or YV7 defectives Fiche DP032 Only travel micro speed remains available on the machine regardless of the speed selected Machine unfolded Contactors 502 SQ3 504 incorrectly set or defective Wiring harness defective Electronic module U1 defective Printed circuit defective Fiche DP056 Machine travel speed does not correspond to the selec tor Electrovalve YV8 YV10 YV12 or YV17defective Coil of electrovalve YV8 YV10 or YV12 de fective Wiring harness defective Printed circuit defective Speed selector SA11 defective Electronic module U1 defective Fiche DP034 Sudden stop of travel during a platform lifting operation Contactors SQ3 SQ4 SQ2 incorrectly set or defective Wiring harness defective Electronic module U1 defective Fiche DP058 No differential blocking during action on switch SA3 Switch SA3 or SA11 defective Electronic module U1 defective Wiring harness defective Contactors SQ3 509 502 incorrectly set or defective Printed circuit defective Coils of electrovalves YV9 or YV13 defective Electrovalves YV9 or YV13 defective Fiche DP036 No grip on a drive wheel Insufficient load on one wheel Act on the blocking button 71 Pinguely Haulotte 2 10 1 4 Steering sy
54. M4ab 1 and HM4 1et 501 1 or machine folded and SM31ab 0 and SM2ab 0 then YV6 and YV7 LS MV HS Full setpoint Micros low setpoint YV1 is time delayed for 2 seconds If SQ6 passes to O during a movement this one is not cut machine folded gt SQ2 1 and SQ3 1 and SQ9 1 Repair manual Pinguely Haulotte 7 5 9 TELESCOPING 5 9 1 Turntable 5 9 1 1 Out If SA8b 1 and 501 1 or machine folded then YV1 1 and YV4 1 YV1 is time delayed for 2 seconds machine folded gt SQ2 1 and SQ9 1 and SQ3 1 If SQ6 passes to O the movement is carried more slowly 5 9 1 2 In If SA8a 1 then YV1 1 and YV4 1 YV1 is time delayed for 2 seconds If SQ6 passes to O the movement is carried more slowly 5 9 2 Platform 5 9 2 1 Out If SM2ab 1 and SQ6 1 and HM2 1 and 501 1 or machine folded then YV1 1 and YV4 1 YV1 is time delayed for 2 seconds machine folded gt 502 1 and 509 1 and SQ3 1 If SQ6 passes to O during a movement this one is not cut 5 9 2 2 In If SM2ab 1 and 506 1 and HM2 1 then YV1 1 and YV4 1 YV1 is time delayed for 2 seconds If SQ6 passes to O during a movement this one is not cut 5 10 ROTATION 5 10 1 Turntable 5 10 1 1 Left If SA15a 1 then YV1 1 and YV5 1 YV1 is time delayed for 2 seconds If SQ6 passes to O the movement is carried more slowly 5 10 1 2 Right If SA15b 1 then YV1 1 and YV5 1 YV1 is time delayed for 2 seconds If SQ6 passes to O the movement is carried more slowly 33 Pinguel
55. MAINTENANCE SHEET Folio 1 2 DISMANTLING RE ASSEMBLING THE JIB Caution Ensure that the oil is not too hot Make sure that the lifting equipment is in good condition and of sufficient capacity Caution Use a container to collect oil to prevent pollution of the environment Jb Caution It is essential to put the component in slings before dismantling re assembling it 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Remove contactor SQ2 see corresponding sheet 2 Removing the platform support assembly NB Mark disconnect the electric connections at the platform box Mark and disconnect the hydraulic hoses of the platform rotation motor and the jib cylinder 1 Unscrew the hoses slowly to release residual hydraulic pressure Fit caps to the hoses Open the two cable passage collars on the platform and the three collars along the jib Mark the path of the electric cables and hoses then remove all cables passing along the length of the jib Put the platform into slings Put the jib cylinder 1 and vertical elements 2 and 3 into slings Remove the four bolts and pin stop rings 5 fixing the platform assembly 4 Remove the two M canindus pins blocking the pins 5 Remove the two pins 5 and remove the platform assembly
56. Pinguely Haulotte 4 REPAIR MANUAL SOS RR SAN VR ESS PAS SELF PROPELLED TELESCOPIC PLATFORM 14 16 242 031 9500 E 02 03 NE ADS i 7 ARTICULEES MATS TELESCOPIQUES CISEAUX TRACTEES L ACCES L ESPACE PINGUELY HAULOTTE LA PERONNIERE 42152 L HORME T l 33 0 4 77 29 24 24 Fax SAV 33 0 4 77 31 28 11 email haulotte haulotte com e Web www haulotte com Repair manual Pinguely Haulotte Z 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
57. Put a new component and seal into place on the front panel of the top con trol panel NB In the case of a lever switch adjust the position of the fixing nut and counter nut so that the switch lever s articulation pin is at the same level as the seal to ensure tightness Reconnect the electric connections according to the marks made during dismantling e Fix the closing plate using the four fixing screws Reconnect the then terminals of the battery Put the machine back into the operational configuration Perform the function corresponding to the replaced component to check that it works properly Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet 044 CHANGING AN ELECTRIC COMPONENT Folio 1 1 ON THE BOTTOM CONTROL PANEL 1 Preliminary operations Put the machine in the maintenance configuration see corresponding Caution paragraph Jonotuse ati Switch off electric power see corresponding paragraph 4 Disconnect the then terminals to isolate the circuit during maintenance operations 2 Removing a component from the bottom control panel Open the door of the bottom control panel 1 Mark disconect the electric connections 3 of the component to be replaced 2 Remove the component 3 Installing a component in the bottom control panel Puta new component and seal into place on the front panel of the bottom control panel NB I
58. R THE COMPENSATION FUNCTION 1 Preliminary operations Caution Put the 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 a double flow limiter 1 Mark the installation position of the electrodistributor balancing valve and Caution double flow limiter Use a container to collect oil e Remove the 4 fixing screws 2 then take out the electrovalve 3 balan to prevent pollution of the ging valve 4 double flow limiter 1 assembly environment e Remove the double flow limiter 1 3 Installing the double flow limiter Replace the seals and put into place on the hydraulic block a new flow limiter 1 whose characteristics correspond to the machine in question then the balancing valve 4 and the electrovalve 3 Fix the assembly with the 4 fixing screws 2 Tighten to the recommended torque see corresponding chapter Put the machine back into the operational configuration e Make several movements using the replaced double flow limiter to purge the circuit Adjust compensation up and down speeds see corresponding chapter Check that the corresponding movement is made correctly Sheet 120 Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET DISMANTLING AND RE ASSEMBLING THE STEERING SYSTEM Folio 1 2 Caution Ensure that the oil is not too ho
59. REPAIRS AND ADJUSIMEN Tr sa u 12 1 6 VERIFICATIONS WHEN RETURNING TO SERVICE 12 1 BEAUFORT SCALE eat 12 2 PRESENTATION lia 13 2 1 TECHNICAL CHARACTERISTICS 00 13 2 1 1 H14T X technical characteristics 13 2 1 2 Technical characteristics H16TP X nnne 14 OZE u re 16 Pinguely Haulotte Repair Manual nn ti ua e 16 PEER RI N 17 23 TIGAFeNIiNGTOR WVE Lella 18 2 3 1 Tightening torque for large thread 18 2 3 2 Tightening torque for fine thread ie 18 2 3 32 Pressure table dt ia 19 234 Table Of aquusiMent MES u ee 19 3 SAFETYVSSI Mie 21 3 1 MACHINE ELEMENTS sortida a 21 MOTO A ne nee rien 21 3 1 2 Power supplies and fuses 21 3 1 3 Control INPUTS cies ae en 21 EECHER ER agent 22 lo Repeat 22 3 1 6 On off electrovalve outputs nnn nennen 22 3 1 7 Proportional electrovalve outputs ss 22 SEU il RR 23 dos PR D D EE 23 4 WIRING DIAGRAN 25 41e DIAGRAMME 23 FOLIO CIO 25 4 2 DIAGRAM E 523 FOLIO 02 05 nenn 26 4 3 DIAGRAM E 523 FOLIO need 27 DIAGRAM E623 POLIO UA ee a 28 4 5 DIAGRAM E 523 FOLIO 05 05 ne ee 29 5 OPERATING INSTRUCTIONS Ll
60. Ref Operation Every day or before Check the following levels each start of 1 motor oil operations 2 hydraulic oil 3 diesel 4 electric batteries Check the cleanliness 5 disel pre filter replace it if water or impurities are found 6 motor air filter machine in particular check the tightness of connections and hoses use the opportunity to check the condition of the tyres cables and all accessories and equipment 7 Check the hydrualic oil filter for clogging Change the cartridge if the clogging indicator is visible Check the state of wear of the articulation axles The first 50 hours 9 Change the hydraulic oil filter cartridge see frequency 250 hours Change the oil of the drive wheel reducers see frequency 500 hours 2 points for 10 4x2 model 4 points for 4x4 model Check the tightness of the slew ring screws torque 10 daN m Every 50 hours 11 Motor see manufacturer s manual 12 Check the level of the drive wheel reducers see section 5 3 2 2 Grease 14 jib articulation axle for HB44J 2 points 15 basket link part articulation axle 4 points 16 boom base axle 1 point 17 wheel pivot pin axles 8 points 18 steering axle central pivot pin and clevis pin 10 points 19 slew ring bearing 2 points Every 250 hours 20 Motor see manufacturer s manual 21 Grease the friction parts of the telescope spatula At the same time check the condition of the friction pads 23
61. Sheet P006 Folio 1 1 CHANGING THE HYDRAULIC FILTER CARTRIDGE 2 Preliminary operations Put the machine in the maintenance configuration see S 6 3 page 32 Switch off electric power see 6 4 page 32 Use container to collect oil to prevent pollution of the 2 Replacing the hydraulic filter cartridge environment ect 2 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 H14P H16TP HB40 44J Pinguely Haulotte Z PREVENTIVE MAINTENANCE SHEET Pinguely Haulotte 4 MAINTENANCE SHEET Sheet P007 Folio 1 1 CHECKING CHANGING THE OIL OF A WHEEL REDUCING GEAR 3 Preliminary operations Caution e Put the machine in the maintenance configuration see 6 3 page 32 Use a container to collect oil e Switch off electric power see 6 4 page 32 to prevent pollution of the environment 2 Checking the level the wheel so that one cap 1 is on a horizontal line and the other 2 is on a vertical line e Unscrew the cap 1 and check the level that sh
62. TENANCE SHEET Sheet 068 CHANGING THE DOUBLE BALANCING VALVE Folio 1 1 OF THE ROTATION FUNCTION 1 Preliminary operations 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 a double balancing valve e Mark and disconnect the four hydraulic hoses 3 on the double balancing valve unit 1 NB Unscrew the hoses slowly to release residual hydraulic pressure Fit the hoses with caps Remove the unit s 4 unions 2 Remove the unit 1 by unscrewing the 2 fixing bolts 4 Installing double balancing valve Put a new unit into place and fix with the two bolts equipped with new too thed washers Putthe four unions equipped with new O rings back onto the unit Tighten to the recommended torque see corresponding paragraph e Reconnect the hydraulic hoses according to the marks made during dis mantling Tighten to the recommended torque see corresponding graph Put the machine back into the operational configuration Caution e Make several movement cycles using the replaced double balancing valve to purge hydraulic circuit Balancing valves are safety e Check the level of the hydraulic oil tank elements They are calibrated in the plant and must not be re adjusted Sheet 069 Pinguely Haulotte 4 CORRECTIVE
63. THE PLATFORM OR TURNTABLE CONTROL PANEL e Platform jib fault Turntable jib fault Y Y Maintain the control Maintain the control activated and check for activated and check for 12V voltage at terminals 12V voltage at terminals 410 up and 409 down of 406 up and 405 down of the printed circuit the printed circuit Open the platform control panel or turntable and check NO the wiring of jib switch SA7 or SA6 YES NO SE Replace the U1 module See Fiche Repair wiring 058 07 YES END Check the electric continuity of the switch contacts when closed NO The fault persists END Replace the See Fiche NO printed circuit C063 YES Replace the jib switch See Fiche END SAT or SA6 043 Fiche 044 Repair the connection or replace the END electric wiring harness between the jib switch SA7 or SA6 on the printed circuit of the turntable control panel Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet 28 NO JIB MOVEMENT UP AND OR DOWN Folio 5 5 FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Replace the double flow See Fiche limiter C083 The fault persists Replace the electrovalve See Fiche YV18 C067 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet NO BOOM LIFTING MOVEMENT Folio 1
64. VOISIGOW ezsa NOILV3HO 1 dvd 14617 440 NO 14617 10 uooeeg uoisuej snos JueAo Jnajoa oJy aseydosh5 01 20 10 1 90 5 o 02 10 TU Sn 52 OA pd 69 KE 8 e v Y 7 w Es 21 10 En DIS 0 o Nos civ 7 20 ice N N eo Leo mos o 9nd snd 4 See a LVS Anueg 9 zas 3 02 10 jeun S3 WOE e jeno is ai LAV ze oz oz LOL Weg 0 6L 8L ZL 9L SL ri el LL OL 6 4 9 L 26 Repair manual Pinguely Haulotte 7 4 3 DIAGRAM E 523 FOLIO 03 05 amp amp 8 8 8 R pe i5 a g N ur 1 e 5 wm e wey 2 1 1 I u jue SHSM ER arle O oo afevewgg 1 i o 41485 Tn 9 I SH SIN i NI is aleno 2 jun 2 verle 1 I ebenewga Le dn yes N I gt 5 lt 5 I u T a o I 0 Y SH SN S1 AD AN Ad I e Y I I EI HIN Vote I P Cr vroe 5 1 e e i I I S N z d 9 N Or Anueg QI 3 SEN N e asenpuad I y EIER N E I S X jun gt
65. YA2 YES See Fiche Replace relay KT2 NO 062 YES END Replace the coil of motor accelerator Y YA2 or adjust the motor accelerator system see motor manufacturer See Fiche Replace the U1 manual C058 or module C107 END END Repair or replace the electric wiring harness between the accelerator elec trovalve YA2 and the turntable control panel Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP023 Folio 1 5 NO MOVEMENT AVAILABLE FROM TURNTABLE OR PLATFORM CONTROL PANELS No movement available from turntable or platform panels Check the level of hydraulic See Fiche 005 P008 YES Open the turntable control Fill up See Fiche panel Check the state of fuses 005 or 08 FU4 FU7 FU10 END NO YES Activate the boom lifting movement in the Replace the emergency mode defective fuse Put the emergency lever into place on the manual control of the boom lifting control distributor YV3 END Activate the lever up then down while pressing the emergency control of the safety valve YV1 or activate the emergency power unit Movement NO OK YES Connect a pressure gauge to the PVG pressure tap M on the turntable control Place the key switch in the platform position panel Press the pedal and activate the boom
66. Z CORRECTIVE MAINTENANCE SHEET Folio 1 2 CHANGING THE HYDRAULIC PUMP Caution Ensure that the oil is not too hot Caution Use a container to collect oil to prevent pollution of the environment Caution It is essential to put the component in slings before dismantling re assembling it 8 Preliminary operations Put the machine in the maintenance configuration see corresponding para graph Switch off electric power see corresponding paragraph Close the shut off valve if any Otherwise empty the hydraulic tank 2 Removing the hydraulic pump NB Mark disconnect the pump hoses 1 Unscrew the hoses slowly to release residual hydraulic pressure Put caps on the hoses Remove the pump s fixing screws and washers 2 on the motor flange 3 and remove the pump 5 Remove the spined split hub 6 by unscrewing the tightening screw 7 Remove the hydraulic unions 4 screwed on the pump see figure on page 2 2 Discard the O rings Installing the hydraulic pump Fit new O rings to the unions Screw the hydraulic unions to the pump Lubricate then install the spined split hub on a new pump Ensure that the spined hub is against the pump shaft shoulder Coat the hub tightening screw with normal blue loctite 243 then tighten to a torque of 83 N m 61 Ib ft Install the pump on the flange and fix using fixing screws previously coated with normal blue loctit
67. a 35 BA HORN da 35 54152 EE 35 OO M albe 35 A E E M EUM 35 5 18 OTHER FUNCTIONS OVERLOAD 5 36 77 14 07 0 RE 36 918 24 FUSE SAY 36 5 18 3 36 Pinguely Haulotte Repair Manual 5 18 4 Indicator defects 36 6 POSITIONS OF ELECTRIC 37 MOTHER BOARD mr 37 6 1 1 Description Rr Ree nee 37 6 1 2 Positions of screws connectors and relays nn 38 6 1 3 ee aa lee 39 6 1 4 Positions of diagnosis help LEDS uenti tanc einsehen 40 7 HYDRAULIC DIAGRAMS nent ath S sun ue etu 41 7 1 DIAGRAM 14 REFERENCE B TOODT lia 41 7 2 DIAGRAM H16TP X REFERENCE 16009 u 42 8 M 43 8 1 GENERAL RECOMMENDATIONS iii 43 8 2 PARTICULAR RECOMMENDAT IONS nenn 43 EE 43 rnt di SIME IN REC 43 8 2 3 Locating the breakdown ET 44 8 3 MAINTENANCE SYSTEM nn anne aa ie Rees 44 Bde ELECTRIC POWER SUPPLY Lelio 45 55e MAINTENANCE PLAN coins 46 Ro Consumable cani did ie ados 46 Bos OPERATIONS 48 AES CE M T A 48 PRESENCE LABELS cuna t Rennen e aoin pen CR bebo eE C
68. ace the key switch in the platform position Place the speed selector in the High speed position Press the pedal and make a forward travel movement Check for 12V voltage at the terminals of the connector of the electrovalve in question YV8 YV10 and 12 y Open the turntable control panel YES Press the pedal and make a forward travel movement Replace the electrovalve coil Check for 12V voltage on the terminals of the printed circuit associated with the electrovalve in question 813 for YV8 END 814A for YV10 814B for YV12 See Fiche 059 YES Replace the U1 module an 107 Replace the wiring harness between the turntable control panel and the electrovalve in question YV8 YV10 and YV12 The fault persists END Replace the printed circuit See Fiche C063 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP034 Folio 3 4 MACHINE TRAVEL SPEED DOES NOT CORRESPOND TO THE SELECTOR SPEED Press the pedal and make a forward travel movement Check for 12V voltage at the terminals of the connector of electrovalve YV10 lt gt 5 Open the turntable control panel YES Press the pedal and make a See Fiche forward travel movement C059 Replace the coil of Check for 12V voltage at terminal electrovalve YV10 814A of the printed circuit
69. ackets 9 Put the silencer 8 back on its brackets 9 and screw the collars without ti ghtening them Position and tighten the collector screws 7 Tighten the silencer support collars Connections e Reconnect the fuel incoming and outgoing pipes Onthe motor reconnect the electric connectors 1 acceleration set points oil temperature oil pressure starter supply Reconnect the starter terminals 2 and the earth terminal 10 Reconnect the starter battery terminals see corresponding sheet Put back the cover see corresponding sheet Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C136 Folio 2 2 CHANGING THE PETROL GAS GM THERMAL MOTOR Reconnect the gas supply pipe 5 using joint compound on the special gas threading Check that the circuit is tight using a special GAS developing agent on connection and opening the gas cylinder 9 Additional operations Put the machine back in the operational configuration If the motor installed is new follow the first commissioning instructions see motor manufacturer s manual Start the motor and check that it works correctly with both fuel types petrol and gas Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C138 Folio 1 2 CHANGING THE COUNTERWEIGHTS 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see co
70. ake the manipula tor out of the box Installing manipulator e Place the replacement manipulator in position and put back the fixing screws 5 Put back the wires 3 in the cable strand and fasten the strand using plas tic clamps e male reference contacts to the ends of the wires 3 e Connect the wires the plug according to the marks made during dis mantling e the supply wires 211 and then the negative wire Put back the upper panel 4 of the box and fix using screws 1 e then terminals of the battery Put the machine back into its operational configuration e Make several movements controlled from the basket to test manipulator operation Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C046 Folio 1 1 CHANGING THE STARTER BATTERY 1 Preliminary operations Caution Put the machine the maintenance configuration see corresponding Wear protective goggles and paragraph gloves for any operation on Switch off electric power see corresponding paragraph the batteries 2 Removing the starter battery e Disconnect the then terminals 1 of the battery 3 Remove the fixing screws from the battery fixing tab and remove the fixing tab 2 Remove the battery 3 Installing the starter battery Puta new battery into place Putback the fixing tab and secure with the fixing screw eq
71. al lic oil USA z 1 5 x nominal 7 Additional operations Putthe machine back in the operational configuration Remove the slings Extend the machine several times to test operation and purge the hydrau lic circuit Checkthe level of the hydraulic circuit 2 Haulotte Pinguely kE I o O 2 lt 2 E lt lt gt gt F O Folio 4 6 Sheet C129 DISMANTLING RE ASSEMBLING THE BOOM Figure 1 Ti Xd 19 L VH Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C129 Folio 5 6 DISMANTLING RE ASSEMBLING THE BOOM Figure 2 2 seems 2 12 13 eh 8
72. anual 1 2 GENERAL SAFETY INSTRUCTIONS Caution Only trained operators use Haulotte self propelled platforms 1 2 1 Operators Operators must be aged over 18 and hold an operating permit issued by their employer after undergoing a medical check and a practical test that prove they are apt to operate the machine There must always be at least two operators present so that one can always Take fast action if necessary Take over the controls in case of accident or malfunction Monitor and prevent movement of vehicles and people near the plat form Guide the platform operator if required 1 2 2 Environment Never use the machine On ground that is soft unstable congested On a ground that has a slope greater than permissible limit In winds greater than the permissible limit If used outside use an an emometer to ensure that the wind speed does not exceed the permis sible limit Near power lines check minimum safe approach distances according to voltage carried In temperatures less than 15 C especially in refrigerated chambers Consult us if it is necessary to work below 15 C In explosive atmospheres In poorly ventilated areas since the exhaust fumes are toxic During storms risk of lightning In the dark unless the optional floodlight is fitted In the presence of intense electromagnetic fields radar moving and high currents DRIVING ON PUBLIC ROADS IS PRO
73. anufacturer s manual and instructions For the motor part consult the instructions in the Manufacturer s manual Safety mechanisms should be checked regularly Tilt buzzer and movements disabled Buzzer load between 100 and 110 of permitted load Movements disabled Load above 110 of permitted load e Change to micro speed when the machine is unfolded 8 2 PARTICULAR RECOMMENDATIONS Before any maintenance intervention on the elevating platform indicate on the turntable and platform control stations that the machine is being serviced If possible restrict access to the elevating platform to intervention personnel only 8 2 1 Specific tools Personnel should therefore be familiar with the use of the specific tools used measurement device torque tightening device lifting apparatus etc and respect the operating limits specified in the documentation that is supplied with the tools Incorrect use of a tool incorrect adjustment after a reading error may lead to premature deterioration of the elevating platform or more seriously an accident for which PINGUELY HAULOTTE cannot be held responsible 8 2 2 Replacing an element Before replacing an element the machine must be put in the maintenance configuration see chap 8 3 page 38 and the electric power supply cut off see chap 8 4 page 45 All distributing valves are with open centre breaking the electric circuit therefore decreases pressure in the hydraulic
74. arness between the turntable control panel and PVG YV2 END Replace the See Fiche printed circuit C063 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet 28 NO JIB MOVEMENT UP AND OR DOWN Folio 3 5 FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Y Invert the coils of the jib electrovalve YV18A and YV18B Press the pedal and activate the platform or turntable jib switch The defective movement up 1 or down 2 is made in response to an opposite movement control down 1 or up 2 Put coils YV18A and YV18B back in their original positions Press the pedal and activate the jib switch Check for 12V voltage at the terminals of the YV18A down or YV18B up connector Open the turntable control panel Press the pedal and activate the jib switch Check for NO 12V voltage at terminals 407A down or 408A up of the printed circuit YES NO Replace the See Fiche ne C058 or C107 See Fiche Replace coil YV18A 059 down or YV18B Y up YES The fault persists Repair the connection or END replace the wiring harness between the turntable control panel and electrovalve YV18 See Fiche C063 Replace the printed circuit END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP028 NO JIB MOVEMENT UP AND OR DOWN Folio 4 5 FROM
75. asket Pinguely Haulotte 77 CORRECTIVE MAINTEANCE SHEET Folio 1 1 CHANGING THE TILT SENSOR 1 Preliminary operations e Putthe machine on a flat surface with zero slope Put the machine into the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph 2 Removing the tilt sensor Mark and disconnect the electric connections of the tilt sensor Remove the tilt sensor 2 by unscrewing the fixing bolts 1 3 Installing the tilt sensor Put a new tilt sensor into place and fix using the fixing bolts 1 Reconnect the electric connections according to the marks made during dismantling Place a spirit level on the top surface of the tilt sensor and set the adjust ment screws 4 so that the tilt sensor is level NB The spirit level 3 is built into certain tilt sensors Putthe machine back into the operational configuration 4 Tilt sensor operating test e Extend the machine Tiltthe tilt sensor and check that the buzzer sounds Check that after 1 or 2 seconds extension or travel movements have been disabled Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C040 Folio 1 1 CHANGING THE HORN 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 h
76. ator Charge the batteries and replace if necessary Replace the batteries See Sheet C046 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP016 THE MOTOR DOES NOT START THE STARTER IS NOT ACTIVATED Open the turntable control panel and check the state of fuses FU1 FU4 and FU8 NO YES Replace the defective fuse Check the 12V on line 242 of the turntable control panel 5 YES Repair key switch SA1 wiring or replace the switch Activate switch SB3 turntable or SB4 platform and check continuity between the 2 switch terminals NO m Z O Replace the defective See Fiche switch C044 ES Folio 2 3 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP016 Folio 3 3 THE MOTOR DOES NOT START THE STARTER IS ACTIVATED Activate the starter switch SB3 or SB4 and check for 12 V voltage between terminals 242 and 146 in the turntable control box NO YES Check wiring between switch SB3 or SB4 and the turntable Replace the relay See Fiche control box 2 062 fault persists Check continuity of the electric wiring harness between relay 2 terminal 103 of the turntable box and the starter solenoid 5 Replace the defective electric wiring harness
77. ble control panel Press the pedal and activate the compensation switch NO Check for 12V voltage on terminals 401A up or 402A down of the printed circuit YES NO Replace the See Fiche gt U1 module 058 See Fiche Replace coil YV15A ee C059 up or YV15B Y down YES The fault persists Repair the connection or repla END ce the electric wiring harness between the turntable control panel and electrovalve YV15 See Fiche C063 Replace the printed circuit END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP026 Folio 4 5 NO COMPENSATION MOVEMENT UP AND OR DOWN G Maintain the control activated and check for 12V voltage at terminals 401 up and 402 down of the printed circuit Open the platform control panel and check the wiring of NO the compensation switch SA5 YES NO _ Replace the U1 module SeeFiche Repair wiring 58 5 END Check the electric continuity of the switch contacts when closed NO The fault persists END Replace the See Fiche NO printed circuit C063 5 Replace the See Fiche END compensation switch 043 5 5 Repair the connection or replace the wiring END harness between the compensation switch SA5 and the printed circuit of the turntable control panel Pinguely
78. ble control panel Press the pedal and activate the platform rotation switch Check for 12V voltage on terminal 305 415 for H14 16 HB40 44J of the printed circuit See Fiche Replace the PVG C077 YV2 control head NO Replace the See Fiche 2 module C058 YES Repair the connection or The fault NO replace the electric wiring persists harness between the turntable control panel and PVG YV2 END Replace the See Fiche C063 printed circuit Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP027 Folio 3 5 NO PLATFORM ROTATION MOVEMENT RIGHT AND OR LEFT Y Invert the coils of the platform rotation electrovalve YV19A and YV19B Press the pedal and activate the platform or turntable rotation switch The detective movement left 1 or right 2 is made in response to an opposite movement control right 1 or left 2 Put coils YV19A and YV19B back in their original positions Press the pedal and activate the platform rotation switch Check for 12V voltage at the terminals of the YV19A left or YV19B right connector Open the turntable control panel Press the pedal and activate the platform rotation NO switch Check for 12V voltage on terminals 310A left or M 3114 right of the printed circuit YES NO Replace the See Fiche gt U1 m
79. ble electric box Remove the fixing flange 2 from the U1 electronic module Remove the U1 electronic module 86 gt gt 3 a gt s gt 3 Installing the U1 electronic module e Install a new U1 electronic module previously programmed by the manu facturer Install the fixing flange Close the electric box Reconnect the then terminals of the starter battery Put the machine back into the operational configuration Check that the U1 electronic module works perfectly using the check list for the machine concerned 4 Testing U1 electronic module Make all movements from the bottom control panel for two seconds Make all movements from the top control panel for two seconds Caution Lift the jib gt 0 Computers are not Make a travel movement with the selector on high speed and check that interchangeable they have a movement speed is actually micro speed serial number corresponding Lower the jib to a given machine If this rule Lift the arm to 3 metres is ignored dangerous Make a travel movement with the selector on high speed and check that malfunctions may occur movement speed is actually micro speed Lower the arm Lift the boom e Makea travel movement with the selector on high speed and check that movement speed is actually micro speed Lower the boom Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet 059 Fo
80. c motor Caution Mark disconnect the hoses 1 of the hydraulic motor 3 Put the turntable rotation blocking pin into place NB Unscrew the hoses slowly to release residual hydraulic pressure Fit caps to the hoses Place a wedge under the hydraulic motor Remove the hydraulic motor by removing its fixing bolts 2 Caution Use a container to collect oil 3 Installing the hydraulic motor to prevent pollution of the Put a new hydraulic motor into place environment e Fix the hydraulic motor using fixing bolts equipped with new spring washers e Re connect the hydraulic hoses according to the marks made during dis mantling Caution Put the machine back into the operational configuration Itis essential to put the e Remove the turntable rotation blocking pin component in slings before e Make several turntable rotation movements to purge the hydraulic circuit dismantling re assembling it Checkthe level of the hydraulic oil tank Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C051 Folio 1 1 CHANGING THE SWING JOINT 1 Preliminary operations Caution Lift the arms sufficiently to enable access to the swing joint Ensure that the oil is not too Place wedges under the arm to support it hot Putthe machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Block turntable rotation using
81. check for 12V voltage at the terminals See Fiche C108 Replace the PVG YV2 control head Folio 2 4 Open the turntable control panel Press the pedal and activate the REAR steering manipulator SM4 and check for 12V voltage on terminal 305 of the printed circuit YES NO Repair the connection or replace the wiring harness between the turntable control panel and the PVG YV2 See Fiche C107 Replace the U1 module The fault NO persists Replace the See Fiche C063 printed circuit Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP060 Folio 3 4 NO STEERING MOVEMENT RIGHT OR LEFT Invert the coils of the jib electrovalve YV16A and YV16B Press the pedal and activate the REAR steering manipulator SM4 The defective movement right 1 or left 2 is made in response to a control for the opposite movement left 1 or right 2 See Fiche 067 Replace electrovalve YV16 Put coils YV16A and YV16B back in their original positions Press the pedal and activate the REAR steering manipulator SM4 and check for 12V voltage at the terminals of the YV16A or YV16B connector Open the turntable control panel Press the pedal and activate the jib switch and check NO for 12V voltage at terminals or 306A of the printed circuit
82. circuit See motor manufacturer manual NO YES Repair diesel supply circuit See motor manufacturer Activate the starter switch SB3 or m ual SB4 and check for 12V between terminals 242 and 150 of the turn table control box NO i Z Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP015 Folio 2 2 See Fiche Check wiring between the motor starter 062 switch SB3 SB4 and the printed circuit of the turntable control box THE MOTOR DOES NOT START THE STARTER IS ACTIVATED Replace relay KP1 The fault NO persists NO END Check continuity of the electric wiring harness between relay KP1 Repair wiring terminal 115 of the turntable box and motor stop solenoid 1 NO Replace module U1 See Fiche C058 Replace the defective YES wiring harness END Replace the motor stop solenoid END YA1 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP016 Folio 1 3 THE MOTOR DOES NOT START THE STARTER IS ACTIVATED The motor does not start the starter is not activated Check the position of the platform and turntable emergency stop buttons Position Unlock the emergency stop button unlocked Check the state of battery charge Battery charge OK NO r Check the state of the gener
83. circuits up to the non return valves flanged on the cylinders An element can be replaced safely if the procedures described in the maintenance sheets are respected unscrew hydraulic connectors slowly to release residual pressure 43 Pinguely Haulotte 2 8 3 Photo 1 44 MAINTENANCE SYSTEM Repair manual To preserve the integrity of the safety systems and the technical characteristics of the elevating platform it is essential to use original parts and to respect the initial setting and tightening torque values see Chapitre 2 page 11 8 2 3 Locating the breakdown Certain checks require 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 deterio rate the live components e g dropping a spanner during an interven tion on the batteries Instructions Maintenance configuration Position the elevating platform on a firm horizontal surface If possible fold the machine completely Put the turntable rotation blocking pin into place ref 1 Photo 1 page 44 Restoring operational configuration Remove the blocking pin ref 1 Photo 1 page 44 Repair manual Pinguely Haulotte 1 8 4 ELECTRIC POWER SUPPLY Instructions Cutting off the electric power supply Press the turntable emergency stop ref 1 P
84. commended torque see tightening torque value table Putthe machine back into the operational configuration Caution Use a container to collect oil to prevent pollution of the environment It is essential to put the component in slings before dismantling re assembling it Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C035 CHANGING WHEEL REDUCING GEAR Folio 1 2 OR TRAVEL HYDRAULIC MOTOR 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph um Switch off electric power see corresponding paragraph Caution Remove the wheel corresponding to the element to be removed see cor Ensure that the oil is not too responding sheet hot 2 Removing a wheel reducing gear or a hydraulic motor n NB Figure 1 steering axle A Caution Figure 2 fixed axle Use a container to collect oil to prevent pollution of the If working on a steering axle uncouple the steering connecting rod from environment the pivot Mark disconnect the hoses of the hydraulic motor 1 and reducing gear 2 Caution NB Unscrew the hose slowly to release residual hydraulic pressure It is essential to put the component in slings before dismantling re assembling Put caps on hoses Place a wedge under the wheel reducing gear it Remove the reducing gear motor assembly by removing the fixing bolts
85. ctronic module Changing a coil Changing relay Changing a printed circuit Changing the fail safe pedal Changing the distribution hydraulic block Changing an electrovalve Changing the double balancing valve of the rotation function Dismantling re assembly the jib Adjusting a pressure limiter Changing the jib cylinder Changing the boom lifting cylinder Dismantling re assembly the distribution hydraulic block Changing a control unit of the distribution block 149 Pinguely Haulotte 2 Repair manual Sheet no Description Changing a flow separator Changing a pressure limiter telescope out function Changing a balancing valve compensation function Changing a double flow limiter compensation function Dismantling and re assembling the steering system Changing an end of stroke contactor Changing a motor cover Changing a control panel cover Changing a tank cover Changing a front cover on the motor or tank side Changing a steering pivot Changing the emergency unit Changing the slew ring Dismantling re assembling the boom Changing the DEUTZ diesel thermal motor Changing a non return valve Changing the petrol gas GM thermal motor Changing the counterweight 150 Sheet 010 Caution Ensure that the oil is not too hot Caution Use
86. d SA11a 0 HS 0 then YV9 1 and YV13 1 If SQ11 1 and Platform position and KA2 0 and D 1 then YV24 1 The generator functions only if the machine is in turntable position if the thermal engine turns and if the operator engaged the button located in the platform In this case the green indicator is light Dans ce cas le voyant vert est allum SAFETY AT START If the button is in ON position during all the phase of start the generator and the accelerator are cut Once this phase finished the generator is automatically given in service If SB5 1 then HA1 1 If SQ1 0 and machine unfolded then the buzzer sounds continuously If B4 0 then the buzzer sounds with a frequency F1 If SQ6 0 and turntable position then the buzzer sounds with a frequency F1 If travel Buzzer_option 1 and HM4 1 then the buzzer sounds with a frequency F2 If movements are carried out YV1 1 SA4a 1 or SA4b 1 movement Buzzer option 1 then the buzzer sounds with a frequency F2 Machine unfolded gt SQ2 0 or SQ9 0 or SQ3 0 If B1 0 then HL2 1 If B3 0 then HL4 1 35 Pinguely Haulotte 2 Repair manual 5 18 OTHER FUNCTIONS OVERLOAD SAFETY 36 5 18 1 Overload The overload through SQ6 cuts all the ordered movements of the platform When one passes in turntable position one recovers the movements with a limited speed Moreover the turntable buzzer sounds 5 18 2 Fuse safety If an electrovalve is controlled
87. ding the electric wires at the bottom of the boom Remove the two support tabs ref 6 Figure 2 Mark then unscrew the bulkhead unions ref 46 Figure 2 on the bar welded at the rear of the boom drum Remove the telescope contactor protective plate and unscrew the support Put the chute ref 3 Figure 2 and the chain support ref 2 Figure 2 in slings Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C129 Folio 3 6 DISMANTLING RE ASSEMBLING THE BOOM Put wedges under these two elements and remove the screws and washers Photo 6 ref 18 and 19 Figure 2 Remove the assembly taking care not to trap the hoses or electric wires It is possible to fasten them together using Colson collars Remove the chain roller ref 27 Figure 2 5 Re assembly Perform the dismantling operations in reverse order eme 6 Some advice for re assembly Change all pins and rings showing signs of wear Lubricate them when re assembling Take care to install all pin stop systems properly Replace worn friction pads sii CAUTION when replacing a telescope or boom drum it may be Caution necessary to wedge the rear side pads to reduce clearance Max Replacement of safety parts clearance 3 mm Front pads are adjusted using the pad holder screws must be validated by static Lubricate the telescope tests Purge the compensation and telescope cylinder and then top up the hydrau CE 1 25 x nomin
88. e ref 1 Photo 6 Photo 7 n 5 Installing a non return valve Check the direction of oil passage shown by an arrow ref 6 Photo 7 engraved on the valve body ref 1 Photo 6 Screw the union ref 3 Photo 6 and adapter ref 4 Photo 6 onto the valve e Screw the adapter ref 4 Photo 6 onto the T ref 7 Photo 6 Screw the hose ref 3 Photo 6 Open the pump shut off valve the machine back in the operational configuration Make several movements using the replaced non return valve to purge the circuit Check the corresponding movement is made correctly Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET CHANGING NON RETURN VALVE Folio 2 2 Sheet C131 Pnoto Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C136 Folio 1 2 CHANGING THE PETROL GAS GM THERMAL MOTOR 1 Preliminary operations Caution Put the machine in the maintenance configuration see corresponding Leave the motor and exhaust paragraph to cool sufficiently before Switch off electric power see corresponding paragraph performing any maintenance e Close the hydraulic tank suction valve operation on these elements 2 Removing the connections Remove the covers on the motor side see corresponding sheet Disconnect the starter battery terminals see corresponding sheet Pivot the motor housing to enable access to the rear of the motor Onthe motor disconnec
89. e 243 bleu and fitted with new grower washers Tighten to a torque of 86 N m Reconnect the hydraulic hoses according to the marks made during dismant ling Open the shut off valve if any Check the level of the hydraulic tank and top up if necessary Before re starting fill the pump pan with hydraulic oil hole L 4 Additional operations Put the machine back into the operational configuration Make several extension cycles to purge the hydraulic circuit Check the level in the hydraulic oil tank Adjust pump output the load sensing pressure limiter and the main pressure limiter see corresponding sheet Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C042 Folio 2 2 CHANGING THE HYDRAULIC PUMP Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C043 CHANGING AN ELECTRIC COMPONENT Folio 1 1 ON THE TOP CONTROL PANEL 1 Preliminary operations Putthe machine in the maintenance configuration see corresponding ZN Caution A Switch off electric power see corresponding paragraph Da the machme Disconnect the then terminals of the starter battery during maintenance operations 2 Removing a component from the top control panel Remove the closing plate 1 by removing the four fixing screws 4 e Mark and disconect the electric connections 3 of the component to be replaced 2 e Remove the component 3 Installing a component in the top control panel
90. e Fiche P005 or P008 END Check that the oil used is the recommended oil problem of oil viscosity being too high NO Change the hydraulic oil YES END Check that the hydraulic tank air vent is not blocked NO Clean the hydraulic tank air vent YES END On certain platforms check that the suction valves are open Pinguely Haulotte BREAKDOWN DETECTION FLOW Sheet DP025 Folio 2 2 NOISY HYDRAULIC PUMP Open the suction valves Check the state ofthe suction pipes clogging etc Replace the hydraulic pump suction pipes Pipes NO OK YES See Fiche C042 or C091 Incorrect operation of the hydraulic pump replace it END Sheet DP026 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Folio 1 5 NO COMPENSATION MOVEMENT UP AND OR DOWN No compensation movement up and or down Place the key switch in the platform position Press the pedal and activate the basket rotation switch on the platform control panel he basket rotates Y YES Stop movement and release the pedal Open the turntable control panel and check that the LED associated with electrovalve YV15A up or YV15B down is off TO Press the pedal and activate the compensation switch Check that the LED associated with electrovalve YV15A up or YV15B down is on YES YES
91. e emergency lever into place on the manual control of the rotation distributor YV5 Activate the lever right left while pressing the emergency control of the safety valve YV1 NO Movement Fiche DP023 OK Replace PVG electrovalve YV3 See Fiche 077 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP032 Folio 1 4 NO MACHINE TRAVEL MOVEMENT No machine travel movement Place the key switch in the platform position Press the pedal and make an arm lifting movement Movement NO See Fiche DP023 OK y YES Put the machine on wedges so that the wheels are not touching the ground From the platform control panel select low speed Press the pedal and make a travel movement in the FOR direction Put the emergency lever on the manual control of the travel distributor YV6 and tilt the lever in the FOR operation direction The wheels turn Y Maintain action on the platform panel controls Putthe emergency lever into place on the manual travel distributor YV7 and tilt the lever in the FOR operation direction The wheels turn Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP032 Folio 2 4 NO MACHINE TRAVEL MOVEMENT Open the turntable control panel and check connection of PVG travel connectors 25 and 26 Y Conn
92. e p iE 49 8 7 1 Label reierences seen 49 8 7 2 Common red labels nennen 51 8 7 3 Common yellow labels E 52 8 7 4 Various common labels 53 8 7 5 Labels specific to Australia se 54 8 7 6 Labels specific to Holland 55 8 7 7 Built in generator in option are nl 55 Repair Manual Pinguely Haulotte 7 8 8 Label a UE data ina ice bias 57 9 PREVENTIVE MAINTENANCE 6 4 442 22 59 10 OPERATING INGIDENTS au anne 67 INCIDENT TABLE ans er 67 10 1 1 General 68 10126 Loser 70 10 13 Travel e 71 RE ECO RR RITO 72 10 1 5 Turntable rotation system ne alada dine 72 10 2 BREAKDOWN DETECTION FLOWCHART aa 72 11 CORRECTIVE MAINTENANCE PROCEDURE 44 1 1 149 Pinguely Haulotte Repair Manual Repair manual Pinguely Haulotte Z 1 GENERAL RECOMMENDATIONS SAFETY 1 1 GENERAL WARNING Caution To attract the reader s attention instructions are indicated by this standardised sign 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 person working on the site equipment The site manager must inform opera
93. e the printed See Fiche Ee circuit 063 Y Replace wiring harness 804 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP036 Folio 1 3 NO DIFFERENTIAL BLOCKING WHEN SWITCH SA3 15 ACTIVATED No differential blocking when switch SA3 is activated Place the key switch in the platform position Do not press the pedal Open the turntable control panel and check that the LEDs associated with electovalves YV9 and YV13 are off All the LEDs are Note the LED that is on off Put the machine on wedges so that the wheels are not touching the ground Place switch SA3 in the differential blocked position Press the pedal and make a forward travel movement Check that the LEDs associated with electrovalves YV9 and YV13 are on Allthe LEDs are on NO e Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP036 Folio 2 3 NO DIFFERENTIAL BLOCKING WHEN SWITCH SA3 IS ACTIVATED Press the pedal and make a forward travel movement Check for 12V voltage at the terminals of the connector of the electrovalve in question YV9 and YV13 NO YES Open the turntable control panel Press the pedal and make a forward See Fiche Replace the coil of the travel movement C059 electrovalve Check for 12V voltage at the terminals of the p
94. e turntable control Le panel and check the state of accelerates fuse FU3 Open the turntable control panel Place the key switch in the turntable position and activate the accelerator switch SA2 from the turntable control panel Check for 12V voltage on terminal 605 of the printed circuit Fuse NO OK YES Replace fuse FU3 Y Open the turntable control panel Place the key switch in the turntable position and activate the accelerator switch SA2 from the turntable control panel Check for 12V voltage on terminal 118 of the Replace the See Fiche printed circuit accelerator switch C044 SA2 Y Repair the connection or replace the electric wiring harness between the accelerator switch SA2 and the printed circuit of the turntable control panel END END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP022 NO MOTOR ACCELERATION ON ACTIVATING THE Folio 2 2 ACCELERATOR SWITCH SA2 FROM THE TURNTABLE CONTROL PANEL Voltage NO OK YES Maintain activation of the accelerator switch SA2 of the turntable control panel Check for 12V voltage on terminal 605A of the printed circuit Y Place the key switch in the turntable position and activate the accelerator switch SA2 from the turntable control panel Voltage NO Check for 12V voltage at the terminals OK of connector
95. ections oK YES Check operation of the travel manipulator SM4 Activate the fail safe HM4 alone and check for voltage at HM4 output and no voltage at SM4ab output Reconnect the connectors Y YES Check for setpoints at inputs 29 2 29 3 and 29 4 of the U1 electronic module Setpoints Replace the manipulator See Fiche HM4 12V C045 SMdab OV an END While maintaining the fail safe 4 activate the travel manipulator SM4 and check the setpoint at output Y ofthe manipulator 5 4 Setpoints Forward 2 5 to 4 5V Replace the manipulator See Fiche Reverse 2 5 to 0 5V HM4 C045 SM4ab 12V END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP032 Folio 3 4 NO MACHINE TRAVEL MOVEMENT Check setpoint at output 26 3 and 25 3 of U1 electronic module Setpoint Output 26 3 and 25 3 Replace the U1 electronic See Fiche Forward 6 to 9V module C058 or C107 Reverse 6 to 3V YES Check for setpoint at input of The fault NO electrovalve YV6 and YV7 persists YES END Replace the printed See Fiche circuit C063 END Setpoint Output 26 3 and 25 3 Forward 6 to 9V Reverse 6 to 3V Replace wiring harness no 612A Replace 6 or YV7 See Fiche control
96. ee corresponding Caution paragraph Ensure that the oil is not too Switch off electric power see see corresponding paragraph hot Close the pump oil suction valve 2 Removing a non return valve fitted towards the hydraulic filter _ Remove the fixing collar ref 2 Photo 6 from the hose on the filter sup ZN Caution port Use a container to collect oi rserew and hose Deet f th prevent Uem orie Unscrew the union ref 5 Photo 6 and adapter ref 4 Photo 6 of the environment valve ref 1 Photo 6 Installing a non return valve Checkthe direction of oil passage shown by an arrow ref 6 Photo 7 engraved on the valve body ref 1 Photo 6 Screw the union ref 3 Photo 6 and adapter ref 4 Photo 6 onto the valve Screw the adapter ref 4 Photo 6 onto the T ref 7 Photo 6 Screw the hose ref 3 Photo 6 into place Putthe collar into place ref 2 Photo 6 Open the pump shut off valve Putthe machine back in the operational configuration Make several movements using the replaced non return valve to purge the circuit e Check that the corresponding movement is made correctly Photo 6 3 4 4 Removing a non return valve fitted on an emergency electropump unit ref 8 Photo 8 Unscrew and cap the hose ref 3 Photo 6 Unscrew the connector ref 4 Photo 6 Unscrew the union ref 5 Photo 6 and adapter ref 4 Photo 6 on the valv
97. eet C121 Folio 1 4 CHANGING AN END OF STROKE CONTACTOR 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph Photo 12 Switch off electric power see corresponding paragraph 2 Removing an SQ9 end of stroke contactor telescope Pu Remove the protective plate ref 1 Photo 12 Unscrew the fixing screws ref 2 Photo 12 of the contactor support Remove the end of stroke contactor Open the end of stroke contactor mark and disconnect the electric con nections 3 Installing an SQ9 end of stroke contactor telescope Open the new end of stroke contactor reconnect the electric connections and close the end of stroke contactor Putthe end of stroke contactor back into place in the position marked during dismantling and fix on its support using screws ref 2 Photo 12 Fixthe support to the telescope 4 Adjustment and testing Putthe machine back in the operational configuration Makea telescoping movement Adjust the contactor if necessary NB Ensure that the end of stroke contactor roller is not at its limit against the telescope A slight gap should be left in the plunger 5 Checking break actions When the telescope is extended travel should switch to micro speed and if the machine is tilted all movements are disabled except telescope in boom lifting rotation basket rotation and compensation For the USA if the machine is tilted the
98. eida 31 Sde START 31 52 SJOP MOTOR it 31 Digi ACCELERA TOR lecca 31 5 44 GOMPENSATION A A A 31 Repair Manual Pinguely Haulotte 7 31 NT 31 5 5 ROTATION 31 Ddl ToC 31 bo E A 31 SOs 32 5 6 1 ZE 32 56 2 DOWN ttes tee E eas 32 5 7 icalmizcce 32 um 32 5 1 2 Some 32 5 8 TRANSGLATION 60600 perra rre nenn 32 5 9 TELESGCORING menes 33 e PEUT Qe ETE 33 5 92 Plato Mii eo Senet e Ea Era Paare ce Stand ed ue Ere FE Era a 33 5 10 ROM ON ener rre snas 33 5 10 1 Turntable m mI 33 SIO2 DE PAU LE 0 o o 34 OIL INR ia 34 A ea RE 34 A PA EE LAC aa 34 5 12 DIFFERENTIAL 1 0 35 5 13 ala lan
99. electric wires Replace the U1 module See Fiche C058 or C107 NO The fault persists Replace the printed circuit See Fiche C063 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP021 MOTOR ACCELERATION FOR ANY MOVEMENT CONTROLLED Folio 1 1 FROM THE PLATFORM ACCELERATION TRAVEL LIFTING TURNTABLE ROTATION TELESCOPE No motor acceleration regardless of the movement controlled from the platform acceleration travel lifting turntable rotation telescope Place the key switch in the turntable position and activate the accelerator switch SA2 on the turntable control panel The motor See Fiche accelerates DP022 Check electric continuity of the wiring harness between the turntable control panel and the platform control panel NO YES Replace U1 See Fiche module C058 or C107 END Y Replace the wiring harness Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP022 NO MOTOR ACCELERATION ON ACTIVATING THE Folio 1 2 ACCELERATOR SWITCH SA2 FROM THE TURNTABLE CONTROL PANEL No motor acceleration on activating the accelerator switch SA2 from the turntable control panel Place the key switch in the platform position Press the pedal and make a telescoping movement from the platform Check that the motor accelerates Y Open th
100. ent and not controlled LED on electrovalve present and controlled If an electrovalve is not connected the corresponding LED is permanently on Instructions Identify the defective function Machine power on but not started check the presence of the electro valves LED off No electrovalve should be controlled LED on Check that the outputs corresponding to the function are active using the LEDs and directly on the electrovalve heads If they are not active check which inputs create the function Test the inputs with a voltmeter 67 Pinguely Haulotte 2 10 1 1 General operation Repair manual ANOMALY PROBABLE CAUSE SOLUTION The motor does not start the starter is activated Diesel tank empty Fuse FU1 defective Diesel supply circuit defective Wiring defective Module U1 defective Stop motor solenoid YA1 defective Fiche DP015 The motor does not start the starter is not activated Emergency stop locked Generator defective Batteries defective Fuses FU1 FUA FU8 defective Wiring defective Switch SB3 or SB4 defective Relay KA2 defective Fiche DP016 The motor starts then stops after 55 Diesel tank empty Diesel supply circuit defective Fiche DP041 The motor does not start from the platform station but does start from the turntable station Fuse FU6 defective Defective connection of switch SB4 Switch 5 4 defective Wiring harness defec
101. er operators must follow these instructions Never disable the limit switches of the safety devices Never move the control handles from one direction to the other with out stopping in the O position To stop when travelling gradually move the handle to O keeping your foot down on the pedal Do not exceed the maximum load or the number of occupants allowed in the platform Spread the load and if possible place in the centre of the platform Check that the ground resists the pressure and load per wheel Avoid contact with stationary or moving obstacles Do not drive the platform at high speed in narrow or congested areas Avoid contact with stationary or moving obstructions Do not drive the platform in reverse gear poor visibility Do not use the machine with a congested platform Do not use the machine with equipment or objects hanging from the guardrails or boom Do not use the machine with items liable to increase the wind load e g panels Never carry out maintenance on the machine with the platform raised without first installing the required safety provisions overhead crane crane Perform the daily checks and monitor the machine s good working or der during periods of use NOTA 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 Caution Operation direction be inverted on a turntable machine after
102. for HA16TPX HA46JRT Put the machine in the maintenance configuration see see corresponding paragraph Switch off electric power see see corresponding paragraph Disconnect the battery see corresponding sheet Remove the closing plate on the turntable at the back of the telescope Open the turntable electric control panel Disconnect plugs 3 29 30 and 49 on the printed circuit Disconnect the terminal of wire 16 Take the two cables out of the electric control panel and bring them to the rear of the telescope REMINDER Weight of the elements Boom assembly drum telescope telescoping cylinder approx 850 kg 187416 Hose guide chain approx 100 kg 2211 Boom drum approx 300 kg 662 Ib Telescope approx 200 kg 441 Ib Telescoping cylinder approx 200 kg 441 Ib 2 Dismantling the boom At the rear of the telescope mark and disconnect the emitting compensa tion cylinder hoses ref 2 Figure 1 Plug the connectors Remove the lower pin of the emitting compensation cylinder ref 50 Figure 1 see Photo 14 Mark and disconnect the telescope cylinder hoses ref 3 Figure 1 Put caps on the connectors On either side of the boom unscrew the two collars holding the hoses against the sides Mark and disconnect the hoses on the bulkhead unions on the bar on the right side of the boom see Photo 2 Put caps on the connectors On the basket control panel unscrew the two plugs and if the 220V plu
103. g hot paragraph e Switch off electric power see corresponding paragraph Close the shut off valve if any Otherwise empty the hydraulic tank A Sandan 2 Removing the hydraulic filter Use a container to collect oil Disconnect the hydraulic filter hoses 1 to prevent pollution of the 22 2 environment NB Unscrew the hoses slowly to release residual hydraulic pressure e Fit caps to hoses e Unscrew the fixing screws 2 and remove the hydraulic filter Remove the two connectors 3 from the hydraulic filter Installing the hydraulic filter e Install the two connectors on a new hydraulic filter see the table of tighte ning torque values e Put the equipped hydraulic filter back into place respecting the oil flow direction and fix using the fixing screws Reconnect the hydraulic hoses Put the machine back into the operational configuration Make several lifting cycles to purge the hydraulic circuit H14 16TPX HB40 44J Pinguely Haulotte Z Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C058 Folio 1 1 CHANGING THE U1 ELECTRONIC MODULE 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 to isolate the electric circuit 2 Removing the U1 electronic module Openthe turnta
104. g is present remove the wiring Mark and disconnect the hoses on the basket rotation hydraulic motor jib cylinder HA16 and HA46 only and compensation cylinder Put caps on all the connectors Remove the various collars holding the wires and hoses on the jib mark the length of the different loops Bring all the wires and hoses to the end of the telescope chute see Photo 3 Put the jib and basket assembly in slings Remove the receiver compensation cylinder pin ref 48 Figure 1 To do this remove the ref 49 Figure 1 Remove the pin ref 47 Figure 1 of the link part ref 8 Figure 2 To do this remove the screw and pin stop clevis Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C129 Folio 2 6 DISMANTLING RE ASSEMBLING THE BOOM Take out the jib and basket assembly Putthe boom assembly in slings at both ends see Photo 4 Wedge the boom lifting cylinder see Photo 5 Remove the pin ref 8 Figure 1 from the boom lifting cylinder To do this remove the screw and washers from the stop clevis e Remove the stop clevis and remove the pin Remove the pin ref 51 Figure 1 fixing the boom drum to the turntable Remove the boom assembly taking care that none of the electric wires and hoses are trapped during the operation e Remove the boom and wedge it on a suitable safety stand see Photo 6 Photo 2 Removing the telescope Remove the pin ref 35 Figure 1 of the te
105. he machine in question into the hydraulic block Tighten to the recommended torque Flow separator ref FDC1 10 47 to 54 Nm 34 to 39 8 Ib ft Flow separator ref FDC1 16 108 to 122 Nm 79 6 to 89 9 Ib ft Putthe machine back into the operational configuration Make several movements using the replaced flow separator to purge the circuit Check that the corresponding movement is made correctly Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet 81 CHANGING PRESSURE LIMITER Folio 1 1 FOR THE TELESCOPE EXTENSION FUNCTION 1 Preliminary operations Put the machine in the maintenance configuration see corresponding Caution paragraph Ensure dist tho oil is nation Switch off electric power see corresponding paragraph wi 2 Removing a pressure limiter Mark the installation position of the pressure limiter unit electrodistributor Remove the 4 fixing screws 1 then take out the electrovalve 3 pres sure limiter 2 assembly Remove the pressure limiter 2 3 Installing a pressure limiter Replace the seals and put into place on the hydraulic block a new pres sure limiter 2 whose characteristics correspond to the machine in ques tion then the electrovalve 3 Fixthe assembly with the 4 fixing screws 1 Tighten to the recommended torque see corresponding chapter Putthe machine back into the operational configuration Make several movements using the
106. his one is not cut 5 5 1 Right If SA4b 1 and SM31ab 0 and HM31 0 then YV19b 1 and YV2b 1 and YV1 1 YV1 is time delayed for 2 seconds 5 5 2 Left If SA4a 1 and SM31ab 0 and HM31 0 then YV19a 1 and YV2b 1 and YV1 1 1 is time delayed for 2 seconds 31 Pinguely Haulotte 2 Repair manual 5 6 5 7 5 8 32 JIB STEERING TRANSLATION 5 6 1 Up If SA6b 1 or SA7b 1 and 501 1 or machine folded and SQ6 1 or turntable position then YV18b 1 and YV2a 1 and YV1 1 YV1 is time delayed for 2 seconds machine folded gt SQ2 1 and SQ9 1 and SQ3 1 If SQ6 passes to O during a movement this one is not cut 5 6 2 Down If SA6a 1 or SA7a 1 and SQ6 1 or turntable position then YV18a 1 and YV2a 1 and YV1 1 YV1 is time delayed for 2 seconds If SQ6 passes to O during a movement this one is not cut Rear Axle 5 7 1 Left If SM4d 1 then YV16a 1 and YV2b 1 and YV1 1 YV1 is time delayed for 2 seconds 5 7 2 Right If SM4c 1 then YV16b 1 and YV2b 1 and YV1 1 YV1 is time delayed for 2 seconds LS MV HS MicroS If SQ2 0 SQ3 0 or 509 0 then MicroS 1 If MicroS 0 then NoMicroS 1 If SA11a 0 and SA11b 1 and NoMicroS 1 and SM4ab 0 and HM4Y then LS 1 If SA11a 0 and SA11b 0 and NoMicroS 1 and SM4ab 0 and HM4Y then MV 1 If SA11a 1 and SA11b 0 NoMicroS 1 and SM4ab 0 and HM4Y then HS 1 If NoMicroS 1 and HS 1 then YV8 1 and YV1 1 If HS 1 or MV 1 NoMicroS 1 then YV12 1 and YV10 1 and YV1 1 If S
107. hoto 2 page 45 Restoring the electric power supply Reset the emergency stop ref 1 Photo 2 page 45 45 Pinguely Haulotte 2 Repair manual 8 5 MAINTENANCE PLAN The plan shows the frequency and area of maintenance and the consumables to be used The reference shown in the symbol shows the area maintained based on the frequency The symbol represents the consumable to use or the operation to be carried out 8 5 1 Consumable Consumable Specification Symbol Lubricants used by ELF TOTAL Pinguely Haulotte SHELL Motor oil SAE 15W40 DO RIMULA X SHELL Tranself Gearbox oil SAE 90 SPIRAX A EP ep won TM 80 90 EP80W 90 AFNOR 48602 SHELL HYDRELF EQUIVIS wenn ISO VG 46 TELLUS T46 DS 46 ZS 46 Optional bio degrada EF E 46 SHELL ble hydraulic oil 27 55 Lithium grease KP2K ur Beacon EP2 Epaxa 2 n ESSO Moly Cadrexa grease NESIZER u Multi Purpose Grease GR1 AL ESSO 67 Multis Lead free grease Grade 2 ou 3 GP GREASE Multimotive 2 EP 2 Exchange or specific operation 46 Repair manual Pinguely Haulotte VA Hours t6 O y na 2 9 10 50 250 500 47 Pinguely Haulotte 2 Repair manual 8 6 OPERATIONS 8 6 1 Summary table Frequency
108. ion 4 Checking the turntable rotation pressure limiter Turntable rotation pressure is preset and may not be modified Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Unscrew the cap of the minimess hydraulic pressure tapping 2 on the distribution block and connect a pressure gauge of at least 0 300 bars 0 4351 PSI Switch electric power on again see corresponding paragraph Put the turntable rotation blocking pin in place to block movement Activate turntable rotation and measure pressure on the gauge Check pressure in both rotation directions If the pressure measured is not conform to the value in the table replace the pressure limiter concerned Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Unscrew the pressure gauge and put the hydraulic pressure tapping cap back into place Put the machine back in the operational configuration Make several turntable rotation movements to check operation 5 Pressure table in bar Load sensing Main Steering prake Right and Lifting Lowering Poom release left rotation lifting stand by HA16 18PX HA46 51JRT 30 240 240 240 100 240 240 240 HA16 18PX NG HA46 51JRT 30 240 240 240 100 240 240 240 New Design Boom Telescope Telesc
109. k 16 and pad 17 into place then the articulation pin assem bly 15 Putinto place the plate 14 elastic washers 13 bushing 12 then the nylstop nut 11 Putinto place the Nylatron washer 10 platform link part 9 cap 8 spacer washer 7 spacer 6 and Stauff collar Fix the assembly using the screw 4 eqipped with a new toothed washer Install the endless screw 2 and adjustment washers 3 if necessary Install the motor fixing flange 1 Install the basket rotation hydraulic motor see corresponding sheet Install the basket see corresponding sheet Lubricate the gearing NB Only use lubricants recommended by the manufacturer Putthe machine back into the operational configuration Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet 055 Folio 2 2 CHANGING THE BASKET ROTATION GEARING 40969 COO EE GEN bia 17723 el LCL LL LA S A A N CA AN 1 SAR ANT DEAN URN D ei Raz IX Se 4 ALL ASSY Al SES Y H a ZN ATH EE N HR TE y y CID d f AS H 4 a RSS AUN rpm Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C056 Folio 1 1 CHANGING THE HYDRAULIC FILTER Canton 1 Preliminary operations Ensure that the oil is not too e Put the machine in the maintenance configuration see correspondin
110. latform 3 Installing the platform Checkthe condition of the elastic parts and wearing parts and replace if necessary spring washers 14 collar rings 15 ring 16 nylatron washer 11 control panel silent blocks circlips Lower part fnecessary adjust the pre stressing system by tightening the pre stres sing nut 13 so that the washers are 108 mm high see figure 3 Putthe platform into place taking care to put the ball 10 nylatron washer 11 and stop 12 in the right places Lubricate the bore and put the lower pivot 7 into place Fix using the fixing screw 8 and washer 9 NB Only use lubricants recommended by the manufacturer Upper part Lubricate then put back the weighing articulation pin 6 Putback the stop tab 5 Install the Nylstop nut 3 and its washer 4 Adjust the stop for the pre stressing system by tightening the screw 1 and the nut 2 Putthe control panel into place on its silent blocks and fix using the screws equipped with new washers Reconnect the control panel wiring harness Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Folio 2 3 Sheet 053 CHANGING THE BASKET If necessary put the platform s electric plug back into place and fix using its fixing bolts equipped with new toothed washers Reconnect the then terminals of the starter battery the machine back into the operational configuration Adjust the
111. lescope case Remove the screws and washers ref 44 and 45 Figure 1 on both sides of the pin Putthe cylinder in slings Take out the pin ref 10 Figure 1 Take out the 4 screws washers and nuts to free the telescope chute ref 3 Figure 2 Put the telescope in slings Remove the 5 pad supports and pads ref 31 28 and 20 Figure 1 Puta wedge under the telescope cylinder ref 3 Figure 1 at the rear of the boom Remove the telescope fixing pin ref 7 Figure 1 To do this remove the screw and washer then take out the pin stop clevis e Pull the telescope using a lifting truck or beam to free it from the boom drum INSTALL MORE SLINGS BEFORE COMPLETELY WITHDRAWING THE TELESCOPE Place and secure the case on suitable safety stands Remove the pin ref 36 Figure 1 from the pin ref 9 Figure 1 Holes are provided on and under the case Putthe telescope cylinder into slings and take it out from the rear of the case Remove the pads ref 11 13 and 17 Figure 1 fixed on the rear of the teles cope NB Depending on the max and min tolerances of the case and to limit clearance to 3 mm adjustment wedges may be inserted between the side pads and the telescope 4 Replacing the boom drum if necessary Remove the two protective covers from the hoses along the boom ref 4 and 5 Figure 2 Remove the collars holding the hoses at the top of the boom drum case Remove the collar hol
112. lio 1 1 CHANGING COIL 1 Preliminary operations e Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph 2 Removing a coil e Disconnect the electric connector 2 from the coil concerned Unscrew the nut 3 and remove the coil 1 3 Installing a coil Put a new coil into place 1 and fix with the nut 3 Reconnect the electric connector 2 to the coil Putthe machine back into the operational configuration Check proper operation by making the movement corresponding to the replaced coil Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet 062 Folio 1 1 CHANGING RELAY 1 Preliminary operations e Put the machine in the maintenance configuration see corresponding paragraph e Switch off electric power see corresponding paragraph Disconnect the then terminals of the starter battery 2 Removing a relay e Open the turntable electric box e Mark disconnect the electric connections 1 of the relay 2 Remove the relay by removing the fixing bolt 3 3 Installing a relay Puta new relay into place and fix using its bolt equipped with a new grower washer 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 ope
113. lotte Z CORRECTIVE MAINTENANCE SHEET Sheet 075 Folio 1 2 CHANGING THE BOOM LIFTING CYLINDER 1 Preliminary operations Position the elevating platform on a firm horizontal surface Putthe turntable rotation blocking pin into place Caution Liftthe boom to enable access to the arm lifting cylinder fixtures 1 Ensure that tha ofl fs iol ido Retract the telescope lower the arm and put the jib in the low position hot Switch off electric power see corresponding paragraph Put the boom into slings to take the weight of the boom while the cylinder is removed 2 Removing the boom lifting cylinder Put the boom lifting cylinder into slings Mark and disconnect the two hydraulic hoses on the boom lifting cylinder NB Unscrew the hoses slowly to release residual hydraulic pressure Fit caps to the hoses Remove the male clevis blocking the pin 3 of the boom lifting cylinder on the cylinder body side by removing its fixing screw and washer then remove the pin 3 Remove the male clevis blocking the pin 2 of the boom lifting cylinder on the cylinder rod side by removing its fixing screw and washer then remove the pin 2 Remove the boom lifting cylinder 3 Installing the boom lifting cylinder NB Lubricate all bores before re installing the pins Only use lubricants recommended by the manufacturer Putthe boom lifting cylinder into place and fix the rod side to the boom support
114. low are legible and in the correct place Replace if necessary spare parts can be supplied on request if necessary 8 7 1 Label references Ref Code Qty Description 2 3078148220 2 H14TX logo 2 3078148210 2 H16TPX logo 5 3078146020 2 14 floor height load 5 3078149210 2 H16TPX floor height load 7 3078143450 1 Operating instructions 8 3078143270 1 Manufacturer s plate 9 3078144130 2 Do not park in the work area 10 3078144140 1 Danger of electrocution 11 3078143520 1 Hydraulic oil 12 3078145070 1 Danger travel direction 13 3078143590 1 Oil level 17 3078143640 1 Do not stand on the cover 19 3078143600 2 Do not use as an earth 20 3078143540a 1 Socket 220V 21 3078143680b 1 Read operating manual 30 2420505950 1 Warranty activation 31 3078145180 1 Do not exchange 33 3078144490 4 Sling load capacity for Australia 34 3078144510 1 Fuel tank filling for Australia 40 2421808660 1 Yellow and black reflective adhesive marking 41 3078143570 1 Greasing the slew ring 42 3078143530 1 Remove the pin 44 3078143630 2 Danger of body crushing 47 3078146480 2 Vertical H16TP logo 48 3078143930 1 Green arrow 49 3078143940 1 Red arrow 50 3078148770 1 Haulotte logo 52 3078144530 1 Emergency operation for Australia 53 3078144520 2 Harness load for Australia 54 3078148970 2 Large size Haulotte logo 55 3078148410 1 Manual trouble shooting 56 3078144930 1 Basket load conform to standard EN280 for Australia 14 3078143620 2 Risk of injury to hand and fingers
115. mantling Open the hydraulic tank suction valve Putthe machine back in the operational configuration Perform an emergency operation to check that the emergency unit works properly 4 Additional operations If it is necessary to change the calibration valve unit of the emergency cir cuit Perform the preliminary operations Calibrate the emergency unit at 110 bar Make a movement to its limit e g telescoping Adjust the screw 4 Open the hydraulic tank suction valve Put the machine back in the operational configuration Perform an emergency operation to check that the emergency unit works properly Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C128 Folio 1 6 CHANGING THE SLEW RING 1 Preliminary operations Caution Turn the turntable to the locking position Ensure that the oil is not too Putthe machine the maintenance configuration see see corresponding hot paragraph Switch off electric power see see corresponding paragraph e Close the valve on the pump suction circuit at the hydraulic tank Caution Disconnect the battery see corresponding sheet Make sure that the lifting Removethebcom assembly sce corresponding in Remove the counterweight H14 HB40 700 kg 1543 Ib H16 HB44J 1450 kg 3197 LB Photo 21 Mark and disconnect the two hoses ref 1 Photo 2 located in the chas Caution sis of the steering cylinder and plug the
116. marked during dismantling and fix with their bolts 7 Installing the platform support assembly Put the platform support assembly into place and install the two articula tion pins Block the pins with new M canindus pins Install the four pin stop rings and fix using their fixing bolts Pass the hydraulic hoses and electric cables along the jib according to the marks made during dismantling and reconnect Install the two cable passage collars on the platform and the three collars along the length of the jib Install and set the contactor SQ2 see corresponding sheet Put the machine back into the operational configuration Make several jib lifting boom lifting and platform rotation movements to purge the hydraulic circuit Check the level of the hydraulic oil tank Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C073 Folio 1 4 ADJUSTING PRESSURE LIMITER Ensure that the oil is not too hot Caution Use a container to collect oil to prevent pollution of the environment Before any adjustment operation operate the machine so that the oil in the tank is at a temperature of approximately 50 1 Adjusting the load sensing pressure 4 Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Unscrew the cap of the minimess hydraulic pressure tapping 2 on the distribution
117. movement Micro speed and tilt are only activated when the jib is above 0 The support is equipped with lights enabling transversal adjustment of the end of stroke contactor and longitudinal adjustment of the contactor sup port NB Ensure that the end of stroke contactor roller is not at its mechanical stop with the cam ref 4 Photo 20 A slight gap should be left in the plunger 17 Checking break actions For the USA if the machine is tilted the tilt buzzer sounds and the fault light on the platform panel comes on Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C121 Folio 4 4 CHANGING AN END OF STROKE CONTACTOR Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C122 Folio 1 1 CHANGING MOTOR COVER 1 Preliminary operations Put the machine the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Do not use the machine 2 Removing a cover during maintenance operations Open the motor cover Dismount the support 1 Remove cover s two support washers 2 on the right and left side of the cover support Remove the locking pins from the upper ball pivots on the 2 gas springs 3 Free the ball pivots from the 2 pin gas springs Put in slings then close the cover Remove the cover by raising it to free it from the two supports 4 3 Installing a cover
118. n s il y a une tourelle 2 IMPORTANT La prise doit tre raccord e sur une installation lectrique prot g e par un disjoncteur diff rentiel 30 mA NORME 15 100 MISE EN ROUTE 1 D verrouiller l arr t d urgence puis actionner le bouton de d marrage 2 En cas de non fonctionnement attendre 10 s et renouveler l op ration INTERDICTION D UTILISER L APPAREIL PENDANT LA CHARGE DES BATTERIES 7814 342 7814 368 b 55 7814 352 7814 359 7814 841 53 Pinguely Haulotte 2 Repair manual 8 7 5 Labels specific to Australia RESCUE OPERATIONS Turn the key operated selector to turntable position Basket design loading is in accordance with EN 280 Activate and hold the switch and use the emergency lever on the distributor corresponding with the movment required 7814 453 WARNING IF DIRECTION OF TRAVEL IS OBSCURED ROTATE UNIT THROUGH 180 DEGREES AND NOTE COLOUR OF DIRECTION OF TRAVEL ARROWS ON THE CHASSIS IN RELATION TO TRAVEL CONTROL JOYSTICK ARROWS 5 LIFTING POINT USE 4000 Kg MIN RATED HOOK 7814 449 a 7814 523 WARNING This accumulator contains pressurissed oil Care must be taken whilst carrying out maintenance on this Component 7814 520 CAUTION FULL BODY HARNESS MUST BE USED 7814 452
119. n the case of a lever switch adjust the position of the fixing nut and counter nut so that the switch lever s articulation pin is at the same level as the seal to ensure tightness Reconnect the electric connections according to the marks made during dismantling Close the door of the bottom control panel Reconnectthe then terminals of the battery 4 Test Putthe machine back into the operational configuration Perform the function corresponding to the replaced component to check that it works properly Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet 045 Folio 1 1 CHANGING MANIPULATOR 1 Preliminary operations A Caution e Put the machine the maintenance configuration see corresponding Do not use the machine paragraph during maintenance Switch off electric power see corresponding paragraph operations Disconnect the then terminals to isolate the circuit 2 Removing a manipulator 2 Remove the upper panel 4 of the top control box by removing its fixing screws 1 Using cutters remove the cable clamps from the defective manipulator wires Carefully mark the positions of the different manipulator wires 3 on the top control panel connector Disconnect the wires from the top control panel plug Disconnect the positive wires 211 from the switches and then the nega tive wire Remove the fixing screws 5 from the manipulator and t
120. n the counter nut 13 Adjustment and testing of the SQ6 e Put the machine back in the operational configuration Put a load of 250 kg 551 Ib in the basket Unscrew the adjustment wheel ref 2 Photo 16 until movements are disa bled the turntable buzzer sounds and the red alert light indicator is lit on the platform control panel Tighten the counter nut If necessary adjust the basket stops ref 5 Photo 18 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C121 Folio 3 4 CHANGING AN END OF STROKE CONTACTOR In the event of overload the basket stops protect the contactors by preven ting the basket from reaching its mechanical stop against the contactors NB In the event of overload movements from the turntable remain pos sible but are very slow 14 Removing an end of stroke contactor 502 jib 16 and HB44J only Unscrew the fixing screws ref 2 Photo 19 e Unscrew the screws ref 3 Photo 19 fixing the contactor on the support e Remove the end of stroke contactor Open end of stroke contactor mark and disconnect the electric con nections 15 Installing an end of stroke contactor 502 Open new end of stroke contactor reconnect the electric connections and close the end of stroke contactor e Fix the contactor on its support Fix the support on the jib _ 16 Adjustment and testing Put the machine back into its operational configuration Make a jib
121. ning radius 2 00 m Max allowed tilt 5 li Hydraulic tank 150 Fuel tank 150 Total weight 4 4 6800 Kg Number of drive wheels 4 4 4 Number of steering wheels 2 Differential blocking yes Hydraulic brakes 2 Freewheel yes Tightening torque Wheel nuts 320 m N Slew ring 1000 Repair manual Pinguely Haulotte Z DESCRIPTION H16TP X Unit DEUTZ diesel motor F3L1011F Power 38 CH 28 Kw 28 33 hp 2400 min 1 Idling power 20 4 15KW 15 21 hp 1250 min 1 Consumption 2309 kwh Idling consumption 2309 kwh Hydraulic pump 45 3 85 l min Hydraulic pressure General 24 Travel 24 Steering 24 Slew 10 Travel speed Low speed 1 6 Medium speed 3 0 High speed 6 0 Max force on one wheel 3596 Kg Max pressure on the floor hard floor concrete 10500 Kg m soft floor beaten earth 3500 Ignition battery 12 V 95Ah 450A Supply voltage 104 dB 71 5 dB Acoustic power 15 Pinguely Haulotte 2 Repair manual 2 2 SIZE 2 2 1 H14T X size 7586 mm 24ft 10in 1958 mm 6ft 5in 342 mm 7ft 2in Art din 2204 mm 1ft 6ft 800 2ft 2300 mm 7ft 2278 mm 7ft Sin _ 2300 mm _ 7ft Gin d 16 Repair manual Pinguely Haulotte VA 2 2 2 H16TP X size 8429 mm 27 ft 7in 6712mm 22 ft 1951 mm 6ft Ain 2204 mm 7ft
122. nto place and fix with 6 screws equipped with new grower washers Put the earth braid into place do not tighten immediately Put back the oil filter support and exhaust support and fix to the flange with 4 screws equipped with new grower washers Tighten the 10 fixing screws 10 and 12 on the flange to a torque of 49 Nm Put back the hydraulic pump see corresponding sheet Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C130 Folio 2 2 CHANGING THE DEUTZ DIESEL THERMAL MOTOR 9 Installing the exhaust Position the exhaust and fix using fixing collars 7 and 8 Adjust the angle of the exhaust later to simplify its passage in the cover tighten the collars 10 Connection e Reconnect the fuel incoming and outgoing pipes motor reconnect the electric connectors acceleration setpoints oil temperature oil pressure starter supply Reconnect the starter battery terminals see corresponding sheet Putback the cover see corresponding sheet 1 Additional operations Put the machine back in the operational configuration motor installed is new follow the first commissioning instructions see motor manufacturer s manual e Start the motor and check that it works properly Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C131 Folio 1 2 CHANGING NON RETURN VALVE 1 Preliminary operations Putthe machine in the maintenance configuration see s
123. o control panel and the turntable terminals of the switch control panel NO gt NO Replace See Fiche YES YES Repair wiring of the switch 5 4 C043 key switch SA1 or replace the switch END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP019 THE MOTOR DOES NOT START Folio 2 2 FROM THE PLATFORM PANEL BUT DOES START FROM THE TURNTABLE PANEL i Activate SB4 and check for 12V voltage at terminal 117B of the printed circuit Repair wiring or replace the wiring harness between the NO platform control panel and the turntable control panel YES END Replace the U1 module See Fiche C058 or C107 The fault NO persists YES END Replace the printed circuit See Fiche C063 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet 0 020 THE MOTOR DOES NOT START Folio 1 1 FROM THE TURNTABLE CONTROL PANEL BUT DOES START FROM THE PLATFORM CONTROL PANEL The motor does not start from the turntable control panel but does start from the platform control panel Open the turntable control panel Activate switch SB3 and check continuity between the two terminals of the switch See Fiche Replace the switch SB3 NO C044 YES END Activate SB3 and check for 12V voltage at terminal 117A of the printed circuit Repair wiring of switch SB3 NO connection or replacement of
124. odule 058 See Fiche YV19A C059 left or YV19B Y right YES The fault persists Repair the connection or END replace the wiring harness between the turntable control panel and electrovalve YV19 See Fiche C063 Replace the printed circuit END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP027 Folio 4 5 NO PLATFORM ROTATION MOVEMENT RIGHT LEFT G Maintain the control activated and check for 12V voltage at terminals 311 right and 310 left of the printed circuit Open the platform control panel and check wiring of the NO jib switch SA4 YES NO a Replace the U1 module See Fiche Repair wiring C058 YES END Check the electric continuity of the switch contacts when closed NO The fault persists END Replace the See Fiche NO printed circuit C063 5 the platform See Fiche END rotation switch SA4 043 Repair the connection or replace the END electric wiring harness between the platform rotation switch SA4 and the printed circuit of the turntable control panel Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP027 Folio 5 5 NO PLATFORM ROTATION MOVEMENT RIGHT AND OR LEFT Replace the electrovalve See Fiche YV19 C067 Pinguely Haul
125. ol panel Fold the machine except for the boom Place the key switch in the turntable or platform position Activate the telescoping switch from the turntable control panel SA8 or the telescoping manipulator SM2 from the platform control panel elescoping movement OK Open the platform or turntable control panel and check the wiring of the telescoping manipulator SM2 or telescoping switch SA8 NO Repair wiring YES Platform panel END telescoping fault Turntable panel Y telescoping fault Place the key switch in the turntable position Open the turntable control panel Activate the telescoping switch SA8 and check for 12V on terminals 412 or 411 of the printed circuit Place the key switch in the platform position Open the platform control panel Tilt the telescoping manipulator SM2 as far as possible Check for 0 5V or 4 5V voltage depending on movement direction on terminal 506 of the printed circuit Replace the telescoping manipula See Fiche tor SM2 or telescoping switch SA8 C045 Fiche C044 Repair the connection or replace the wiring harness END between the telescoping manipulator SM2 or telescoping switch SA8 to the printed circuit of the turntable control panel END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP072 NO TELESCOPING MOVEMENT Folio 2 4
126. on the platform control panel comes on 10 Removing 505 SQ6 end of stroke contactor Weighing EC only Remove the protective plate ref 1 Photo 17 Unscrew the fixing screws ref 2 Photo 17 e Remove the end of stroke contactor Open end of stroke contactor mark and disconnect the electric con nections eS 11 Installing 505 SQ6 end of stroke contactor Weighing EC only Photo 16 SQ5 1st threshold detection platform control panel buzzer 5 506 2nd threshold detection movements disabled turntable buzzer red light indicator lit on platform control panel Screw the two adjustment wheels as far as possible ref 2 and 3 Photo 16 Open the new end of stroke contactor reconnect the electric connections and close the end of stroke contactor Put the end of stroke contactor back into place in the position marked during dismantling e Fix the contactor e Adjust the levers ref 4 Photo 16 of the contactors so that when idle the rollers are aligned with the wheels IF THIS PROCEDURE IS RESPECTED AND THE MACHINE JOLTS 15 RISK THAT THE ROLLER MAY MOVE Photo 17 OUTSIDE THE ADJUSTMENT WHEEL 12 Adjustment and testing of the SQ5 Put the machine back in the operational configuration Put a load of 230 kg 507 Ib in the basket e Unscrew the adjustment wheel ref Photo 16 until the basket control panel buzzer sounds Tighte
127. onnectors of the starter 4 accessible by pivoting the motor housing 3 Removing the air suction and ventilation duct Remove the suction duct by unscrewing the collar 5 Remove the ventilation duct by unscrewing the Cerflex collar 6 4 Removing the exhaust Remove the fixing bolts from the collars 7 and 8 Remove the exhaust 5 Removing the coupling Remove the hydraulic pump 9 see corresponding sheet Remove the two fixing screws 10 from the hydraulic oil filter support 11 and the two screws from the exhaust collar support plate Remove the 6 screws 12 fixing the flange 13 of the motor flap then remove the flap and earth braid Remove the 8 fixing screws 14 from the coupling 15 6 Removing the thermal motor Putthe motor in slings as instructed by the motor manufacturer Remove the 4 fixing screws 16 from the motor and remove the motor 7 Installing the thermal motor e Visually check the condition of the silent blocks and replace if necessay Position the thermal motor and fix using the 4 fixing screws previously coated with normal blue loctite 243 equipped with new grower washers Putback the air filter duct with its collar Putback the ventilation duct with its collar 8 Installing the coupling Position the coupling and fix with 8 fixing screws previously coated with nor mal blue loctite 243 Tighten to a torque of 25 Nm 18 4 Ib ft Put the motor flap flange i
128. ons Put the machine in the maintenance configuration see corresponding para Caution graph Ensure that the oil is not too Switch off electric power see corresponding paragraph hot 2 Removing the steering cylinder Open the upper chassis cover Caution Mark and disconnect the two hoses 2 of the steering cylinder 1 Use a container to collect oil to prevent pollution of the NE Unscrew the hoses slowly to release residual hydraulic pressure environment Put caps hoses wr Putthe oylinder in slings A Caution Remove the Nylstop nuts 4 then remove the two fastening pins 3 from the It is essential to put the steering cylinder component in slings before Remove the steering cylinder dismantling re assembling it 3 Installing the steering cylinder Puta new steering cylinder into place Install the fastening pins and fix using new Nylstop nuts and their washers Reconnect the hydraulic hoses according to the marks made during dismant ling Putthe machine back into the operational configuration Make several steering movements to purge the hydraulic circuit Checkthe level of the hydraulic oil tank HA16 18 HA46 51 JRT HA16 18 HA46 51 JRT Sheet Do not use the machine during maintenance operations HA16 18PX nouvelle g n ration HA46 51JRT New Design AN Caution The buzzer should be audible from the b
129. onverter for bi energy machine Motor wiring harness Petrol gas switch Top control panel FUSES Top control panel Motor stop Top control panel Maintain accelerator 5011 Main SQ10 Bottom position 506 Tilt Top position Hydraulic tank temperature probe 4 Electrovalve SQ3 Permanent sensor supply 504 or 5014 Accessories SQ7 Load Sensing valve for machine with PVG 508 509 37 Repair manual Pinguely Haulotte Z 6 1 2 Positions of screws connectors and relays se T DE TR A ur e n gi um 13 49 50 45 46 42 43 44 40 41 38 Repair manual Pinguely Haulotte VA 6 1 3 Positions of fuses 20 19 21 22 26 27 25 23 24 39 Pinguely Haulotte Z Repair manual 6 1 4 Positions of diagnosis help LEDs Se T PAN Rie j ES F3 RIA SA YV16B 16 198 YV19A 40 Pinguely Haulotte 2 Repair manual T HYDRAULIC DIAGRAMS DIAGRAM H14T X REFERENCE B16007 7 1 SNISHHLS z S a YE 15 TT 6 54 pom H GER HH la
130. ope Travel Compensation Jib lifting Jib Standby lowering out in lowering unit HA16 18PX HA46 51JRT 240 110 240 240 240 240 240 manual HA16 18PX NG HA46 51JRT 240 110 240 240 240 240 240 210 New Design Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C073 Folio 3 4 ADJUSTING PRESSURE LIMITER 6 Pressure table in psi Lead Brake Right and di Boom sensing Main Steering Lifting Lowering release left rotation lifting stand by HA16 18PX HA46 51JRT 435 3481 3481 3481 1450 3481 3481 3481 HA16 18PX NG HA46 51JRT 435 3481 3481 3481 1450 3481 3481 3481 New Design Boom Telescope Telescope Travel Compensation Jib lifting Standby lowering out in lowering unit HA16 18PX HA46 51JRT 3481 1595 3481 3481 3481 3481 3481 manual HA16 18PX NG HA46 51JRT 3481 1595 3481 3481 3481 3481 3481 3045 New Design Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C073 Folio 4 4 ADJUSTING PRESSURE LIMITER Sheet 074 Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Folio 1 2 CHANGING THE JIB CYLINDER ZB Caution Ensure that the oil is not too hot 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Secure the platform to the ground 2 Removing the jib
131. orn 1 Remove the horn by unscrewing the fixing bolts 2 3 Installing the horn 2 1 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 Put the machine back into the operational configuration Activate the horn switch from the platform control panel and check that the horn sounds horn should audible from the basket Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C041 Folio 1 1 CHANGING THE TILT SENSOR BUZZER Caution 1 Preliminary operations Switch off electric power see corresponding paragraph Do not use the machine during maintenance 2 Removing the buzzer operations Mark disconnect the buzzer s electric connections 1 Remove the buzzer by unscrewing the fixing bolts 2 HA16 18PX HA46 51JRT 3 Installing the buzzer Putthe buzzer back into place and fix with the fixing bolts e Reconnect the electric connections according to the marks made during dismantling 4 Test Putthe machine back into the operational configuration Extend the machine tilt the tilt sensor and check that the buzzer sounds HA16 18PX New design HA46 51JRT New Design buzzer should audible from the basket Sheet 042 Pinguely Haulotte
132. orresponding Ensure that the oil is not too paragraph hot Switch off electric power see corresponding paragraph HA16 18PX HA46 51JRT 2 Removing the hydraulic block Mark and disconnect the hydraulic block s 1 electric connections 2 e Mark and disconnect the hoses 4 of the hydraulic block NB Unscrew the hoses slowly to release residual hydraulic pressure Fitcaps to the hoses Remove the lower protective plate 5 only in presence of this one Place a wedge under the hydraulic block Remove the hydraulic block by removing the fixing screws and washers 4 Take out the block from the turntable Dismantle the hydraulic block to replace one of its elements if necessary see corresponding sheet 3 Installing the distribution hydraulic block e When installing a new distribution block equip the new block with the unions retained from the old block after replacing the O rings Tighten to the recommended torque see corresponding paragraph Putthe hydraulic block into place and fix using the screws equipped with new toothed washers Install the lower protective plate Reconnect the hydraulic hoses according to the marks made during dis mantling Tighten to the recommended torque see corresponding para graph Reconnect the hydraulic block s electric connections according to the marks made during dismantling Putthe machine back into the operational configuration Make several
133. otte Z BREAKDOWN DETECTION FLOW CHART Sheet 28 NO JIB MOVEMENT UP AND OR DOWN Folio 1 5 FROM THE PLATFORM OR TURNTABLE CONTROL PANEL No jib movement up and or down from the platform or turntable control panel Place the key switch in the platform position Press the pedal and activate the basket rotation switch on the platform control panel he basket rotates Stop the movement and release the pedal Open the turntable control panel and check that the LED associated with electrovalve YV18A down YV18B up is off TO Press the pedal and activate the platform or turntable jib switch Check that the LED associated with electrovalve YV18A down or YV18B up is on YES YES Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART NO JIB MOVEMENT UP AND OR DOWN Folio 2 5 Sheet DP028 FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Press the pedal and activate the jib switch Check for 12V at the terminals of the PVG connector YV2a Open the turntable control panel NO Press the pedal and activate the jib switch Check for 12V voltage on terminal 305 of the printed circuit See Fiche Replace the PVG C077 or YV2 control head C108 NO Replace the See Fiche module 58 107 YES Repair the connection or The fault NO replace the electric wiring persists h
134. ould be up to the hole Top up if necessary Caution Screw the cap back into place Make sure that the machine is properly stabilised and NB Only use the oil recommended by the manufacturer that the lifting means are in good condition and of sufficient capacity 3 Changing the oil Inthe same position unscrew the 2 caps and let the oil flow out Re fill as described above Screw the caps back into place NB Collect old oil to prevent pollution of the environment 4 Additional operations Putthe machine back into the operational configuration HA16 18PX HA46 51JRT HA20 26 PX HA61 80JRT H14T X H16TP X HB40 44J Pinguely Haulotte Z PREVENTIVE MAINTENANCE SHEET Repair manual Pinguely Haulotte Z 10 10 1 INCIDENT TABLE OPERATING INCIDENTS Before diagnosing a failure check that the fuel tank is not empty the batteries are properly charged the turntable and platform palm button emergency stop buttons are unlocked the relays platform control panel turntable box are correctly pushed into their compartments see 4 2 page 26 the main tank oil level is OK the state of the fuses see 4 2 page 26 the electrovalves are working properly by checking the state of the LEDs in the turntable box Check the state of the LEDs see 4 2 page 26 The LEDs inside the turntable box indicate the state of the electrovalves NB LED off electrovalve pres
135. pair the connection or replace the electric wiring END harness between the rotation manipulator SM31 or rotation switch SA15 and the printed circuit in the turntable control panel END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP018 NO TURNTABLE ROTATION MOVEMENT Folio 2 3 RIGHT AND OR LEFT FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Activate the rotation movement in the emergency mode Put the emergency lever in place on the rotation distribu tion platform control YV5 Activate the lever to the right and left while pressing the emergency control of the safety valve YV1 Movement OK Activate the rotation switch SA15 from the turntable panel and check for 3V or 9V voltage depending on the movement direction at the terminals of electrovalve YV5 Maintain the control activated and check for 3V or 9V voltage depen ding on the movement direction on terminal 512A of the printed circuit Voltage OK See Fiche 077 Voltage Replace electrovalve YV5 y OK Replace the U1 See Fiche module C058 VE END Repair the connection or replace the electric wiring harness between the turn table control panel and electrovalve YV5 Voltage OK Replace the See Fiche printed circuit 063 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART
136. permanently for any reason short circuited electrovalve etc fuse FU7 is destroyed The emergency stop is relayed For any reasons we must constantly monotor that the relay does not remain stuck after an emergency stop 5 18 3 Fail safe If the fail safe is held for 10 seconds Controller or neutral movement is de validated X 6s for travel x 4s for movements 5 18 4 Indicator defect If SQ6 0 or SA8a 1 or SA8b 1 or 2 1 and 5 2 1 or SA13a 1 or SA13b 1 or HM31 1 and SM1ab 1 then HL9 1 Repair manual Pinguely Haulotte 7 POSITIONS ELECTRIC COMPONENTS 6 1 BOARD 6 1 1 Description SCREW Connector Battery Flashing light Bi energy machine option Bottom box door Main Top control panel Starter Bottom box door Accelerator control KMG main relay Main supply after switch 4 standby pump switch Emergency stop circuit Console connector Emergency stop circuit HAT horn N OO P Battery Gas electrovalves option Petrol gas machine option Proportional valve output a O Petrol gas machine option Buzzer RELAYS 5013 N Start Boom lifting PVG Motor stop Electric power thermal power switch Telescoping or arm lifting PVG Rotation PVG Accelerator Travel PVG Standby pump safety system Travel PVG C
137. pinion 4 Adjusting the gap between the slew ring teeth and the rotation reducing gear pinion The coloured mark corresponds to the most excentric point of the ring Ad just the gap between teeth to 300 um using a set of flakes Adjust using the reducing gear s adjusting screws ref 6 Photo 11 When the gap is correct block the 4 screws fixing the reducing gear to the turntable to a torque of 270 Nm 199 Ib ft Tighten the reducing gear adjusting screw counter nuts Turn the reducing gear to position the ring quenching connector point mar ked by the letter S in the reducing gear axis When putting the turntable into place on the chassis ensure that point S is in the zone that is not subject to the main load in the transversal axis of the chassis 5 Installing a slew ring cont Remount the rotation reducing gear s hydraulic motor and connect the ho ses Put the turntable in slings and position the assembly on the chassis see Photo 8 TAKE CARE NOT TO TRAP THE HYDRAULIC HOSES OR WIRING HARNESS DURING THIS OPERATION Fix the ring to the chassis using new flat washers and screws Tighten to a torque of 100 Nm 73 75 Ib ft Put the rotation blocking screws into place on the lower part of the hydraulic swing joint see Photo 5 Make the swing joint s electric connections in the chassis see Photo 4 Reconnect the hoses on the steering cylinder and travel block see Photo 2 and Photo 3 Put back the counterweigh
138. rational configuration Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C062 CHANGING RELAY Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C063 Folio 1 1 CHANGING THE PRINTED CIRCUIT 1 Preliminary operations e Put the 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 e Remove the U1 electronic module 4 see corresponding sheet Remove the bolts 3 fixing the board to the box and their sealing washers e Remove the printed circuit and silent blocks equipping the fixing bolts 3 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 Install the U1 electronic module 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
139. raulic circuit and adjust rotation speed using the flow limiter adjustment buttons see Table of adjustment times Check the level of the hydraulic oil tank Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet 053 Folio 1 3 CHANGING THE BASKET 1 Preliminary operations Caution e Put the machine in the maintenance configuration see corresponding It is essential to put the paragraph component in slings before Switch off electric power see corresponding paragraph dismantling re assembling Disconnect the then terminals of the starter battery it 2 Removing the platform Disconnect the platform control panel electric wiring harness Remove the control panel fixing screws 17 e Remove the control panel and its silent blocks 18 Remove the platform s electric plug 19 if any by unscrewing its fixing bolts Putthe platform in slings Remove the pre stressing stop by unscrewing the screw 1 and nut 2 Upper part Remove the Nylstop nut 3 and its washer 4 on the platform side Remove the stop pad 5 on the platform side Remove the weighing articulation pin 6 Lower part Remove the lower pivot pin 7 by removing its fixing screws 8 and washer 9 e Remove the platform and retain the ball 10 the nylatron washer 11 and the stop 12 If necessary unscrew the pre stressing nut totally 13 as a safety measure before performing any operation on the p
140. ravel movement during a platform lifting operation Check the setpoint at the output of detectors SQ3 SQ2 and SQ9 Adjust the detector s See Fiche Setpoint replace the defective 110 12V detector s Check the continuity of wiring END harnesses no 207 206 and 204 Continuity of harn sses na 207 an Replace the defective harness es p 206 OK no 207 206 and 204 Check operation of the See Fiche electronic module U1 C107 and replace if necessary Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP060 Folio 1 4 NO STEERING MOVEMENT RIGHT OR LEFT No steering movement right or left Place the key switch in the platform position Press the pedal and activate the basket rotation switch on the platform control panel he basket rotates Stop the movement and release the pedal Open the turntable control panel and check that the LED associated with electrovalve YV16A YV16B is off NO o Press the and activate the REAR steering manipulator SM4 Check that the LED associated with electrovalve YV16A or YV16B is on YES YES Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP060 NO STEERING MOVEMENT RIGHT OR LEFT Press the pedal and activate the of the PVG YV2a connector REAR steering manipulator SM4 and
141. rinted circuit associated with the electrovalve in question e 807A for YV9 END e 807B for YV13 NO YES Replace the U1 module an 107 Replace the wiring harness between the turntable control panel and the electrovalve in question YV9 and YV13 The fault persists END Replace the printed circuit See Fiche C063 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP036 Folio 3 3 NO DIFFERENTIAL BLOCKING WHEN SWITCH SA3 15 ACTIVATED Open the platform control panel Press the pedal activate switch SA3 and check the setpoint at the output of switch SA3 807 Setpoint Replace See Fiche 12V switch SA3 C044 END Open the turntable control panel Maintain the pedal and switch SA3 activated Check for 12V voltage on terminal 807 of the printed circuit NO Replace wiring harness no 807 YES Make sure that switch SA11 is in the LS low speed or MS me dium speed position LS and MS not See Fiche DP034 available Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP041 Folio 1 1 THE MOTOR STARTS THEN STOPS AFTER 5 SECS The motor starts then stops after 5 seconds Check the level of the diesel tank Fill the diesel tank END Check the diesel supply circuit See motor manufacturer s manual NO Repair the diesel supply circuit See motor
142. rm 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 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 travel ling or manoeuvring equipment The operator must assess the risks above him before using the ma chine 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 inspection
143. ronic module U1 defective rotation movement Wiring harness defective Printed circuit defective Basket rotation swtich SA4 defective No platform up and or down compensation movement Fiche DP027 Electrovalve YV18 or YV2 defective Coil defective No jib movement up and or Electronic module U1 defective down from the platform or Wiring harness defective Fiche DP028 turntable control station Printed circuit defective Flow limiter defective Jib switch SA7 or SA6 defective Electrovalve YV14 or YV2 defective Coil defective Electronic module U1 defective Wiring harness defective Fiche DP072 Printed circuit defective Telescoping switch SA9 or SA8 defective Pressure limiter defective Electrovalve YV3 defective No boom lifting movement Electronic module U1 defective up and or down from the Wiring harness defective platform or turntable con Printed circuit defective trol station Lifting switch SA13 defective Lifting manipulator SM31 defective The arms and boom do not Battery discharged by more than 8096 Change the batteries move up Charge check device defective Replace the charge check device No telescoping movement out and or in from the plat form or turntable control station Fiche 70 Repair manual 10 1 3 Travel system ANOMALY PROBABLE CAUSE SOLUTION Pinguely Haulotte Z No machine travel movement Connectors disconnected e Manipulator
144. rresponding paragraph Put the boom into slings 1 to prevent tipping when the counterweight is removed e Fix a vehicle lift to the lifting beam and apply tension to the vehicle lift 2 Removing the counterweight Remove the cover see corresponding sheet Sling the counterweight by screwing 2 hooks of handling 2 M24 in the nuts envisaged for this purpose on the top of the counterweight Remove the screws 3 M24x90 the washer TREP type AL and the washer Ref 178015857 for H14PX HB40 and the screws and washers 4 for H16TPX HB44J Remove the counterweight 3 Installing the counterweight e Put back the three fixings screws and washers Tighten to the torque recommended see tightening torque value table 4 Additional operations Check that the counterweight is properly secured to the machine Remove the straps from the counterweight Remove the sling from the boom Putthe machine back in the operational configuration Caution Ensure that the lifting equipment is in good condition and of sufficient capacity Caution It is essential to put the component in slings before dismantling re assembling it Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C138 CHANGING THE COUNTERWEIGHTS
145. rthermore 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 hazardous situations concerning safety devices load limiters tilt sensor cylinder leaks deformation welds bolt tightness hoses electrical connections tyre state excessive mechanical gaps NOTA In the case of rental the user of the rented device respon sible for the machine condition and suitability inspection He must check with the renting party that the general periodic checks and checks prior to operation have been carried out 11 Pinguely Haulotte 2 1 5 1 6 1 7 BEAUFORT SCALE Repair manual 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 VERIFICATIONS WHEN RETURNING
146. s 2 of the control unit 3 Remove control unit by removing its 4 fixing screws 4 e Discard the O rings 5 Installing the control unit Replace the O rings e Install the control unit and fix using the 4 fixing screws Tighten the screws to a torque of between 7 5 and 8 5 N m 5 53 and 6 26 Ib ft Reconnect the control unit s electric connections For HA16 18PX and HA46 51JRT old design Install the turntable box and horn and fix with the 4 fixing bolts and silent blocks Put the machine back in the operational configuration the movement corresponding to the replaced control unit Make seve ral movements to purge the hydraulic circuit e Check the level of the hydraulic tank Pinguely Haulotte Caution Use a container to collect oil to prevent pollution of the environment Sheet 79 Ensure that the oil is not too hot Caution Use a container to collect oil to prevent pollution of the environment Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Folio 1 1 CHANGING FLOW SEPARATOR 1 Preliminary operations e Putthe machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph 2 Removing a flow separator Remove the flow separator 1 by unscrewing it 3 Installing a flow separator Screw a new flow separator whose characteristics correspond to t
147. s 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 committee 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 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 agen cies The designated persons must be experienced in risk prevention Articles R 233 11 or order 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 e capable of performing the work in complete safety and in compliance with the operating manual Fu
148. sheet Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C064 Folio 1 1 CHANGING THE FAIL SAFE PEDAL 1 Preliminary operations e Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph e Disconnect the then terminals of the starter battery 2 Removing the fail safe pedal Open the platform electric box e Mark disconnect the electric connections 1 of the fail safe pedal 2 in the box Mark the pedal cabling path 1 along the vertical platform parts and then cut the fixing collars 3 Remove the pedal by removing the pedal s fixing bolts 4 and their washers 3 Installing the fail safe pedal Puta new into place and fix using the bolts and their washers Reconnect the electric connections in the box according to the marks made during dismantling Close the platform box Fixthe electric cable to the vertical platform parts using collars Reconnectthe then terminals of the starter battery Putthe machine back into the operational configuration Check that movements from the platform are possible only if the fail safe pedal is pressed Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C066 Folio 1 1 CHANGING THE DISTRIBUTION HYDRAULIC BLOCK 1 Preliminary operations Caution Put the machine in the maintenance configuration see c
149. sket 27s 5s Compensation speed down From the basket 35s 5s Steering out From the basket 12s Steering in From the basket 12s Boom lifting H14 From the turntable 48s 2s Boom lifting H16 From the turntable 40s 2s Boom lowering H14 From the turntable 38s 2s Boom lowering H16 From the turntable 30s 2s Telescope out From the turntable 30s 2s Telescope in From the turntable 25s 2s Rotation left and right From the turntable 30s 1s per 1 4 turn Jib up From the turntable 30s 2s Jib down From the turntable 23s 2s 19 Pinguely Haulotte 2 Repair manual 20 Repair manual Pinguely Haulotte D 3 SAFETY SYSTEM 3 1 MACHINE ELEMENTS 3 1 1 Motor Ref Description G2 Generator M3 Starter YA2 Accelerator YA1 Motor stop U3 Frequency module 3 1 2 Power supplies and fuses Ref Description FU1 10A Motor stop 80A Accelerator FUA 30A Main FU5 3A 212 Turntable FU6 3A 211 Platform FU7 20A 201 Electrovalves FU8 5A 242 Permanent FU9 20A Accessories FU10 3A LS Valve FU11 250A Standby pump 3 1 3 Control inputs SA2 Accelerator SA3 Differential blocking SA4 Platform basket rotation SA5 Platform compensation SA6 Turntable jib
150. stem PROBABLE CAUSE Repair manual SOLUTION ANOMALY No steering movement right and or left on the rear axle ANOMALY Electrovalve YV16 or YV2 defective Coil defective Electronic module U1 defective Wiring harness defective Printed circuit defective Travel switch 5 4 defective Fiche 6 10 1 5 Turntable rotation system PROBABLE CAUSE SOLUTION No turntable rotation move ment right and or left from the platform or turntable control station Electrovalve YV5 defective Electronic module U1 defective Wiring harness defective Printed circuit defective Rotation switch SA15 defective Rotation manipulator SM31 defective Sheet DP018 The turntable does not turn The blocking pin has not been removed from the chassis Remove the pin NB In the turntable box LEDs indicate the state of each output so that you can check if an output is activated 10 2 BREAKDOWN DETECTION FLOW CHART 72 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP015 Folio 1 2 THE MOTOR DOES NOT START THE STARTER IS ACTIVATED The motor does not start the starter is activated Check the level of the diesel tank Diesel OK Fill the diesel tank END Open the turntable control panel and check the state of fuse FU1 NO Replace fuse FU1 YES END Check the diesel supply
151. t Caution Use a container to collect oil to prevent pollution of the environment Caution It is essential to put the component in slings before dismantling re assembling it Caution When replacing a steering bar check that the adjustment clevis is on the steering lever side If the bar is fitted the wrong way round there may be interference between the clevis counter nut and the hydraulic motor when turning to maximum 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph 2 Removing a steering bar see figure 1 Remove the fixing screws 23 from the two steering clevis pins 1 Remove the two steering clevis pins 11 Remove the steering bar 6 3 Removing the steering lever Open the upper cover of the chassis Remove the Nylstop nut 24 and the washer 23 from the cylinder faste ning pin Remove the pin 27 from the steering cylinder clevis Unscrew the screws 23 and washers 24 Remove the two pins 11 from the clevises 8 of the two steering bars 6 linked to the lever 26 Remove the screw 16 and support washer 25 from the smooth male clevis 31 Remove the smooth male clevis 31 Remove the central pin 12 from the lever Remove the lever 4 Installing the steering lever NB When re installing the pins take the measures necessary to avoid
152. t see corresponding sheet Put back the boom see corresponding sheet Put back the covers see corresponding sheet Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C128 Folio 5 6 CHANGING THE SLEW RING 6 Additional operations Reconnect the battery see corresponding sheet Open the pump suction valve at the hydraulic tank Make several turntable rotation steering and travel movements using all available speeds to purge the hydraulic circuit Fill up with the oil recommended by the manufacturer Using the lubricators lubricate the slew ring bearing path Lubricate the ring teeth For the ring only use recommended by the manufacturer Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C128 Folio 6 6 CHANGING THE SLEW RING Sheet 129 Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Folio 1 6 DISMANTLING RE ASSEMBLING THE BOOM Caution Make sure that the lifting means are in good condition and of sufficient capacity It is essential to put the component in slings before dismantling re assembling it Caution Ensure that the oil is not too hot Caution Use a container to collect oil to prevent pollution of the environment Photo 14 1 Preliminary operations Extend the telescope so that the receiver compensation cylinder pin is visible ref 10 Figure 1 Rest the boom on its support Lower the jib
153. t the electric connectors 1 oil temperature oil pressure generator etc Remove the starter terminals 2 after marking them and the earth termi nal 10 Disconnect the incoming and outgoing fuel pipes 3 and 4 Disconnect the gas supply pipe 5 3 Removing the air suction duct Remove the suction duct by unscrewing the collar 14 Ifthe air filter is to be recovered unscrew the nuts 6 and collar 15 4 Removing the exhaust Remove the fixing nuts on the flange 7 Remove the silencer flanges 8 Remove the exhaust Remove the brackets 9 fixed on the radiator Removing the thermal motor e Remove the hydraulic pump 13 see corresponding sheet Put the motor in slings according to the motor manufacturer s instructions Remove the 4 fixing screws 16 from the motor and remove the motor Retain the motor fixing support parts 12 if necessary to be remounted on the new motor Installing the thermal motor e Visually check the condition of the silent blocks and replace if necessary Position the thermal motor and fix using the 4 fixing screws previously coated with normal blue loctite 243 equipped with new grower washers e Put back the air filter with its collar Put back the air filter suction duct with its collar e Put back the hydraulic pump see corresponding sheet I LI Installing the exhaust Put back and fix the exhaust silencer support br
154. the arm Make several steering and travel movements using all possible travel speeds to purge the hydraulic circuit Checkthe level of the hydraulic oil tank Sheet 52 Ensure that the is not too hot Caution Use a container to collect oil to prevent pollution of the environment Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET CHANGING THE BASKET ROTATION Folio 1 1 HYDRAULIC MOTOR 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph 2 Removing the hydraulic motor NB Mark disconnect the hoses 2 from the hydraulic motor 4 Unscrew the hoses slowly to release residual hydrualic pressure Fit caps to the hoses Remove the flow limiters 1 by unscrewing the unions 5 and adapters 6 Remove the hydraulic motor by unscrewing its fixing screws 3 Installing the hydraulic motor Replace the flow limiters if necessary Put a new hydraulic motor into place Fix the hydraulic motor using fixing screws equipped with new grower washers Screw the unions adapters and flow limiters onto the motor Reconnect the hydraulic hoses according to the marks made during dis mantling see table of tightening torque values Put the machine back into the operational configuration Make several platform rotation movements to purge the hyd
155. the blocking pin Caution Use a container to collect oil 2 Removing the swing joint to prevent pollution of the Open chassis box mark and disconnect all electric connectors 5 environment e Removethe wiring harness 2 that passes through the swing joint Mark and disconnect the hoses and hydraulic caps 1 on the swing joint 3 turntable and the bottom of the chassis Caution NB Unscrew the hoses slowly to release residual hydrualic pressure It is essential to put the component in slings before dismantling re assembling it Put caps on the hoses Put the swing joint into slings Remove the stop 4 of the swing joint by removing the 2 fixing screws e Remove the 3 fixing screws from the swing joint on the chassis Remove the swing joint Installing the swing joint Put the swing joint into place and fix with the fixing screws equipped with new washers Block swing joint rotation using the swing joint stop Fix the swing joint stop using the two fixing screws equipped with new washers e Re connect the hydraulic hoses and caps on the swing joint according to the marks made during dismantling Pass the wiring harness through the swing joint and the elec tric connections in the chassis box according to the marks made during dismantling 4 Additional operations Put the machine back into the operational configuration Remove the wedges from under
156. the pivot reducing gear assembly in slings 34 Take out the two M canindus pins 30 then remove the two pins 14 Take the pivot reducing gear assembly out of the machine Take the reducing gear 34 off the pivot 1 Installing a reducing gear or hydraulic motor Ensure that there are rings on the new pivot Remount the reducing gear on the pivot with screws and conical washers see tightening torque values Put the pivot reducing gear into slings and re install on the machine Put the washers into place 15 Put the pins back into place and block with new m canindus pins Put back the two lubricators and lubricate the pins Put back the pivot pin caps and fix with screws and brake washers Put back the hydraulic motor and connect the hoses Put back the steering bar clevis pin and fix with the screw equipped with a grower washer Lubricate this pin When re installing pins take the necessary measures to avoid da maging the pins rings and bores 4 Additional operations Put back the motor and reducing gear see corresponding sheet Put back the wheel see corresponding sheet Put the machine back in the operational configuration Make several travel movements to purge the hydraulic circuit Check the level of oil in the wheel reducing gear see corresponding sheet Check the level of the hydraulic oil tank Lubricate the pins using the lubricators Pinguely Haulotte MAINTENANCE SHEET
157. the tank air vent Noisy hydraulic pump closed Fiche DP025 Defective pipes Hydraulic pump defective Insufficient oil level Insufficient pressure or power at the pump Clogged air filter Motor speed too low Oil leak on connector hose or component Clogged oil filter Change the filter Adjust speed Repair or replace Replace oil filter cartridge No travel telescope out boom and arm lifting buz zer sounding Slope or tilt 25 First retract the telescope and lower the boom to reset Buzzer sounding Slope or tilt gt 5 Platform load close to cut off Hydraulic oil temperature too high Reset by retracting the teles cope and lowering the boom Remove load Leave to cool The electropump does not work Battery breaker open Fuses broken Defective or discharged batteries The battery wires do not make contact Close the battery breaker Replace the fuses Replace or recharge the batte ries Clean or tighten the terminals 69 Pinguely Haulotte 2 Repair manual 10 1 2 Lifting system ANOMALY PROBABLE CAUSE SOLUTION Electrovalve YV15 or YV2 defective Coil defective Electronic module U1 defective Wiring harness defective Fiche DP026 Printed circuit defective Compensation switch SA5 defective Lifting manipulator defective Electrovalve YV19 or YV2 defective Coil defective No platform right and or left Elect
158. tive Fiche DP019 The motor does not start from the turntable station but does start from the platform station Switch SB3 defective Wiring harness defective Fiche DP020 No motor acceleration regar dless of the movement con trolled from the platform Electronic module U1 defective Wiring harness defective Fiche DP021 No motor acceleration by activating the accelerator Switch SA2 on the turntable control station Fuse FU3 defective Relay KT2 defective Electronic module U1 defective Wiring harness defective Accelerator switch SA2 defective Motor accelerator coil YA2 defective Fiche DP022 No movement available from turntable or platform station 68 Insufficient hydraulic oil Fuse FU7 or FU4 or FU10 defective Wiring harness defective Electrovalve YV1 defective Incorrect Load sensing pressure setting Motor pump coupling defective Hydraulic pump defective Pressure limiter defective Distribution block input module defective Pump regulation unit incorrectly set or de fective Hydraulic pump defective Electronic module U1 defective Relay KMG defective Printed circuit defective Key switch SA1 defective Fiche DP023 Repair manual Pinguely Haulotte Z No movement available from Fuse FU1 defective Platform control station defective the platform control station Fail safe pedal defective un Wiring harness defective Oil non conform Obstruction of
159. tors 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 Label 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 pesrsonnel 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 Pinguely Haulotte 2 Repair m
160. turer e Re install the basket see corresponding sheet Putthe machine back in the operational configuration Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet 55 Folio 1 2 CHANGING THE BASKET ROTATION GEARING 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph e Remove the basket see corresponding sheet Remove the basket rotation hydraulic motor see corresponding sheet 2 Removing the gearing Remove the motor fixing flange 1 Caution Remove the endless screw 2 and adjustment washers 3 if any It is essential to put the Remove the Stauff collar fixing screw 4 Retain the toothed washer 5 component into slings before spacer 6 and spacer washer 7 dismantling re assembling it e Remove the cap 8 then the platform link part 9 Nylatron washer 10 Remove the nylstop nut 11 bushing 12 elastic washers 13 plate 14 Remove the articulation pin assembly 15 then the disk 16 and pad 17 Remove the screws and washers 18 and 19 and remove the pin 15 tangent wheel 22 keys 17 hub 20 key 21 1 Installing the gearing Replace rings pads and keys if necessary Putinto place on the articulation pin 15 the key 21 hub 20 2 keys 17 tangent wheel 22 Put back screws and washers 18 and 19 Putthe dis
161. u cing gear ref 3 Photo 11 hydraulic motor ref 4 Photo 11 Put caps on the connectors NB Unscrew the hoses slowly to release residual hydraulic pressure Unscrew the four screws ref 5 Photo 11 and washers fixing the reducing gear to the turntable Unscrew reducing gear s 4 adjusting screws ref 6 Photo 11 Remove the reducing gear Secure the slew ring on the forks of a lift truck and unscrew the 31 screws ref 1 Photo 11 and washers holding the ring to the turntable Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C128 Folio 4 6 CHANGING THE SLEW RING Caution 3 Installing slew ring For this operation all slew Position the ring ref 1 Photo 13 on the turntable ring fixing screws and Putthe cap ref 2 Photo 13 in the zone that is not subject to the main load washers are to be replaced on the transversal axis of the turntable with new ones Fix the ring using screws and flat washers ref 1 Photo 12 Tighten in a star pattern to a torque of 100 Nm 73 75 Ib ft NB Four Hm 12 55 30 screws are to be positioned in the counterbores Photo 13 i under the rotation reducing gear Put back the rotation reducing gear without blocking it if the pinion shows signs of wear replace it Remove the hydraulic motor see corresponding sheet to be able to turn the ring Turn the reducing gear to position the ring teeth marked with colour opposite the reducing gear
162. uipped with a new toothed washer Re connect the then terminals of the battery and lubricate them to improve contact Putthe machine back into its operational configuration Start the machine to check that the battery works properly Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C047 Folio 1 1 CHANGING COVER GAS SPRING 1 Preliminary operations Put the machine in the maintenance configuration see corresponding AN Caution paragraph S Switch off electric power see corresponding paragraph Do not use the machine during maintenance 2 Removing a gas spring operations Open the cover 1 concerned Put the cover in slings Remove the fixing nuts and washers 2 at both ends of the gas spring 3 HA16 18PX HA46 51JRT 3 Installing a gas spring Put a new gas spring into place and fix at both ends using the fixing nuts and washers Put the machine back into the operational configuration Check that the cover opens and closes correctly HA16 18 PX New design HA46 51JRT New Design Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet 050 CHANGING THE TURNTABLE ROTATION Folio 1 1 HYDRAULIC MOTOR 1 Preliminary operations Ensure that the oil is not too Put the machine in the maintenance configuration see corresponding hot paragraph Switch off electric power see corresponding paragraph 2 Removing the hydrauli
163. ver adjustment may be necessary For this purpose the supports 3 are equipped with adjustment lights Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C124 Folio 1 1 CHANGING TANK COVER 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph Caution f Switch off electric power see corresponding paragraph Do not use the machine during maintenance 2 Removing a cover operationis Open the tank cover Unscrew the nut 1 fixing the cover to the support Raise the cover until the support pins are free of the bosses fixed on the side plate Remove the cover 3 Installing a cover Position the cover so that the support pins are facing the bosses Block the fixing nut 1 e Check that the cover opens and closes properly Put the machine back in the operational configuration Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C125 Folio 1 1 CHANGING FRONT COVER ON THE MOTOR OR TANK SIDE 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph Caution f Switch off electric power see corresponding paragraph Do not use the machine during maintenance 2 Removing a cover operations Open large motor cover Open the spring clip 1 Putthe cover in slings Remove the cover by raising it until the support pins 2
164. when using high pressure cleaning equipment around the machine 6 Not remove any machine parts which might affect the stability 7 Not modify the machine without the manufacturer s written approval 8 Do not use the machine as a welding earth 9 Not carry out repairs on the machine involving welding without first disconnecting the battery DAILY INSPECTION 1 Check the level of diesel fuel for diesel engine platforms 2 Check that there are no apparent defects hydraulic leaks loose bolts loose electric connections 3 Check that the tilt indicator operates correctly by manually tilting the switch with the power on INSTRUCTIONS BEFORE USE 1 Remove the rotation locking pin if fitted 2 IMPORTANT when connecting AC power supply to the work platform the wall power supply must be protected by 30 mA circuit breaker START UP 1 Turn the battery isolator switch if fitted to the on position 2 Unlock the emergency stop button then press the engine starter button 3 If the engine does not start wait 10 seconds then repeat the operation THE MACHINE MUST NOT BE USED WHILE CHARGING THE BATTERIES Repair manual Pinguely Haulotte 7 8 7 6 Labels specific to Holland 8 7 7 Built in generator in option OFF ON 7815 050 55 Pinguely Haulotte Z Repair manual 56 Pinguely Haulotte 4 Repair manual 8 7 8 Label positioning seulyoew juawajddns
165. wigs 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 Repair manual Pinguely Haulotte Z 2 PRESENTATION Self propelled platforms models 14 and H16TPX are designed for all types of overhead work within the limits of their characteristics Operating and maintenance instructions manual and provided all the safety recommendations specific to the equipment and operating environment are respected The main control panel is situated in the platform The control panel situated on the turntable is to be used in emergencies or cases of machine failure 2 1 TECHNICAL CHARACTERISTICS 2 1 1 H14T X technical characteristics DESCRIPTION H14T X Unit Load 230 2 peoples Kg Max lateral manual force 400 N Max wind speed 60 Km h Floor height 12 07 m Working height 14 07 m Overall length 7 58 m Overall width 2 27 m Overall height 2 20 m Wheel base 2 00 m Floor clearance 0 34 m Max bearing distance 10 60 m Boom range 13 75 Telescoping travel 4 33 m Turntable rotation 360 continu Reducer torque 950 Max travel slope 4 4 50 Tyre dimensions 14 17 5 SKS HAULER Interior turning radius 2 m Max allowed tilt 5 S Hydraulic tank 150 Fuel tank 150 Total weight 4 4 6040 Kg Number of drive wheels 4 4 4 Number
166. y Haulotte 2 Repair manual 5 11 34 LIFTING 5 10 2 Platform 5 10 2 1 Left If SM31ab 1 and SQ6 1 and HM31 1 then YV1 1 and YV5 1 YV1 is time delayed for 2 seconds If SQ6 passes to O during a movement this one is not cut 5 10 2 2 Right If SM31ab 1 and SQ6 1 and HM31 1 then YV1 1 and YV5 1 YV1 is time delayed for 2 seconds If SQ6 passes to O during a movement this one is not cut 5 11 1 Turntable 5 11 1 1 Up If SA13a 1 and SQ1 1 or machine folded or SQ9 1 then YV1 1 and YV3 1 YV1 is time delayed for 2 seconds machine folded gt SQ2 1 and SQ9 1 and SQ3 1 If SQ6 passes to O the movement is carried more slowly 5 11 1 2 Down If SA13b 1 and SQ1 1 or machine folded or SQ9 1 then YV1 1 and YV3 1 YV1 is time delayed for 2 seconds If SQ6 passes to O the movement is carried more slowly 5 11 2 Platform 5 11 2 1 Up If SM31ab 1 SQ6 1 and HM31 1 and SQ1 1 or machine folded or SQ9 1 then YV1 1 and YV3 1 YV1 is time delayed for 2 seconds machine folded gt SQ2 1 and SQ9 1 and SQ3 1 If SQ6 passes to O during a movement this one is not cut 5 11 2 2 Down If SM31ab 1 and SQ6 1 and HM31 1 and SQ1 1 or machine folded or SQ9 1 then YV1 1 and YV3 1 YV1 is time delayed for 2 seconds If SQ6 passes to O during a movement this one is not cut Repair manual Pinguely Haulotte Z 5 12 DIFFERENTIAL BLOCKING 5 13 GENERATOR 5 14 HORN 5 15 BUZZER 5 16 HL2 5 17 HL4 If SA3 1 an

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