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8 - AJ Maskin AS

1. 1 ME indicator light Low position end 39 Not in use I 501 Horn control 28 Overload pres Not in use sure switch input SP1 Input Tilt indicator Kk 1 in use signal EENS RE 28 Repair manual Pinguely Haulotte D 5 HYDRAULIC DIAGRAM 5 1 HYDRAULIC DIAGRAM FOR OPTIMUM 6 AND 8 B16288B MODEL POTHOLES DIRECTION o 5 5 STEERING So g 32 20 course 85 40 20 course 114 x FREIN ESSIEU ARRIERE 14 ver ESSIEU AVANT REAR AXLE BRAKE Y e sul FRONT AXLE peo LESS CS B B A 1 2 BSPP 1 2 Ce 1 2 BSPP A 1 2 BSPP eve D L_ 1 3 8 A2 3 8 ___ 8 A4 3 8 FRM A Bala pla Balyyar Olag pilya D2 4 lt lt o S e i E X 1 H H g Tg mal t b 1 va SN JA 5 8 i KS s 8 amp 5 8 zd 5 w g X Hm 1 RX YV 2 b P jg YV 5a YV 5b 1 1 I I 110 bar vun RAM 230bar qs d MX ya T 1 2 P 3 8 3 4 TO 128
2. Optimum Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET REPLACING A COMPONENT ON THE Sheet 1 1 CHASSIS CONTROL PANEL 1 Preliminary operations Putthe machine in the maintenance configuration see S 7 2 page 51 Cut off the electric power supply see 7 3 page 52 2 Removing a component from the chassis control panel 1 Remove the protective plate 2 from the chassis control panel Mark and disconnect the electric connections of the component requiring replacement Remove the component 3 Replacing a component in the chassis control panel Putthe new component and seal on the front of the chassis control panel NB If itis a lever switch adjust the position of the fixing nut and counter nut so that the switch lever joint axle is on the same level as the seal to ensure tightness Reconnectthe electric connections according to the marks made when dismantling e Put back the chassis control panel protective plate 4 Test Put the machine back into the operational configuration Perform the function corresponding to the replaced component to check that it works properly Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C006 Sheet 1 1 REPLACING THE TILT DETECTOR 1 Preliminary operations Place the platform on a flat level floor with no slope e Putthe machine in the maintenance configuration see 7 2 page 51 Caution Cut off the elec
3. Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART Sheet 3 4 SHEET DP003 NO UP MOVEMENT FROM THE CHASSIS OR PLATFORM CONTROL Check operation of tilt detector SQ10 Check supply connection Check operation NO Check the setting Input 27 at 24V Replace the See Input 29 NO connectororthe SHEET at 24V tilt detector C006 Input END 25 at 24V below 1 5m or 4ft92in Check operation of the end of stroke Input 24 at 24V contactor SQ3 Check supply connection Check operation Check setting Y Y Replace the speed See SHEET variator U1 C003 Y Check operation of end of stroke contactors SQ1 SQ5 and SQ6 END Check supply connection Check operation Check setting Adjust or replace the See SHEET defective detector or its C018 wiring Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART Sheet 4 4 SHEET DP003 NO UP MOVEMENT FROM THE CHASSIS OR PLATFORM CONTROL Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP004 Sheet 1 2 NO DOWN MOVEMENT FROM THE PLATFORM OR CHASSIS CONTROL No down movement from the chassis or platform controls Y Check the allowed load on the platform Reduce load Load correct Disconnect the wiring harness from pressure contact SP1 on up cylinder Check for 24V on on
4. 3 WIRING DIAGRAM Repair manual Pinguely Haulotte 4 WIRING DIAGRAM E 591A PRESSURE SWITCH VERSION 3 1 Lo add ec 002 60 21 DEER SE EE Saud VIN3HOS ay NOILVOIAIMAA EE BANAN 1 po doe SS EE 8 9 WNWILdO 8 ZL OL NOL M8 8 LOVINOD ee geg anune Aon 00z 60 zL 60 50110414 Moi SEN VSIA NOILVOISIGOW 699 NOILLV3HO Siva aNissaa 3LLO1NVH ATA NON Id z 10 Sr 8 10 r UoH HOT esse gt e SESCH 7 Z 7 UOXEIH x ies Cow B BAA INA ISM GAA TAA IZMA eZAA qe Sess o W you 1 0 N N N N N N N N a a d A i 69 1 asi 25 gt 29 2 S 20 20 Pr gt gt Ps 5 5 or 19 5 55 2 5 52 67 lt 58 u 88 55 L Eri 8 gt 3 an e 2 2 5 Fu 5 iQ 1 180 22 g 44 B 88 e P 8 88 5 1 88 aan 2 25 89 ag dH EE 1 8 2 orm os zu OE 0 12 8 400 2 85 amp IN E gt Ip tee M ES 8 so 5 5 EE oo A 5 MI So 8a 27 EO E 82 o go SG c 2 o ce OL Eur 5 3 ag 2 5 858 SE it TET 2 8 F me
5. Defective wiring harness Defective manipulator Defective steering cylinder Defective steering pressure limiter 63 Pinguely Haulotte 4 Number of flashes MDI 9 1 5 List of MDI codes Message EVP NOT OK Description Defective coil or YV7INV9 coil s supply Repair manual Solution Look for failure on the lifting cylinders lowering coil s SERIAL ERROR 1 e Incorrect or lack of reception of serial card s signal to chopper Look for failure on the platform console s serial card the bundle the connections between the platform s console and the chopper Other possible reason incorrect cabling on the MDI line or the MDI display EEPROM KO Fault in the chop pers EEPROM Replace the chopper VMN NOT OK Low VMN at rest or inconsistent with the applied VMN at work Check the chopper s isolation between B and P terminals If the value is below 65 KOhms replace the chopper Otherwise replace the motor CONTACTOR CLOSED e SB1 s contact stuck Check SB1 CONTACTOR OPEN e B1 s auxiliary con tact faulty Check SB1 1 0 EVER e Null current on movement request Replace the chopper STBY HIGH High current at rest Replace the chopper CAPACITOR CHARGE e Capacitors do not charge on starting the machine Replace the chopper TH PROTECTION e Choppers thermal protectio
6. No up movement from the chassis or platform control Y Check that there are no hydraulic leaks Repair the NO hydraulic links YES END Check supply of the electrovalve YV1 coil disconnect the coil connector and measure supply voltage NO 24V coil supply Check electrical continuity of the wiring harness betwen coil YV1 and the speed variator Check continuity of coil YV1 ontinuity NO Replace the correct gt wiring harness Continuity correct Replace the SeeSHEET coil C007 Check the speed variator s safety inputs Tilt SQ10 input 27 High position contactor SQ3 input 29 Connect a pressure gauge to the hy Potholes SQ5 SQ6 input draulic block s minimess pressure tap 24 associated with position Activate the up movement and note switch SQ1 input 25 pressure Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART Sheet 2 4 SHEET DP003 NO UP MOVEMENT FROM THE CHASSIS OR PLATFORM CONTROL Pressure 165 bars or 150 bars compact 12 NO 2393 psi or 2175 psi compact 3347E Zero pressure YES SeeSHEET Replace the lifting C001 hydraulic cylinder s YES See SHEET Adjust or replace the SHEET END limiter C012 Replace See electrovalve SHEET YV1 C030 END
7. HL6 Weighing light indicator M1 Motorpump unit PT1 display RCH Battery charger relay SA1 Control post selection SA2 Movement selection SA3 Platform travel lifting selection SA4 Working light switch SB1 Battery cut off Emergency stop chassis SB2 Emergency stop platform SB3 Buzzer control SM1 Manipulator SP1 Pressure switch 501 Low position contactor 5010 Tilt sensor SQ3 Top position contactor SQ4 Travel interruption switch SQ5 SQ6 Pothole system out U Battery charger U1 Electronic chopper U2 Serial card YV Electrovalve 19 Repair manual WEIGHING CARD VERSION WIRING DIAGRAM E591A A AAA A LI E002 60 21 BzaNaa SE LO Mna VIN3HOS ERE EN HE d NOLVOIIIMIAIGILVA SAIA EEN ee eBesed 002 60 2 AMMAS EES LOVANOD 8002 60 21 byona awane IJLLOINVH AITINDNId 002 60 21 e 60 W104 VSIA NOILVOISIGOW alva Om 699
8. NO MOVEMENT Check electric continuity of the motor pump set connection to the speed variator NO YES See SHEE Replace the motor T C019 pump set END Restore the electric connection between the motor pump set and the speed variator Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP007 Sheet 4 4 NO MOVEMENT Check cabling of the electrovalve supply line line 7 at fuse FU2 output Cabling NO OK YES See SHEE Replace speed T C003 variator U1 Replace cabling END Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP008 NO STEERING 4 No steering Y Check for absence of hydraulic leaks Absence of Sheet 1 2 leaks Make a lifting movement Lifting movement occurs Disconnect electrovalve YV5 electric connectors Activate steering and check for 24V on connector YV5a left or YV5b right NO gt Repair hydraulic connectors END NO p gt SHEET DP007 Make a steering movement right and left and check for 24V on input B1 or B12 of printed circuit U2 ofthe platform control 24V NO present zi panel 24V 24V NO present on present outputs 3 or 6 ofthe manipulator NO Check continuity of coils YES Y YES YV5a or YV5b S
9. ScreWg L Nut ScrewNut Nut TOT SS Nut Za Score a rt G Nut Nut Screw ECROU Fig 1 RON Fig 2 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C028 Sheet 1 2 REPLACING A SCISSOR RING OR AXLE 1 Preliminary operations Put the machine in the low position Cut off the electric power supply see 7 3 page 52 2 Removing a scissor axle 1 or ring 2 Remove the platform see SHEET C026 Remove the elastic ring and washer from the scissor axle in question Remove the axle stop bolt Take out the scissor axle Take out the two scissor rings 3 Replacing a scissor axle or ring Putnew scissor rings into place Putthe scissor axle into place and secure using the axle stop bolt NB Fit the axle stop bolts so that the screw is above the axle and the nut underneath when the platform is in the high position see figure below Putthe washer and elastic ring back into place Putthe platform back see SHEET C026 Putthe machine back into the operational configuration Make several lifting movements and check that the scissors work properly Ss ETT 09 Nuts Nut EX sii Nut E E ECROU Fig 1 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 Pingue
10. terminals of the batteries Put the machine back in the operational configuration Optimum Optimum Compact Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C003 BYEN IE Laf STAR 6 STAR 13 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C004 Sheet 1 1 REPLACING A COMPONENT ON THE PLATFORM CONTROL PANEL 1 Preliminary operations Cut off the electric power supply see S 7 3 page 50 Caution 2 Removing a component from the platform control panel Do not use the machine Remove the closing plate 1 by unscrewing the four fixing screws during maintenance Mark and disconnect the electric connections of the component to be operations replaced Remove the component 3 Replacing a component on the platform control panel Puta new component and seal into place on the front of the platform con trol panel NB If itis a lever switch adjust the position of the fixing nut and counter nut so that the switch lever joint axle is on the same level as the seal to ensure tightness Reconnectthe electric connections according to the marks made when dismantling Fixthe closing plate with the four fixing screws Perform the function corresponding to the replaced component to check that it works properly Star 8 HM10P star 10 Pinguely Haulotte 4 SHEET C005 Caution Do not use the machine during maintenance operations Compact
11. 1 amp 2 I 2 GG 3 4 bs 3 4 3 8 3 4 20L RESERVOIR TANK 5 1 1 Components Marker Qty Comments 2420703820 Motor pump unit 3KW 24V 2427010430 Oil filter 3 4 BSPP 2420212090 MK4 distribution block 2431202110 Hydraulic motor 162cm3 1180149380 Cylinder SP 5090 5093 1180170040 Lifting cylinder Oak wn NI N gt 29 Repair manual Pinguely Haulotte 4 HYDRAULIC INSTALLATION DIAGRAM A14681D 5 2 JOLON LNOUX LHOTA LIONG LNVAV ANALON HHONITAO SOIASG ATAO D ONIAAIL IINY LHOIN LIONG TTOHLOA 8 NINJA o E HHONITAO a SNINSSLS NOILOSNIG NINTA SOLONW LIST HHOnVO LNVAV UNHLOWN TDIVHH NOVH LHDIY Toad UHANITAD HOIAHA YAO PNIdaIL ILNV LAT HHOQVO HTOHLOd NIJHA HHONITAO LAIT HOYAYT NINJA PT89 7IY Ava MOVE LAIAT SHONYD T HIAAV NIHUA 30 Repair manual Pinguely Haulotte D 5
12. 2 1 Components listed in diagram A14681d 7 AT468id Pats Marker Qty Comments 2369117210 Union piece M JIC 37 1 1 2369117190 Union piece M JIC 37 2 1 2369110160 Union piece M JIC37 16 M 3 4 BSPP 3 1 2369110170 Union piece M JIC37 16 M 1 2 BSPP 4 1 2369117370 Union piece JIC 37 BS 5 4 2369117360 Union piece M JIC37 6 9 2369117120 Union piece M JIC 37 7 6 2369111440 Union piece male JIC37 6 M 7 16 20 UNF 8 2 2369109100 Union piece TC M JIC 37 10 9 2 2369132200 Adjustable bend M JIC37 10 2 2369132090 Bend 7 90 11 7 2369135180 Bend 37 90 12 1 2369147000 Equal T piece JIC 37 13 1 2441604150 Minimess tap 1 4 14 1 2369073050 Hose S5241 Lg 290 D C90 15 1 2369073040 Hose S5028 Lg 1130 D D 16 1 2369073030 Hose S5028 Lg 420 D D 17 1 2369073310 Hose S5415 Lg 2050 D C135 18 1 2369070890 Hose SP 1756 1 750m 19 1 2369071650 Hose SP 5250 2 050m 20 1 2369073000 Hose S5250 Lg 2000 D C90 21 2 2369072890 Hose S5250 Lg1850 22 1 2369058550 Hose S1756 LG 1m 23 1 2369073080 Hose S1756 Lg 2350 D D 24 1 2369073300 Hose S5250 Lg 2400 D C90 25 1 2369071160 Hose S1707 2 19m 26 2 2369073020 Hose S1707 Lg 1660 D D 27 2 2369070260 Hose S1707 Lg 1550 D D 28 1 2369072380 Hose S1707 1 47m 29 1 2369072530 Hose Lg 860 D C90 30 1 2369071800 Hose SP 5238 0 530m 31 1 2301231750 Screw H M8X80 22 CL8 8 ZB 32 1 2421608490 Protective plate GD2 D 33 1 2389003250 Collar 216 16 PP 34 2
13. 2349221500 Nut M8 CL8ZB 35 1 2389002540 Collar 36 1 1180160570 Washer 36 27 ep 2 37 2 118D160560 Washer 23 5 17 ep 2 38 1 2421903390 Flexible plastic spiral 900952 12 39 1 0 31m 2421903430 Flexible plastic spiral 40 22m 31 Pinguely Haulotte 4 Repair manual 32 Repair manual Pinguely Haulotte FA 6 DESCRIPTION OF THE HYDRAULIC CIRCUIT 6 1 HYDRAULIC BLOCK S COMPONENTS Ru Maer Pn p 244 050 7620 Parallel serial coupling Low speed High speed travel 244 050 7610 Parallel serial coupling Low speed High speed travel 244 050 8580 Solenoid valve selecting direction of travel 244 050 8590 Pothole control solenoid valve 244 050 7590 Travel lifting selection solenoid valve 242 220 4980 Priority valve 242 120 3240 Main pressure regulating valve 242 120 3510 Lifting pressure regulating valve 244 050 8570 Steering solenoid valve 242 120 3520 Steering pressure regulating valve 242 040 2610 Travel flow divider 242 220 5310 Balancing valve 242 220 5310 Balancing valve O1 A Go N gt 33 Pinguely Haulotte 4 Repair manual Description Rear brakes power supply output 244 050 8560 Lifting solenoid valve 242 180 8630 Brake release discharge valve 242 180 8630 Balancing valves by pass valve 242 160 9590 Hand pump 35 25 33 29 36 Block s output Marken Part description Part description A1 Front left travel mot
14. 39 05 17 80 813 Fax Fax 39 05 16 05 33 28 Haulotte Scandinavia AB u b T l Phone 46 31 744 32 90 Fax Fax 46 31 744 32 99 Haulotte Iberica Sevilla T l Phone 34 95 493 44 75 Fax Fax 34 95 463 69 44 Repair manual Pinguely Haulotte 4 AN Caution The technical data in this manual is not binding and we reserve the right to make improvements or modifications without altering this manual GENERAL This manual gives the information required for you to perform servicing and repair operations on certain pieces of equipment yourself However we would like to bring your attention to the importance of respecting the safety instructions concerning the machine itself its use and its environment use within the limits of its performance correct servicing to ensure long service life During and after the guarantee period our After Sales service is available to perform any servicing operations you may require In this case contact our local agency or our Plant After Sales service specifying the exact type of machine and its serial number To order consumables or spare parts use the Instructions for use and maintenace manual and the Spare parts catalogue to order original parts the only guarantee of interchangability and perfect operation REMINDER We would like to remind you that our machines comply with the clauses of the Machines Directive 89 392 CEE dated June 14th 1989 modified by di
15. 990 Ib H12SN outdoor use 120kg 265 Ib outdoor use 120kg 265 Ib 3347E indoor use 300kg 660 Ib indoor use 300kg 660 Ib Optimum 6 outdoor use 115kg 254 Ib outdoor use 115kg 254 Ib 1530E indoor use 270kg 595 Ib indoor use 270kg 595 Ib Optimum 8 indoor use 230kg 500 Ib indoor use 230kg 500 Ib 1930E tolerance or 10
16. C020 Replacing a hydraulic block valve SHEET C021 Replacing a wheel SHEET C022 Replacing the brake release pull SHEET C023 Replacing the steering cylinder SHEET C024 Replacing a pothole cylinder SHEET C025 Replacing the platform extension SHEET C026 Replacing the platform SHEET C027 Replacing the scissors and pads SHEET C028 Replacing a scissor ring or axle SHEET C029 Replacing the balancing valves SHEET C030 Replacing a cartridge electrovalve SHEET C031 Replacing the chassis emergency stop button SHEET C032 Replacing the hydraulic pump SHEET C033 Replacing and adjusting the pressure switch 105 Pinguely Haulotte 4 Repair manual 106 SHEET C001 Caution Ensure that oil temperature is not too high Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 1 1 REPLACING A LIFTING CYLINDER 1 Preliminary operations Put the machine in the maintenance configuration see 7 2 page 51 Cut off the electric power supply see 7 3 page 52 2 Removing the cylinder Remove the cylinder remote control if any see SHEET C017 Mark and disconnect the cylinder pressure switch s electric connections Mark and disconnect the cylinder s hydraulic hoses Fit caps to the hoses Put the cylinder into slings Remove the two cylinder axle stop bolts 1 on the rod and body side Remove the two
17. Description Checking filling the hydraulic oil tank Replacing the hydraulic filter cartridge Greasing the steering wheel pivots Greasing the slides 51 Pinguely Haulotte 4 Repair manual 52 Pinguely Haulotte 4 PREVENTIVE MAINTENANCE SHEET Sheet 1 1 SHEET P001 CHECKING THE HYDRAULIC OIL TANK LEVEL 1 Preliminary operations e Put the machine in the low position and maintenance configuration see 7 2 page 49 AN Caution Ensure that oil temperature NOTA Do notuse the maintenance stands leave the platform in the low po is not too high sition Cut off the electric power supply see 8 7 3 page 50 2 Checking the hydraulic oil tank level Ensure that the oil level in the tank is sufficient Top up if necessary NOTA Only use the oil recommended by the manufacturer Put the machine back into operational configuration MAX MIN OIL LEVEL Pinguely Haulotte 4 PREVENTIVE MAINTENANCE SHEET Pinguely Haulotte 4 PREVENTIVE MAINTENANCE SHEET Sheet 1 1 SHEET P002 REPLACING THE HYDRAULIC FILTER CARTRIDGE 1 Preliminary operations Put the machine in the maintenance configuration see S 7 2 page 49 Caution i Cut off the electric power supply see 7 3 page 50 Ensure that oil temperature is not too high 2 Replacing the hydraulic filter cartridge Unscrew the body and remove the hydrualic filter cartridge Screw a new cartridge int
18. MOVEMENT TO CONTACTOR BE MADE CHECK Lifting end of stroke Liftin Lifting disabled in the high posi SQ3 g tion Extension of the potholes when the platform reaches Lifting 1 5m Pothole end of stroke Microspeed present SQ5 and SQ6 Disconnect YV6 Lifting impossible beyond Lifting 1 5m Travel impossible beyond 1 5m Tilt reset end of Lifting beyond GE GEN 2221 501 1 5m lowering H tion at 1 5m 8m end of stroke switch SQ4 Lifting beyond 8m H12SN only Travel impossible microspeed disabled Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C019 Sheet 1 2 REPLACING THE MOTOR PUMP SET 1 Preliminary operations e Put the machine in the maintenance configuration see S 7 2 page 51 ER Cut off the electric power supply see S 7 3 page 52 aution Ensure that oil temperature is not too high NB Lift the platform using a gantry crane or fork lift truck 2 Removing the motor pump set Remove the upper inspection flap for Compact machines Mark and disconnect the motor s electric connections 1 Mark and disconnect the hydraulic pump s hoses 3 Fitcaps to the hoses Remove the fixing collars 2 from the motor pump set and remove the motor pump set Remove the hydraulic pump s suction and backflow flanges 4 3 Replacing the motor pump set Putthe suction and backflow flanges equipped with n
19. axles 2 also see figure 1 and remove the cylinder 3 Replacing the cylinder Put the new cylinder into place using slings Put back the cylinder axle on the cylinder body side and secure using the axle stop bolt Fit so that the screw is above the axle and the nut underneath see figure 2 Reconnect the cylinder s hydraulic hoses according to the marks made when dismantling Reconect the pressure switches electric connections according to the marks made when dismantling Reconnect the cylinder s remote control if any see SHEET C017 Put the machine back into the operational configuration Perform several lifting cycles to purge the hydraulic circuit Check the oil level in the hydraulic oil tank Fig 2 Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C002 Sheet 1 2 ADJUSTING A HYDRAULIC BLOCK PRESSURE LIMITER 1 Adjusting the general pressure limiter 1 Caution Ensure that oil temperature is not too high Optimum Put the machine in the low position Cut off the electric power supply see S 7 3 page 52 Unscrew the cap of the hydraulic pressure tap marked MX on the hydraulic block and connect a pressure gauge with sufficient range to measure overall pressure Restore the electric power suply see S 7 3 page 52 Bring the machine against a wall to
20. block the travel movement Request a travel movement and measure overall pressure on the pressure gauge Adjust the hexagonal hollow head screw on the overall pressure limiter 1 so that movements are disabled at the pressure indicated in the table below Put the machine in the maintenance configuration see S 7 2 page 51 Cut off the electric power supply see S 7 3 page 52 Unscrew the pressure gauge and put the cap back on the hydraulic pressure tap Put the machine back in the operational configuration Make several travel movements to check that the machine works properly Adjusting the steering pressure limiter 2 Put the machine in the low configuration Cut off the electric power supply see S 7 3 page 52 Unscrew the cap of the hydraulic pressure tap marked MX on the hydraulic block and connect a pressure gauge with sufficient range to measure the steering pressure Restore the electric power supply see S 7 3 page 52 Activate the steering command as far as possible to the right or left Maintain the steering command and measure the steering pressure on the pressure gauge Steering is disabled after a certain period when at the maximum in one direction and only the other direction is possible and can re authorise steering in the initial direction The steering pressure measurement time is therefore limited If necessary adjust the hexagonal hollow head screw on the steering pres sure limiter 2 to disabl
21. control panel 414 or 1 24V and the chassis Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP014 Sheet 2 4 NO MOVEMENT FROM THE PLATFORM CONTROL PANEL Replace the See SHEET manipulator C013 END Check voltage on the inputs of printed circuit U2 10V AT 10V A9 between 10V and 10V B5 and B13 24V Repair cabling between the manipulator SM1 and printed circuit U2 Check for variable setpoint voltage between terminals C2B and C4 of printed circuit U2 Replace printed See SHEET circuit U2 C004 Presence of a setpoint voltage Check for setpoint voltage between terminals 2 and 21 ofthe speed variator U1 Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP014 Sheet 3 4 NO MOVEMENT FROM THE PLATFORM CONTROL PANEL Replace the wiring harness between the platform control panel and the speed variator Setpoint voltage present END Replace speed See SHEE variator U1 T C003 Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP014 Sheet 4 4 NO MOVEMENT FROM THE PLATFORM CONTROL PANEL Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP061 PLATFORM ABOVE 1 5M OR 4FT92IN DESCENT Sheet 1 2 IS SLOW FROM THE PLATFORM OR CHASSIS CONTROL Platform above 1 5m or 4ft92in descent is slow from the platform
22. current DO NOT DRIVE ON THE PUBLIC HIGHWAY 1 2 3 Using the machine It is important to ensure that in normal use i e platform operation the platform station selection key remains in the the platform position to enable control of the machine from the platform If a problem occurs on the platform a person present and trained in emergency standby manoeuvres can help by putting the key in the ground control position Never use the machine with a load greater than the nominal load more people than the authorised number lateral force in the platform greater than the level permitted wind speed higher than the permitted level Repair manual AN Caution Never use the platform as a crane goods lift or elevator Never use the platform or tow 1 3 or haul RESIDUAL RISKS Pinguely Haulotte 4 To avoid all risk of serious fall operators must respect the following instructions Hold the hand rails firmly when climbing onto or operating the platform Wipe any traces of oil or grease off the steps floor and hand rails Wear protective clothing suited to working conditions and current local legis lation in particular when working in hazardous areas Do not disable the safety system end of stroke contactors Avoid contact with fixed or mobile obstacles Do not increase working height by using ladders or other accessories Never use the hand rails as a means of access for getting onto and off the platfo
23. electrovalve s coil and its connections WRONG INPUT CONF The platform conso les ENABLE starting switch is closed while a movement is requested from the chassis control panel Replace the chassis control panels lift switch MICRO CONTROL KO Siemens calcu lator does not respond correctly Replace the chopper CURR PROTECTION e Current out of con trol Replace the chopper The hour shown on the MDI and the chopper differ Wait for 6 minutes after putting into service If the problem remains connect the console instead of the MDI In this configuration if the ma chine functions again MDI fault If the machine still does not function defective bundle or chopper CHECK UP NEEDED Check up func tion has been activated Deactivate the CHECK UP ENABLE function using the console 65 Pinguely Haulotte 2 Repair manual NB If no situation and red and green last light indicators are on SPEED VARIATOR is INOPERATIVE Alarm 01 ifallthe green light indicators are on speed variator ino perative Check YV7 connector Disconnect the plug on electrovalve YV7 Take YV1 coil for testing The fault disappears replace coil the fault does not disappear Disconnect the plug connecting with the chassis wiring harness Check the pin of wire 26 for incorrect connection Tests Alarm 98 when replacing the speed vari
24. or chassis controls Check for 24V at the terminals of the coil supply connector of electrovalve YV9 2O Check electrovalve YV9 coil continuity 24V present YES NO Continuity correct YES Change electrovalve See SHEET YV9 coil C007 Y Change See SHEET electrovalve YV9 C030 Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP061 PLATFORM ABOVE 1 5M OR 4FT92IN DESCENT Sheet 2 2 IS SLOW FROM THE PLATFORM OR CHASSIS CONTROL Check for 24V absence on input 25 of the speed variator 24V NO Check absence of short circuit in the absent gt wiring harness between pressure contact SP1 and speed variator U1 YES Check electric continuity ofthe wiring NO harness between electrovalve YV9 and the speed variator Replace the electric NO wiring harness Continuity correct END See SHEET C003 Replace the speed variator Replace the speed Replace the wiring 2 GHEET harness C003 END SHEET DP062 Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART Sheet 1 4 NO TRAVEL MOVEMENT IN BOTH DIRECTIONS FORWARD AND BACKWARD No travel movement in either forward or backward direction Y Check platform load Reduce load END Make a lifti
25. position remains correct before replacing the cylinder Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C025 Sheet 1 2 REPLACING A PLATFORM EXTENSION 1 Preliminary operations Put the machine in the low position Cut off the electric power supply see S 7 3 page 52 2 Removing the platform extension Remove the electric plug and its support if any from the platform Remove the control panel 1 and the platform wiring harness 2 Putthe platform extension 3 into slings Remove the locking pedal 4 and support 5 assembly Remove the two roller and roller axle assemblies at the back of the extension by unscrewing the fixing screws 6 Remove the two safety brackets 7 Remove the platform extension 3 Replacing the platform extension Putthe platform extension into place Secure the two safety brackets Putthe locking pedal and support assembly the two rollers and their axles back into place and secure with screws equipped with new toothed washers Install the electric plug support Putthe platform control panel back into place and reconnect the platform wiring harness Grease the friction parts of the slides Only use the grease recommended by the manufacturer Put the machine back into the operational configuration Check that the platform extension can be extended and retract
26. safety Operating instructions Photo 2 page 45 These operations are to be carried out on both sides of the platform Putting the maintenance stand into place Position the platform on a firm horizontal floor Ensure that the two emergency stop buttons are ON Turn the chassis ignition key to the Chassis position Push the chassis lifting switch up to raise the platform Unscrew and turn the maintenance stand and allow to hang vertically Push the lifting switch down to lower the platform gradually until the mainte nance stand comes up against the two fixing points top and bottom Removing the maintenance stand Push the chassis lifting switch up and gradually raise the platform until the maintenance stand is free Turn the maintenance stand until it comes into its storage position and screw back into place Push the chassis lifting switch down and lower the platform completely 45 Pinguely Haulotte 4 Repair manual 7 3 ELECTRICITY SUPPLY Photo 3 Operating instructions Cutting off the electricity supply Press the chassis emergency stop Photo 3 page 46 Starting the electricity supply Reset the emergency stop 7 4 MAINTENANCE PLAN The plan overleaf indicates frequency servicing points device and the consumables to be used The reference in the symbol indicates the servicing point according to the frequency The symbol represents the consumable to be used or t
27. size 700 va La d 12 2 6 S 7 OQ Se o R ojee n 2 5 A Or IC 3 1380 760 1839 zl p 2 2 2 Optimum 8 size 700 kn mm 1 6 Ji S T 3 el amp oke m V L 2 S 1380 E 760 _ 1839 Pinguely Haulotte 2 2 3 14 TIGHTENING TORQUE Nominal diameter M 6 1 Repair manual 2 3 1 Tightening torque for large thread screws 9 to 11 Tightening torque in N M 10 9 13 to 14 15 to 17 M 7 1 15 to 19 21 to 24 26 to 28 M 8 1 25 22 to 27 31 to 34 37 to 41 M 10 1 5 43 to 45 61 to 67 73 to 81 M 12 1 75 75 to 94 110 to 120 130 to 140 M 14 2 120 to 150 170 to 190 200 to 220 M 16 2 190 to 230 260 to 290 320 to 350 M 18 2 5 260 to 320 360 to 400 440 to 480 M 20 2 5 370 to 450 520 to 570 620 to 680 M 22 2 5 500 to 620 700 to 770 840 to 930 M 24 3 3 630 to 790 890 to 990 1070 to 1180 M 27 3 930 to 1150 1300 to 1400 1560 to 1730 M 30 3 5 Nominal diameter M 8 1 1260 to 1570 1770 to 1960 2200 to 2350 2 3 2 Tightening torgue for fine thread screws 24 to 29 Tightening torgue in N M 10 9 33 to 37 40 to 44 M 10 1 25 46 to 57 64 to 71 77t0 85 M 12 1 25 83 to 100 120 to 130 140 to 150 M 14 1 5 130 t
28. FU2 FU3 and FU4 NO Replace defective fuses YES END Request a platform lifting movement and check motor pump operation audible Maintain the activated lifting control check for setpoint voltage between terminals B and VMNP of the speed variator The motor pump set works YES Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP007 Sheet 2 4 NO MOVEMENT Check electric continuity of chassis emergency stop contacts SB1 NO Replace the chassis See SHEET emergency stop C031 YES Check for 24V at key switch SA1 END input on the chassis control panel Check electric continuity of plat form emergency stop contacts SB2 24V present Wa UJ N YES Place the chassis control panel key NO switch SA1 in the chassis position and check for 24V between terminals 13 and 2 4 YES and 2 34 and 2 of the speed variator U1 Replace the wiring harness between the platform control panel and the chassis Y See END Replace the platform SHEET emergency stop C004 24V NO present Y END YES Repair electric cabling between key switch SA1 on the chassis control panel and the speed va riator U1 END Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP007 Sheet 3 4
29. IAGRAM FOR OPTIMUM 6 AND 8 B16288B MODEL 29 5 2 HYDRAULIC INSTALLATION DIAGRAM 146810 30 6 DESCRIPTION OF THE HYDRAULIC CIRCUIT eene 33 6 1 HYDRAULIC BEOGKS COMPONENTS nenne ae 33 6 2 4 HYDRAULIC BLOCK SPECIFICATIONS eese 35 6 3 HYDRAULIC FUNCTIONING 2 39 7 MAINTENANCE TT 45 7 1 GENERAL RECOMMENDATIONS 45 7 2 MAINTENANCE DEVICE enne Ee ENEE CES as 45 Jf ELECTRICITY SUPPLY een ee heise 46 TAS MAINTENANCE PEAN zes en eu ae re 46 P MENS I eost au 48 7 6 PRESENCE OFELABEIS 22 49 1 1 PRESENCE OF MANUALS tite seggt 49 8 PREVENTIVE MAINTENANCE SHEETS eere 51 9 OPERATING INGIDENTS un ae gege 61 9 1 TABLE OF INCGIDEN E 61 9 2 FAILURE DETECTION FLOW Ree 67 Repair Manual Pinguely Haulotte A 10 CORRECTIVE MAINTENANCE PROCEDURES ss 105 Pinguely Haulotte 7 Repair Manual Repair manual Pinguely Haulotte A 1 GENERAL RECOMMENDATIONS SAFETY 1 1 GENERAL WARNING 1 1 1 Manual This manual aims to help maintenance personnel service and repair the machine It cannot however replace the basic training required by any person working on the site equipment The site manager must inform operators of the recommendations in the instruction manual He is also responsi
30. NO and output 5 of the control panel or change the control panel link wiring harness See SHEET Replace printed END C004 circuit U2 Replace speed variator U1 END See SHEET Replace the END C013 manipulator Y wiring harness Renovate cabling or change PB SB2 END Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART NO UP AND DOWN MOVEMENT FROM THE PLATFORM CONTROL Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP002 Sheet 1 2 NO UP AND DOWN MOVEMENT FROM THE CHASSIS CONTROL No up and down movement from the chassis control Place the key switch in the chassis control position and check for 24V on its terminal connected to wire no 10 24V present Replace the See SHEET switch C005 END Check for voltage on switch SA2 wire no 10 24V present Replace wire no 10 YES Check operation of switch SA2 Change SA2 up down 24V at terminals 37 or 38 of the speed variator Replace switch SA2 See SHEET C003 Replace speed See SHEET variator U1 C005 Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART NO UP AND DOWN MOVEMENT FROM THE CHASSIS CONTROL Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART Sheet 1 4 SHEET DP003 NO UP MOVEMENT FROM THE CHASSIS OR PLATFORM CONTROL
31. OG NO TRAVEL MOVEMENT IN BOTH DIRECTIONS SEET FORWARD AND BACKWARD 24V present Close valve NV1 ofthe hydraulic block and release the brakes manually Request a travel movement The travel movemen occurs See SHE ET C014 Replace the defective motor Replace the See SHE defective brake ET C011 Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP062 Sheet 4 4 NO TRAVEL MOVEMENT IN BOTH DIRECTIONS FORWARD AND BACKWARD Repair manual Pinguely Haulotte 4 10 CORRECTIVE MAINTENANCE PROCEDURES List of corrective maintenance sheets Sheet no Description SHEET C001 Replacing a lifting cylinder SHEET C002 Adjusting a hydraulic block pressure limiter SHEET Replacing a speed variator SHEET C004 Replacing a component on the platform control station SHEET C005 Replacing a component on the chassis control station SHEET C006 Replacing the tilt detector SHEET C007 Replacing a coil SHEET C008 Replacing the travel eletrovalve SHEET C009 Replacing the hydraulic filter SHEET C010 Replacing a hose SHEET C011 Replacing a vacuum brake SHEET C013 Replacing a manipulator SHEET C014 Replacing a hydraulic travel motor SHEET C015 Replacing the buzzer SHEET C016 Replacing the distribution block SHEET C017 Replacing the remote control system SHEET C018 Replacing the end of stroke sensor SHEET C019 Replacing the motor pump set SHEET
32. OMPACT87 10712 IMUMO A GOSSIAUX M JEANNARD gt Z O a LL Repair manua Pinguely Haulotte 4 Pinguely Houlotte fl DES I GNAT I ON VALVE DE PRIORITE REP 1 _ a 3 IMIT DE PRESS ON LEVAGE 4 LIMITEUR DE PRESSION DIRECTION D DER EN XN TROVA N CARTQUCHE 24V u 5 ELECTROVALVE EN CARTOUCHE 24V 2 2 10 ELFCTROVALVE EN CARTOUCHE 24V 2 2 11 ELECTROVALVE EN CARTOUCHE 24 473 EE a 14 POMPE A MAIN mm 15 SICL EUR mm BOUCHON ROBINET Date 13 03 01 Page 5 5 SPECIFICATION Numero CODE HAULOTTE 2422204980 2421205240 2421203510 2421203520 2440507590 2440508580 2440507610 2440507620 2440508590 2440508560 2440508570 2420402610 2422205310 2421609590 2420703510 2420212100 2420209890 2421808630 5625 QUANTITE 1 1 H 38 Repair manual Pinguely Haulotte D 6 2 1 List of components Page 5 of 5 in 55625 Description Haulotte reference Priority valve 242 220 4980 Main pressure regulating valve 242 120 3240 Lifting pressure regulating valve 242 120 3510 Steering pressure regulating valve 242 120 3520 Screw in cartridge electrovalve 244 050 7590 Screw in cartridge electrovalve 244 050 8580 Screw in cartridge electrovalve 244 050 7610 Screw in cartridge electrovalve 244 050 7620 Screw in cartridge electrovalv
33. Pinguely Haulotte 4 REPAIR MANUAL SELF PROPELLED SCISSOR PLATFORM 242 031 8680 E 05 05 GB GROUPE 9 Matte ARTICULEES MATS TELESCOPIQUES GSEAUX TRACTEES ES EE EE PINGUELY HAULOTTE LA PERONNIERE BP 9 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 Web www haulotte com Distribu par Distributed by Distribuito da KAKA 8 Haulotte France Tel Phone 33 0 4 72 88 05 70 Fax Fax 33 0 4 72 88 01 43 Haulotte Hubarbeitsb hnen Tel Phone 49 76 33 806 920 Fax Fax 49 76 33 806 82 18 Haulotte UK T l Phone 44 0 1952 292753 Fax Fax 44 0 1952 292758 Haulotte Asia T l Phone 65 6536 3989 Fax Fax 65 6536 3969 Haulotte Australia PTY Ltd T l Phone 61 3 9706 6787 Fax Fax 61 3 9706 6797 Haulotte Do Brazil T l Phone 55 11 3026 9177 Fax Fax 55 3026 9178 Haulotte Iberica Madrid T l Phone 34 91 656 97 77 Fax Fax 34 91 656 97 81 Centre Mondial Pieces de Rechange Spare Parts International Centre T l Phone 33 0 4 77 29 24 51 Fax Fax 33 0 4 77 29 98 88 Haulotte Portugal T l Phone 351 21 955 98 10 Fax Fax 351 21 995 98 19 Haulotte U S Inc Main tool free 1 877 HAULOTTE Service tool free 1 87 7 HAULOT S Haulotte Netherlands BV T l Phone 31 162 670 707 Fax Fax 31 162 670 710 Haulotte Italia T l Phone
34. Solenoid valve that controls high or low travel speed at rest low speed working high speed wire 22 Solenoid valve that controls steering right Solenoid valve that controls left steering Solenoid valve that controls the potholes spreading out movement only when SQ is on 1 Solenoid valve that pilots the low cylinder lowering wire 26 Solenoid valve principal descent ON when SQ1 is 0 wire 50 24 Repair manual Pinguely Haulotte 4 4 4 END OF TRAVEL SWITCHES CHART Switch Movement to perform Recommended adjustment Optimum 6 Optimum 8 Check End of travel lifting SQ3 Lifting 4 33 m 5 80 m 15 cm 15 cm Lifting movement cut off in high position Pothole end of travel SAS amp SQ6 Lifting Potholes extension when the plateform is raised at 1 5m Microspeed activation Disconnect YV6 Lifting Lifting movement impossible above 1 5 m Travel movement impossible above 1 5 m SQ1 Fin de course r armement d vers 4 5 Lifting above 1 5m and lowering SERIAL CARD Check that the lowering movement is properly performed the movement must be interrupted at 1 5 m 24 512 13 AT Wire 51 A9 Wire 39 A6 Wire 52 Accelerator potentiometer m P Em gm Bs 2 Ab 1151913 AL B1 wire 40 Left steering switch B12 wire 41 Ri
35. YDRAULIC FILTER 1 Preliminary operations Putthe machine in the maintenance configuration see S 7 2 page 51 Cut off the electric power supply see 7 3 page 52 Caution Ensure that oil temperature 2 Removing the hydraulic filter is not too high Disconnect the two hydraulic filter hoses Fitcaps on the hoses Unscrew the fixing screws 1 and remove the hydraulic filter Remove the two hydraulic filter connections 2 3 Replacing the hydraulic filter Putthe two connections 2 on a new hydraulic filter Putthe equipped hydraulic filter into place respecting the oil flow direc tion secure with the fixing screws Reconnectthe hydraulic hoses Putthe machine back into the operational configuration Perform several lifting cycles to purge the hydraulic circuit Compact Optimum Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C010 Sheet 1 1 REPLACING A HOSE 1 Preliminary operations Put the machine in the maintenance configuration see corresponding Ser paragraph Caution e Cut off the electric power supply see corresponding paragraph Ensure that oil temperature is not too high 2 Removing a hose Disconnect the hose from the equipment it connects NB Unscrew the hose slowly to allow residual hydraulic pressure to dissipate Fit caps to the equipment holes to protect them 3 Replacing a hose Reconnect a new hydraulic h
36. ace for Com pact machines Putthe machine back into the operational configuration Raise the platform to a height of 2m or 6ft56in and activate the emergency pull to check that it works properly Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 SHEET C018 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 1 1 REPLACING AN END OF STROKE CONTACTOR Caution Do not use the machine during maintenance operations 1 Preliminary operations Put the machine in the maintenance configuration see 7 2 page 51 Cut off the electric power supply see 7 3 page 52 2 Removing an end of stroke contactor Mark the position of the end of stroke contactor 1 and its lever 2 Remove the end of stroke contactor Open the end of stroke contactor mark and disconnect the electric connec tions 3 Replacing an end of stroke contactor Open the new end of stroke contactor reconnect the electric connections and close the end of stroke contactor Move the end of stroke contactor s lever 2 back to the position marked when dismantling Put the end of stroke contactor into place in the position marked when dis mantling and secure with bolts 3 without tightening 4 Test Put the machine into the operational configuration Perform the movement using the contactor concerned see table and check that it works properly Adjust the contactor position if necessary and tighten the fixing bolts
37. air of the machine s essential devices any accident caused by failure of an essential device A suitability examination examination of the condition static test and dynamic test must all be carried out see coefficient paragraph 1 4 2 page 8 1 5 REPAIRS AND ADJUSTMENTS 1 6 1 7 BEAUFORT SCALE The Beaufort Scale of wind force is accepted internationally and is used when communicating weather conditions It consists of number 0 17 each representing a certain strength or velocity of wind at 10m 33 ft above ground level in the open Description of Wind Specifications for use on land MPH m s 0 Calm Calm smoke rises vertically 0 1 0 0 2 1 Light Air Direction of wind shown by smoke 1 5 0 3 1 5 2 Light Breeze Wind felt on face leaves rustle ordinary vanes moved by 6 11 1 6 3 3 wind 3 Gentle Breeze Leaves and small twigs in constant motion wind extends 12 19 3 4 5 4 light flag 4 Moderate Breeze Raises dust and loose paper small Branches are moved 20 28 5 5 7 9 5 Fresh Breeze Small trees in leaf begin to sway crested wavelets form 29 38 8 0 10 7 on inland waterways 6 Strong Breeze Large branches in motion whistling heard in telephone 39 49 10 8 wires umbrellas used with difficulty 13 8 7 Near Gale Whole trees in motion inconvenience felt when walking 50 61 13 9 against wind 17 1 8 Gale Breaks twigs off trees generally impedes progress 62 74 17 2 20 7 9 Strong Ga
38. anssaa 2 10 r 8 10 won 77 HESSE 72 gt zn Td eZ og WE uoxe y x V LVH 5 8 BAA INA JAA ISM EGAA BAA TAA SAA IZM EZAMA INA lt 4 4 3 21 10 o IN 5i N 0 N R PE 7 P bb 69 1 25 uc E af a ooa el ab sl LPS 3 se sm ab ooh aM og o al E aN 25 gt 2 2 2D 20 20 co EK 55 oc 19 5 __ E ES 5 5 OT OT lt 56 85 28 28 25 L 1158 e 1 82 So 8 3 00 e 2 2 5 Fu OG GI 18 2 amp as ad 2 se gt 9o E RL cs 2 On gt ES aoe So 1 88 a 25 so I CS 1 5 0 93 ENN tz PR ES oo 3 6 1 gan 5 zu e TD 5 L 8 2 929 amp N so 0 lo 1 29 m 83 5 5 p eo 18 1 ve do amp 3zzna 9 Go m o 28 55 j 6 Ss l EE 5 9 ae 52 5 gt 858 ES ta ovs i 80 88 8 25 ER 2 HE 28 2 8 p 1 aa a OS 30 Sist JnaJedIPUI a xb R aS 25 i Ee r tegmen Te Ir be oi decree ney T E a EE TT KER FE p vt FE Y BE P 2 b Lin m moo Fass a o wW N po NON p N In In JA In Lh IN b d jo p 0 e p p fo fo N jo In p P N hp fp os oo fo pa eee eee EE B eo 9 906 ees 189 1 YOS E v N O EOS b H 505 A d 0 2 10 d K ch 59 d 5 M E 0 0 evs 0 ch a e o A 5 2 9 9 Fleege se meme ses s
39. ator or MDI this code may appear when restarting the machine In this case leave the machine live for approximately 1 4 hour to allow the speed variator to re establish communication with the M D I 66 Repair manual Pinguely Haulotte 7 9 2 FAILURE DETECTION FLOW CHARTS 67 Pinguely Haulotte 2 Repair manual 68 SHEET DP001 Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART Sheet 1 2 NO UP AND DOWN MOVEMENT FROM THE PLATFORM CONTROL No up and down movement from the platform control Y Place the movement selector Switch SA3 in the position HS then in the up position Check that light indicators HL4 up and HL5 HS come on Open the plat form control panel and LEDs come check for 24V on between terminals 7 and 4 Open the platform control Y panel and activate NO 24V between 7 and 4 the fail safe and tilt the manipulator Check the presence of a set point value on input A9 of printed circuit U2 and the YES of setpoint at CA Repair cabling or replace switch SA3 presence of 24V on input B5 and B13 of printed circuit U2 output of printed Continuity between coils 1 and 2 of the platform control panel Change the control panel link END between terminal CA Renovate cabling A9 setpoi value and 24V on B5 and B13
40. ble for application of current user regulations in the country of use Before operating on the machine it is essential to be familiar with all the recommendations in this manual and the user manual to ensure personnel and equipment safety 1 1 2 Labels Potential dangers and recommendations for the machine are indicated on labels and plates Read the instructions on them All labels conform to the following colour code Red indicates a potentially fatal danger Orange indicates a danger that may cause serious injury Yellow indicates a danger that may cause material damage or slight injury Maintenance 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 AN Caution To attract the reader s attention instructions are indicated by this standardised sig
41. bove 1 5m or 4ft92in Y Lower the platform below 1 5m or 4ft92in Check that the lowering movement stops normal procedure with lowering restarted after releasing the manipulator for 3s Check electric continuity of the wiring harness between the end of stroke contactor SP1 1 5m or 4ft92in and speed variator U1 The platform stops its descent at 1 5m or Aft92in YES Replace the speed See SHEET variator U1 C003 ne Fe harness END es END Adjust or replace the See SHEET end of stroke contac C018 tor SQ1 1 5m or Aft92in END Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP012 Sheet 2 2 ONLY MICRO SPEED IS AVAILABLE BELOW 1 5M OR 4FT92IN Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP013 Sheet 1 2 THE POTHOLE SYSTEM IS NOT EXTENDED WHEN THE PLATFORM IS LIFTED The pothole system is not extended when the platform is lifted Disconnect the electric connector of electrovalve YV6 Check 24V supply to the electrovalve A i Replace the See SHEET 24V t ON QURU variator C003 pre 18 of the speed em END Check coil continuity Replace the wiring harness ref 25 NO Replacer the coil of See SHEET electrovalve YV6 C007 YES Check electrovalve operation Electrovalve Replace See SHEET
42. chine folded 0 4 5 km h Travel speed with machine lifted 0 0 6 km h Internal turning radius External turning radius 1 8m Maximum slope in travel 25 Maximum tilt allowed 2 Hydraulic tank 201 Total mass 1335 Kg 1420 Kg Maximum load on one wheel 605 daN 750 daN Maximum floor pressure 14 9 daN cm 17 8 daN cm Number of drive wheels 2 2 Number of steering wheels 2 2 Tyres Non marking Solid rubber Wheel diameter 317 mm Free wheel YES Movements proportional control Batteries 24 V 180 Amp h C5 General hydraulic pressure Travel Steering 230 bars 230 bars 100 bars Lifting 110 bars 130 bars Lifting time 20s 235 Lowering time 35s 32s CE standards 12 Repair manual Pinguely Haulotte A 2 2 SIZE 2 2 1 Optimum 6
43. e 244 050 8590 Screw in cartridge electrovalve 244 050 8560 Screw in cartridge electrovalve 244 050 8570 Flow divider 242 040 2610 Balancing valve 242 190 5310 Hand pump 242 160 9590 Spray nozzle Orifice plug 242 070 3510 Block 242 021 2100 Plug 242 020 9890 Safety valve 242 180 8630 6 3 HYDRAULIC FUNCTIONING 6 3 1 Operating equation Steering Right YV5 A Left YV5 B Lifting YV1 YV6 When lt 501 Descent gt SQ1 YV9 YV 7 YV8 if C12 YV6 lt 501 YV 7 YV 8 if C12 Travel motion Slow speed frontward gear YV2A Slow speed backward gear YV2B High speed frontward gear YV2A YV3 YV4 High speed backward gear YV2B YV3 YV 4 39 Pinguely Haulotte 4 Repair manual 40 6 3 2 Solenoid valves functioning Common hydraulic diagram for compact and optimum machines Front axle Brake Steering Lifting rear zz vede a N e ZE 2 y AB FESIFU AVANT mh pe m gt AA em D d A aga s N FL e Balancing valve one way valve Forward or reverse gear selection solenoid valve Repair manual Pinguely Haulotte A 6 3 4 Speed selection Forward gear slow speed Forward gear high speed travel motor in parallel travel motor in series Reverse gear slow speed Reverse gear high sp
44. e movement at the pressure indicated in the table below Put the machine in the maintenance configuration see S 7 2 page 51 Cut off the electric power supply see S 7 3 page 52 Unscrew the pressure gauge and put the cap back on the hydraulic pressure tap Put the machine back in the operational configuration Make several steering movements to check that the machine works properly Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C002 Sheet 2 2 ADJUSTING A HYDRAULIC BLOCK PRESSURE LIMITER 3 Adjusting the lifting pressure limiter 3 Put the platform in the low configuration Unscrew the lifting pressure limiter adjusting screw 3 Place a load corresponding to nominal load 10 in the platform see table below Lift the platform and tighten the pressure limiter adjustment screw until move ments are disabled for this load e Place a load corresponding to nominal load in the platform see table below Check that the lifting movement is not disabled for this load e Put the machine back into the operational configuration 4 Load and pressure table Nominal load Overall Steerin Nominal load hydraulic g 10 pressure pressure outdoor use outdoor use H8SN 120kg 265 Ib 132kg 290 Ib 200 bars 150 bars 2032E indoor use indoor use 3335 PSI 2175 PSI 350kg 770 Ib 385kg 850 Ib outdoor use outdoor use H8SW 120kg 265 Ib 132kg 290 Ib 200 bars 150 bar
45. e nut 3 or 4 Reconnect the electric connector 2 on the coil Putthe hydraulic block back into place and secure with the screws 1 equipped with new flat and toothed washers Putthe machine back into the operational configuration Check that the coil works properly by performing the movement corresponding to the replaced coil Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C008 Sheet 1 1 REPLACING THE TRAVEL ELECTROVALVE Caution 1 Preliminary operations Ensure that oil temperature Putthe machine in the maintenance configuration see S 7 2 page 51 is not too high Cut off the electric power supply see 7 3 page 52 2 Removing the travel electrovalve Unscrew the two screws 1 on the fixing lug and take out the hydraulic block Mark and disconnect the coil s electric connections Remove the coils of the electrovalve 2 and remove it 3 Replacing the travel electrovalve Put a new electrovalve equipped with its seal into place e Reconnect the electric connections on the coils e Put back the hydraulic block and secure using the screws 1 equipped with new flat and toothed washers Put the machine back into the operational configuration Make several travel movements to check that it works properly Compact Optimum Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C009 Sheet 1 1 REPLACING THE H
46. e of the two wiring harness terminals 24V t Replace wiring harness presen Place a shunt between the two terminals of the wiring harness NO The platform comes down Adjust or replace pressure See SHEET C033 Check for 24V on input 26 of contact SP1 the speed variator END Replace the wiring harness 24V present Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP004 Sheet 2 2 NO DOWN MOVEMENT FROM THE PLATFORM OR CHASSIS CONTROL Q Y Check supply to electrovalve YV7 disconnect the coil s electric connector and measure supply voltage 24V coil supply NO Check electric continuity of the wiring harness between the electro valve and speed variator YES Check continuity of the coil of electrovalveYV7 Replace wi ring harness oil continuit Replace the BEER Replace the See Fiche correct coil CUT speed variator Replace See END electrovanne SHEET YV7 C030 Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP007 Sheet 1 4 NO MOVEMENT No movement Check battery charge Recharge or replace defective batteries Check the oil level in the hydraulic tank NO Top up with oil See SHEET P001 YES Check the state of fuses END FU1
47. ect the lifting electric connector 1 from the lifting cylinder s pres sure switch Disconnect the pressure switch s hydraulic hose 2 Fita cap to the hose Unscrew and remove the pressure switch fixing screws 3 Replacing the pressure switch Screw a new pressure switch equipped with its seal into place Reconnect the pressure switch s hydraulic hose Reconnect the pressure switch s electric connector Putthe machine back into the operational configuration 4 Adjusting the pressure switch Place aload corresponding to movement disabling load in the platform see table below raise the platform until the small rod of the lifting cylin der is disengaged and adjust the pressure switch screw 3 located on the lifting cylinder so that the movements are disabled for this given load Check that the machine works properly in all positions with a load slightly less than nominal load on the platform Nominal load Load setting for disabling movements H8SN outdoor use 120kg 265 Ib outdoor use 120kg 265 Ib 2032E indoor use 350kg 770 Ib indoor use 350kg 770 Ib H8SW outdoor use 120kg 265 Ib outdoor use 120kg 265 Ib 2247E indoor use 450kg 990 Ib indoor use 450kg 990 Ib H10N indoor use only 230 kg 500 Ib indoor use only 230 kg 500 Ib 2632E H10S outdoor use 120kg 265 Ib outdoor use 120kg 265 Ib 2747E indoor use 450kg 990 Ib indoor use 450kg
48. ed easily Optimum Compact Optimum Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C026 Sheet 1 2 REPLACING THE PLATFORM 1 Preliminary operations Put the machine in the low position Cut off the electric power supply see 7 3 page 52 2 Removing the platform Disconnect the wiring harness 1 from the platform control panel Remove the control panel and remove the wiring harnesses from the plat form Remove the electric plug and its support if any from the platform e Put the platform into slings Remove the axle stop bolts from the four platform axles two fixed axles 2 and two moving axles 3 and remove the four axles Remove the platform Remove the four pads and check their condition remove the adjustment wed ges if necessary 3 Replacing the platform Putthe four pads into place fixed and moving on the platform Put the plaform on the scissors Putthe four fixed and moving platform axles into place and secure with the axle stop bolts NB Fit the bolts so that the screw is on the outside of the platform and the nut on the inside see diagram Remount the electric plug if applicable on the platform Put back the platform control panel Grease the slides using a spatula Only use the grease recommended by the manufacturer Put the machine back into the operational configuration Pe
49. ee SHEET Replace printed C004 circuit U2 Repair cabling between the manipulator and the circuit NO imprim U2 END YES Replace the See SHEET END defective coil C007 Replace the See SHEE manipulator T C013 Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP008 Sheet 2 2 NO STEERING o Connect a pressure gauge to the minimess tapping on the hydraulic block Activate steering and note the pressure value value disappears after 5s Pressure 150 bars or ND 2175 psi YES Replace the steering See SHEET Replace See SHEE cylinder C023 electrovalveYV5 T C030 END END Y See SHEET Adjust or replace the steering C012 pressure limiter Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP009 Sheet 1 2 NOISY HYDRAULIC PUMP The hydraulic pump makes a noise Check the oil level in the circuit Oil level Top up with oil See SHEET zen P001 Incorrect operation of the hydraulic See SHEET pump replace the pump C032 Pinguely Haulotte 7 FAILURE DETECTION FLOW CHART SHEET DP009 Sheet 2 2 NOISY HYDRAULIC PUMP Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP010 Sheet 1 2 NO TRAVEL IN JUST ONE DIRECTION No travel in just one travel direction Disconnect the connector 2 or YV2b B concerned by the faul
50. eed travel motor in parallel travel motor in series 6 3 4 1 Fonctioning of balancing valves The solenoid valve in use is that placed on the return position its main role consists in keeping an equilibrium in the travel circuit pressures and ensuring a constant speed preventing the machine from rolling when on ramps In the following diagram we shall consider that the machine is in forward gear YV1 Travel movement selection solenoid valve Oil circulation ES D is stopped on the valve P Accumulation of pressure on both control pipes allows opening the balancing valve Cil circulates through the one way valve Towards P supply Towards T return LLLI 41 Pinguely Haulotte 4 Repair manual 6 3 4 2 Rear wheels brake release power supply o Sri Q p CH YVA n 1 A By V2 cvs S rm WYV2 Potholes s supply Pressure being present in the travel pressure pipe feeds the brake release device ar vv COMPACT 8W 10 220 bar 6 3 4 3 Potholes functioning When using the lifting command hydraulic oil circulation is supervised through the following solenoid valves YV1 in operation position Travel lifting selection In the lifting position the oil is directed towards the lowering solenoid valve as indicated in the diagram above by passed during lifting and
51. emoving a hydraulic travel motor see figure 1 Remove the pin 2 and nut 1 fixing the wheel and remove the wheel 7 Mark and disconnect the two hydraulic motor hoses Fit caps to the hoses Place a wedge under the hydraulic motor Remove the hydraulic motor 4 by removing its four fixing bolts 3 5 6 Replacing a hydraulic travel motor Put a new hydraulic motor into place Secure the hydraulic motor using the four fixing bolts equipped with new elastic washers Reconnect the hydraulic hoses according to the marks made when dis mantling Put the wheel back and secure with the fixing nut and pin Put the machine back into the operational configuration Make several travel movements to purge the hydraulic circuit Check the oil level in the hydraulic oil tank Wheel nut tightening torque 25 N m 18 Ibf ft To fix the pin the slot must be in front of an hole at this time we can screw until 30 N m 22 Ibf ft Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C015 Sheet 1 1 REPLACING THE BUZZER 1 Preliminary operations Cut off the electric power supply see 7 3 page 52 Caution Do not use the machine during maintenance operations 2 Remove the buzzer Mark and disconnect the buzzer s electric connections 1 Remove the buzzer by unscrewing the fixing bolt 3 Replacing the buzzer Putthe new buzzer into place a
52. ers to problems asosciated with rental examination of the condition verifications before starting work after repair and conditions of static test coefficient 1 25 and dynamic test coefficient 1 1 All responsible users should find out about and respect the requirements of this decree 1 4 3 Condition Detect any deterioration liable to cause dangerous situations safety devices load limiters tilt detector cylinder leaks deformation weld condition tightness of bolts hoses and electric connections tyre condition excessive mechanical play Repair manual Pinguely Haulotte 4 NB In the case of rental responsible users of the rented machine must examine the condition and check suitability They must check with the rental company that the general regular checks and checks be fore starting work have been performed Major repairs interventions or adjustments on the safety systems or elements concerning mechanical hydraulic and electric systems must be carried out by PINGUELY HAULOTTE personnel or personnel working on behalf of PINGUELY HAULOTTE who will only use original spare parts Any modification outside PINGUELY HAULOTTE s control is unauthorised The manufacturer is not responsible if original spare parts are not used or if the work specified above is not performed by PINGUELY HAULOTTE approved personnel VERIFICATIONS BEFORE RESTARTING WORK To be performed after major dismantling reassembly operations rep
53. ess x ee 0 OL UH i 6 819 og EE gs c L D LL IR 0 gt 38 oS 2 m E co EE DS 1 a ES wo 2 S 1 a 2 55 N d 1 N LZ LO OO eas 1 M NOL elg sa 9v Lv i Te SOS EES TEET E L0 o b buh p 0 N Wop SE 974 A 1 ae ee i Id WH i i i mI ENT 8 10 E A i i 1 GOL r Vag 1 i lt AOL AZZ LL 9 1 1 T v 4 LS e er Te 2 er sr pi ET ze 3e OR 6 8 Ts s p qe p a Pinguely Haulotte 4 3 2 20 Repair manual Pinguely Haulotte 7 3 2 1 Electric components weighing card version Component Description A1 Weighing angle sensor FU1 Power fuse 300A FU2 Chopper output protective fuse FU3 Controls protective fuse FU4 Working light protective fuse G1 Pressure sensor GB1 Battery Buzzer HL1 Situation light indicator HL2 Flashing light HL3 Working light HL4 Lifting light indicator HL5 Machine travel light indicator HL6 Weighing light indicator M1 Motorpump unit PT1 display RCH Battery charger relay SA1 Control post selection SA2 Movement selection SA3 Platform travel lifting selection SA4 Working light switch SB1 Battery cut off Emergency stop chassis SB2 Emergency
54. ew seals on a motor pump set Putthe motor pump set into place and secure with the collars Reconnect the hydraulic hoses to the pump according to the marks made when dismantling Reconnectthe electric connections to the motor according to the marks made 4 when dismantling Close the inspection flap for Compact machines Putthe machine back into the operational configuration Perform several lifting cycles to purge the hydraulic circuit Checkthe oil level in the hydraulic oil tank Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C020 Sheet 1 2 REPLACING A HYDRAULIC BLOCK VALVE 1 Preliminary operations e Put the machine in the maintenance configuration see S 7 2 page 51 Caution Cut off the electric power supply see 7 3 page 52 Ensure that oil temperature is not too high 2 Pen a valve from the hydraulic block Unscrew the fixing screws 3 and take out the hydraulic block 4 if neces sary to make access easier Open the valve concerned Unscrew the base 2 of the valve 1 and remove from the hydraulic block Fitacap to the hydraulic block hole to protect it 3 Replacing a valve in the hydraulic block Screw a new valve onto the hydraulic block Putthe valve back into its initial state Fixthe hydraulic block on with the fixing screws 3 Putthe machine back into the operational configuratio
55. fective electrovalve YV9 coil Defective electrovalve YV9 Defective electric wiring harness Defective speed variator SHEET DP061 The platform moves up and down with a jerky movement 62 Insufficient oil in the hydraulic circuit Top up with oil as ne cessary Repair manual Pinguely Haulotte A 9 1 3 Travel system ANOMALY CHECK PROBABLE CAUSE SOLUTION No movement available Defective pothole cylinder Defective wiring harness Defective pothole end of stroke con SHEET DP062 tactor Defective brake Defective motor No travel movement in either direction FORWARD or BACKWARD No travel in one Defective speed variator direction FORWARD Defective wiring harness SHEET DP010 or BACKWARD Defective YV2a or YV2b coil Defective electrovalve YV3 or YV4 High d coil igh spee unavailable below SHEET DP011 1 5m Defective wiring harness Defective printed circuit U2 Defective speed selector switch SA3 Defective speed variator Defective electric wiring harness SHEET DP012 Defective contactor SQ1 Only micro speed is available below 1 5m The machine goes into Balancing valve incorrectly set or not Replace the balan runaway downhill working properly cing valve 9 1 4 Steering system ANOMALY CHECK PROBABLE CAUSE SOLUTION Hydraulic leak No lifting Defective printed circuit U2 Defective electrovalve YV5a or YV5b coil Defective electrovalve YV5 GEET BUE
56. g screws and washers Put the machine back into the operational configuration Perform several lifting steering and travel cycles to purge the hydraulic circuit Check the oil level in the hydraulic oil tank Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C017 Sheet 1 2 REPLACING THE REMOTE CONTROL 1 Preliminary operations Putthe machine in the maintenance configuration see S 7 2 page 51 Cut off the electric power supply see 8 7 3 page 52 2 Removing the remote control Remove the protective plate 4 of the chassis control station for Compact machines Release the manual control cable 2 of the covered distributing valve on the lifting cylinder Unscrew the plate sheath stop 3 supporting the cable Mark the cable route in the scissor ducts and remove the cable from the ducts Unscrew the blocking nut of the emergency pull 1 and remove the pull and cable assembly Compact Optimum 3 Replacing the remote control Put the remote control cable back into place in the scissor ducts according to the route marked when dismantling Put the emergency pull 1 in place on the chassis and secure with the bloc king nut Screw the sheath stop onto the cable support plate 3 at the distributing valve level Seoure the cable to the distributing valve manual control Putthe chassis control panel protective plate 4 back into pl
57. ght steering switch B13 wire 38 Except neutral B5 wire 37 Dead man switch B2 wire 35 Travel selection B4 wire 34 Movement selection B8 wire 36 Horn C1 battery C2 battery C4 battery signal 25 Pinguely Haulotte 4 Repair manual 4 5 1 Serial card initialization Emergency stop not pressed Putthe key on OFF stop Shunt the serial card J1 with the help of a crimp Put the key on ON start and operate as follows slowly 1 Advance high speed Return to neutral position Release the joystick 2 Backward movement high speed Return to neutral position Release the joystick 3 Climbing Return to neutral position Release the joystick 4 Going down Return to neutral position Release the joystick When these operations have been done release the shunt Wait 5 seconds Put the key in position OFF Test the platform The state of charge of the batteries is displayed through a series of 5 LED S 4 yellow LEDs 4 LEDs lit batteries charged 1 red LED signals that the battery unit is discharged Hour meter A liquid crystal alphanumerical display unit situated at the centre of the charge indicator dial informs the user about the number of hours performed Alarms The same display unit used for the hour meter also plays the part of a state of alarm indicator providing a code corresponding to the type of alarm reported The red LED flashes in order to attract the user s a
58. h Insufficient hydraulic oil in the tank Repair manual SOLUTION Empty the circuit and replace with the re commended oil Top up with oil as neces sary The system works irregularly The hydraulic oil is not at optimum operating temperature 9 1 2 Platform lifting system CHECK ANOMALY No up or down movement from the platform control PROBABLE CAUSE Defective wiring harness Defective printed circuit U2 Defective manipulator Defective platform emergency stop button Defective speed variator Make some move ments without load to enable the oil to heat up SOLUTION SHEET DP001 No up or down movement from the chassis control Defective key switch Defective wire no 10 Defective switch SA2 Defective speed variator SHEET DP002 No up movement from the chassis or platform controls Hydraulic leak Defective wiring harness Defective electrovalve YV1 coil Defective lifting cylinder Defective electrovalve YV1 Defective or badly adjusted limiter Defective tilt detector Defective speed variator Defective end of stroke contactor SHEET DP003 No down movement from the platform or chassis controls Defective wiring harness Badly adjusted or defective pressure contact SP1 Defective electrovalve YV7 coil Defective electrovalve YV7 Defective speed variator SHEET DP004 The platform above 1 5m comes down slowly by platform or chassis controls De
59. he operation to be performed 7 4 1 Consumables Lubrifiers used by Consumable Specification Symbol Pinguely Haulotte ELF TOTAL REESEN AFNOR 48602 BP HYDRELF EQUIVIS ISO VG 46 SHF ZS 46 DS 46 ZS 46 Organic hydraulic oil Ee cold hydraulic SISO ag oil d ISO 6743 4 SHELL TELLUS 32 bu 7 SHELL ALVANIA um grease LF 3 Exchange or specific operation 7 4 1 1 Intense cold hydraulic oil conditions of use This oil is meant for working at low temperature N Caution The ambient temperature must not exceed 15 C In the opposite case use 46 Repair manual Pinguely Haulotte 7 4 2 Maintenance diagram 50 250 500 1 000 3 000 50 250 500 1 000 3 000 47 Pinguely Haulotte 4 Repair manual 7 5 OPERATIONS 7 5 1 Summary table IMPORTANT If ORGANIC OR EXTREME COLD OIL IS USED FREQUENCIES IN THE TABLE BELOW ARE REDUCED BY HALF FREQUENCY OPERATIONS Every day or before each start of operation Check presence and legibility of CE manual of danger warning stickers of instruction stickers Check prese
60. le Slight structural damage occurs chimney pots and slates 75 88 20 8 removed 24 4 Pinguely Haulotte 2 Repair manual Repair manual Pinguely Haulotte D 2 SPECIFICATION Self propelled platforms models Optimum 6 and 8 are designed for any overhead work within the limits of their characteristics see paragraph 2 1 page 12 and within the respect of all safety instructions specific to the equipment and places of use The main operating station is on the platform The operating station from the chassis is a standby or emergency station REMINDER For any information intervention of spare part requests please spe cify the machine type and serial number 11 Pinguely Haulotte 2 2 1 TECHNICAL CHARACTERISTICS Description Load Optimum 6 270kgincluding 115kgincluding 2 people 1 people Inside use outside use Repair manual Optimum 8 230 kg including 2 people Inside use Manual lateral force 40 daN 20 daN 40 daN Maximum wind speed 0 Km h 45 Km h 0 Km h Floor height 5 8m Working height 7 6m Folded length with steps Overall width Folded height safety barrier Folded height platform Wheelbase 1 38 m Floor clearance 80 mm Floor clearance with Pot Hole in use 14 mm Platform dimension 1 73 m x 0 68 m Extension dimension 0 92 m Extension capacity 115 Kg Travel speed with ma
61. ly Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 1 1 SHEET C029 REPLACING THE BALANCING VALVES 1 Preliminary operations AN Caution Putthe machine in the low position Ensure that oil temperature Cut off the electric power supply see S 7 3 page 52 is not too high 9 2 Removing the balancing valves Disconnect the hydraulic brake hoses 2 and close the holes on the pipework and hydraulic block Unscrew the two screws 1 of the fixing lug and take out the hydraulic block Remove the balancing valves 3 by unscrewing them 3 Replacing the balancing valves Screw the new balancing valves whose characteristics correspond to the machine in question into the hydraulic block Putthe hydraulic block back into place and secure using the screws 1 equipped with new flat and toothed washers Reconnect the hydraulic brake hose onto the block Make several travel movements to purge the circuit Position the machine on a 4096 slope and check that the machine does not go into runaway during a travel movement Optimum AN Caution The balancing valves are safety elements They are calibrated in the plant and must not be re adjusted Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 1 1 HEET C030 REPLACING A CARTRIDGE ELECTROVALVE 1 Preliminary operations Putthe machine in the maintenance configuration see S 7 2 page 51 Cut off the elec
62. m 8 221 8 GEEL BS oii ws FT TT aa a OS 216 An8 29 pul a x5 R AS 33 RE ke TE DET PE JP Et Ye He JE 5 n isse N B ID IA A H d o jo No In m N L an T3 Lld is a 0 o H 0 0 2 10 K EY d 2 voL 0105 SE a b 9 b evs 0 0 ch a e 5 555 4 2 9 9 E Gem EE ue mesi eum mum Ra 1 8 10 D OL i H 5 6 amp lt UH lo 9TH e S Je PR ERE e 1 1 os 819 SS E 5 D 1 0 6 o 28 25 eas n_ 2 5224 88 NASE i b 1 LVS 0 L0 0 fo ser 0 ME d WA pm 4 n i 1 1 s 2 Lec a zes il 3 o er V t E du L ou 022 AOL 9119 LL EW i M 4 PII LS e er St Zt er a pi ET ar ir Tor S Zz e 6 TZ x 18 Repair manual Pinguely Haulotte 4 3 1 1 Electric components pressure switch version Component Description FU1 Power fuse FU2 Chopper output protective fuse FU3 Controls protective fuset FU4 Working light protective fuse GB1 Battery HA1 Buzzer HL1 Situation light indicator HL2 Flashing light HL3 Working light HLA Lifting light indicator HL5 Machine travel light indicator
63. must be disconnected This may reduce battery life After movement reconnect the charger 4 7 5 Precautions of use Avoid recharging batteries if the electrolyte temperature is higher than 40 C Leave to cool Keep the top of the batteries dry and clean Incorrect connection or corrosion may lead to serious power loss If new batteries are used re charge them 3 to 5 times after 3 or 4 hours use The charger has been configured in the plant with the cable provided If the cable needs replacing contact PINGUELY HAULOTTE for authorisation 27 Pinguely Haulotte 4 Repair manual 4 8 CHOPPER 4 8 1 Terminal wire connections chart Terminal wire terminal wre Hee Iw D uu Not in use 15 Not in use Top position end of travel input SQ3 Input Lifting solenoid MDI signal valve output Hi ZZ Fra control ET Not in use MDI HI M i valve Input Pothole com PNE signal mand solenoid FT SE 16 Output SB1control 24 Left steering so MDI signal lenoid valve con trol ouput YV5b Output 23 Right steering Top control panel YV4 HS control solenoid valve validation control ouput YV5a 7 21 Output 21 43 Series signal 35 Not in use stem 7 14 me PT JE 20 Output 22 12 Not in use 36 31 Batterie YV 2 b Reverse gear ae control TTT 19 Output MDI signal Chassis lifting con YV2a Forward gear trol control 18 Output supplying Pothole end of Chassis lowering YV1 travel move travel input SQ5 input ment selection and SQ6
64. n Make several travel movements to purge the hydraulic circuit Optimum Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C021 Sheet 1 2 REPLACING A WHEEL 1 Preliminary operations Put the machine in the low configuration Cut off the electric power supply see 7 3 page 52 Raise the machine using a jack or hoist 2 Removing a wheel Remove the pin 1 and fixing nut 2 from the wheel and remove the wheel 3 3 Replacing a wheel Replace the key 4 if necessary Puta new wheel into place and secure with the fixing nut and pin Putthe machine back into the operational configuration EH Wheel nut tightening torque 25 N m 18 Ibf ft To fix the pin the slot must be in front of an hole at this time we can screw until 30 N m 22 Ibf ft Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C022 Sheet 1 2 REPLACING THE BRAKE RELEASE HAND PUMP 1 Preliminary operations e Put the machine in the maintenance configuration see S 7 2 page 51 Cut off the electric power supply see S 7 3 page 52 Caution e Check that the brake release valve NV1 is open Ensure that oil temperature is not too high 2 Removing the brake release hand pump Unscrew the brake release hand pump 1 and take it out of the hydra
65. n Pinguely Haulotte 2 Repair manual 1 2 GENERAL SAFETY RECOMMENDATIONS AN Caution Only trained operators may use Haulotte self propelled platforms SS 1 2 1 Operators Operators must be aged 18 or over and hold an operating permit issued by the employer after verification of medical aptitude and the practical platform operation test There must be at least two operators present so that one of them can intervene rapidly if necessary take over the controls in the case of accident or breakdown monitor and prevent machines or people from circulating around the plat form guide the platform operator if necessary 1 2 2 Environment Never use the machine On soft unstable or cluttered floors On a floor with a tilt greater than the allowed limit With a windspeed above the permitted level In case of outdoor use check that windspeed is lower or equal to the permitted level using an anemome ter Near electric lines find out about minimum distances according to current In temperatures of less than 15 C in particular in cold rooms consult our service department if work is required in conditions below 15 C In an explosive atmosphere In an incorrectly ventilated area as exhaust fumes are toxic During storms risk of being struck by lightning At night if the machine is not equipped with an optional light In the presence of intense electromagnetic fields radar mobile and high
66. n temperature over 75 C 167F Replace the chopper BATTERY LOW e Batteries dischar ged Check the batteries the charger the electric circuit s supply POWER FAILURE Short circuit on an electrovalve s coil or the horn or SB1 s coil Check the electrovalves various coils the horn SB1 contactor s coil DRIVER SHORTED e conctactor s dri ver faulty or in short cir cuit Defective SB1 or chopper 64 CONTACTOR DRIVER SB1 conctactor s dri ver malfunctioning or will not close Defective SB1 or chopper Repair manual Number of flashes MDI Message VACC NOT OK Description e Manipulator at rest Pinguely Haulotte 4 Solution Check the joystick s output vol tage using the console s TESTER mode In the case of an incorrect pro graming adjust the values calibrating the serial card Otherwise replace the chopper INCORRECT START e Incorrect starting sequence Check the joystick s output data using the consoles TESTER mode then replace either the joystick or the chopper according to the tests results FORW BACK Backward and forward movements re quested simultaneously Check the joystick s output data using the console s TESTER mode then replace either the joystick or the chopper according to the tests results DRIVER 1 KO e coil in short cir cuit Check YV6
67. nce of screws etc Check levels of hydraulic oil see paragraph 8 sheet P001 battery electrolyte Check the condition of wheel solid tyres battery charge on the discharge indicator wear of the hydraulic hoses hydraulic connections no leaks electric cables and wiring harnesses no corrosion or stripped areas wear of scissor arm slides and pads Check proper operation of the tilt detector Every 50 hours Only the first 50 hours change the hydraulic filter see paragraph 8 sheet P002 Check the tightness of screws etc in general front motor fixing screws 9 daNm rear brake fixing screws 9 daNm front wheel nuts 25 daNm rear wheel nuts 25 daNm Check the condition of electric cables change if corroded density of battery electrolyte no battery electrolyte leaks Every 250 hours Check the connection of the battery charger no cylinder leaks Grease wheel pivot pins see paragraph 8 sheet P003 friction parts of the scissor arm slides see paragraph 8 sheet P004 Change the hydraulic oil filter Clean the motor pump unit ventilation hole Every 500 hours Oil change organic hydraulic oil tank option Every 1000 hours or every year Empty the hydraulic oil tank the hydraulic circuit Clean the motor pump unit carbon Adjust the pressure limiters Check ring wear Every 3000 hours or every 4 years 48 Replace hydra
68. nd secure with the fixing bolt Reconnectthe electric conections according to the marks made when dis mantling 4 Test Putthe machine back into the operational configuration Check that the buzzer gives a signal below 1 5 metres or 4ft92in during lowering Compact Optimum Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C016 Sheet 1 1 REPLACING THE DISTRIBUTION BLOCK 1 Preliminary operations Caution Ensure that oil temperature is not too high NB Optimum Put the machine in the maintenance configuration see 7 2 page 51 Cut off the electric power supply see 7 3 page 52 2 Removing the distribution block Remove the fixing lug 1 securing the distribution block to the chassis and take out the distribution block 2 to access its components Mark and disconnect the distribution block s electric connections Mark and disconnect the distribution block s hydraulic hoses Unscrew the hoses slowly to allow the residual hydraulic pressure to dissipate Fit caps to the hoses Remove the distribution block 2 Replacing the distribution block Put the new distribution block into place Reconnect the hydraulic hoses according to the marks made when dis mantling Reconnect the distribution block s electric connections according to the marks made when dismantling Secure the distribution block to the chassis using the fixing lu
69. ng movement from the chassis he latf No movement is See SHEET porn available rises YES Make a lifting movement from the platform lifting control panel he platform No movement is available from the See SHEET rises platform DP014 Make a lowering move ment from the platform The platform goes See SHEET DP014 down YES Lower the platform below 1 5m or 4ft92in Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP062 Sheet 2 4 NO TRAVEL MOVEMENT IN BOTH DIRECTIONS FORWARD AND BACKWARD Request a travel movement Disconnect the two coils a and b of m The electrovalve YV2 rave movemen Request a travel movement and check for operates 24V Raise the platform above Ke 1 5m or 4ft92in and check that the othole sys tem extends See SHEET DP013 Check for 24V on input 24 of the speed variator 24V present Check electric continuity of the wiring harness between the pothole end of stoke contactor SQ5 and SQ6 and the variator Replace the See SHEE Continuit variator U1 T C003 Re y Replace a wiring END END See SHEET C018 Adjust or replace the defective pothole end of stroke contactor SQ5 or SQ6 Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART prea DR
70. nnector 24V present YES Check electric continuity of the coil of electrovalve YV4 24V present Check for 24V between terminals 7 and 34 of the speed variator U1 24V present Replace the wiring harness between electrovalve YV3 and speed variator U1 Check for 24V between terminals 6 and 34 of speed variator U1 24V present Replace the wiring harness between electrovalve YV3 and speed variator U1 Replace the coil of See SHEET electrovalve YV4 C007 END Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP011 Sheet 2 2 HIGH SPEED UNAVAILBLE BELOW 1 5M OR 4FT92IN Check for 24V on input B2 of printed circuit U2 of the platform control Repair cabling between the speed selector switch SA3 and printed circuit U2 of the platform control or replace the speed selector switch SA3 see SHEET C004 24V present Replace printed See SHEET circuit U2 C004 END Replace See SHEET electrovalve YV4 C007 The fault persists Replace See SHEET electrovalve YV3 C007 Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP012 Sheet 1 2 ONLY MICRO SPEED IS AVAILABLE BELOW 1 5M OR 4FT92IN Only micro speed is available below 1 5m or 4ft92in Raise the platform a
71. o 160 180 to 200 220 to 240 M 16 1 5 200 to 250 280 to 310 340 to 370 M 18 1 5 290 to 360 410 to 450 490 to 540 M 20 1 5 410 to 510 570 to 630 690 to 760 M 22 1 5 550 to 680 780 to 870 920 to 1000 M 24 1 5 690 to 860 970 to 1070 1160 to 1290 M 27 2 1000 to 1300 1400 to 1560 1690 to 1880 M 30 2 Component 1400 to 1700 1960 to 2180 2 3 3 Recommended torques Tightening torques in N M 2350 to 2610 Brakes 90 N m Hydraulic motors 90 N m Wheels 250 N m Repair manual Pinguely Haulotte A 2 4 PRESSURE TABLES IN BARS Steering pressure Machine Useful load Useful load 10 Main pressure Outd 115 Kg Outd 132 K Optimum 6 KAA 230 bars 100 bars Indoor use 270 Kg Indoor use 292 Kg Optimum 8 Outdoor use forbidden Outdoor use forbidden Ban ban 300 bars Indoor use 230 Kg Indoor use 253 Kg Margin 10 The lifting pressure is adjusted according to the actual load 2 5 ADJUSTEMENT TIMES TABLE Movement duration Movement Optimum 6 Optimum 8 Travel Slow speed 16 s 2s for 10m Travel High speed 8s 2s for 10m Travel Micro speed 87 s 19s for 10m Steering right and left 5to6s Raising 21s 3s 23s 3s Lowering 37s 5s 29s 5s 15 Pinguely Haulotte 2 Repair manual Repair manual Pinguely Haulotte D
72. o place Put the machine back into the operational configuration Optimum Pinguely Haulotte 4 PREVENTIVE MAINTENANCE SHEET Pinguely Haulotte 4 PREVENTIVE MAINTENANCE SHEET SHEET P003 GREASING THE STEERING WHEEL PIVOTS 1 Greasing the steering wheel pivots Cut off the electric power supply see S 7 3 page 52 Grease the pivots NOTA Only use the grease recommended by the manufacturer Put the machine back into the operational configuration Compact optimum previous design D e Compact optimum current design Star 22J Star 8 Pinguely Haulotte 4 PREVENTIVE MAINTENANCE SHEET Pinguely Haulotte 4 PREVENTIVE MAINTENANCE SHEET SHEET P004 GREASING THE SLIDES 1 Preliminary operations Put the machine in the maintenance configuration see 7 2 page 51 Cut off the electric power supply see 7 3 page 52 2 Greasing the slides Grease the slides using a spatula NOTA Only use the grease recommended by the manufacturer Put the machine back into the operational configuration Pinguely Haulotte 4 PREVENTIVE MAINTENANCE SHEET Repair manual Pinguely Haulotte A 9 OPERATING INCIDENTS 9 1 TABLE OF INCIDENTS Before anything else check that the batteries are charged the green light indicators should be on the two palm button emergency stops on the chassis control box and on the platform control box are unlocked the
73. o the operational configuration Checkthat the emergency stop button works properly Optimum Compact Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 1 2 SHEET C032 REPLACING THE HYDRAULIC PUMP 1 Preliminary operations e Put the machine in the maintenance configuration see S 7 2 page 51 Cut off the electric power supply see 8 7 3 page 52 AN Caution 2 Removing the hydraulic pump Ensure that oil temperature Remove the motorpump set see SHEET C019 is not too high Remove the screws securing the pump to the motor and remove the pump 3 Replacing the hydraulic pump Puta new pump equipped with seal onto the electric motor and secure with the fixing screws e Remount the motor pump set see SHEET C019 Putthe machine back into the operational configuration Perform several lifting cycles to purge the hydraulic circuit Checkthe oil level in the hydraulic oil tank Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C033 Sheet 1 1 REPLACING AND ADJUSTING A PRESSURE SWITCH Caution 1 Preliminary operations Ensure that oil temperature e Put the machine the maintenance configuration see 7 2 page 51 is not too high Cut off the electric power supply see S 7 3 page 52 e Check low pressure with the emergency control 2 Removing the pressure switch Disconn
74. oil level in the tank is OK AN Caution Bubbles pressure heat NB Cavitation emulsified oil may cause incorrect operation of hydraulic unacceptable situation components It takes approximately 4 hours for oil that has been Risk of explosion emulsified under the effects of cavitation to get back to its normal condition 9 1 1 General operation ANOMALY CHECK PROBABLE CAUSE SOLUTION Defective batteries Oil level low Defective fuses Defective chassis emergency stop No movement Defective platform emergency stop SHEET DP007 Defective wiring harness Defective motorpump set Defective printed circuit Defective control unit Hydraulic pump noisy 5 DEER SHEET DP009 Defective speed variator Pothole system does Defective wiring harness not extend when the Defective electrovalve YV6 coil SHEET DP013 platform is raised Defective electrovalve YV6 Defective pothole cylinders Defective key switch SA1 Defective electric wiring harness Defective speed variator SHEET DP014 Defective manipulator Defective printer circuit U2 No movement from the platform control station Hydraulic pump The hydraulic oil Oil viscosity too high Empty the circuit and cavitation becomes cloudy refill with the recom Vacuum in the pump and white with mended oil due to insufficient oil bubbles 61 Pinguely Haulotte 4 CHECK ANOMALY Overheating of the hydraulic circuit PROBABLE CAUSE Oil viscosity too hig
75. on the two pothole cylinders chambers The oil present in the small chambers is sent back to the tank through the YV6 solenoid valve This solenoid valve will be powered as long as the machine is under the SQ1 switch e YV6 Pothole control solenoid valve Lifting power supply 13 8 2 MB 4 579 124 910 17 4 84 82 4 Bice CI YY3 14 A DETERMINER AVEC CHARGE PRESS ON 200 bar 42 Repair manual a VA AZ MR 3 84 AA Seng FR ives b D D Yv3 DN pw D TIC Kod 5 D SNE mo Peer COMPACT COMPACT Pinguely Haulotte Z 1 1 4 84 174 E A y eit JE TERMI NE CHARGE AVEC PRESS ON A I I Al 378 A2 MR A3 3 5 Bl 124 84 4 2 4 B3 17 CT YY3 dra Li mi YVE mn if 7 A DETERMINER AVEC CHARGE PRESS ON Lowering Potholes re entry on starting a travel movement under SQ1 43 Pinguely Haulotte 4 Repair manual 6 3 5 Steering funtioning In the hydraulic block input the oil first passes through a priority valve The latter powers steering through a priority flow It is necessary that YV1 be at rest Travel selection The choice of YV5A or B depends on the direction requested for steering Right or lef
76. ors power supply output MX Minimess tap output port gauge B1 Pothole re entry block output D1 Steering cylinder power supply output B4 Pothole re entry block output B3 Pothole spreading out device B2 Potholes spreading out device A2 Front left travel motors power supply output C1 YV9 lifting power supply output A3 Front right travel motors power supply output T Block output for returning to the tank through P Block input taken on the block s output the hydraulic filter 34 A4 Front right travel motors output D2 Steering cylinder power supply output Repair manual Pinguely Haulotte FA 6 2 HYDRAULIC BLOCK SPECIFICATIONS Pinguely Houlotte Y SPECIFICATION Dote 01 07 03 Numero S5625 Mach nes Auteur V rificoteur COMPACT4 10 12 OPTI d GOSSIAUX M JEANNARD l ARE SPECIF ONS Haulotte reference 242 021 2090 Maximum pressure 240 bar Flow 18 l minute 5 8 2 378 mi 9 oi 9 C2 02 1 4 Di 1 4 35 Pinguely Haulotte 4 Repair manual 36 Pinguely Houlotte ZZ SPECIFICATION Num ro 55625 Machines Auteur V rificcteur COMPACTB 10212 OPT IMUM6 A GOSSIAUX M JEANNARD NE REAR VIEW 2 tapped holes M 8 RIGHT SIDE VIEW Repair manual Pinguely Haulotte FA s Le Pinguely Haulotte 2 SPECIFICATION Num ro 5825 Machines Auteur V rificateur PD
77. ose Put the machine back into the operational configuration Make several movements using the replaced hose to purge the hydraulic circuit Check the oil level in the hydraulic oil tank Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 SHEET C011 Caution Ensure that oil temperature is not too high Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 1 1 REPLACING A VACUUM BRAKE 1 Preliminary operations Put the machine in the low configuration Cut off the electric power supply see 7 3 page 52 Raise the machine using a jack or hoist 2 Removing a vacuum brake see figure 1 Remove the pin 3 and nut 4 fixing the wheel and remove the wheel 1 Place a wedge under the vacuum brake Disconnect the vacuum brake s hose Fit a cap to the hose Remove the vacuum brake 2 by removing its fixing bolts 5 6 7 Replacing a vacuum brake Put the new vacuum brake 2 into place Secure the vacuum brake using the fixing bolts equipped with new elastic washers 5 Reconnect the hydraulic hose Put the wheel 1 into place and secure using the fixing nut and pin Put the machine back into the operational configuration Perform several brake release operations to purge the hydraulic circuit Check the oil level in the hydraulic oil tank Wheel nut tightening torque 25 N m To fix the pin the slot must be in front of an hole at this
78. r elements starting from the top 4 Reassembling the scissors Reassemble according to the dismantling procedure in reverse order respec ting the marks made when dismantling 5 Replacing the scissors Checkthe condition of the pads and replace if necessary Putthe scissors into slings and into place on the chassis e Check that the axial clearance between the chassis and the lower arm 6 does not exceed 1mm otherwise adjust the clearance using the adjustment wedges 7 provided see figure 2 Putthe two fixed chassis axles into place and secure using the two axle stop bolts NB Fit the bolts so that the screw is on the top of the axle and the nut is un derneath see figure 1 Replace the hydraulic hoses and electric wiring harness routed along the scissors according to the marks made when dismantling Replace the lifting cylinder s see SHEET C001 Replace the platform see SHEET C025 Putthe machine back into the operational configuration Grease the slides using lead free grease Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C027 Sheet 2 2 REPLACING THE SCISSORS NB Only use the grease recommended by the manufacturer Perform several lifting cycles to check that the machine works properly ILS ER t Nut 5 Screv run lui Screen VAT ee s T Em E lt
79. re use Comply with current national legislation in the country of use In FRANCE Order dated June 9th 1993 circular DRT 93 22 dated September 1993 specifying 1 4 1 Regular checks The devices must be regularly inspected every 6 months to detect any defect liable to cause an accident These inspections are to be carried out by an organisation or person specially appointed by the site manager and under his responsibility company personnel or otherwise Articles R 233 5 and R 233 11 of the Labour Code The result of these inspections is recorded in a safety register updated by the site manager and constantly available to the Works Inspector and the company s safety committee if any and the list of specially appointed personnel Article R 233 5 of the Labour Code NB This register can be obtained from professional organisations and for some from the OPPBTP or private prevention organisations The appointed people must be experienced in the field of risk prevention Article R 233 11 of decree no 93 41 It is forbidden to allow anyone to perform any checks during machine operation Article R 233 11 of the Labour Code 1 4 2 Examination of device suitability The manager of the site on which the equipment is used must ensure that the machine is suitable i e appropriate to the work to be carried out safely and that it is used in accordance with the instruction manual Moreover the French order dated June 9th 1993 ref
80. rectives 91 368 CEE dated June 21st 1991 93 44 CEE dated June 14th 1993 93 68 CEE 98 37 CE dated July 22nd 1993 and 89 336 CEE dated May 3rd 1989 to directive 2000 14 CE and directive EMC 89 336 CE Pinguely Haulotte 7 Repair manual Repair Manual Pinguely Haulotte 7 SUMMARY GENERAL susanne 1 1 GENERAL RECOMMENDATIONS SAFETY 4 5 1 1 GENERAL WARNING sauna ee 5 1 2 GENERAL SAFETY RECOMMENDATIONS eene eene 6 er RESIDUAL RISKS une ee 7 14 VERIFIEATONS see 8 1 5 REPAIRS AND ADJUSTMENT n 22 SB 9 1 6 VERIFICATIONS BEFORE RESTARTING WORK 9 E Ae 9 2 SPECIFICATION emat Dc 11 2 1 TECHNICAL ee e Ne 12 ce 13 255 TIGHTENING TORQUE cc 14 2 4 PRESSURE TABLES IN BARS sans Maceo 15 2 5 ADJUSTEMENT TIMES TABLE zn aa a deeg egen 15 3 WIRING TER 17 3 1 WIRING DIAGRAM E 591A PRESSURE SWITCH VERSION 18 3 2 WIRING DIAGRAM E591A WEIGHING CARD VERSION 20 4 ELECTRIC COMPONENTS DESCRIPTION 23 41 CHASSIS CONTROL POST NEEN 23 4 2 PLATFORM CONTROL POST EQUIPMENT nenn 24 SOLENOID AVES de 24 Pinguely Haulotte 7 Repair Manual 44 END OF TRAVEL SWITCHES CHART 2 a 25 49 SER 25 Ads MB a ea iu Mu nee es a le 26 4 7 USING THE ON BOARD CHARGER 27 F8 CHOPPER RS 28 5 HYDRAULIC DIAGRAM unse 29 5 1 HYDRAULIC D
81. rform several lifting cycles to check that the machine works properly W ES e E ut Nut lt Screw Scre Screw 7 E uL Nut EIS Nut ECROU Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C027 Sheet 1 2 REPLACING THE SCISSORS 1 Preliminary operations Put the machine in the low position Cut off the electric power supply see 7 3 page 52 2 Remove the scissors Remove the platform see SHEET C025 Remove the lifting cylinder s see SHEET C001 Mark and remove the hydraulic hoses and electric wiring harness routed along the scissors Fitcaps on the hoses and hydraulic equipment Putthe scissors into slings Remove the two axle stop bolts 8 on the two fixed chassis axles Remove the two fixed chassis axles using the threaded holes Remove the scissors and pads 3 Dismantling the scissors Carefully mark the equipment s assembly Remove the cable passage ducts 1 counterbore the eight rivets 2 at both ends of the duct and remove the straps remove the duct remove the upper duct stop bracket Puteach element into slings and remove one after the other removing the elastic rings 3 and washers 4 from the articulation axles 5 NB Remove the scisso
82. rm use the steps provided on the machine Never climb on the hand rails when the platform is raised Never drive the platform at high speed in narrow or cluttered areas Never use the machine without installing the platform protective bar or clo sing the safety barrier Never climb on the covers To avoid risks of tipping over operators must respect the following instructions NB Do not disable the safety system end of stroke contactors Avoid moving the steering control levers in the opposite direction without stopping in the O position to stop during a travel manoeuvre move the manipulator lever gradually Respect maximum load and maximum number of people authorised on the platform Distribute the load evenly and place in the centre ofthe platform if possible Check that the floor resists the pressure and load per wheel Avoid contact with fixed or mobile obstacles Do not drive the platform at high speed in narrow or cluttered areas Do not drive the platform in reverse inadeguate visibility Do notuse the machine ifthe platform is cluttered Do not use the machine with eguipment or objects hanging from the hand rails Do notuse the machine with elements that may increase the wind load e g panels Do not perform machine maintenance operations when the machine is raised without setting up the reguired safety means gantry crane crane Make daily checks and monitor proper operation during periods of use Preser
83. s 2247E indoor use indoor use 3335 PSI 2175 PSI 450kg 990 Ib 495kg 1090 Ib H10N indoor use only indoor use only 220 bars 150 bars 2632E 230 kg 500 Ib 253 kg 520 Ib 3190 PSI 2175 PSI outdoor use outdoor use H10S 120kg 265 Ib 132kg 290 Ib 220 bars 150 bars 2747E indoor use indoor use 3190 PSI 2175 PSI 450kg 990 Ib 495kg 1090 Ib outdoor use outdoor use H12SN 120kg 265 Ib 132kg 290 Ib 240 bars 150 bars 3347E indoor use indoor use 3480 PSI 2175 PSI 300kg 660 Ib 330kg 730 Ib outdoor use outdoor use Optimum 6 115kg 254 Ib 126 5kg 280 Ib 230 bars 100 bars 1530E indoor use indoor use 3335 PSI 1450 PSI 270kg 595 Ib 297kg 655 Ib Optimum 8 indoor use only indoor use only 230 bars 100 bars 1930E 230kg 500 Ib 253kg 520 Ib 3335 PSI 1450 PSI tolerance or 10 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C003 Sheet 1 2 REPLACING THE SPEED VARIATOR 1 Preliminary operations Put the machine in the low position Cut off the electric power supply see 7 3 page 52 Disconnect the and terminals of the batteries to isolate the electric circuit Removing the speed variator Disconnect the speed variator s electric connections Remove the speed variator 1 Replacing the speed variator Put the speed variator back into place and secure with the fixing screws Reconnect the speed variator s electric connections Compact Reconnect the and
84. stop platform SB3 Buzzer control SM1 Manipulator 501 Low position contactor 5010 Tilt sensor SQ3 Top position contactor SQ4 Travel interruption switch SQ5 SQ6 Pothole system out U Battery charger U1 Electronic chopper U2 Serial card U3 Weighing card YV Electrovalve 21 Pinguely Haulotte 2 Repair manual 22 Repair manual Pinguely Haulotte 4 A ELECTRIC COMPONENTS DESCRIPTION 4 1 CHASSIS CONTROL POST IS U1 Main switch including battery cut off function Key contactor selection of the command either on the top console with the possibility to take off the key or on the turntable console with no need to maintain the command Command switch driving the platform up or down 14 Up 15 Down Multifunction indicator hour recorder unloading indicator and numeric indicator of codes statements Chopper Battery charger relay SQ4 501 SQ3 505 506 5010 TILT SENSOR TEST MODE 0 Low position switch wire 28 1 low position of the platform 0 high position of the platform Low position switch wire 29 gets on position 0 at the end of lifting and cuts the lifting command Position switch to stop traveling at a platform height of 8 meters from the floor wire 31 SQ5 amp 506 Position switch to control the extension of potholes The wire 31 of this circuit must be closed before SQ1 gets on 0 otherwise it prevents lifting and traveling Lo
85. t Request the defective travel movement and check for 24V at the connector s terminals Check for 24V between outputs 8 and 34 for FORWARD 9 and 34 for BACKWARD Voltage present 24V present Invert coils YV2a and YV2b NO Replace the See SHEET speed variator C003 he fault is still o the same travel direction NO Replace the wiring harness between the electrovalve and the speed variator YES Replace See SHEE electrovalve YV2 T C008 Replace coil YV2a or See SHEET YV2b corresponding to C007 the defective travel direction Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP010 Sheet 2 2 NO TRAVEL IN JUST ONE DIRECTION FORWARD or BACKWARD Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP011 Sheet 1 2 HIGH SPEED UNAVAILBLE BELOW 1 5M OR 4FT92IN High speed unavailable below 1 5m or 4ft 92 in Disconnect the connector of electrovalve YV3 Request a high speed travel movement and check for 24V on the disconnected wiring harness connector Check electric continuity of the coil of electrovalve YV3 NO Replace the coil of See SHE electrovalve ET C007 YES Disconnect the connector of END electrovalve YV4 Request a high speed travel movement and check for 24V on the disconnected wiring harness co
86. t cylinder power supply output according to the direction requested d YVSa L va A DETERM AVEC CHA PRESSION Ee Priority flow 275 bor Km Priority valve Ek ITI A ae eg A LEES 1 lt Ai Pump output flow CH m SN Filter on G Es return Ki ul EC 8 5 u er VEL TI Motor pump Ki run by the Hydraulic tank 271 7 gallon chopper 44 Repair manual Pinguely Haulotte 4 7 MAINTENANCE 7 1 GENERAL RECOMMENDATIONS AN Caution Do notuse the machineasa welding ground Do not weld without disconnecting the and battery terminals Do not start other vehicles with the batteries connected Servicing operations described in this manual are given for normal conditions of use In difficult conditions extreme temperatures high hygrometry polluted atmosphere high altitude etc certain operations must be carried out more freguently and specific precautions must be taken consult the PINGUELY HAULOTTE After Sales Service for information Only authorised and competent personnel may operate on the machine and must comply with the safety instructions related to Personnel and Environment protection Regularly check that the safety systems work properly 1 Tilt buzzer stop travel and lifting disabled 2 Platform overload load 7 2 MAINTENANCE DEVICE The maintenance stand enables the operator to work under the machine in total
87. time we can screw until 30 N m Fig 1 Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C013 Sheet 1 1 REPLACING THE MANIPULATOR 1 Preliminary operations Putthe machine in the maintenance configuration see S 7 2 page 51 Caution Cut off the electric power supply see 8 7 3 page 52 Do not use the machine du ring maintenance opera 2 Removing the manipulator 2 tions Remove the closing plate 1 by removing the four fixing screws Mark and disconnect the manipulator s electric connections Remove the manipulator by removing its fixing screws 3 Replacing the manipulator Fix a manipulator equipped with new seals to the platform control panel Reconnect the electric connections according to the marks made when dismantling Put the closing plate back into place and secure with the four fixing screws e Put the machine back into the operational configuration Make several up and down movements from the plaform to check that the manipulator works properly Pinguely Haulotte 4 SHEET C014 Caution Ensure that oil temperature is not too high Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 1 1 REPLACING A HYDRAULIC TRAVEL MOTOR 1 Preliminary operations Put the machine in the low configuration see 7 2 page 51 Cut off the electric power supply see 7 3 page 52 Raise the machine using a jack or hoist 2 R
88. tric power supply see 7 3 page 52 AN Caution 2 Removing a cartridge electrovalve Remove the coil s 2 of the electrovalve see SHEET C007 Unscrew the electrovalve 1 with the Allen key and remove from the hydraulic block Ensure that oil temperature is not too high 3 Replacing a cartridge electrovalve Screw a new electrovalve equipped with its seal into the hydraulic block e Put the coil s back into place on the electrovalve and put the hydraulic block back into place see SHEET C007 Putthe machine back into the operational configuration Perform several movements using the replaced electrovalve to check that it works properly Optimum Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 1 1 SHEET C031 REPLACING THE CHASSIS EMERGENCY STOP BUTTON 1 Preliminary operations Caution e Put the machine in the maintenance configuration see S 7 2 page 51 e Disconnect the and terminals of the batteries to isolate the electric cir Do not use the machine cuit during maintenance operations 2 Remove the emergency stop button Mark and disconnect the emergency stop button s electric connections 1 Remove the emergency stop button 2 3 Replacing the emergency stop button Puta new emergency stop button into place Reconnectthe electric connections according to the marks made when dismantling 4 Test Putthe machine back int
89. tric power supply see 7 3 page 52 Do not use the machine du ring maintenance operations 2 Removing the tilt detector Mark and disconnect the tilt detector s electric connections Remove the tilt detector by unscrewing the three fixing bolts 3 Replacing the tilt detector Puta new tilt detector into place and secure with the three fixing bolts Reconnect the electric connections according to the marks made when dismantling Place a spirit level on the top of the tilt detector and adjust the fixing screws to align the tilt detector NB A spirit level is built into certain tilt detectors Putthe machine back into the operational configuration 4 Operating test of the tilt detector Liftthe platform to a height of 2m Tiltthe tilt detector see photo and check that a signal is given the signal should be audible from the platform Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C007 Sheet 1 1 REPLACING A COIL 1 Preliminary operations e Put the machine in the maintenance configuration see 7 2 page 51 Cut off the electric power supply see 7 3 page 52 4 5 2 Removing a coil Unscrew the two fixing screws 1 from the fixing lug and take out the hydraulic block Disconnect the relevant coil s electric connector 2 Unscrew the nut 3 or 4 and remove the coil 5 3 Replacing a coil Puta new coil 5 into place and secure with th
90. ttention Software version On switching off the key the eeprom version is displayed on the dial for a few seconds EPXXX where XXX represents the version The English key symbol also appears during this phase 26 Repair manual Pinguely Haulotte 4 4 7 USING THE ON BOARD CHARGER AN Caution Set the chassis emergency stop button on the OFF position before recharging AN Caution In cold weather the charging time increases Photo 1 4 7 1 Characteristics Traction batteries must be charged with the charger provided DO NOT OVERCHARGE THEM Charger 24V 30A Power supply 220V single phase 50 Hz Operating voltage 24V Charging time approximately 11 hours for batteries discharged by 7096 to 80 4 7 2 Starting the charge Charging is started automatically when the charger is connected to the mains The charger is equipped with a light indicator the indicator shows the current state of charge State Description RED on Machine charging YELLON on 80 charged GREEN on Machine charging complete 4 7 3 Maintenance charging If the charger remains connected to the mains for more than 48 hours it starts a charge cycle after the end of the previous charge in order to compensate for self discharge 4 7 4 Charge interruption Charging is stopped by disconnecting the charger from the mains If the machine has to be moved during a charge cycle the charger
91. ulic block Puta cap on the hydraulic block hole to protect it 3 Replacing the manual brake hand pump Screw a new brake release hand pump into place Putthe machine back in the operational configuration Apply and release the brakes manually several times to purge the hydraulic circuit Compact 9 Optimum Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C023 Sheet 1 2 REPLACING THE STEERING CYLINDER 1 Preliminary operations Caution Put the machine in the low configuration Ensure that oil temperature Cut off the electric power supply see S 7 3 page 52 is not too high Raise the machine with a jack or hoist 2 Removing the steering cylinder Mark and disconnect the two steering cylinder hoses 1 NB Unscrew the hose slowly to allow residual hydraulic pressure to dissipate Fit caps to the hoses Put the cylinder into slings Remove the screws 3 and blocking yokes 4 then remove the steering cylinder s two axles 2 Remove the steering cylinder Replacing the steering cylinder Put a new steering cylinder into place Replace the axles and blocking yokes and secure with screws equipped with new toothed washers Reconnect the hydraulic hoses according to the marks made when dismant ling Put the machine back into the operational configuration Make several steering mo
92. ulic circuit hoses batteries Repair manual Pinguely Haulotte D REMINDER AII these frequencies must be reduced if working in difficult condi tions consult After Sales if necessary 7 6 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 in the operator s manual are legible and in the correct place Replace if necessary spare parts can be supplied on request if necessary 7 7 PRESENCE OF MANUALS It is important to ensure that the manuals supplied with the machine are in good condition and stored in the document holder provided on the platform An illegible manual may lead to incorrect or dangerous use of the machine Operating instructions Check presence of manuals Check that all the manuals are legible complete and stored in the document holder provided on the platform Replace if necessary extra copies can be supplied on request by the manufacturer 49 Pinguely Haulotte 4 Repair manual 50 Repair manual Pinguely Haulotte A 6 PREVENTIVE MAINTENANCE SHEETS List of preventive maintenance sheets Sheet no
93. ve the machine from any uncontrolled operation when it is not in ser vice Do not tow the platform it is not designed to be towed and must be transported on a trailer 1 3 1 Risks of jolting tipping over The risks of jolting or tipping over are high in the following situations sudden action on the control levers platform overload uneven floor pay attention to thaw periods in winter gusts of wind contact with obstacles on the ground or in the air working on quays pavements etc Allow sufficient stopping distances 3 metres at high speed 1 metre at low speed Pinguely Haulotte 2 Repair manual AN Caution If the machihe has a 220 V plug with max 16A the extension must be connected to a mains socket protected by a 30mA differential circuit 1 4 breaker VERIFICATIONS 1 3 2 Electric risks Electric risks are high in the following situations contact with a live line use during stormy weather 1 3 3 Risks of explosion or burning The risks of explosion or burning are high in the following situations work in an explosive or inflammable atmosphere filling the fuel tank near a naked flame contact with the hot parts of the motor use of a machine with hydraulic leaks 1 3 4 Risks of collision Risks of crushing people present in the machine s movement area travel or when manoeuvring the equipment The operator must assess any overhead risks befo
94. vements to purge the hydraulic circuit Check the oil level in the hydraulic oil tank Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 SHEET C024 Caution Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet 1 2 REPLACING A POTHOLE CYLINDER 1 Preliminary operations Put the machine into the maintenance configuration see 7 2 page 51 Cut off the electric power supply see 7 3 page 52 Ensure that oil temperature 23 Removing a pothole cylinder is not too high Mark and disconnect the two hoses 2 of the pothole cylinder 1 Fit caps to the hoses Remove the special screw 5 washer 6 and nut 7 from the lower axle Remove the pin 3 and washer 4 from the cylinder s upper joint and remove the pothole cylinder 3 Replacing a pothole cylinder Put a new pothole cylinder into place on the upper axle Put the washer into place and secure a new pin Fix the pothole cylinder rod yoke with the special screw washer and a new nut Reconnect the hydraulic hoses according to the marks made when dismant ling Put the machine back into the operational configuration Perform several up down movements from the plaform above 1 5 meters or 4ft92in and travel movements with the platform lowered to purge the hydrau lic circuit Check that the pothole protective system extends and retracts correctly NOTA If counterweights are fitted with the potholes check that their
95. wering is the only solution left SQ10 Slope wire 12 1 at rest O tilt SP1 Pressure switch wires 28 23 Pinguely Haulotte 4 Repair manual 4 1 2 Fuses and motors FU2 10A Command fuse protection of solenoid valves and horn FU3 10A Command fuse to feed the command circuit It protects the whole command circuit FU4 10 Fuse protecting the feeding of the optional circuit of working head lights or flashing lights FU1 250A Power protection fuse M1 Pump motor 24V 3000W 4 2 PLATFORM CONTROL POST EQUIPMENT EI SM1 HL 1 U2 HL6 HL4 SA3 HA HL5 SB2 The serial card allows compiling the different elements of the console in order to get a digital transmission signal Joystick Switch selecting either lifting or slow amp high travel speed Upside console emergency push button Buzzer Light visualising alarm codes Flashing codes Light visualising travel motion position slow or high travel speed of SA3 Light visualising lifting position of SA3 Weighing light indicator 4 3 SOLENOID VALVES Solenoid valve selecting travel or up amp down operations At rest it controls travel working it drives lifting wire 18 Solenoid valve that controls the forward gear wire 19 Solenoid valve that controls backward gear wire 20 Solenoid valve that controls high or low travel speed At rest low speed working high speed wire 21
96. works properly electrovalve YV6 Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP013 Sheet 2 2 THE POTHOLE SYSTEM IS NOT EXTENDED WHEN THE PLATFORM IS LIFTED Check operation of the pothole system cylinder s Cylinder s work properly Replace defective See SHEET cylinder s C024 Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP014 Sheet 1 4 NO MOVEMENT FROM THE PLATFORM CONTROL PANEL No movement from the platform control panel Place the key switch SA1 in the platform position and check for 24V at terminals 9 and 11 of SA1 Replace the key See 24V present switch SA1 SHEET C004 YES Check for 24V on wires 9 and 11 of B the platform control panel between the platform control panel 24V present and the chassis YES Check for 24V between terminals END C1B and C2B of printed circuit U2 24V present YES Replace the electric wiring harness Check for 24V between terminals 34 and 2 of the speed variator Request a travel or lifting 24V present Replace speed See SHEE movement from the platform and p variator U2 T C003 measure voltage at the manipulator s output terminals YES e 9 10V 11 10V END 10 between 10V and 10V Replace the electric wiring harness 5 24V between the platform

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