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HA20_26 GB Maintenance.backup.book

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2. 17 Pinguely Haulotte 4 2 3 4 Pressure values in bar Pump Flow cancellation Load sensing standby pressure Danfoss distributor Entry presure protection Rotation pressure limiter Telescoping Output pressure Input chamber Large chamber braking valve Boom lifting Lowering pressure Valve de freinage grande chambre Arm lifting Lowering pressure Large chamber braking valve Compensation Up down braking valve Jib Large chamber braking valve Emergency unit 18 Repair Manual 240 bars 30 bars 270 bars 100 bars 100 bars 160 bars 100 bars 130 bars 210 bars 100 bars 210 bars 210 bars 210 bars 130 bars Repair manual Pinguely Haulotte 4 2 3 5 Adjustment time Movement Control Movement duration Arm lifting From the turntable 70 s 4s Arm lowering From the turntable 70s 4s Boom lifting From the turntable 40s 3s Boom lowering From the turntable 30 s 3s Rotation left From the turntable 60 s 4s per 1 2 turn Rotation right Movement Arm lifting From the turntable 60 s 4s per 1 2 turn Control From the basket Movement duration HA20P HA26P 50s 4s 60s 4s Arm lowering From the basket 50s 4s 60s 4s Boom
3. a gt SL pe gt 0 ee T ES ES NS ETE ez 14244 1 3 70 Repair manual Pinguely Haulotte 4 12 7 5 Model specific labels 12 7 5 1 HA20PX 400 N Dd pum 2 A 7814 387 C 400 N 40 kg El E 7 um 71 Pinguely Haulotte 2 Repair manual gt 7814 925 12 7 6 Description 72 Ref Code Qty Description 1 30 7814 3570 1 Ring lubrication 2 30 7814 3530 2 Remove the pin 3 30 7814 3640 2 Do not stand on the cover 4 30 7814 3540 a 1 The plug must be connected 5 30 7814 3600 2 Do not use as an earth 4 30 7814 5730 1 240V plug position Holland 6 30 7814 3420 1 Operating instructions 7 30 7814 5180 1 Do not interchange 8 30 7814 3490 1 Machine uninsulated 9 30 7814 3880 2 Do not stop in the work area 10 30 7814 3630 2 Risk of body crushing 11 30 7814 3620 2 Risk of hand crushing 12 30 7814 5070 1 Travel direction danger 13 30 7814 3520 1 Hydraulic oil label 14 30 7814 3590 1 Oil level 15 3 07814 3930 a 1 Green arrow 16 30 7814 3940 a 1 Red arrow 17 30 7814 3060 1 Chassis control
4. NO The fault persists END the See Fiche pe printed circuit C063 YES Replace the REAR See Fiche END steering switch 5 4 C043 Repair the connection or replace the wiring END harness between the REAR steering switch SMA and the printed circuit of the turntable control panel Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART THE MOTOR DOES NOT START FOROS THE STARTER IS ACTIVATED The motor does not start the starter is activated Check the level of diesel in the tank Fill the diesel tank END Open the turntable control panel and check the state of fuse FU1 NO Replace fuse FU1 YES END Check the diesel supply circuit See motor manufacturer s manual Repair the diesel supply circuit See motor manufacturer s manual Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP066 Folio 2 4 THE MOTOR DOES NOT START THE STARTER IS ACTIVATED Y o Check the setpoint at the outputs Activate the starter switch SB3 or of detectors SQ7 and SQ8 SB4 and check for 12V voltage between terminals 242 and 150 of the turntable control panel Setpoint SQ7 OV and 508 0 NO NO Check the continuity of wiring YES harnesses no 115A and 115B Continuity o harnes
5. 59 Repair Manual Pinguely Haulotte 7 12 MAINTENANCE een 61 12 1 GENERAL RECOMMENDATIONS nun 61 12 2 PARTICULAR RECOMMENDATIONS nun aaa 61 12 2 15 Specilie OO ea dani 61 12 2 2 Replacing an SI Bees a TR 62 12 2 3 Locating the dei GOW e 62 12 3 MAINTENANCE SYSTEM aaa ae 62 12 4 ELECTRIC POWER SUPPLY nen en nn 63 125 MAINTENANCE PLAN oo dd 64 126 OPERATIONS see 66 1201 Summary tables nie ee 66 4 PRESENCE OF EE 67 12 7 1 Common yellow label ne Eee 67 12 7 2 Commom orange label c 68 12 7 3 Common red label APP ote A 69 12 7 4 70 12 7 5 sisi 71 12 1 6 Description anne dns 72 Label DOS 1 01 09 Sd en 73 12 8 PRESENCE MANUALS scene 74 13 PREVENTIVE MAINTENANCE SHEET 2400 011112222 75 14 OPERATING INCIDENTS ae 83 141 INCIDENT TABLE EE 83 14 1 1 General operation 2 84 url EE 86 14 1 3 ae 87 14 1 4 Steering EE E 88 14 1 5 Turntable folalionsystef za aus en oen nU due nid 88 14 2 BREAKDOWN DETECTION FLOW 20 2 1106 66 60 88 Pinguely Haulotte Repair Manual 15 CORRECTIVE MAINTENANCE 6 22
6. 2600mm 8ft 6in 3710mm 12ft 2in 100mm 3in 765mm 21 EEN 5555559 5 5555 SS os 2 RR xx 5 RL e e x ses lt lt 2 eS d SS 250 dy 2 e 55 de RL 95 25 gt te M 8 RR SL 220 RL KN gt e 25 25 ss 25 x d 2 Se 99 RE 5 lt lt x lt lt 55 SL SL d lt lt 5ft 10in e di 9 2 5 ses lt lt d 99 5 Se d 99 5 OS x 1090000050508 2555055 1990mm Gft 2345mm Tft 8in 15 Pinguely Haulotte 4 2 3 16 TIGHTENING TORQUE Nominal diameter M 6 1 Repair Manual 2 3 1 Tightening torque for large thread 9 11 Tightening torque in N M 10 9 13 14 15 17 M 7 1 15 19 21 24 26 28 M 8 1 25 22 27 31 34 37 41 M 10 1 5 43 45 61 67 73 81 M 12 1 75 75 94 110 120 130 140 M 14 2 120 150 170 190 200 220 M 16 2 190 230 260 290 320
7. Maximum lateral manual force 40 kg Max wind speed 60 km h Floor height 18 65 m Working height 20 65 m Overall length 9 00 m Overall width 2 35 m Overall height 2 67 Wheelbase 2 60 m Ground clearance 420 mm max reach 13 50 m Boom range 0 75 Telescoping stroke 4200 mm Turret rotation Continuous Max force on wheel 6194 daN Reducer efficiency 95 30 Max travel slope 40 Tyre sizes 15 R22 Outside turning radius 3 9 m Tilt Monitor 5 9 Hydraulic reservoir 150 litres Diesel tank 150 litres Total weight 12 260 kg Number of drive wheels 4 Number of steered wheels 4 Differential lock YES Hydraulic brakes YES Freewheeling YES Wheel nut tightening torque 32 mdaN Slewing ring nuts tightening torque 27 mdaN Vibration level at feet lt 0 5 82 Vibration level at hands lt 2 5 82 DEUTZ diesel engine FAL 1011 F Power Idling power output Consumption Idling consumption 51 6 HP 38 kW at 2400 rpm 20 4 HP 15 kW at 1250 rpm 230 g kWh 230 g kWh 45 cm3 rev LOADSENSING hydraulic pump 85 l min max 11 Pinguely Haulotte 2 Repair Manual Hydraulic pressure General Travel Steering Slewing Equipment 240 bar 240 bar 240 bar 100 bar 240 bar Travel speed proportional LS 1 2 km h HS 4 5 km h max ground pressure with 250 kg hard ground concrete loose ground mud 14 0 daN cm2 4 3 daN cm2 Starting battery 1 12 95 Ah
8. 33 5 4 2 On Off electrovalves A S 33 5 4 3 Proportional electrovalves 34 Repair Manual Pinguely Haulotte 7 5 4 4 Buzzer and We l int 34 6 OPERATING EQUATIONS ioni 35 le SIAR Meri cial ee 35 822 STOP MOTEUR ee 35 53 ACCELERATOR una c 35 COMPENSATION Mcr 35 Ga mnm 35 1 eegener 36 ROTATION ee ee 36 SE OEB an LEE 36 Porc UN SSSR D en 37 6 e TELESCOPING 37 TRAVEL 37 6 12 STEERING pit sd 37 6 13 DIFFERENTIAL BLOGRIN Oscos eee dede dettes 38 6 14 HORN BUZZER dE 38 6 15 INDICATORS cis 38 6 16 OTHER FUNCTIONS OVERLOAD DEAD MAN SLOPE 39 LEAD MEER OLD E o EE rennen 39 6 16 En ib tii 39 A e 39 17 gt lt REACH MB ppc 39 7 ef ldcEe sio 41 8 POSITIONS OF ELECTRIC 444 00 nn 43 8 1 MOTHER BOARD a 43 8 1 1 Descrip n 43 Pinguely Haulotte Repair Manual 8 1 2 Positions of screws connectors and relays 44 8 1 3 Positions 45 8 1 4 Positions of diagnosis help LEDs une 46 9 HYDRAULIC DIAGRAMS 2 2 1 4 1
9. p 4 E i Lan 8 ipn its ER ee a N i i wo N 38 44 Repair manual 20 d CON El Pinguely Haulotte 4 8 1 3 Positions of fuses 21 22 26 27 25 23 24 Eire 2 Cen 12 28 20 4 N AAN 45 Pinguely Haulotte 4 Repair manual 8 1 4 Positions of diagnosis help LEDs gt T SCH Ovi y CH E ER e ei SG x m3 d Cap de Se ue La NN RNA YV16B 16 YV19B YV19A 46 Pinguely Haulotte 4 Repair manual 9 HYDRAULIC DIAGRAMS HYDRAULIC DIAGRAM FOR 20 26 AND HA61 80JRT MODELS 1539 0 9 1 axe 28H axe 499np91 ayesg Of KEE 499np81 par a aigue neiss3 i nass sinejonpei Sue SISA le AX 1 Ch T1 1 m 2 6 Jeay alge neissj juene neiss3 apxe 0 peo1 OpZ 9U9E opeyouoc einsseid
10. END Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP026 Folio 4 5 NO COMPENSATION MOVEMENT UP AND OR DOWN G Y Maintain the control activated and check for 12V voltage at terminals 401 up and 402 down of the printed circuit Open the platform control panel and check the wiring of NO the compensation switch SA5 YES NO ee Replace the U1 module SeeFiche Repair wiring C058 YES END Check the electric continuity of the switch contacts when closed NO The fault persists END Replace the See Fiche NO printed circuit C063 5 Replace the See Fiche END compensation switch C043 SA5 Repair the connection or replace the wiring END harness between the compensation switch SA5 and the printed circuit of the turntable control panel Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP026 Folio 5 5 NO COMPENSATION MOVEMENT UP AND OR DOWN Replace the double flow See Fiche limiter C083 The fault persists Replace the balancing See Fiche valve C082 The fault persists YES Replace the electrovalve See Fiche YV15 C067 Sheet DP027 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Folio 1 5 NO PLATFORM ROTATION MOVEMENT RIGHT AND OR LEFT No platform rotation movement right
11. 20 Gi 18K 9 25 Pinguely Haulotte 2 Repair manual 12 6 OPERATIONS 12 6 1 Summary table e following levels each putting into engine oil service hydraulic oil diesel electric batteries Check the cleanness of the following gasoil pre filter engine air filter machine check in particular the watertightness of the connectors and hoses take this opportunity to check the condition of the tyres cables and all accessories and equipment Check the clogging of the hydraulic oil filter an indicator indicates clogging change the cartridge when the mark appears Every 50 hours Engine see engine manufacturer s manual Check the level of the drive wheel reducers see Chapter 5 3 2 2 page 49 Grease the wheel pivot pins 8 points steering axle centre pivot and slot pin 10 points slewing ring bearing 2 points slewing ring teeth brush pendular hinge pin 2 points pendular link piece hinge pin 4 points boom bottom shaft 1 point Clean gasoil pre filter After the first 50 hours Change the hydraulic filter s cartridge
12. the machine back into the operational configuration Make several movements using the replaced flow separator to purge the circuit Check that the corresponding movement is made correctly Sheet C082 Caution Ensure that the oil is not too hot Caution Use a container to collect oil to prevent pollution of the environment Caution Balancing valves are safety elements They are calibrated in the plant and must not be re adjusted Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET CHANGING A BALANCING VALVE Folio 1 1 FOR THE COMPENSATION FUNCTION 1 Preliminary operations the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph 2 Removing a balancing valve Remove the balancing valve 1 by unscrewing it 3 Installing a balancing valve Screw a new balancing valve whose characteristics correspond to the machine in question into the hydraulic block Tighten to a torque of 45 to 50 Nm 33 to 36 7 Ib ft Putthe machine back into the operational configuration Make several movements using the replaced balancing valve to purge the circuit Check that the corresponding movement is made correctly Pinguely Haulotte 4 CORRECTIVE MAINTEANCE SHEET Sheet C083 CHANGING A DOUBLE FLOW LIMITER Folio 1 1 FOR THE COMPENSATION FUNCTION 1 Preliminary operations Caution Putt
13. Put coils YV18A and YV18B back in their original positions Press the pedal and activate the jib switch Check for 12V voltage at the terminals of the YV18A down or YV18B up connector Open the turntable control panel Press the pedal and activate the jib switch Check for NO 12V voltage at terminals 407A down or 408A up of the printed circuit YES NO Replace the See Fiche D UE C058 or C107 See Fiche Replace coil YV18A C059 down or YV18B Y up YES The fault persists Repair the connection or END replace the wiring harness between the turntable control panel and electrovalve YV18 See Fiche C063 Replace the printed circuit END Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP028 NO JIB MOVEMENT UP AND OR DOWN Folio 4 5 FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Platform jib fault Turntable jib fault Y Y Maintain the control Maintain the control activated and check for activated and check for 12V voltage at terminals 12V voltage at terminals 410 up and 409 down of 406 up and 405 down of the printed circuit the printed circuit Open the platform control panel or turntable and check NO the wiring of jib switch SA7 or SA6 YES NO SE Replace the U1 module See Fiche Repair wiring C058 or C07
14. 47 9 1 HYDRAULIC DIAGRAM FOR HA20 26PX AND HA61 80JRT MODELS B1539 0 47 10 HYDRAULICS COMPONENTS DESCRIPTION nnne 49 10 1 0 0 0000000 49 l E 1 0 49 10 1 2 1 OUTDUL ui ida Tree 51 10 2 2 5 2 00000 hrs re rer ree ret r rere 52 102 5 AAA A a 52 10 2 2 Input and output 53 10 3 CETOP AUXOLIARY BLOCK iii em nennen nennen nnnnnnnn nennen 54 100321 EE ere iilo n EEN 54 10 4 EMERGENCY PUMP UNITA 55 10 4 55 10 5 5 ina 56 10 5 AS E el O 56 10 6 STEERING BLOCK 00000 57 10 61 ee ee 57 10 6 2 Input and output 57 11 HYDRAULIC 65 1 111 nen nun 59 11 1 TRAVEL 59 11 2 TURNTABLEROTATION 59 11 3 ARM LIFTING 00 nnnnnnnnn nennen riis 59 11 4 5 59 11 5 TELESCODING 59 11 6 OTHER
15. YES END Check the electric continuity of the switch contacts when closed NO The fault persists END Replace the See Fiche NO printed circuit C063 YES Replace the jib switch See Fiche END SAT or SA6 C043 or Fiche C044 Repair the connection or replace the END electric wiring harness between the jib switch SA7 or SA6 on the printed circuit of the turntable control panel Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP028 NO JIB MOVEMENT UP AND OR DOWN Folio 5 5 FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Replace the double flow See Fiche limiter C083 Thefault persists Replace the electrovalve See Fiche 18 067 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP031 NO ARM LIFTING MOVEMENT Folio 1 3 UP AND OR DOWN FROM THE PLATFORM OR TURNTABLE CONTROL PANEL No arm lifting movement up and or down from the platform or turntable control panel Place the key switch in the turntable or platform position Activate the boom lifting switch SA 14 from the turntable control panel or the lifting manipulator SM2 from the platform control panel Lifting movement OK Open the platform or turntable control panel and check the wiring of the lifting manipulator SM2 or lifting switch SA14 NO Repair wirin
16. 177 Repair manual Pinguely Haulotte 7 1 GENERAL RECOMMENDATIONS SAFETY 1 1 GENERAL WARNING 1 1 1 Manual This manual aims to help maintenance personnel service and repair the machine It cannot however replace the basic training required by any person working on the site equipment The site manager must inform operators of the recommendations in the instruction manual He is also responsible for application of current user regulations in the country of use Before operating on the machine it is essential to be familiar with all the recommendations in this manual and the user manual to ensure personnel and equipment safety 1 1 2 Labels Potential dangers and recommendations for the machine are indicated on labels and plates Read the instructions on them All labels conform to the following colour code Red indicates a potentially fatal danger Orange indicates a danger that may cause serious injury Yellow indicates a danger that may cause material damage or slight injury Maintenance 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
17. the maintenance configuration see corresponding Do not use the machine paragraph during maintenance Switch off electric power see corresponding paragraph operations Disconnect the then terminals to isolate the circuit 2 Removing a manipulator 2 Remove the upper panel 4 of the top control box by removing its fixing screws 1 Using cutters remove the cable clamps from the defective manipulator wires Carefully mark the positions of the different manipulator wires 3 on the top control panel connector Disconnect the wires from the top control panel plug Disconnect the positive wires 211 from the switches and then the nega tive wire Remove the fixing screws 5 from the manipulator and take the manipula tor out of the box 3 Installing a manipulator Place the replacement manipulator in position and put back the fixing 4 screws 5 Put back the wires 3 in the cable strand and fasten the strand using plas tic clamps Fit male reference contacts to the ends of the wires 3 Connect the wires the plug according to the marks made during dis mantling e the supply wires 211 and then the negative wire Put back the upper panel 4 of the box and fix using screws 1 Re connectthe then terminals of the battery Putthe machine back into its operational configuration Make several movements controlled from the baske
18. 350 M 18 2 5 260 320 360 400 440 480 M 20 2 5 370 450 520 570 620 680 M 22 2 5 500 620 700 770 840 930 M 24 3 3 630 790 890 990 1070 1180 M 27 3 930 1150 1300 1400 1560 1730 M 30 3 5 Nominal diameter 1260 1570 1770 1960 2200 2350 2 3 2 Tightening torque for fine thread Tightening torque in N M 10 9 M 8 1 24 29 33 37 40 44 M 10 1 25 46 57 64 71 77 85 M 12 1 25 83 100 120 130 140 150 M 14 1 5 130 160 180 200 220 240 M 16 1 5 200 250 280 310 340 370 M 18 1 5 290 360 410 450 490 540 20 1 5 410 510 570 630 690 760 M 22 1 5 550 680 780 870 920 1000 M 24 1 5 690 860 970 1070 1160 1290 M 27 2 1000 1300 1400 1560 1690 1880 M 30 2 1400 1700 1960 2180 2350 2610 Repair manual Pinguely Haulotte 7 2 3 3 Tightening torque for hydraulic hoses Torque to apply Description in Ib ft mini maxi 2369068950 Hose SP 1756 H LG 0 620 18 5 25 81 2369069070 Hose SP 1707 H LG 2 080 74 11 2369069290 Hose SP 5043 LG 0 770 44 3 7 4 2369069320 Hose SP 5043 LG 1 510 44 3 59 2369069510 Hose SP 1756 LG 0 420 18 4 25 8 2369069640 Hose SP 1707 LG 1 510 7 5 11 2369069650 Hose SP 1707 LG 1 640 7 5 11 2369069660 Hose SP 1707 LG 2 150 7 5 11 2369070120
19. Hd 5 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C108 CHANGING A CONTROL UNIT Folio 1 1 OF THE DISTRIBUTION BLOCK Caution 1 Preliminary operations Ensure that the oil is not too the machine in the maintenance configuration see corresponding hot paragraph Switch off electric power see corresponding paragraph 2 Removing the coil Caution Mark and disconnect the electric connections 2 of the coil 1 Remove the coil by removing the fixing screws 4 Use a container to collect oil Discard the O rings 3 to prevent pollution of the environment 3 Installing the coil Replace the O rings Put back the coil and fix using fixing screws Tighten the screws to a tor que between 7 5 and 8 5 N m 5 53 and 6 26 Ib ft e Reconnect the coil s electric connections Check that there is sufficient oil in the hydraulic circuit tank Put the machine back in the operational configuration Test the movement corresponding to the replaced coil Make several movements to purge the hydraulic circuit Check the level of the hydraulic tank Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C109 Folio 1 1 CHANGING THE EMERGENCY ELECTROPUMP UNIT 1 Preliminary operations Putthe machine in the maintenance configuration see corresponding Caution paragraph Basura aie otre Switch off electric power see corresponding paragr
20. Hose SP 5043 LG 2 610 44 3 59 2369070160 Hose SP 5043 LG 1 110 44 3 59 2369070190 Hose SP 5043 LG 0 970 44 3 59 2369070310 Hose SP 1786 2 650m 18 5 25 81 2369070330 Hose SP 1663 LG 2 380 29 5 36 8 2369070340 Hose SP 1707 LG 6 700 75 11 2369070350 Hose SP 1707 LG 21 40 75 41 2369070360 Hose SP 1707 LG 7 100 75 11 2369070370 Hose SP 1707 LG 18 40 75 11 2369070380 Hose SP 1707 LG 18 20 75 11 2369070390 Hose SP 1756 LG 6 50 18 5 25 81 2369070400 Hose SP 5043 LG 1 010 44 3 59 2369070410 Hose SP 5043 LG 1 170 44 3 59 2369070420 Hose SP 5051 LG 1 570 154 8 177 2369070430 Hose SP 1756 LG 2 620 18 5 25 81 2369070480 Hose SP 1707 LG 0 750 75 11 2369070490 Hose SP 1707 LG 1 350 7 5 11 2369070490 Hose SP 1707 LG 1 350 7 5 11 2369070500 Hose SP 1707 LG 2 250 75 11 2369070510 Hose SP 1707 LG 2 900 75 11 2369070520 Hose SP 1707 LG 2 950 75 11 2369070540 Hose SP 1786 LG 2 900 18 5 25 81 2369070560 Hose SP 5043 LG 1 210 44 3 59 2369070570 Hose SP 5043 LG 2 430 44 3 59 2369070580 Hose SP 5043 LG 2 470 44 3 59 2369070590 Hose SP 5043 LG 2 710 44 3 59 2369070600 Hose SP 5043 LG 3 410 44 3 59 2369070780 Hose SP 1223 0 570m 29 5 50 2369071030 Hose SP 1707 11 840m 7 5 11 2369071050 Hose SP 1707 11 140m 7 5 11 2369071070 Hose SP 5043 0 900m 44 3 59 2369071080 Hose SP 1786 1 020m 18 5 25 81 2369071090 Hose SP 5043 1 270m 44 3 59
21. Pinguely Haulotte 2 Repair manual 60 Repair manual Pinguely Haulotte 12 MAINTENANCE 12 1 GENERAL RECOMMENDATIONS The maintenance operations indicated in this manual are given for normal conditions of use In difficult conditions extreme temperatures high humidity polluting atmosphere high altitude etc some operations must be carried out more frequently and special precautions must be taken Refer to the engine manual and your local PINGUELY HAULOTTE agent Only qualified and competent personnel can carry out any work on the machine and they must comply with the safety instructions relating to the protection of personnel and environmental protection Regularly check the operation of the safety devices Tilt buzzer stop travel cut as well as boom raising arm rais ing and telescope extension Platform overload load gt permitted load see tables corres ponding paragraph Chapter 2 6 page 15 buzzer complete stopping of all movements except basket rotation 1 High speed impossible or intermediate speed for 4x4 model if boom raised arm raised telescope extended ZN Attention Do not use the machine as a welding earth Do not weld without disconnecting thebattery s and terminals Do not start other vehicles with the batteries connected 12 2 PARTICULAR RECOMMENDATIONS Before any maintenance intervention on the elevating platform indicate on the turntable and platfor
22. Putthe machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Remove the basket see corresponding sheet Remove the basket rotation hydraulic motor see corresponding sheet 2 Removing the gearing Remove the motor fixing flange 1 Caution Remove the endless screw 2 and the adjusting washers 3 if any It is essential to put the Remove the screw 4 and the toothed washer 5 component in slings before Remove the end cap 8 then the platform link part 9 and the Nylatron dismantling re assembling it washer 10 SE Remove the nylstop nut 11 bushing 12 elastic washers 13 plate 14 Remove the articulation pin assembly 15 then the disk 16 and pad 17 Remove the screws and washers 18 19 and remove the pin 15 wormwheel 6 keys 21 hub 20 key 7 1 Installing the gearing Change the rings pads and keys if necessary Putinto place on the articulation pin 15 the key 7 hub 20 keys 21 wormwheel 6 and put back the screws and washers 18 and 19 Putinto place the disk 16 and pad 17 then the articulation pin assem bly 15 Putinto place the plate 14 elastic washers 13 bushing 12 then a new nylstop nut 11 Putinto place the Nylatron washer 10 platform link part 9 end cap 8 and Stauff collar Fixthe assembly with the screw 4 equipped wit
23. Y e 0 Put the machine on wedges so that the wheels are not touching the ground YES Press the pedal and make a travel movement Activate the FRONT steering switch SA12 Check that the LED associated with electrovalve YV22A left or YV22B right is on YES Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP037 Folio 2 4 NO STEERING MOVEMENT RIGHT AND OR LEFT ON THE FRONT AXLE Press the pedal and make a travel movement Activate the FRONT steering switch SA12 and check for 12V voltage at the terminals of the PVG connector YV2a Open the turntable control panel Press the pedal and make a travel movement Activate the FRONT steering switch SA12 and check for 12V voltage on terminal 305 of the printed circuit See Fiche Replace the PVG C077 YV2 control head NO Replace the See Fiche U1 module C058 YES Repair the connection or replace the electric wiring harness between the turntable control panel and PVG YV2 The fault persists NO END Replace the printed circuit See Fiche C063 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP037 Folio 3 4 NO STEERING MOVEMENT RIGHT AND OR LEFT ON THE FRONT AXLE Invert the coils of the jib electrovalve YV22A and YV22B Press the pedal and make a travel movement Activate the FRONT steering swit
24. replace if necessary Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP071 ONLY TRAVEL MICRO SPEED REMAINS AVAILABLE Folio 1 2 MACHINE REGARDLESS OF THE SPEED SELECTED Only travel micro speed remains available on the machine regardless of the speed selected Check that the machine is folded SQ2 1 509 1 and SQ4 1 Machine folded Fold the machine Check the setpoint at the output of detectors SQ2 SQ9 and SQ4 Adjust the detector s or SeeFiche 2 replace the defective C061 detector s YES END Check the continuity of harnesses no 206 204 and 232 NO Replace the defective har ness es no 206 204 or 232 YES END Replace the U1 module See Fiche 058 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP071 ONLY TRAVEL MICRO SPEED REMAINSAVAILABLEONTHE Folio 2 2 MACHINE REGARDLESS OF THE SPEED SELECTED The fault NO persists Replace the printed circuit SeeFiche C063 END Repair manual Pinguely Haulotte 4 15 CORRECTIVE MAINTENANCE PROCEDURES List of corrective maintenance sheets Sheet no Description SHEET 010 Changing a hose SHEET C034 Changing a wheel SHEET C038 Changing the steering cylinder SHEET C039 Changing the tilt sensor SHEET 040 Changing the horn SHEET C041
25. 1002 60 12 6661 70 80 014074 Ia jeune TVLOL VSIA NOILVOISIGOW 0 31101 nvH ATANON Id 190 np TOS 9 9 4 220 IN X 24 x x EX 24 EX 24 x X0 LE ZLAA OLAA S8CCAA VCCNA VIZA 96 VELNA 8S8LAA VSLAA 88LAA V8LAA gt A S e LI P d d yf aL aL a 0 N a 0 N gt gt gt r o o T 2 3 lt E 2 a R H 8 E E T gt 2 A A 2 3 El 2 8 2 8 8 5 5 8 E 3 8 8 8 p 5 3 8 5 B LSZ Er 247 62 pec poc 62 proe 08 vo Up B 0 GIE pr BOE poe 0 FOE 62 782 d E 0 F 3 N Is lo a a IA a a A Ju o a 0 0 0 2 a fa o i o 10 0 2 Jo 0 0 3 N 0 5 0 0 0 0 a N 0 a N 0 gt sony eas M cS el 6vs 9875 ANS 9vs SYS ws el el a lt lt Grue 9 9 riz 6 0220 9 so 4 0220 0 e e ure 6 0220 a uE 02 20 L 25 Repair Manual Pinguely Haulotte 4 WIRING DIAGRAM E 448 FOLIO 04 05 4 4 SVNAHO 6661 F0 0 AZANA ere a 401 89119 ans junus 00
26. 12 vo e e ire lt 9 4 0 0 074 GL SL ZL OL SL bl el cl LL OL 6 2 9 v e L 27 Pinguely Haulotte 2 4 6 28 PARTLIST Repair Manual Mushroom headed button Turret starting switch Platform starting switch Warning switch Post selection key switch Accelerator switch Differential lock switch Platform rotation switch Platform compensation switch Turret pendular switch Platform pendular switch Turret telescoping switch Platform telescoping switch Low medium high speed switch Forward direction switch Turret raising switch Turret lifting switch Turret slewing switch Battery charging light Air filter light Oil temperature light Oil pressure light Power light Boom raising slewing control Arm lifting controller Travel direction controller Tilt detector Pendular position switch Arm boom position switch Threshold 1 weighing position switch Threshold 2 weighing position switch Telescoping position switch General relay Engine stop relay Accelerator relay Starter relay Engine stop circuit fuse Accelerator circuit fuse General circuit fuse Turret movements control circuit fuse Platform movements control circuit fuse Solenoid valves supply circuit fuse Turret platform common circu
27. 2 Removing the connections On the motor disconnect the battery connection cables 1 the starter connection the motor s electric connectors 2 and free the duct from the plastic collars the fuel incoming 3 and outgoing pipes Remove the hydraulic filter support 3 Removing the exhaust Remove the exhaust fixing collar Remove the exhaust output pipe 4 4 Removing the coupling Remove the hydraulic pump 5 see corresponding sheet Remove the screws 6 fixing the flange 7 of the motor flap then remove the flange Remove the fixing screws 8 from the coupling plate 9 and remove it 5 Removing the thermal motor Put the motor in slings according to the instructions in the motor manufac turer s manual Remove the motor s 4 fixing screws 10 and remove the motor 6 Installing the thermal motor Check the condition of the 4 silent blocks and replace if necessary Put the thermal motor into place and fix using 4 fixing screws previously coated with normal blue loctite 243 and equipped with new grower washers 7 Installing the coupling Put the coupling plate into place 9 and fix using fixing screws previously coated with normal blue loctite 243 Tighten to a torque of 25 N m 18 43 Ib ft Put the motor flap flange into place and fix using screws equipped with new grower washers Tighten to a torque of 49 N m 36 14 Ib ft Put back the hydraulic pump see corr
28. C077 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP069 Folio 1 4 MACHINE TRAVEL SPEED DOES NOT CORRESPOND TO THE SELECTOR Machine travel speed does not correspond to the selector speed Do not press the pedal Open the turntable control panel and check that the LEDs associated with electovalves YV8 YV10 and YV12 are off All LEDs are off Note the LED that is on Put the machine on wedges so that the wheels do not touch the ground Place the key switch in the platform position Place the speed selector in the high speed position Press the pedal and make a forward travel movement Check that the LEDs associated with electrovalves YV10 and YV12 are on Allthe LEDs are NO Allthe LEDs are off Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP069 Folio 2 4 MACHINE TRAVEL SPEED DOES NOT CORRESPOND TO THE SELECTOR Place the key switch in the platform position Place the speed selector in the High speed position Press the pedal and make a forward travel movement Check for 12V voltage at the terminals ofthe connector of the electrovalve concerned YV10 and YV12 NO YES Open the turntable control panel Press the pedal and make a Fiche Replace the electrovalve coil forward travel movement god S
29. Check for 12V on the terminals of the printed circuit associated with the electrovalve concerned 814A for YV10 END 814B for YV12 NO YES Replace the U1 module See Fiche C058 Replace the wiring harness between the turntable control panel and the electrovalve concerned YV10 and YV12 The fault persists END Replace the printed circuit See Fiche C063 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP069 Folio 3 4 MACHINE TRAVEL SPEED DOES NOT CORRESPOND TO THE SELECTOR Press the pedal and make a forward travel movement Check for 12V voltage at the terminals of the electrovalve YV10 connector lt gt E Open the turntable control panel YES Press the pedal and make a See Fiche Replace the coil of forward travel movement 059 lect Ive YV10 Check for 12V voltage on terminal 814A of the printed circuit NO 12V OK YES Replace the U1 module See Fiche Replace the wiring harness between C058 the turntable control panel and the electrovalve concerned YV10 END The fault persists See Fiche C063 Replace the printed circuit END Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP069 DOESN Folio 4 4 MACHINE TRAVEL SPEED OT CORRESPOND TO THE SELECTOR Open the platform control panel Y Y Place the speed selector SA11 on
30. Replace the hydraulic pump suction pipes Pipes NO OK YES See Fiche C042 or C091 Incorrect operation of the hydraulic pump replace it END Sheet DP026 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Folio 1 5 NO COMPENSATION MOVEMENT UP AND OR DOWN No compensation movement up and or down Place the key switch in the platform position Press the pedal and activate the basket rotation switch on the platform control panel he basket rotates Y YES Stop movement and release the pedal Open the turntable control panel and check that the LED associated with electrovalve YV15A up or YV15B down is off TO Press the pedal and activate the compensation switch Check that the LED associated with electrovalve YV15A up or YV15B down is on YES YES Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP026 Folio 2 5 NO COMPENSATION MOVEMENT UP AND OR DOWN Press the pedal and activate the compensation switch and check for 12V vol tage on the terminals of the PVG connector YV2a YV2b for H14 16 HB40 44J Open the turntable control panel Press the pedal and activate the compensation switch Check for 12V voltage on terminal 305 415 for H14 16 HB40 44J of the printed circuit See Fiche Replace the PVG 077 2 control head NO Replace the See Fic
31. Supply voltage 12V Acoustic power 108 dB A Noise level at 10 meters 73 9 dB A 2 1 2 HA 26PX technical characteristics 5 AT A ON TA kg including 2 peoples Maximum lateral manual force 40 kg Max wind speed 45 km k Floor height 24 00 m Working height 26 00 m Overall length 11 90 m Overall width 2 35 m Overall height 2 67 Wheelbase 2 60 m Ground clearance 420 mm max reach 14 6 m Boom range 0 75 Telescoping stroke 6915 mm Turret rotation Continuous Reducer efficiency 95 30 Max travel slope 40 Tyre sizes 15 R22 Outside turning radius 3 9 m Tilt Monitor 3 Hydraulic reservoir 150 litres Diesel tank 150 litres Total weight 14 150 kg Number of drive wheels 4 Number of steered wheels 4 Differential lock YES Hydraulic brakes YES Freewheeling YES Wheel nut tightening torque 32 mdaN Slewing ring nuts tightening torque 2 mdaN Vibration level at feet lt 0 5 s Vibration level at hands lt 2 5 s DEUTZ diesel engine FAL 1011 Power Idling power output Consumption Idling consumption 51 6 HP 38 kW at 2400 rpm 20 4 HP 15 kW at 1250 rpm 230 g kWh 230 g kWh 45 cm3 rev LOADSENSING hydraulic pump 85 l min max 12 Repair manual Pinguely Haulotte 7 Hydraulic pressure General 240 bar Travel 240 bar Steering 240 bar Slewing 100 bar Equipment 240 bar
32. Travel speed LS 1 2 km h proportional HS 4 5 km h max ground pressure with 250 kg hard ground concrete 16 0 daN cm2 loose ground mud 4 6 daN cm2 Max force on wheel 6970 daN Starting battery 1 12 95 Ah Supply voltage 12V Acoustic power 108 dB A Noise level at 10 meters 73 9 dB A 13 Repair Manual Pinguely Haulotte 4 OVERALL DIMENSIONS 2 2 2 2 1 HA 20PX overall dimensions 6754mm 22ft 1in 2600mm 8ft 3710mm 12ft 2in 1070mm 8925mm 29ft 3in EE SC LL Jus EE EE EE EE NNN ROLE RAR FES 50 55455 EE EEE SR GA RES d e e 8 YE uu078 14 Pinguely Haulotte 4 Repair manual 2 2 2 HA 26PX overall dimensions 11890mm 39ft E 9570mm 31ft Ain A 3000mm 9ft 10in 1ft 4in eft Yin 2670mm
33. and the printed circuit of the turntable control panel Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART SR ver NO TELESCOPING MOVEMENT OUT AND OR IN FROM iod THE PLATFORM OR TURNTABLE CONTROL PANEL Replace the pressure See Fiche limiter C081 The fault persists Replace electrovalve See Fiche YV14 C067 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP068 NO BOOM LIFTING MOVEMENT Folio 1 4 UP AND OR DOWN FROM THE PLATFORM OR TURNTABLE CONTROL PANEL No boom lifting movement up and or down from the platform or turntable control panel Place the key switch in the turntable or platform position Activate the turntable control panel lifting switch SA14 or platform control panel lifting manipulator SM31 Lifting movement OK Open the platform or turntable control panel and check the wiring of the boom lifting manipulator SM31 or boom lifting switch SA13 NO Repair wiring YES Turntable panel boom Platform panel boom END y lifting fault lifting fault Place the key switch in the turntable Place the key switch in the platform position position Open the platform control panel Open the turntable control panel Tilt the boom lifting manipulator SM31 as far as possible Activate the boom lifting switch SA 13 Check for 0 5V or 4 5V voltage d
34. empty the hydraulic tank 2 Removing a hose NB Disconnect the hose from the equipment to which it is connected Unscrew the hose slowly to release residual hydraulic pressure Protect the holes of the equipment using caps 3 Installing a hose Reconnect a new hydraulic hose Put the machine back into the operational configuration Make several movements using the hose to purge the hydraulic circuit Check the level in the hydraulic oil tank Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C034 Folio 1 1 CHANGING A WHEEL 4 Preliminary operations Putthe machine in the maintenance configuration see corresponding para graph Switch off electric power see corresponding paragraph 5 Removing a wheel Unblock without completely unscrewing the fixing screws 1 of the wheel to be removed Raise the machine using a jack or hoist Remove the fixing screws 1 from the wheel and remove the wheel 2 6 Installing a wheel Put a new wheel into place and put back the fixing screws e Put the machine on the ground Tighten the fixing screws to the recommended torque see tightening torque value table Putthe machine back into the operational configuration Caution Usea container to collect oil to prevent pollution of the environment Caution It is essential to put the component in slings before dismantling re assembling it Pinguely Haulotte 4 CORRECTIVE
35. 2 pressure adjustment set at 100 bars 1450 PSI Supply output for 1st boom lift output A 1st boom raising output B 1st lifting Supply output for 2 boom output 2nd boom raising output B 2nd lifting Supply output for non proportional movements Output A Cetop supply YV14 A and B output B auxi liary block supply with YV15 A and B YV19 A and B YV18 A and B pressure sent towards outlet 6 from slewing ring towards steering block command Valves supply YV21 A and B and YV22 A and B 53 Pinguely Haulotte 4 Repair manual 10 3 CETOP 3 AUXOLIARY BLOCK 10 3 1 Location Description YV2 Non proportional valve from PVG32 supply ofthe non proportional functions YV9 Proportional valve for boom lifting supply B output A input YV10 Proportional valve for arm lifting supply B output A input YV11 Proportional valve for rotation command YV14 Proportional valve for driving command output A towards input 1 of slewing ring output B towards input 4 of slewing ring YV15 Proportional valve for driving command output A towards input 2 of slewing ring output B towards input 3 of slewing ring 54 Repair manual Pinguely Haulotte m 10 4 EMERGENCY PUMP UNIT 10 4 1 Location Description Emergency pump pressure regulator Emergency electric pump 55 Pinguely Haulotte 4 Repair manual 10 5 TELECOPING BLOCK 10 5 1 Location Description Telescop su
36. 3 3 Installing a relay Puta new relay into place and fix using its bolt equipped with a new grower washer Reconnect the electric connections according to the marks made during dismantling Close the turntable box Reconnectthe then terminals of the starter battery Putthe machine back into the operational configuration Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C063 Folio 1 1 CHANGING THE PRINTED CIRCUIT 1 Preliminary operations Putthe machine in the maintenance configuration see corresponding paragraph 2 4 Switch off electric power see corresponding paragraph Disconnect the then terminals of the starter battery 2 Removing the printed circuit Open the turntable electric box Carefully mark and disconnect all the electric connections 1 of the prin ted circuit 2 Remove the U1 electronic module 4 see corresponding sheet Remove the bolts 3 fixing the board to the box and their sealing washers Remove the printed circuit and silent blocks equipping the fixing bolts 3 Installing the printed circuit Puta new printed circuit into place and fix using the bolts equipped with silent blocks sealing rings and new toothed washers Install the U1 electronic module see corresponding sheet Reconnect the electric connections according to the marks made during dismantling COSS Close the
37. 3 6 4 6 5 START STOP MOTEUR ACCELERATOR COMPENSATION ROTATION Pinguely Haulotte Z 6 OPERATING EQUATIONS The lights inside the panel show the solenoid valve s consitions Light off solenoid valve present but not activated Weak light solenoid valve not connected Strong light solenoid valve present and activated Machine folded SQ2 1 and 504 1 and 509 1 Machine unfolded 502 0 ou SQ4 0 ou 509 0 if SB3 1 or SB4 1 and W 0 and D 0 and YV1 pas aliment e then KA2 1 if KA2 1 or No motor fault for more than 6 seconds then KP1 1 motor fault gt D 1 and B2 1 B3 1 if AM4 1 or HM31 1 or HM2 1 or SA9a 1 or SA9b 1 and SQ6 1 or 5 2 1 then KT2 1 Accelerator is time delayed for 0 5 seconds Up if SA5a 1 and 506 1 and 5 0 and SA9b 0 and SM31ab 0 and SM2ab 0 then YV15a 1 and YV2b 1 and YV1 1 Down if SA5b 1 and SQ6 1 and 5 0 and 5 9 0 and SM1ab 0 and SM2ab 0 then YV15b 1 and YV2b 1 and YV1 1 Right if SA4a 1 then YV19b 1 and YV2b 1 and YV1 1 Left if SA4b 1 then YV19a 1 and YV2b 1 and YV1 1 35 Pinguely Haulotte 2 Repair manual 6 6 6 7 6 8 36 JIB ROTATION ARM LIFTING Up if SA6b 1 or SA7b 1 and SQ1 1 or machine folded and SQ6 1 or turntable position then YV18b 1 and YV2b 1 and YV1 1 Down if SA6a 1 or SA7a 1 and SQ6 1 or Turntable position then 18 1 YV2b 1 and YV1 1 Turntble Left if SA15a 1 the
38. 417A out of the printed circuit NO Replace the See Fiche U1 module C058 YES The fault Repair the connection or replace the wiring harness between the turntable control panel and electrovalve YV 14 persists See Fiche C063 Replace the printed circuit Y END Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP067 NO TELESCOPING MOVEMENT OUT AND OR IN FROM Folio 5 6 THE PLATFORM OR TURNTABLE CONTROL PANEL Platform telescope fault Y Turntable Y telescope fault Maintain the control activated and check for 12V voltage at terminals 419 out and 418 in of the printed circuit Maintain the control activated and check for 12V voltage at terminals 412 out and 411 in of the printed circuit Open the platform or turnta ble control panel and check the wiring of the telescope switch SA9 or SA8 NO YES Replace the U1 module See Fiche C058 NO The fault persists YES Repair wiring Check the electric continuity of the switch contacts when closed Replace the printed circuit SeeFiche C063 NO YES Replace the telescope See Fiche switch SA9 or SA8 C043 or Fiche C044 Repair the connection or replace the wiring harness between the telescope switch SA9 or SA8
39. 47 Pinguely Haulotte 2 Repair manual DESCRIPTION B15390 Left front engine Right front engine Left rear engine Right rear engine Turret slewing Arm lifting Boom raising Telescoping Pendular arm Platform rotation Compensation Front axle Rear axle Travel On off movement Hydraulic reservoir unit LS piston pump max 45cm3 rev 1500W 3cm3 12V electric pump unit 3 8 BSPP in line pressure limiter 3 4 BSPP non return valve 0 5 bar 3 8 BSPP non return valve 0 5 bar Pressure filter clogging indicator PVG32 12V S5086 distribution block NN s i OI SI Sit ACA E OU mm DO gt 10 4x4 12V S5095 travel block 11 Double displacement hydraulic motor 12 Hydraulic motor 13 Cartridge balancing valve r 3 1 14 Cartridge pressure limiter 15 S5136 telescoping block 16 Cartridge non return valve 18 Hydraulic motor 19 Flanged piloted double non return valve 20 CETOP5 base plate 1 section 21 12V NG10 4 3 AB towards T solenoid valve 22 CETOP5 double pressure limiter 23 CETOP3 base plate 3 sections 24 12V NG6 4 3 AB towards T solenoid valve 25 CETOP3 double pressure flow limiter 26 CETOP3 piloted double non return valve 28 CETOP3 body 2 T11 housings 29 12V S5054 steering brake release block 48 Repair manual Pinguely Haulotte 7 10 HYDRAULICS COMPONENTS D
40. Changing the tilt sensor buzzer SHEET C043 Changing an electric component on the top control panel SHEET C044 Changing an electric component on the bottom control panel SHEET C045 Changing a manipulator SHEET 046 Changing the starter battery SHEET C047 Changing a cover gas spring SHEET 052 Changing the basket rotation hydraulic motor SHEET C053 Changing the basket SHEET C054 Changing a weighing system rolling bearing SHEET C056 Changing the hydraulic filter SHEET C058 Changing the 1 electronic module SHEET C059 Changing a coil SHEET C062 Changing a relay SHEET C063 Changing the printed circuit SHEET C064 Changing the fail safe pedal SHEET C067 Changing an electrovalve SHEET C068 Changing the double balancing valve of the rotation function SHEET C069 Dismantling re assembling the jib SHEET C079 Changing a flow separator SHEET C082 Changing a balancing valve for the compensation function SHEET C083 Changing a double flow limiter for the compensation function SHEET C084 Changing a non return valve on the steering hydraulic block SHEET C085 Changing a steering pivot on a non drive wheel SHEET C086 Dismantling and re assembling the steering system SHEET C087 Changing the steering cylinder SHEET C091 Changing the hydraulic pump SHEET C092 Chan
41. HA2 platform sounds continuously if B1 0 then HL2 1 if B2 0 then HL3 1 if B3 0 then HL4 1 Repair manual Pinguely Haulotte D 6 16 OTHER FUNCTIONS OVERLOAD DEAD MAN SLOPE 6 16 1 Overload Overload through SQ6 cuts out all the movements controlled from the basket When you switch to turntable position the movements are slower Moreover the turntable buzzer sounds If SQ6 gets to O during a movement controlled from the basket the latter is not cut out If SQ gest to O during a movement controlled from the turntable the latter is slowed down 6 16 2 Dead man During the movement dead man pedals can be released for 0 5 seconds If the dead man is actuated for x seconds joystick neutral the movement can not be actuated Travel x 6s Movements x 4s 6 16 3 Slope When the machine is unfold ans in slope position boom lifting jib lifting and travel cut out The buzzer sounds continuously 6 17 HA26P REACH LIMIT Refer to working area diagram area no cut out B area slower movements C area telescope extraction cut out D area boom lowering cut out E area telescope extraction cut out F area engine cut out 39 Pinguely Haulotte 2 Repair manual 40 Repair manual Pinguely Haulotte T SAFETY LOCATION E O SQ4 E Ot OQ co oO 41 Pinguely Haulotte 2 Repair manual 42 Repair manual Pinguely Haulotte 7 8 POSITIONS OF ELECTRIC COMPONENT
42. MAINTENANCE SHEET Sheet 038 Folio 1 1 CHANGING THE STEERING CYLINDER 7 Preliminary operations Putthe machine in the maintenance configuration see corresponding Caution graph Ensure that the oil is not too Switch off electric power see corresponding paragraph hot 2 Removing the steering cylinder Open the upper chassis cover Caution Mark and disconnect the two hoses 2 of the steering cylinder 1 Use a container to collect oil to prevent pollution ofthe NE Unscrew the hoses slowly to release residual hydraulic pressure environment Put caps on the hoses Put the cylinder in slings A Caution Remove the Nylstop nuts 4 then remove the two fastening pins 3 from the It is essential to put the steering cylinder component in slings before Remove the steering cylinder dismantling re assembling it 3 Installing the steering cylinder Puta new steering cylinder into place Install the fastening pins and fix using new Nylstop nuts and their washers Reconnect the hydraulic hoses according to the marks made during dismant ling Putthe machine back into the operational configuration Make several steering movements to purge the hydraulic circuit Checkthe level of the hydraulic oil tank HA16 18 HA46 51 JRT HA16 18 HA46 51 JRT Sheet C039 Caution Do not use the machine during maintenance operations HA16 18P
43. Nylstop nuts and washers Reconnect the hydraulic hoses according to the marks made during dismant ling Check that there is sufficient oil in the hydraulic tank Putthe machine back into the operaitonal configuration Make several steering movements to purge the hydraulic circuit Checkthe level of the hydraulic oil tank Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C091 Folio 1 2 CHANGING THE HYDRAULIC PUMP Caution Ensure that the oil is nottoo 44 Preliminary operations hot Put the machine in the maintenance configuration see corresponding para graph Switch off electric power see corresponding paragraph Caution Close the shut off valve if any otherwise empty the hydraulic oil tank Close the shut off valve if any otherwise empty the 12 Removing the hydraulic pump hydraulic oil tank Mark and disconnect the pump hoses 1 Caution NB Unscrew the hoses slowly to release residual hydraulic pressure Use a container to collect oil to prevent pollution of the Put caps on the hoses Remove the hydraulic unions 4 screwed on the pump Remove the screws and washers 2 fixing the pump to the motor flange 3 then remove the pump 5 Remove the split spined hub 6 by unscrewing its tightening screw 7 Discard the O rings Caution 13 Installing the hydraulic pump It is essential to put the component in sli
44. Obstruction of the tank air vent Suction valves closed Defective pipes Hydraulic pump defective Insufficient oil level Fiche DP025 Insufficient pressure or power at the pump Clogged air filter Motor speed too low Oil leak on connector hose or component Clogged oil filter Change the filter Adjust speed Repair or replace Replace oil filter cartridge No travel telescope out boom and arm lifting buz zer sounding Slope or tilt 25 First retract the telescope and lower the boom to reset Buzzer sounding Slope or tilt gt 5 Platform load close to cut off Hydraulic oil temperature too high Reset by retracting the teles cope and lowering the boom Remove load Leave to cool The electropump does not work Battery breaker open Fuses broken Defective or discharged batteries The battery wires do not make contact Close the battery breaker Replace the fuses Replace or recharge the batte ries Clean or tighten the terminals 85 Pinguely Haulotte 4 Repair manual 14 1 2 Lifting system PROBABLE CAUSE Electrovalve YV15 or YV2 defective Coil defective Electronic module U1 defective Wiring harness defective SOLUTION ANOMALY No platform up and or down Fiche DP026 compensation movement Printed circuit defective Compensation switch SA5 defective Lifting manipulator defective No pl
45. and or left Place the key switch in the platform position Press the pedal and activate the compensation switch on the platform control panel Compensation movement OK Stop the movement and release the pedal Open the turntable control panel and check that the LED associated with the electrovalve YV19A left or YV19B right is off 70 Press the pedal and activate the platform rotation switch Check that the LED associated with the electrovalve YV19A left or YV19B right is on YES YES Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP027 Folio 2 5 NO PLATFORM ROTATION MOVEMENT RIGHT AND OR LEFT Press the pedal and activate the platform rotation switch Check for 12V vol4 tage at the terminals of the PVG connector YV2a YV2b for H14 16 HB40 44J Open the turntable control panel Press the pedal and activate the platform rotation switch Check for 12V voltage on terminal 305 415 for H14 16 HB40 44J of the printed circuit See Fiche Replace the PVG 077 2 control head NO Replace the See Fiche module C058 YES Repair the connection or The fault NO replace the electric wiring persists harness between the turntable control panel and PVG YV2 END Replace the See Fiche C063 printed circuit Pinguely Haulotte 4 BREAKDOWN DETECTIO
46. e 45 e e 2 v GL SL ZL OL GL EL LL OL 6 8 2 9 6 v c L 26 Pinguely Haulotte 4 Repair manual WIRING DIAGRAM E 448 FOLIO 05 05 4 5 SVWSAHOS saa PSL jns unus oooz vo z EE 9 4 anyoHnea er aljesen Looz Lo 80 O8rr3 DE Een bz 62 LL vO TAL JUNys LOOZ 0 LzZ 9 6661 70 02 014014 1 1ueune W101 VSIA NOLLVOIJIGOIN d9cvH d0cvH 31va 31101 nvH A13N9NId Loe LOZ oui N YOLA E M r 2 1 w gt E 3 8 3 2 a o o 5 5 w gt z E o z gt z w o 3 o S D 5 ES 3 ES o 3 2 a v o e D D 3 2 2 2 a 9 o 8 gt 3 5 S 5 5 5 5 8 9 A 5 3 5 in ez e Fe Fe Foz 762 Frez Eroe roe roe foe fez A A 4 0 0 u 5 D a a a Ja a la 2 0 4 2 N 2 2 N 5 N 0 0 2 4 H a 0 0 A 0 4 0 2 H N la pa IN 0 10 gt n H 0 gt 3 YS SWS M 8 5 b YINS 9
47. ft Remove the slings from the turntable Putback the rotation stop screw 5 of the swing joint 4 Reconnect the hoses of the swing joint 4 according to the marks made during dismantling Reconnect the electric connectors 2 of the chassis box 1 according to the marks made during dismantling Adjust the position of the reducing gear 11 using the adjusting screws 12 and 13 Turn the reducing gear to position the ring teeth marked with a colour opposite the reducing gear pinion this coloured mark corresponds to the most excentric point of the ring Adjust the gap between the teeth to 300um with a set of flakes When the gap is set block the counter nuts of the adjustment screws 12 and 13 4 Additional operations Putthe machine back in the operational configuration Lubricate the ring Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Fiche C106 Folio 2 3 CHANGING THE SLEW RING NB Only use lubricants recommended by the manufacturer Make several turntable rotation steering and travel movements using all possible travel speeds to purge the hydraulic circuit Check that the electric controls work properly Check the level of the hydraulic oil tank 9 8 _ SNS SN ANS em ZZ bol 6 7 4 5 3 Figure 1 Figure 2 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C106 Folio 3 3 CHANGING THE SLEW RING
48. initial setting and tightening torque values see corresponding paragraph 12 2 3 Locating the breakdown Certain checks require the elevating platform to be switched on In this case personnel must ensure that the measurement devices used are properly insulated that they do not touch the live parts that they are not wearing or carrying metal objects that may deterio rate the live components e g dropping a spanner during an interven tion on the batteries Instructions Maintenance configuration Position the elevating platform on a firm horizontal surface f possible fold the machine completely Otherwise for specific ope rations put the various components into slings Put the turntable rotation blocking pin into place ref Photo 1 page 62 Restoring operational configuration Remove the blocking pin rep 1 Photo 1 page 62 Repair manual Pinguely Haulotte 7 12 4 ELECTRIC POWER SUPPLY Instructions Cutting off the electric power supply Press the turntable emergency stop ref 1 Photo 2 page 63 Photo 2 Restoring the electric power supply Reset the emergency stop ref 1 Photo 2 page 63 63 Pinguely Haulotte 4 12 5 MAINTENANCE PLAN CONSUMABLE Engine oil SPECIFICA TION SAE 15W40 Repair manual The plan shows the frequency area of maintenance device and the consumables to be used The reference shown in the symbol shows the area maintained based o
49. is off TO Press the pedal and activate the platform or turntable jib switch Check that the LED associated with electrovalve YV18A down or YV18B up is on YES YES Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART NO JIB MOVEMENT UP AND OR DOWN Folio 2 5 Sheet DP028 FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Press the pedal and activate the jib switch Check for 12V at the terminals of the connector YV2a Open the turntable control panel NO Press the pedal and activate the jib switch Check for 12V voltage on terminal 305 of the printed circuit See Fiche Replace the PVG C077 or YV2 control head C108 NO Replace the See Fiche VM U4 module C058 or C107 YES Repair the connection or The fault NO replace the electric wiring persists harness between the turntable control panel and PVG YV2 END Replace the See Fiche printed circuit C063 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP028 NO JIB MOVEMENT UP AND OR DOWN Folio 3 5 FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Y Invert the coils of the jib electrovalve YV18A and YV18B Press the pedal and activate the platform or turntable jib switch The defective movement up 1 or down 2 is made in response to an opposite movement control down 1 or up 2
50. low speed Check the setpoints at the terminals of selector SA11 Y Place the speed selector SA11 on high speed Check the setpoints at the terminals of selector SA11 SA11a OV 804 NO SA11a 12V 804 SA11b 12V 805 r SA11b OV 805 YES Replace the See Fiche speed selector C044 SA11 END Y Open the turntable control Open the turntable control Replace the U1 See Fiche panel panel module C058 Check for 12V at terminal 804 Check for 12V at terminal 805 Replace harness 805 NO The fault persists YES Replace the printed See Fiche 5 circuit C063 Y Replace harness 804 END Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP070 Folio 1 1 SUDDEN STOP OF TRAVEL MOVEMENT DURING A PLATFORM LIFTING OPERATION Sudden stop of travel movement during a platform lifting operation Check the setpoint at the output of detectors SQ9 SQ4 SQ2 Adjust the detector s See Fiche Setpoint replace defective C061 2412V detectors Check the continuity of harnesses END no 204 232 206 Harness no 204 232 206 NO Replace the defective harness es ao p continuity OK no 204 232 206 Check operation of the See Fiche U1 electronic module 058
51. maintenance ofthe machine must also be in good condition An illegible label may result in incorrect or dangerous use of the machine Instructions Check that the labels are present Check that all the labels described below are legible and in place Replace them if necessary additional copies can be supplied on request if necessary 12 7 1 Common yellow label 7814 357 q 7814 354 67 Pinguely Haulotte 4 Repair manual 12 7 2 Commom orange label CONSIGNE D UTILISATION POUR UTILISER CET APPAREIL L OPERATEUR DOIT 1 Lire et comprendre les informations contenues dans le manuel de conduite et les inscriptions appos es sur la machine se familiariser avec les commandes 2 Etre form et entra n pour la conduite de celui ci sous la responsabilit de son employeur 3 Assurer correctement l entretien suivant le catalogue constructeur 4 Ne pas utiliser en cas de disfonctionnement 5 Ne pas laver sous pression les composants lectriques 6 Ne rien d monter la stabilit serait modifi e 7 Ne pas modifier sans accord du constructeur 8 Ne pas utiliser la machine comme masse de soudure 9 Ne pas souder sur la machine sans d connecter les cosses des batteries se r f rer la notice de conduite et d entretien INSPECTIO
52. nuts and washers 2 at both ends of the gas spring 3 HA16 18PX HA46 51JRT 3 Installing a gas spring Puta new gas spring into place and fix at both ends using the fixing nuts and washers Putthe machine back into the operational configuration Check that the cover opens and closes correctly HA16 18 PX New design HA46 51JRT New Design Sheet 052 Caution Ensure that the oil is not too hot Caution Use a container to collect oil to prevent pollution of the environment Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET CHANGING THE BASKET ROTATION Folio 1 1 HYDRAULIC MOTOR 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph 2 Removing the hydraulic motor NB Mark and disconnect the hoses 2 from the hydraulic motor 4 Unscrew the hoses slowly to release residual hydrualic pressure Fit caps to the hoses Remove the flow limiters 1 by unscrewing the unions 5 and adapters 6 Remove the hydraulic motor by unscrewing its fixing screws 3 Installing the hydraulic motor Replace the flow limiters if necessary Put a new hydraulic motor into place Fix the hydraulic motor using fixing screws equipped with new grower washers Screw the unions adapters and flow limiters onto the motor Reconnect the hydraulic hoses according to the marks
53. panel 18 30 7814 9940 1 Platform control panel 19 30 7814 3870 2 Floor height load HA20 PX 19 30 7814 6470 2 Floor height load HA26 PX 24 30 7814 3680 1 Read user manual 26 B12759 HAULOTTE logo 27 30 7814 3240 a 1 Manufacturer s plate 28 30 7814 7650 1 Name logo 29 S2954 HAULOTTE logo 75 30 7814 8740 1 Acoustic power 77 3078149230 1 Manual trouble shooting 78 30 7814 9240 2 Do not spray water near the built in generator 79 30 7814 9250 1 Built in generator ON button 80 242 180 8660 Yellow and black reflective adhesive marking Pinguely Haulotte 4 Repair manual 12 7 7 Label positioning 7 Nie 64 Pla a alesny enbiogds 52 enbyiogds puepuejs O pi y 73 Pinguely Haulotte 4 Repair manual 12 8 PRESENCE OF MANUALS It is important to ensure that the manuals supplied with the machine are in good conditions 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 manual
54. rod and body side of the cylinder Putback the pin stop rings 4 and fix with their bolts Put back the pin stop clevis 5 Remove the slings Reconnect the cylinder s hydraulic hoses 1 4 Additional operations Free the basket Putthe machine back in the operational configuration Ensure that there is oil in the hydraulic tank Make several jib movements to test operation and purge the hydraulic cir cuit Checkthe level of the hydraulic circuit Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C115 Folio 2 2 CHANGING THE JIB CYLINDER Sheet C117 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Folio 1 2 CHANGING THE TURNTABLE ROTATION REDUCING GEAR 1 Preliminary operations 4 Lift the boom to enable access to the turntable rotation reducing gear 1 Wedge the boom to take its weight place on firm supports Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Remove the turntable rotation hydraulic motor 5 see corresponding sheet Removing the turntable rotation reducing gear Release then unscrew the counter nuts and screws 2 as far as possible Tighten the screws 2 as far as possible Release the counter nuts from the two screws 3 Unscrew the two screws 3 by a few turns without removing them Remove the four fixing screws 4 from the turntable rotati
55. the platform are possible only if the fail safe pedal is pressed Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 067 Folio 1 1 CHANGING AN ELECTROVALVE 1 Preliminary operations Caution Putthe machine in the maintenance configuration see corresponding Ensure that the oil is not too paragraph hot Switch off electric power see corresponding paragraph 2 Removing an electrovalve Markand disconnect the electric connections 1 of the coils N Caution Mark the installation position of the electrovalve on the block Unscrew the four fixing screws 3 of the electrovalve 2 and remove Use a container to collect oil to prevent pollution of the 3 Installing an electrovalve environment Puta new electrovalve equipped with its seals into place and fix using the 4 screws in the position of the electrovalve on the block Tighten to the recommended torque see corresponding paragraph Reconnect the electrovalve s electric connections according to the marks made during dismantling Putthe machine back into the operational configuration Make several movement cycles using the replaced electrovalve to purge the hydraulic circuit Checkthe level of the hydraulic oil tank Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C068 CHANGING THE DOUBLE BALANCING VALVE Folio 1 1 OF THE ROTATION FUNCTION 1 Preliminary operations Caution Putthe machine in
56. 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 Caution To attract the reader s attention instructions are indicated by this standardised sign Pinguely Haulotte 2 Repair manual 1 2 GENERAL SAFETY RECOMMENDATIONS Caution Only trained operators may use Haulotte self propelled platforms 1 2 1 Operators Operators must be aged 18 or over and hold an operating permit issued by the employer after verification of medical aptitude and the practical platform operation test There must be at least two operators present so that one of them can intervene rapidly if necessary take over the controls in the case of accident or breakdown monitor and prevent machines or people from circulating around the plat form guide the platform 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 tem
57. turntable box Reconnect the then terminals of the starter battery Putthe machine back into the operational configuration a Test the printed circuit 4 Testing the printed circuit Perform the computer operating test see changing the U1 electronic module sheet Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C064 Folio 1 1 CHANGING THE FAIL SAFE PEDAL 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Disconnect the then terminals of the starter battery 2 Removing the fail safe pedal Open the platform electric box Mark and disconnect the electric connections 1 of the fail safe pedal 2 in the box Mark the pedal cabling path 1 along the vertical platform parts and then cut the fixing collars 3 Remove the pedal by removing the pedal s fixing bolts 4 and their washers 3 Installing the fail safe pedal Puta new pedal into place and fix using the bolts and their washers Reconnect the electric connections in the box according to the marks made during dismantling Close the platform box Fixthe electric cable to the vertical platform parts using collars Reconnectthe then terminals of the starter battery Putthe machine back into the operational configuration Check that movements from
58. turntable station but does start from the platform station Switch SB3 defective Wiring harness defective Fiche DP020 No motor acceleration regar dless of the movement con trolled from the platform Electronic module U1 defective Wiring harness defective Fiche 021 No motor acceleration by activating the accelerator Switch SA2 on the turntable control station Fuse FU3 defective Relay KT2 defective Electronic module U1 defective Wiring harness defective Accelerator switch SA2 defective Motor accelerator coil YA2 defective Fiche DP022 No movement available from turntable or platform station 84 Insufficient hydraulic oil Fuse FU7 or FU4 or FU10 defective Wiring harness defective Electrovalve YV1 defective Incorrect Load sensing pressure setting Motor pump coupling defective Hydraulic pump defective Pressure limiter defective Distribution block input module defective Pump regulation unit incorrectly set or de fective Hydraulic pump defective Electronic module U1 defective Relay KMG defective Printed circuit defective Key switch SA1 defective Fiche DP023 Repair manual Pinguely Haulotte 4 ANOMALY PROBABLE CAUSE SOLUTION No movement available from the platform control station Fuse FU1 defective Platform control station defective Fail safe pedal defective Wiring harness defective Fiche DP024 Noisy hydraulic pump Oil non conform
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60. 04 0v if temperature gt 130 C D Alternator 109 12v If the alternator work W Anti starter 108 12v When the engine is on 5 4 OUTPUT 5 4 1 Relay KP1 Motor stop KT2 Accelerator KA2 Starter 5 4 2 On Off electrovalves 12v lectro command e 0 lectro non command e YV1 Load Sensing 303 time delayed for 2 seconds YV2a Telescope 305 YV2b Steerinf rotation compensation jib 415 YV9 Differential blocking 807A YV10 High speed 814B YV12 High speed 814A YV13 Differential blocking 807B YV14a Telescope in 414A YV14b Telescope out 417A YV15a Compensation up 401A YV15b Compensation down 402A YV18a Jib down 407A YV18b Jib up 408A YV19a Basket rotation left 310A YV19b Basket rotation right 311A YV21a Rear left steering 4 4 307 YV21b Rear right steering in 4 4 308 YV22a Front right steering in 4 4 304 YV22b Front left steering in 4 4 306 33 Pinguely Haulotte 2 Repair manual 34 5 4 3 Proportional electrovalves The supply oltage of proportional electrovalves varies from 6 to 3V in one direction ans 6 to 6V in the other YV3 Lifting 403A YVA Telescoping 506A YV5 Rotation 512A YV6 Travel 612A YV7 Travel 612A 5 4 4 Buzzer and light indicators HA1 Horn 260 261 HA2 Overload 1st threshold buzzer 213 HA4 Tilt overload temperature buzzer 210 HL1 Battery charge 109 HL2 Air filter 110A HL3 Motor oil temperature 111A HL4 Motor oil pressure 112A Repair manual 6 1 6 2 6
61. 1 5 NO MOVEMENT AVAILABLE FROM TURNTABLE OR PLATFORM CONTROL PANELS No movement available from turntable or platform panels Check the level of hydraulic See Fiche oil P005 or P008 NO YES Open the turntable control Fill up See Fiche panel Check the state of fuses 005 or 08 FU4 FU7 and FU10 END NO YES Activate the boom lifting movement in the Replace the emergency mode defective fuse Put the emergency lever into place on the manual control of the boom lifting control distributor YV3 END Activate the lever up then down while pressing the emergency control of the safety valve YV1 or activate the emergency power unit Movement NO oK YES Connect a pressure gauge to the PVG pressure tap M on the turntable control Place the key switch in the platform position panel Press the pedal and activate the boom lifting Start the platform start the thermal motor manipulator SM31 while pressing the emergency without making a movement control of the safety valve YV1 Check the load sensing pressure reading tap M 25 to 30 bars Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP023 Folio 2 5 NO MOVEMENT AVAILABLE FROM TURNTABLE OR PLATFORM CONTROL PANELS Movement NO OK Open the turntable control panel Press the pedal and activate the b
62. 1Unys moly 002 0 12 _ 6661 0 80 IQ uaine SOMOS TVLOL VSIA NOILVOISIGOW d9cVH dOcVH 31101 NVH ON Id 4617 44Q NO 346171005 uooeeg 01 20 10 0 8 9 9 lt x o 02 10 7271 69 NH 1 SH vy ved 91H ie 1 0 0 o z1 10 WH 0 9 5 N M a 2 2 T Leo SIDE X Nes Zoe e a sce N 2 0 eo lt 02 10 ena N N ZOL 0 VOZ vs 0 9 6nd I 8nd ind NN A Xo NOL ore ore e SLZ Aueo 68 zas lt lt SEE e e cU SLZ 02 10 01 20 ON St jeun 53 O HL 02 10 oz GL SL 21 OL GL FL ei LL ol 6 8 2 9 6 v c L 24 Pinguely Haulotte 4 Repair manual WIRING DIAGRAM E 448 FOLIO 03 05 4 3 E 666 0 06 CU SVIN3 H 25 8 SL 19 v sy INS NYS 0006 40 10 e NOLLVOIAISAN UVA uS i 301 edwod dg L002 10 80 O8rr3 a is 6 jnofy
63. 2 Removing the horn operations Mark and disconnect the electric connections from the horn 1 Remove the horn by unscrewing the fixing bolts 2 3 Installing the horn Putthe horn back into place and fix with the fixing bolt Reconnect the electric connections according to the marks made during dismantling 4 Test Select the top control panel and switch on machine power Putthe machine back into the operational configuration Activate the horn switch from the platform control panel and check that the horn sounds The horn should audible from the basket Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C041 Folio 1 1 CHANGING THE TILT SENSOR BUZZER Caution 1 Preliminary operations Switch off electric power see corresponding paragraph Do not use the machine during maintenance 2 Removing the buzzer operations Mark and disconnect the buzzer s electric connections 1 Remove the buzzer by unscrewing the fixing bolts 2 HA16 18PX HA46 51JRT 3 Installing the buzzer Putthe buzzer back into place and fix with the fixing bolts Reconnect the electric connections according to the marks made during dismantling 4 Test Putthe machine back into the operational configuration Extend the machine tilt the tilt sensor and check that the buzzer sounds HA16 18PX New design HA46 51JRT New Design Caution The buzzer sho
64. 2 Removing the slew ring Open the chassis box 1 mark and disconnect all electric connectors 2 Freethe electric wiring harness 3 of the swing joint 4 after marking its path Mark and disconnect the hoses of the swing joint 4 under the chassis travel motor oil supply and return Unscrew the hoses slowly to release residual hydraulic pressure Putcaps on the hoses Remove the swing joint s rotation stop screw 5 Putthe turntable in slings and unlock the turntable rotation blocking pin Remove the 24 screws 6 and washers fixing the slew ring to the lower part 7 of the machine Remove the turntable carefully avoiding damage to the swing joint 4 Wedge the ring 8 mark its position in relation to the turntable Remove the 24 screws 9 bolts 10 and washers fixing the slew ring 8 to the turntable Freethe turntable Installing the slew ring Putthe slew ring 8 into place on suitable supports in the position marked during dismantling Position the turntable on the ring Fixthe ring with the 24 screws 9 bolts 10 and washers without pre stressing Tighten in a star pattern see figure 2 to a torque of 27 m daN 199 Ib ft Place the turntable ring assembly on the chassis in the locking position Fixthe ring 8 to the chassis 7 using the 24 screws 6 and washers without pre stressing Tighten in a star pattern see figure 2 to a torque of 27 m daN 199 Ib
65. 2 2 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C132 Folio 1 1 CHANGING A TURNTABLE COVER 1 Preliminary operations e machine in the maintenance configuration see corresponding paragraph Caution f Switch off electric power see corresponding paragraph Do not use the machine during maintenance 2 Removing a cover operations Open the relevant cover 1 Putthe cover in slings Remove the gas springs see corresponding sheet Remove the screws 3 fixing the cover 1 to the two hinges 2 Remove the cover 3 Installing a cover Puta new cover into place and fix onto the two hinges 2 using screws 3 Install the gas springs see corresponding sheet Putthe machine back in the operational configuration Check that the cover opens and closes properly If necessary adjust the cover using the screws 3 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C133 Folio 1 2 CHANGING THE THERMAL MOTOR Caution 1 Preliminary operations Leave the motor and exhaust the machine in the maintenance configuration see corresponding pipe to cool sufficiently paragraph before performing any Switch off electric power see corresponding paragraph maintenance operation on Disconnect the then terminals of the starter battery these elements Remove the cover on the motor side see corresponding sheet
66. 4 CHANGING AN ELECTRIC COMPONENT Folio 1 1 ON THE BOTTOM CONTROL PANEL 1 Preliminary operations Putthe machine in the maintenance configuration see corresponding Caution paragraph Jonotuse dfe nei Switch off electric power see corresponding paragraph 4 Disconnect the then terminals to isolate the circuit during maintenance operations 2 Removing a component from the bottom control panel Open the door of the bottom control panel 1 Mark and disconect the electric connections 3 of the component to be replaced 2 Remove the component 3 Installing a component in the bottom control panel Put a new component and seal into place on the front panel of the bottom control panel NB In the case of a lever switch adjust the position of the fixing nut and counter nut so that the switch lever s articulation pin is at the same level as the seal to ensure tightness Reconnect the electric connections according to the marks made during dismantling Close the door of the bottom control panel Reconnectthe then terminals of the battery 4 Test Putthe machine back into the operational configuration Perform the function corresponding to the replaced component to check that it works properly Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C045 Folio 1 1 CHANGING A MANIPULATOR 1 Preliminary operations A Caution e Put the machine
67. 5 See Fiche 077 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP019 THE MOTOR DOES NOT START Folio 1 2 FROM THE PLATFORM PANEL BUT DOES START FROM THE TURNTABLE PANEL The motor does not start from the platform but does start from the turntable Place the key switch in the platform position Check that the platform panel power light indicator is on NO Open the turntable control panel and check the state of fuse FU6 YES NO Open the platform control panel and E check the connection continuity and connector of switch SB4 YES Replace fuse FU6 Connection OK END In the turntable control panel Repair the YES check for 12V voltage on lines connection of 211 and 242 of the wiring switch SB4 Activate switch SB4 harness connection terminal and check continuity block between the platform between the two control panel and the turntable terminals of the switch control panel NO gt NO Replace See Fiche YES YES Repair wiring of the switch SB4 C043 key switch SA1 or replace the switch END Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP019 THE MOTOR DOES NOT START Folio 2 2 FROM THE PLATFORM PANEL BUT DOES START FROM THE TURNTABLE PANEL i Activate SB4 and check for 12V voltage at terminal 117B of the printed circuit Repair wiri
68. AULIC BLOCK 1 Preliminary operations Putthe machine in the maintenance configuration see corresponding Caution paragraph Ensure that the oil is not too Switch off electric power see corresponding paragraph hot 2 Removing the distribution hydraulic block Mark and disconnect the electric connections 1 of the hydraulic block 3 Markand disconnect the block s hoses 2 A 1 iPad NB Unscrew the hoses slowly to release residual hydraulic pressure Use a container to collectoil to prevent pollution of the Put caps on the hoses environment Put the hydraulic block in slings Remove the fixing screws and washers 4 from the hydraulic block Take out the block from the top of the turntable Dismantle the hydraulic block to change one of its elements if necessary see corresponding sheet 1 Installing the distribution hydraulic block H the distribution block installed is new fit the new block with the unions retained from the old one but replace the O rings Tighten to the recom mended torque see concerned chapter Putthe hydraulic block into place and fix with screws equipped with new grower washers Reconnect the hydraulic hoses according to the marks made during dis mantling Tighten to the recommended torque see chapter concerned Reconnect the hydraulic block s electric connections according to the marks made during dismantling Putthe machine back
69. Calm smoke rises vertically 0 1 0 0 2 1 Light Air Direction of wind shown by smoke 1 5 0 3 1 5 2 Light Breeze Wind felt on face leaves rustle ordinary vanes moved by 6 11 1 6 3 3 wind 3 Gentle Breeze Leaves and small twigs in constant motion wind extends 12 19 3 4 5 4 light flag 4 Moderate Breeze Raises dust and loose paper small Branches are moved 20 28 5 5 7 9 5 Fresh Breeze Small trees in leaf begin to sway crested wavelets form 29 38 8 0 10 7 on inland waterways 6 Strong Breeze Large branches in motion whistling heard in telephone 39 49 10 8 wires umbrellas used with difficulty 13 8 7 Near Gale Whole trees in motion inconvenience felt when walking 50 61 13 9 against wind 17 1 8 Gale Breaks twigs off trees generally impedes progress 62 74 17 2 20 7 9 Strong Gale Slight structural damage occurs chimney pots and slates 75 88 20 8 removed 24 4 10 Repair manual 2 1 Pinguely Haulotte 4 2 SPECIFICATIONS HA 20PX and HA 26PX self propelled lifts are designed for any high work within the limit of their characteristics and complying with all the safety instructions particular to the machine and to the locations where it is used The main operating post is in the basket The turret operating post is an emergency or back up post TECHNICAL CHARACTERISTICS 2 1 1 HA 20PX technical characteristics kg including 2 peoples
70. E MAINTENANCE SHEET Sheet 058 Folio 1 1 CHANGING THE U1 ELECTRONIC MODULE 1 Preliminary operations the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Disconnect the then terminals of the starter battery to isolate the electric circuit 2 Removing the U1 electronic module e Open the turntable electric box Remove the fixing flange 2 from the U1 electronic module Remove the U1 electronic module 3 Installing the U1 electronic module Install a new U1 electronic module previously programmed by the manu facturer Install the fixing flange Close the electric box Reconnectthe then terminals of the starter battery Putthe machine back into the operational configuration Checkthat the U1 electronic module works perfectly using the check list for the machine concerned 4 Testing the U1 electronic module Make all movements from the bottom control panel for two seconds Make all movements from the top control panel for two seconds Caution Lift the jib gt 0 Computers are not Make a travel movement with the selector on high speed and check that interchangeable they have a movement speed is actually micro speed serial number corresponding Lower the jib to a given machine If this rule Liftthe arm to 3 metres is ignored dangerous Make a travel movement w
71. EAR steering switch SM4 Check that the LED associated with electrovalve YV21A left or YV21B right is on Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP038 Folio 2 4 NO STEERING MOVEMENT RIGHT AND OR LEFT ON THE REAR AXLE Press the pedal and make a travel movement Activate the REAR steering switch SM4 and check for 12V voltage at the terminals of the PVG connector YV2a Open the turntable control panel Press the pedal and make a travel movement Activate the REAR steering switch SM4 and check for 12V voltage on terminal 305 of the printed circuit See Fiche Replace the PVG C077 YV2 control head NO Replace the See Fiche U1 module C058 YES Repair the connection or replace the electric wiring harness between the turntable control panel and PVG YV2 The fault persists NO END Replace the printed circuit See Fiche C063 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP038 Folio 3 4 NO STEERING MOVEMENT RIGHT AND OR LEFT ON THE REAR AXLE Invert the coils of the jib electrovalve YV21A and 21 Press the pedal and make a travel movement Activate the REAR steering switch SM4 The defective REAR steering movement left 2 or right 1 is made in Replace See Fiche response to an opposite m
72. ESCRIPTION 10 1 TRAVEL BLOCK 10 1 1 Location Description YV12 high speed solenoid valve AF1 flow divider YV13 differential lock solenoid valve AF2 flow divider YV9 YV10 High speed solenoid valve supply and control of 2 control valves AA1 and AA2 49 Pinguely Haulotte 4 Repair manual Description AD1 Equilibrating valve of front motor only using in low speed AD2 Equilibrating valve of front motors only using in low speed 50 Repair manual Pinguely Haulotte 7 10 1 2 Input and output Rear right engine feeding outlet Rear left engine feeding outlet Common outlet for both front driving engines Front left engine feeding outlet Rear left engine feeding outlet Rear right engine feeding outlet Rear left engine feeding outlet Stroke volume change driving engines feeding outlet Engines drain retourn Pressure input coming from proportional Danfoss valve outlet A from YV7 passage n 2 from slewing collector Pressure input coming from proportional Danfoss valve outlet A from YV6 passage n 1 from slewing collector Pressure input coming from proportional Danfoss valve outlet B from YV7 passage n 3 from slewing collector Unbreaking supply from steering in stop mode Pressure input coming from proportional Danfoss valve outlet B from YV6 passage n 4 from slewing collector 51 Pinguely Haulotte 4 Repair m
73. G Caution 1 Preliminary operations Ensure that the oil is not too the machine in the maintenance configuration see corresponding hot paragraph Switch off electric power see corresponding paragraph 2 Removing the hydraulic block Caution Remove the chassis inspection enabling access to the hydraulic block Markand disconnect the electric connections 2 of the hydraulic block 1 Markand disconnect the block s hoses 4 Use a container to collect oil to prevent pollution of the environment NB Unscrew the hoses slowly to release residual hydraulic pressure Putcaps on the hoses Place a wedge under the hydraulic block if necessary Remove the hydraulic block by removing the fixing screws and washers 3 1 Installing the hydraulic block Putthe hydraulic block into place and fix using screws equipped with new toothed washers Reconnectthe hydraulic hoses according to the marks made during dis mantling Reconnectthe electric connections of the hydraulic block according to the marks made during dismantling Putthe machine back in the operational configuration Make several movements using the replaced hydraulic block to purge the hydraulic circuit Checkthe level of the hydraulic oil tank On off movement Travel Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C093 Folio 1 2 CHANGING THE DISTRIBUTION HYDR
74. HE COUNTERWEIGHT S IS ARE REMOVED Screw the lifting rings onto the counterweight and secure a lifting beam to them e Fix a vehicle lift to the lifting beam and apply tension to the vehicle lift Switch off electric power see corresponding paragraph 2 Removing the small counterweight HA26 HA80 Remove the fixing screws 2 on the small counterweight HA26 HA80 Remove the small counterweight 3 3 Removing the counterweight HA20 HA26 HA61 HA80 Remove the fixing screws and washers 5 Remove the counterweight 4 4 Installing the counterweight HA20 HA26 HA61 HA80 Putthe counterweight 4 into place against the stops on the turntable Putback the fixing screws and washers see table of torque values 5 Installing the small counterweight HA26 HA80 Position the small counterweight 3 using a lifting truck and push up underneath the turntable Fix with the fixing screws 2 and washer see table of torque values 6 Additional operations Check that the counterweight is properly secured to the machine Remove the counterweight lifting rings HA20 HA61 Remove the sling from the boom Putthe machine back in the operational configuration Caution Ensure that the lifting equipment is in good condition and of sufficient capacity Caution It is essential to put the component in slings before dismantling re assembling it Caution Do not use the mac
75. HYDRAULIC BLOCK 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph 2 Removing a non return valve Remove the non return valve 1 by unscrewing it 3 Installing a non return valve Screw a new non return valve whose characteristics correspond to the machine in question into the hydraulic block Put the machine back into the operational configuration Make several movements using the replaced non return valve to purge the circuit Check that the corresponding movement is made correctly Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Folio 1 2 Sheet 085 CHANGING A STEERING PIVOT ON A NON DRIVE WHEEL 1 Preliminary operations Putthe machine in the maintenance configuration see corresponding Caution paragraph Ensure that the oil is not too Switch off electric power see corresponding paragraph hot Remove the wheel corresponding to the element to be removed see cor responding sheet 2 Removing the bearings if necessary Remove the cap 10 Caution Remove the counter nut 11 brake washer 12 and nut 13 Use a container to collect oil Remove the hub 14 of the pivot 1 to prevent pollution of the Remove the bearings 16 environment Remove the seal 15 3 Removing a pivot see figure 1 Place a wedge under the steering pivot 1 Remov
76. N FLOW CHART Sheet DP027 Folio 3 5 NO PLATFORM ROTATION MOVEMENT RIGHT AND OR LEFT Y Invert the coils of the platform rotation electrovalve YV19A and YV19B Press the pedal and activate the platform or turntable rotation switch The detective movement left 1 or right 2 is made in response to an opposite movement control right 1 or left 2 Put coils YV19A and YV19B back in their original positions Press the pedal and activate the platform rotation switch Check for 12V voltage at the terminals of the YV19A left or YV19B right connector Open the turntable control panel Press the pedal and activate the platform rotation NO switch Check for 12V voltage on terminals 310A left or M 3114 right of the printed circuit YES NO Replace the See Fiche gt U1 module C058 See Fiche YV19A C059 left or YV19B Y right YES The fault persists Repair the connection or END replace the wiring harness between the turntable control panel and electrovalve YV19 See Fiche C063 Replace the printed circuit END Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP027 Folio 4 5 NO PLATFORM ROTATION MOVEMENT RIGHT AND OR LEFT G Y Maintain the control activated and check for 12V voltage at terminals 311 rig
77. N JOURNALIERE 1 V rifier le niveau d huile hydraulique et le liquide des batteries 2 V rifier s il n y a pas de signe apparent de d fectuosit fuite hydraulique boulonnerie liaisons lectriques 3 V rifier le fonctionnement de l indicateur de devers en faisant fonctionner l alarme sonore INSTRUCTION AVANT UTILISATION 1 Enlever la broche de blocage d orientation s il y a une tourelle 2 IMPORTANT La prise doit tre raccord e sur une installation lectrique prot g e par un disjoncteur diff rentiel 30 mA NORME C15 100 MISE EN ROUTE 1 D verrouiller l arr t d urgence puis actionner le bouton de d marrage 2 En cas de non fonctionnement attendre 10 s et renouveler l op ration INTERDICTION D UTILISER L APPAREIL PENDANT LA CHARGE DES BATTERIES 7814 342 68 Repair manual Pinguely Haulotte A 12 7 3 Common red label Composant sp cifique cette machine NE PAS INTERCHANGER Component specific to this machine DO NOT INTERCHANGE Komponenten nur f diese maschine geeignet BITTE AUF EINE ANDERE MASCHINE NIGHT MONTIEREN N MACHINE MASCHINE N 7814 349 7814 518 7814 388 7814 363 7814 362 7814 507 69 Pinguely Haulotte 4 7814 352 a 12 7 4 Other common label Repair manual 906 718
78. Pinguely Haulotte 4 REPAIR MANUAL y GER AT TIE LL Une w E SELF PROPELLED LIFT HA20 PX HA26PX 242 031 9530 02 03 pneuri O Haulotte 7 ARTICULEES MATS TELESCOPIQUES CISEAUX TRACTEES L ACCES A L ESPACE PINGUELY HAULOTTE LA PERONNIERE BP 9 42152 L HORME e T l 33 0 4 77 29 24 24 e Fax SAV 33 0 4 77 31 28 11 email haulotte haulotte com e Web www haulotte com Repair manual Pinguely Haulotte 4 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 pa
79. S 8 1 MOTHER BOARD 8 1 1 Description A SCREW Connector Battery Flashing light Bi energy machine option Bottom box door Main Top control panel Starter Bottom box door Accelerator control KMG main relay Main supply after switch 4 standby pump switch Emergency stop circuit Console connector Emergency stop circuit HAT horn P Battery Gas electrovalves option Petrol gas machine option Proportional valve output a _ Petrol gas machine option Buzzer RELAYS 5013 N Start Boom lifting PVG Motor stop Electric power thermal power switch Telescoping or arm lifting PVG Rotation PVG Accelerator Travel PVG Standby pump safety system Travel PVG Converter for bi energy machine Motor wiring harness Petrol gas switch Top control panel FUSES Top control panel Motor stop Top control panel Maintain accelerator SQ11 Main SQ10 Bottom position 506 Tilt Top position Hydraulic tank temperature probe B4 Electrovalve SQ3 Permanent sensor supply SQ4 or SQ14 Accessories SQ7 Load Sensing valve for machine with PVG SQ8 SQ9 43 Repair manual Pinguely Haulotte 4 8 1 2 Positions of screws connectors and relays 13 N
80. SA17a thermic 917 SA17b electric 918 SA18 Turntable electrical thermical SA18a thermic 919 SA18b electric 920 SM31 Steering and lifting Consign X Rotation 512 Consign Y Lifting 403 Up from 2 5 to 4 5v Down from 2 5 to 0 5v HM31 Fail safe 611B SM31ab Except neutral 420B SM2 Lifting Consign Y lifting 506 Up from 2 5 to 4 5v Down from 2 5 to 0 5v HM2 Fail safe 611B SM2ab Except neutral 420B SM4 Travel Consign Y Travel 612 Forward from 2 5 to 4 5v Reverse from 2 5 to 0 5v HMA Fail safe 611A SM4ab Except neutral 606 Rear steering SM4c left 703 SM4d right 705 32 Repair manual Repair manual Pinguely Haulotte 7 5 3 2 Safety inputs 501 Tilt 205 0v if in slope 592 Jib from 0 to 90 206 0 if with the top of 0 504 Separated boom or arm 207 0 if Separated boom or arm SQ5 1st step loading 213 12v if overload SQ6 2nd step loading 214 0v if overload 507 Outreach limitation cut on engine telescope 508 Outreach limitation cut on engine boom 509 Telescope out 204 0 if telescope 5010 Outreach limitation Telescope extraction cut out 5011 Outreach limitation Boom lowering cut out 5012 8 stopped 250 0v if boom gt 45 5012 8M stopped option 250 0v if boom gt 45 B1 Filter clogged 110 0v if filter clogged B2 Engine oil temperature 111 0v if temperature gt 80 C B3 Engine oil pressure 112 Ov if pressure gt 0 5b B4 Oil tank temperature 9
81. STARTER IS NOT ACTIVATED The motor does not start the starter is not activated Check the position of the platform and turntable emergency stop buttons Position Unlock the emergency stop button unlocked Check the state of battery charge Battery charge OK NO r Check the state of the generator Charge the batteries and replace if necessary Replace the batteries See Sheet C046 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP016 THE MOTOR DOES NOT START THE STARTER IS NOT ACTIVATED Open the turntable control panel and check the state of fuses FU1 FUA and FU8 NO YES Replace the defective fuse Check the 12V on line 242 of the turntable control panel 5 YES Repair key switch SA1 wiring or replace the switch Activate switch SB3 turntable or SB4 platform and check continuity between the 2 switch terminals NO m 2 Replace the defective See Fiche switch C044 ES Folio 2 3 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP016 Folio 3 3 THE MOTOR DOES NOT START THE STARTER IS NOT ACTIVATED Activate the starter switch SB3 or SB4 and check for 12 V voltage between terminals 242 and 146 in the turntable control box NO YES Check w
82. SWITCHES see chap 4 page 25 SB1 Mushroom headed emergency stop button turret SB2 Mushroom headed emergency stop button platform 01 Tilt unit prohibits by a cut the arm lifting raising telescoping pendular raising and trav el movements SQ4 Tilt reset if machine folded arm SQ5 Overload 1st audible alarm Threshold of 90 of maximum charge reached SQ6 Overload 2nd alarm Cut out Cuts all the movements on platform except basket rotation B1 Air filter switch Engine cut out if air filter clogged B2 Engine temperature switch Engine cut out if temperature too high B3 Engine oil pressure switch Engine cut out if pressure insufficient B4 Hydraulic oil temperature switch audible warning if temperature too high 21 Pinguely Haulotte Repair Manual 22 Pinguely Haulotte 4 Repair manual A WIRING DIAGRAM WIRING DIAGRAM E 448 FOLIO 01 05 4 1 23 6661 70 0 3Z3N3Q LO SVWAHOS 8791 19 ans yunus 0002 90 12 e LEA NET dg 1002 10 80 PEE ae ciun S 301
83. T SCALE nee een 10 2 RC gs LE 11 2 1 TECHNICAL CHARACTERISTICS icta ee ea 11 2 1 1 HA 20PX technical characteristics ss 11 2 1 2 HA 26PX technical characteristics ss 12 20e OVERALL DIMENSIONS scr 14 Pinguely Haulotte Repair Manual 2 2 1 HA 20PX overall enn E E 14 2 2 2 HA 26PX A een RR D RM 15 HGOATENING TORQUE een 16 2 3 1 Tightening torque for large thread 16 2 3 2 Tightening torque for fine thread ie 16 2 3 3 Tightening torque for hydraulic hoses E 17 2445s Pressure 18 Bein Adj ustMent di nee 19 3 SAFETY SYSTEM asien 21 3 1 FUNCTIONS OF THE TURRET CABINET FUSES AND 21 32 FUNCTION OF THE SAFETY SWITCHES 222 21 4 WIRING DIAGRA Ms ea 23 4 1 WIRING DIAGRAM 448 FOLIO 01 05 ida 23 4 2 WIRING DIAGRAM E 448 FOLIO O2m0p ne 24 4 3 WIRING DIAGRAM E 448 FOLIO 03 05 25 4 4 WIRING DIAGRAM 448 FOLIO OAI0Op nennen 26 4 5 WIRING DIAGRAM E 448 FOLIO 05 05 0 27 46 PARTES ER 28 5 MACHINES ELEMENTS ciriiinraaianicise salitreras opten a nennen 31 MOTOR ra 31 IP MUNI SR 31 339 INPUT ep cp een 31 5 3 1 Control 8 31 nn E acters 33 Ste P 33 O ad tea eens
84. X New design HA46 51JRT New Design Caution The buzzer should be audible from the basket Pinguely Haulotte 4 CORRECTIVE MAINTEANCE SHEET Folio 1 1 CHANGING THE TILT SENSOR 1 Preliminary operations Putthe machine on a flat surface with zero slope e Putthe machine into the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph 2 Removing the tilt sensor Mark and disconnect the electric connections of the tilt sensor Remove the tilt sensor 2 by unscrewing the fixing bolts 1 3 Installing the tilt sensor Puta new tilt sensor into place and fix using the fixing bolts 1 Reconnect the electric connections according to the marks made during dismantling Place a spirit level on the top surface of the tilt sensor and set the adjust ment screws 4 so that the tilt sensor is level NB The spirit level 3 is built into certain tilt sensors Putthe machine back into the operational configuration 4 Tilt sensor operating test e Extend the machine Tiltthe tilt sensor and check that the buzzer sounds Check that after 1 or 2 seconds extension or travel movements have been disabled Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 040 Folio 1 1 CHANGING THE HORN Caution 1 Preliminary operations Switch off electric power see corresponding paragraph Do not use the machine during maintenance
85. YES END Adjust or replace the pump See Fiche regulation valve pressure C073 or C111 limiter 240 bars The fault NO persists YES END Replace the hydraulic See Fiche pump C042 or C091 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART u eden NO MOVEMENT AVAILABLE FROM TURNTABLE OR PLATFORM CONTROL PANELS Place the key switch in the turntable position Check for 12V voltage between points 0 and 240 of the turntable panel printed circuit NO YES Replace relay KMG See Fiche Replace the U1 module See Fiche C062 C058 or C107 The fault NO The fault NO persists persists YES END YES END Repair the wiring ofthe key See Fiche Replace the printed circuit See Fiche switch SA1 or C044 C063 replace the switch Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP024 Folio 1 2 NO MOVEMENT AVAILABLE FROM THE PLATFORM CONTROL PANEL No movement available from the platform control panel Open the turntable control panel Check the state of fuse FU6 NO Replace the fuse YES Place the key switch in the platform position Open the platform control panel Press the pedal and check for 12V voltage on terminal 2110 or 211A NO Hold down the pedal and check for 12V voltage on terminal 211 of the platform YES control panel Internal wiring
86. ack in the operational configuration Check the level in the hydraulic oil tank Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C115 Folio 1 2 CHANGING THE JIB CYLINDER 1 Preliminary operations Putthe machine in the maintenance configuration see corresponding Caution paragraph Switch off electric power see corresponding paragraph pee EB ie nottoo Anchor the basket on the ground 2 Removing the jib cylinder Put the cylinder 1 and jib vertical elements 2 and 3 in slings Caution Mark and disconnect the jib cylinder s two hydraulic hoses Use a container to collect oil to prevent pollution of the NB Unscrew the hoses slowly to release residual hydraulic pressure environment e Put caps on the hoses Remove the two bolts and pin stop rings from the cylinder pin 4 on the cylinder body side Remove the 4 Caution Remove the pin stop clevis from the cylinder pin 5 on the rod side It is essential to put the Remove the pin 5 component in slings before Remove the jib cylinder 1 dismantling re assembling it 3 Installing the jib cylinder NB Before re installing check the condition of all articulation pin rings and replace if necessary Lubricate all bores before re installing the pins Only use lubricants recommended by the manufacturer Putthe jib cylinder into place and put back the two articulation pins on the
87. anual 10 2 PVG 32 DANFOSS BLOCK 10 2 1 Location Description YV2 Non proportional valve from PVG32 supply of non proportional functions YV9 Proportional valve boom lift from boom output A input YV10 Proportional valve arm lift from boom output A input YV11 Proportional valve for rotation command YV14 Proportional valve for driving command output A towards input 1 towards slewing ring output B towards input 4 from slewing ring YV15 Proportional valve for driving command output A towards input 2 towards slewing ring output B towards input 3 from slewing ring YV1 LS valve for pressure and flow control with proportional pump com mand 52 Repair manual Pinguely Haulotte 7 10 2 2 Input and output Minimess plug for measuring the working pressure inside the circuit Output towards pump plate angle supply control inside the proportional pump pump flowrate control Pressure output inside proportional PVG block Supply feeding for driving towards driving block output A towards outlet 2 from slewing ring and input P1 from driving block output B towards outlet 3 from slewing ring going in P2 from driving block Supply feeding for driving towards driving block output A towards outlet 1 from slewing ring and input B1 from driving block output B towards outlet 4 from slewing ring going in A1 from driving block Supply output for slewing turntable engine equipped with
88. any danaged incorrectly installed modified or missing parts NOTE This register can be obtained from trade organisations and in some cases from the OPPBTP or private prevention agencies The designated persons must be experienced in risk prevention Articles R 233 11 or order n 93 41 No member of personnel is allowed to perform any check whatsoever during machine operation Article R 233 11 of the French Labour Code 1 4 2 Examination of machine suitability The manager of the site where the machine is operated must ensure the machine is suitable e capable of performing the work in complete safety and in compliance with the operating manual Furthermore the French order of 9 June 1993 addresses problems relative to leasing examination of the state of conservation checking upon operation after repairs and test conditions static test coefficient 1 25 dynamic test coefficient 1 1 All users must consult this order s requirements and comply with them 1 4 3 State of conservation Detect any deterioration liable to cause hazardous situations concerning safety devices load limiters tilt sensor cylinder leaks deformation welds bolt tightness hoses electrical connections tyre state excessive mechanical gaps NOTE If the machine is rented leased the user responsible for the machine must examine its state of conservation and suitability He must ob tain assurance from the leaser that general periodic inspectio
89. aph hot Disconnect the then terminals of the starter battery 2 Removing the emergency electropump unit _ e Mark the connections and path of the electric wires 1 of the electropump Caution unit 2 U tai t llect oil Disconnect the electropump unit s electric connections FO CONGC O Disconnect the electropump unit s hydraulic hoses 3 to prevent pollution of the NB Unscrew the hoses slowly to release residual hydraulic pressure Put caps on the hoses Remove the pressure limiter 4 of the emergency hydraulic circuit see corresponding sheet Unscrew the fixing screws and remove the electropump unit Mark and retain the hydraulic connectors and unions 5 screwed on the electropump unit 1 Installing the electropump unit Putthe hydraulic unions and connectors retained from the removal opera tion in the same places on a new electropump unit Putback the pressure limiter see corresponding sheet Putthe electropump back into place using the fixing screws Reconnect the hydraulic hoses Reconnectthe electric wires according to the marks made during dismant ling Reconnectthe then terminals of the starter battery Putthe machine back in the operational configuration Do not start the thermal motor and trip the emergency electropump unit Make several movements to purge the hydraulic circuit Putthe machine back in the op
90. atform right and or left rotation movement Electrovalve YV19 or YV2 defective Coil defective Electronic module U1 defective Wiring harness defective Printed circuit defective Basket rotation swtich SA4 defective Fiche DP027 No jib movement up and or down from the platform or turntable control station Electrovalve YV18 or YV2 defective Coil defective Electronic module U1 defective Wiring harness defective Printed circuit defective Flow limiter defective Jib switch SA7 or SA6 defective Fiche DP028 No telescoping movement out and or in from the plat form or turntable control station Electrovalve YV14 or YV2 defective Coil defective Electronic module U1 defective Wiring harness defective Printed circuit defective Telescoping switch SA9 or SA8 defective Pressure limiter defective Fiche DP067 No boom lifting movement up and or down from the platform or turntable con trol station Electrovalve YV3 defective Electronic module U1 defective Wiring harness defective Printed circuit defective Lifting switch SA13 defective Lifting manipulator SM31 defective Fiche DP068 No arm lifting movement up and or down from the plat form or turntable control station 86 Electrovalve YV4 defective Electronic module U1 defective Wiring harness defective Printed circuit defective Lifting switch SA14 defective Lifting manipulator SM2 defective Fiche DP031 Repair
91. avel lifting turntable rotation telescope Place the key switch in the turntable position and activate the accelerator switch SA2 on the turntable control panel The motor See Fiche accelerates 0 022 Check electric continuity of the wiring harness between the turntable control panel and the platform control panel NO YES Replace U1 See Fiche module C058 or C107 END Y Replace the wiring harness Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP022 NO MOTOR ACCELERATION ON ACTIVATING THE Folio 1 2 ACCELERATOR SWITCH SA2 FROM THE TURNTABLE CONTROL PANEL No motor acceleration on activating the accelerator switch SA2 from the turntable control panel Place the key switch in the platform position Press the pedal and make a telescoping movement from the platform Check that the motor accelerates Y Open the turntable control Le NO The motor panel and check the state of accelerates fuse FU3 Open the turntable control panel Place the key switch in the turntable position and activate the accelerator switch SA2 from the turntable control panel Check for 12V voltage on terminal 605 of the printed circuit Fuse NO oK YES Replace fuse FU3 Y Open the turntable control panel Place the key switch in the turntable position and activate th
92. back into place is properly stabilised and that the lifting means are in Only use the oil recommended by the manufacturer good condition and of PEE sufficient capacity 3 Changing the oil Inthe same position unscrew the 2 caps and let the oil flow out Re fill as described above Screw the caps back into place NB Collect old oil to prevent pollution of the environment 4 Additional operations Putthe machine back into the operational configuration HA16 18PX HA46 51JRT HA20 26 PX HA61 80JRT H14T X H16TP X HB40 44J Pinguely Haulotte 4 PREVENTIVE MAINTENANCE SHEET Repair manual Pinguely Haulotte 4 14 14 1 INCIDENT TABLE OPERATING INCIDENTS Before diagnosing a failure check that the fuel tank is not empty the batteries are properly charged the turntable and platform palm button emergency stop buttons are unlocked the relays platform control panel turntable box are correctly pushed into their compartments see corresponding paragraph the main tank oil level is OK the state of the fuses see corresponding paragraph the electrovalves are working properly by checking the state of the LEDs in the turntable box Check the state of the LEDs see corresponding paragraph The LEDs inside the turntable box indicate the state of the electrovalves NB LED off electrovalve present and not controlled LED on electrovalve present and co
93. ch SA12 The defective FRONT steering movemen left 2 or right 1 is made in Replace See Fiche response to an opposite movement electrovalve YV22 C067 control right 2 or left 1 END gt Put coils YV22A and YV22B back into their original positions Press the pedal make a travel movement and activate the FRONT steering switch SA12 and check for 12V voltage at the terminals of the connector of YV22A or YV22B Open the turntable control panel Press the pedal and make a travel movement activate the FRONT steering switch SA12 and check for 12V voltage on terminals 304 left and 306 right of the printed circuit 12V OK at terminals of electric connectors n NO Replace the See Fiche See Fiche Replace the U1 module C058 C059 defective coil Y YES The fault persists END Repair the connection or replace the wiring harness between the turntable control panel and electrovalve YV22 See Fiche C063 Replace the printed circuit END Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP037 Maintain the control activated and check for 12V voltage at terminals 707 right and 708 left of the printed circuit NO YES Folio 4 4 NO STEERING MOVEMENT RIGHT AND OR LEFT ON THE FRONT AXLE Open the platform control pa
94. circuit See Fiche C063 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP036 Folio 3 3 NO DIFFERENTIAL BLOCKING WHEN SWITCH SA3 IS ACTIVATED Open the platform control panel Press the pedal activate switch SA3 and check the setpoint at the output of switch SA3 807 Setpoint Replace See Fiche 12V switch SA3 C044 END Open the turntable control panel Maintain the pedal and switch SA3 activated Check for 12V voltage on terminal 807 of the printed circuit NO Replace wiring harness no 807 YES Make sure that switch SA11 is in the LS low speed or MS me dium speed position LS and MS not See Fiche DP034 available Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP037 Folio 1 4 NO STEERING MOVEMENT RIGHT AND OR LEFT ON THE FRONT AXLE No steering movement right and or left on the front axle Place the key switch in the platform position Putthe emergency lever into place on the manual control ofthe ON OFF distributor YV2 Press the pedal and make a travel movement Activate the FRONT steering switch SA12 while activating the emergency lever of distributor YV2 direction YV2b Steering movement OK Y Open the turntable control panel and check that the LEDs associated with electrovalve YV22A left YV22B right and YV2B are off
95. e accelerator switch SA2 from the turntable control panel Check for 12V voltage on terminal 118 of the Replace the See Fiche printed circuit accelerator switch C044 SA2 Y Repair the connection or replace the electric wiring harness between the accelerator switch SA2 and the printed circuit of the turntable control panel END END Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP022 NO MOTOR ACCELERATION ON ACTIVATING THE Folio 2 2 ACCELERATOR SWITCH SA2 FROM THE TURNTABLE CONTROL PANEL Voltage NO OK YES Maintain activation of the accelerator switch SA2 of the turntable control panel Check for 12V voltage on terminal 605A of the printed circuit Y Place the key switch in the turntable position and activate the accelerator switch SA2 from the turntable control panel Voltage NO Check for 12V voltage at the terminals OK of connector YA2 YES See Fiche Replace relay KT2 NO C062 YES END Replace the coil of motor accelerator Y YA2 or adjust the motor accelerator system see motor manufacturer See Fiche Replace the U1 manual C058 or module C107 END END Y Repair or replace the electric wiring harness between the accelerator elec trovalve YA2 and the turntable control panel Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP023 Folio
96. e following situations Sudden action on the controls Overloading of the platform Uneven ground Be careful during thaw periods in winter Gusts of wind Contact with an obstacle on the ground or at a height Working on platforms pavements etc Allow sufficient stopping distances 3 meters at high speed 1 meter at low speed Allow sufficient stopping distances 3 metres at high speed and 1 metre at low speed Do not alter or neutralise any components connected in any way to the machine s safety or stability Do not place or fasten a load so that it overhangs the machine s parts Do not touch adjacent structures with the elevator arm 1 3 2 Electrical risk Electrical risks are high in the following situations Contact with a live line check safety distances before operation near electricity lines Use during storms 1 3 3 Risk of explosion or burning The risks of explosion or burning are high in the following situations Working in explosive or inflammable atmosphere Filling the fuel tank near naked flames Contact with the hot parts of the motor Use of a machine generating hydraulic leakage 1 3 4 Risks of collision Risk of crushing people in the machine operation zone when travelling or manoeuvring equipment The operator must assess the risks above him before using the machine Pay attention to the position of the arms during turntable rotation Adapt movement speed
97. e pedal and activate the basket rotation switch on the platform control panel he basket rotates NO Stop the movement and release the pedal Open the turntable control panel and check that the LED associated with electrovalve YV14A in or YV14B out is off Press the pedal and activate the platform or turntable telescope switch Check that the LED associated with electrovalve YV14A in or YV14B out is dei YES YES Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART SR Per NO TELESCOPING MOVEMENT OUT AND OR IN FROM Folo 2 THE PLATFORM OR TURNTABLE CONTROL PANEL Check the setpoint at the output of detectors SQ7 SQ10 and SQ11 Setpoint SQ7 12V SQ10 0V 5011 OV NO Check the continuity of wiring har nesses no 115A 218A and 218B Harness continuity OK NO Replace the defective wiring harness es Check the setting of detectors SQ7 SQ10 and SQ11 END Detector setting OK YES Replace the U1 module See Fiche C058 2 Adjust the detectors END Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP067 NO TELESCOPING MOVEMENT OUT AND OR IN FROM Folio 3 6 THE PLATFORM OR TURNTABLE CONTROL PANEL Press the pedal and activate the telescope switch and check for 12V voltage at the terminals o
98. e rolling bearings NB Only use lubricants recommended by the manufacturer e Re install the basket see corresponding sheet Putthe machine back in the operational configuration Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C056 Folio 1 1 CHANGING THE HYDRAULIC FILTER A Barton 1 Preliminary operations Ensure that the oil is not too Put the machine in the maintenance configuration see corresponding hot paragraph Switch off electric power see corresponding paragraph Close the shut off valve if any Otherwise empty the hydraulic tank A Sandan _ 2 Removing the hydraulic filter Use a container to collect oil Disconnect the hydraulic filter hoses 1 to prevent pollution of the environment NB Unscrew the hoses slowly to release residual hydraulic pressure H14 16TPX HB40 44J Fit caps to the hoses Unscrew the fixing screws 2 and remove the hydraulic filter Remove the two connectors 3 from the hydraulic filter 3 Installing the hydraulic filter Install the two connectors on a new hydraulic filter see the table of tighte ning torque values Put the equipped hydraulic filter back into place respecting the oil flow direction and fix using the fixing screws Reconnect the hydraulic hoses Put the machine back into the operational configuration Make several lifting cycles to purge the hydraulic circuit Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIV
99. e the fixing screw 2 from the steering clevis pin Caution Remove the steering clevis pin 3 Remove the two screws 4 from the two caps on the pivot pin and remove the two caps 5 Take the M canindus pin from each pivot pin 6 and remove the pivot pin and support washer 7 Remove the steering pivot 1 Installing a pivot Putthe steering pivot into place Replace pins lubricators and support washers if necessary Put back the support washers and pivot pins and block using new M ca nindus pins Putback the pivot pin caps and fix using fixing screws and washers Adjust wheel alignment if necessary slacken the counter nut 8 screw or unscrew the clevis 9 to adjust the length of the steering bar tighten the counter nut 8 Putback the steering clevis pin and fix using the screw equipped with a new grower washer It is essential to put the component in slings before dismantling re assembling it A 1 NB When re installing the pins take the measures necessary to avoid damanging the pins rings and bores 5 Installing the bearings if applicable Lubricate the bearings and pivot pin NB Only use lubricants recommended by the manufacturer Install a new seal 15 Install the bearings 16 on the hub 14 Install the hub 14 on the pivot 1 Install the nut 13 Block the nut 13 until the wheel turns with difficulty and turn back one quarter turn Insta
100. e two steering clevis pins 2 Remove the two steering clevis pins 2 Unscrew the counter nut 11 Remove the steering bar 3 Repeat the operation 2 for the other side 3 Removing the steering lever section B B Remove the Nylstop nut 4 and the washer 5 from the cylinder fastening pin Remove the cylinder fastening pin 6 Remove the male clevis 12 Remove the screws and washers 13 14 then the central steering pin 8 Remove the steering lever 9 4 Installing the steering lever NB When re installing the pins take the measures necessary to avoid damanging the pins rings and bores Replace the pins and lubricators if necessary Put the steering lever into place Put back the central steering pin then the screws and new washers 13 14 Put back the male clevis and fix with its fixing screw equipped with a new washer Put back the cylinder fastening pin and fix with a new Nylstop nut and its washer 5 Installing a steering bar Replace the pins and lubricators if necessary Put the steering bar into place performing the removal operations in reverse order Adjust wheel alignment if necessary slacken the counter nut 10 on the steering bar screw or unscrew the clevis 11 to adjust the length of the steering bar tighten the counter nut 10 Put back the two steering clevis pins Put back the fixing screws of the two steering clevis pins 6 Additional operations Put
101. eel Insufficient load on one wheel Act on the blocking button 87 Pinguely Haulotte 4 Repair manual 14 1 4 Steering system ANOMALY PROBABLE CAUSE SOLUTION Electrovalve YV22 or YV2 defective Coil defective No steering movement right Electronic module U1 defective and or left on the front axle Wiring harness defective Printed circuit defective Fiche DP037 Switch SA12 defective Electrovalve YV21 or YV2 defective Coil defective No steering movement right Electronic module U1 defective and or left on the rear axle Wiring harness defective Printed circuit defective Travel switch SM4 defective Fiche DP038 14 1 5 Turntable rotation system ANOMALY PROBABLE CAUSE SOLUTION Electrovalve YV5 defective No turntable rotation move Electronic module U1 defective ment right and or left from Wiring harness defective the platform or turntable Printed circuit defective Fiche 0 018 control station Rotation switch SA15 defective Rotation manipulator SM31 defective The turntable does not turn blocking has not been removed Remove the pin from the chassis NB In the turntable box LEDs indicate the state of each output so that can check if an output is activated 14 2 BREAKDOWN DETECTION FLOW CHART 88 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP016 Folio 1 3 THE MOTOR DOES NOT START THE
102. electrovalve connector YV4 Maintain the control activated and check for 3V or 9V depending on the movement direction on terminal 506A of the printed circuit Voltage OK See Fiche C077 NO Voltage Replace PVG electrovalve YV4 y OK Replace the U1 See Fiche module 058 YES END Repair the connection or replace the wi ring harness between the turntable con trol panel and electrovalve YV4 Voltage oK Replace the See Fiche printed circuit 063 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP031 NO ARM LIFTING MOVEMENT Folio 3 3 UP AND OR DOWN FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Activate the rotation movement in the emergency mode Putthe emergency lever into place on the manual rotation distributor control YV5 Activate the lever right left while pressing the emergency control of the safety valve YV1 NO Movement fiche DP023 OK Replace PVG electrovalve YV4 See Fiche C077 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP032 Folio 1 4 NO MACHINE TRAVEL MOVEMENT No machine travel movement Place the key switch in the platform position Press the pedal and make an arm lifting movement Movement NO See Fiche DP023 OK y YES Put the machine on wedges so that the wheels a
103. epending on movement and check for 12V voltage on terminals direction on terminal 403 of the printed circuit 505 or 504 of the printed circuit Replace the boom lifting See Fiche manipulator SM31 or C045 Fiche lifting switch SA13 044 Repair the connection replace the wiring harness END between the boom lifting manipulator SM31 or boom lifting switch SA13 and the printed circuit of the turntable control panel END Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP068 NO BOOM LIFTING MOVEMENT Folio 2 4 UP AND OR DOWN FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Check the setpoint at the output of detectors SQ7 SQ8 and SQ11 Setpoint SQ7 OV SQ8 12V SQ11 OV NO Check the continuity of wiring har nesses no 115A 115B and 218B Harness continuity OK NO Replace the defective harness es Check the setting of detectors 507 508 and 5011 END Detector setting OK YES Replace the U1 module See Fiche C058 2 Adjust the detectors END Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP068 NO BOOM LIFTING MOVEMENT Folio 3 4 UP AND OR DOWN FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Activate the boom lifting movement the emergency mode Put the emergency lever into place or activate the emergency unit on the manual co
104. erational configuration Checkthe level of the hydraulic oil tank Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C114 Folio 1 1 CHANGING THE EMERGENCY HYDRAULIC CIRCUIT PRESSURE LIMITER e 15 Preliminary operations Putthe machine in the maintenance configuration see corresponding para Ensure that the oil is not too 7 3 WP hot graph Switch off electric power see corresponding paragraph 16 Removing the emergency circuit pressure limiter Disconnect the return hose 1 of the emergency circuit at the pressure limiter nn 2 Attention Use a container to collect oil NB Unscrew the hoses slowly to release residual hydraulic pressure to prevent pollution of the environment Puta cap on hose Remove the pressure limiter 2 by unscrewing the adapter 3 Retain the pressure limiter s union and adapter 17 Installing the emergency circuit pressure limiter Putthe union and adapter on a new pressure limiter Install the pressure limiter by screwing the adapter onto the rigid pipe of the emergency motor Reconnect the hydraulic hose Putthe machine back in the operational configuration Do not start the thermal motor and trip the emergency electropump unit Make several movements to purge the hydraulic circuit Adjust the pressure limiter if necessary see adjusting a pressure limiter sheet Putthe machine b
105. esponding sheet Put back the hydraulic filter support assembly 8 Connection Put into place the exhaust output pipe 4 and fix with the fixing collar Reconnect the fuel incoming and outgoing pipes On the motor reconnect the electric connectors the acceleration coil the starter motor connections and fix the duct using plastic collars On the motor reconnect the battery connection cables 1 Put back the cover see corresponding sheet Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C133 Folio 2 2 CHANGING THE THERMAL MOTOR 9 Additional operations the then terminals of the starter battery Putthe machine back in the operational configuration Ifthe motor installed is new follow the first commissioning instructions see motor manufacturer s manual Start the motor and check that it works properly Seen from below towards starter i COUPLE DE SERRAGE 83 Nm Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C134 Folio 1 1 CHANGING THE COUNTERWEIGHTS 1 Preliminary operations Turn the boom perpendicular to the chassis Raise the arm vertically then turn the wheels as far as possible to change the small counterweight PUT THE BOOM IN SLINGS TO WEDGE THE ARM AND PREVENT TIPPING WHEN T
106. f the PVG YV2b connector Open the turntable control panel NO Press the pedal and activate the telescope switch and check for 12V voltage at terminal 415 of the printed circuit YES See Fiche Replace the PVG 077 YV2 control head NO Replace the See Fiche U1 module 058 YES Repair the connection or The fault NO replace the wiring harness persists between the turntable control panel and PVG YV2 END Replace the See Fiche printed circuit C063 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP067 Folio 4 6 NO TELESCOPING MOVEMENT OUT AND OR IN FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Y Invert the coils of the telescope electrovalve YV14A and YV14B Press the pedal and activate the platform or turntable telescope switch The defective movement out 1 or in 2 is made in response to a control for the opposite movement in 1 or out 2 Put coils YV14A and YV14B back in their original positions Press the pedal and activate the telescope switch and check for 12V voltage at the terminals of the YV14A in or YV14B out connector NO YES See Fiche Replace coil YV14A C059 in or YV14B out Open the turntable control panel Press the pedal and activate the telescope switch and check for 12V voltage at terminals 414A in or
107. form is cluttered Do not use the machine with equipment or objects hanging from the hand rails Do not use the machine with elements that may increase the wind load e g panels Do not perform machine maintenance operations when the machine is raised without setting up the required safety means gantry crane crane Make daily checks and monitor proper operation during periods of use Preserve the machine from any uncontrolled operation when it is not in ser vice Do not tow the platform it is not designed to be towed and must be transported on a trailer Pinguely Haulotte 2 1 3 RESIDUAL RISKS Caution The direction of travel can be reversed after a 180 turntable rotation Take account of the colour of the arrows on the chassis compared with the direction of travel green forward red reverse Thus moving the manipulator in the direction of the green arrow on the control panel will move the machine according to the direction indicated by the green arrow on the chassis Similarly moving a manipulator in the direction of the red arrow on the control panel will move the machine in the direction of the red arrow on the chassis Caution If the machine has a 220 V 16A max plug the extension must be connected to a mains socket protected by a 30 mA differential circuit breaker Repair manual 1 3 1 Risks of jerky movements and tipping over Risks of jerky movement and tipping over are high in th
108. g YES Turntable panel Platform panel arm END y arm lifting fault lifting fault Place the key switch in the turntable Place the key switch in the platform position position Open the platform control panel Open the turntable control panel Tilt the lifting manipulator SM2 as far as possible Activate the lifting switch SA14 and Check for 0 5V or 4 5V voltage depending on the check for 12V voltage at terminals 511 or movement direction on terminal 506 of the printed circuit 510 of the printed circuit Replace the lifting manipulator See Fiche SM2 or lifting switch SA 14 C045 Fiche C044 Repair the connection or replace the electric END wiring harness between the lifting manipulator SM2 or lifting switch SA14 and the printed circuit on the turntable control panel END Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP031 NO ARM LIFTING MOVEMENT Folio 2 3 UP AND OR DOWN FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Activate the arm lifting movement in the emergency mode Put the emergency lever into place on the platform con trol of the boom lifting distributor YV4 Activate the lever up down while pressing the emergency control of the safety valve YV1 Movement oK Activate the lifting switch SA14 of the turntable control panel and check for 3V or 9V voltage depending on the movement direction on the
109. ging the hydraulic block travel on off movement steering SHEET C093 Changing the distribution hydraulic block SHEET C094 Intrinsic dismantling re assembly of the distribution hydraulic block 177 Pinguely Haulotte 4 Repair manual Sheet no Description SHEET C097 Changing a turntable cover SHEET C099 Changing the turntable rotation hydraulic motor SHEET C100 Changing the swing joint assembly SHEET C104 Changing the basket rotation gearing SHEET C106 Changing the slew ring SHEET C108 Changing a control unit of the distribution block SHEET C109 Changing the emergency electropump unit SHEET C114 Changing the emergency hydraulic circuit pressure limiter SHEET C115 Changing the jib cylinder SHEET C117 Changing the turntable rotation reducing gear SHEET C132 Changing a turntable cover SHEET C133 Changing the thermal motor 178 SHEET C134 Changing the counterweights Sheet C010 Caution Ensure that the oil is not too hot Caution Use a container to collect oil to prevent pollution of the environment Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Folio 1 1 CHANGING A HOSE 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Close the shut off valve if any if not
110. h a new toothed washer 5 Putback the endless screw 2 and the adjusting washers 3 if necessary e Put back the motor fixing flange 1 Putback the basket rotation hydraulic motor see corresponding sheet Put back the basket see corresponding sheet Lubricate the gearing NB Only use lubricants recommended by the manufacturer Putthe machine back in the operational configuration Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Folio 2 2 Sheet C104 O 2 X lt ui O 2 O F lt kE O X kE Se lt o I E O 2 O 2 lt O T Ka Omg AIDA NTEN RS E OSEN N Get EE BN x SAO ISS SSS N 5 E 222222222222022 DES la H a L 7 WAVAVAVAVAVAT AV AP AP A hol FESSES NES EEE Sheet C106 Caution Ensure that the oil is not too hot Caution Ensure that the lifting equipment is in good condition and of sufficient capacity ZN Caution Use a container to collect oil to prevent pollution of the environment Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Folio 1 3 CHANGING THE SLEW RING 1 Preliminary operations Move the turntable to the locking position Putthe machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph
111. he module C058 YES Repair the connection or The fault NO replace the electric wiring persists harness between the turntable control panel and PVG YV2 END Replace the See Fiche printed circuit C063 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP026 Folio 3 5 Y Invert the coils of the compensation electrovalve YV15A and YV15B Press the pedal and activate the compensation switch NO COMPENSATION MOVEMENT UP AND OR DOWN The defective ovement up 1 or down is made when an opposite movement is activated down 1 or up 2 Put coils YV15A and YV15B back in their original position Press the pedal and activate the compensation switch Check for 12V voltage at the terminals of the YV15A up or YV15B down connector Open the turntable control panel Press the pedal and activate the compensation switch NO Check for 12V voltage on terminals 401A up or 402A 3 down of the printed circuit YES NO Replace the See Fiche U1 module 058 See Fiche Replace YV15A MOE C059 up or YV15B Y down YES The fault persists Repair the connection or repla END ce the electric wiring harness between the turntable control panel and electrovalve YV15 See Fiche C063 Replace the printed circuit
112. he ball 10 the nylatron washer 11 and the stop 12 If necessary unscrew the pre stressing nut totally 13 as a safety measure before performing any operation on the platform 3 Installing the platform Checkthe condition of the elastic parts and wearing parts and replace if necessary spring washers 14 collar rings 15 ring 16 nylatron washer 11 control panel silent blocks circlips Lower part fnecessary adjust the pre stressing system by tightening the pre stres sing nut 13 so that the washers are 108 mm high see figure 3 Putthe platform into place taking care to put the ball 10 nylatron washer 11 and stop 12 in the right places Lubricate the bore and put the lower pivot 7 into place Fix using the fixing screw 8 and washer 9 NB Only use lubricants recommended by the manufacturer Upper part Lubricate then put back the weighing articulation pin 6 Putback the stop tab 5 Install the Nylstop nut 3 and its washer 4 Adjust the stop for the pre stressing system by tightening the screw 1 and the nut 2 Putthe control panel into place on its silent blocks and fix using the screws equipped with new washers Reconnect the control panel wiring harness Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C053 Folio 2 3 CHANGING THE BASKET fnecessary put the platform s electric plug back into place and fix using its fixing bolts equip
113. he machine in the maintenance configuration see corresponding Ensure that the oil is not too paragraph hot Switch off electric power see corresponding paragraph 2 Removing a double flow limiter 1 e Mark the installation position of the electrodistributor balancing valve and Caution double flow limiter Use a container to collect oil Remove the 4 fixing screws 2 then take out the electrovalve 3 balan to prevent pollution of the ging valve 4 double flow limiter 1 assembly environment Remove the double flow limiter 1 3 Installing the double flow limiter Replace the seals and put into place on the hydraulic block a new flow limiter 1 whose characteristics correspond to the machine in question then the balancing valve 4 and the electrovalve 3 Fixthe assembly with the 4 fixing screws 2 Tighten to the recommended torque see corresponding chapter Putthe machine back into the operational configuration Make several movements using the replaced double flow limiter to purge the circuit Adjust compensation up and down speeds see corresponding chapter e Check that the corresponding movement is made correctly Sheet C084 Caution Ensure that the oil is not too hot Caution Use a container to collect oil to prevent pollution of the environment Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Folio 1 1 CHANGING A NON RETURN VALVE ON THE STEERING
114. he manipulator See Fiche Reverse 2 5 to 0 5V HM4 C045 SM4ab 12V END Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP032 Folio 3 4 NO MACHINE TRAVEL MOVEMENT Check setpoint at output 26 3 and 25 3 of U1 electronic module Setpoint Output 26 3 and 25 3 Replace the U1 electronic See Fiche Forward 6 to 9V module C058 or C107 Reverse 6 to 3V YES Check for setpoint at input of The fault NO electrovalve YV6 and YV7 persists YES END Replace the printed See Fiche circuit C063 END Setpoint Output 26 3 and 25 3 Forward 6 to 9V Reverse 6 to 3V Replace wiring harness no 612A Replace PVG YV6 or YV7 See Fiche control head C077 or C108 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART un NO MACHINE TRAVEL MOVEMENT OISE Setpoints 29 2 exc neutral 29 3 12V 29 4 forward 2 5 to 4 5V Reverse 2 5 to 0 5V Replace defective wiring har nesses no 612 606 and 611A See Fiche C058 or C107 Replace the U1 module The fault NO persists YES Replace the printed circuit See Fiche C063 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP036 Folio 1 3 NO DIFFERENTIAL BLOCKING WHEN SWITCH SA3 IS ACTIVATED No differential blocking when switch SA3 is activated Place the key s
115. hine during maintenance operations Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C134 CHANGING THE COUNTERWEIGHTS
116. ht and 310 left of the printed circuit Open the platform control panel and check wiring of the NO jib switch SA4 YES NO 2 22 Replace the U1 module SeeFiche Repair wiring C058 YES END Check the electric continuity of the switch contacts when closed NO The fault persists END Replace the See Fiche NO printed circuit C063 5 Replace the platform See Fiche END rotation switch SA4 C043 Repair the connection or replace the END electric wiring harness between the platform rotation switch SA4 and the printed circuit of the turntable control panel Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP027 Folio 5 5 NO PLATFORM ROTATION MOVEMENT RIGHT AND OR LEFT Replace the electrovalve See Fiche 19 067 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP028 NO JIB MOVEMENT UP AND OR DOWN Folio 1 5 FROM THE PLATFORM OR TURNTABLE CONTROL PANEL No jib movement up and or down from the platform or turntable control panel Place the key switch in the platform position Press the pedal and activate the basket rotation switch on the platform control panel he basket rotates Stop the movement and release the pedal Open the turntable control panel and check that the LED associated with electrovalve YV18A down or YV18B up
117. icroSpeed 0 then LowSpeed 1bYV1 1 if SA11a 1 and SA11b 0 and MicroSpeed 0 then High Speed 1PYV1 1 and YV12 1 and YV10 1 if HM4 1et SM4ab 0 puis SM4ab 1 and SQ1 1 or machine folded and 5 0 and SA9b 0 and SM31ab 0 and SM2ab 0 then YV6 1 and YV7 1 Low Speed High Speed Full setpoint Micro Speed Low setpoint 8M cut out if SQ12 0 or SQ4 0 and SQ3 0 then cut of travel When the machine is off and in slope both axles can not used at the same time When the machine is driving mode and in slope position both axles can be used at the same time Front axle Left if SA12a 1 and SQ6 1 and SM4ab 1 or SQ1 1 or SM4c 0 and SM4d 0 37 Pinguely Haulotte 4 Repair manual then YV22a 1 and YV2b 1 and YV1 1 Right if SA12b 1 and SQ6 1 and SM4ab 1 or SQ1 1 or SM4c 0 and SM4d 0 then YV22b 1 and YV2b 1 and YV1 1 Rear axle Left if SM4c 1 and SQ6 1 then YV21a 1 and YV2b 1 and YV1 1 Fight if SM4d 1 SQ6 1 then YV21b 1 and YV2b 1 and YV1 1 6 13 DIFFERENTIAL BLOCKING 6 14 HORN BUZZER 6 15 38 INDICATORS if SA3 1 and SA11a 0 and MicroSpeed 0 then YV9 1 and YV13 1 if SB5 1 then HA1 1 if SQ1 0 and machine unfolded then the buzzer sounds continuously if B4 0 then the buzzer sounds with a frequency F1 if SQ6 0 and turntable position then the buzzer HA4 platform sounds with a frequency F1 if travel_Buzzer_option 1 and HM4 1 then the buzzer sounds with a frequency P2 if SQ5 1 then the buzzer
118. in the operational configuration Check that there is sufficient oil in the hydraulic tank Make several lifting travel steering and turntable rotation movements to purge the hydraulic circuit and test block operation Checkthe level of the hydraulic oil tank Pinguely Haulotte 4 Sheet C094 Caution Ensure that the oil is not too hot Caution Use a container to collect oil to prevent pollution of the environment Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Folio 1 1 INTRINSIC DISMANTLING RE ASSEMBLY OF THE DISTRIBUTION HYDRAULIC BLOCK 1 Preliminary operations Remove the distribution hydraulic block see corresponding sheet 2 Dismantling the distribution hydraulic block 1 Mark the assembly position of the input plate input module distribution elements and closing plate If necessary remove the control units see corresponding sheet Remove the fixing nuts and 3 tie rods 2 then separate the elements 3 Re assembling the distribution hydraulic block Replace the O ring seals If necessary put back the control units see corresponding sheet Remount the input plate input module distribution elements and closing plate Put back the fixing nuts and 3 tie rods 2 Tighten to 2 2 daN m 15 91 Ib ft Put back the distribution hydraulic block see corresponding sheet Check that there is sufficient oil in the hydraulic tank Put the machine back in the operati
119. ing joint in slings Caution Remove the swing joint s stop screw 4 Remove screws 7 fixing the swing joint to the chassis Use a container to collect oil Remove the swing joint from underneath the chassis to prevent pollution of the environment 3 Installing the swing joint assembly Put the swing joint into place from underneath the chassis and fix with fixing screws equipped with new nylstop nuts Put back the swing joint rotation stop screw 4 Reconnect the hydraulic hoses and caps on the swing joint according to the marks made during dismantling Pass the wiring harnesses in the machine along their original paths Reconnect the electric connections in the chassis box and turntable box according to the marks made during dismantling A 1 Additional operations Putthe machine back in the operational configuration Remove the wedges from under the boom Make several steering and travel movements using all possible travel speeds to purge the hydraulic circuit Check that the electric controls work properly Checkthe level of the hydraulic oil tank Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C100 Folio 2 2 CHANGING THE SWING JOINT ASSEMBLY ES ED 7 E i LLL AAA Figure 1 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C104 Folio 1 2 CHANGING THE BASKET ROTATION GEARING 1 Preliminary operations
120. ipulator SM2 from the platform control panel with the pedal activated Lifting movement OK i YES Open the platform or turntable control panel and check the wiring of the rotation manipulator SM31 or rotation switch SA15 NO Repair wiring YES Turntable panel Platform panel END y rotation fault rotation fault Place the key switch in the turntable Place the key switch in the platform position position Open the platform control panel Open the turntable control panel Press the pedal and tilt the rotation manipulator as far as Activate the rotation switch SA15 and possible check for 12V on terminals 517 or 516 of Check for 0 5V or 4 5V voltage depending on the the printed circuit direction of movement on terminal 512 of the printed circuit Replace the rotation See Fiche NO manipulator SM31 or lifting C045 Fiche Switch SA15 C044 YES Repair the connection or replace the electric wiring END harness between the rotation manipulator SM31 or rotation switch SA15 and the printed circuit in the turntable control panel END Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DPO18 NO TURNTABLE ROTATION MOVEMENT Folio 2 3 RIGHT AND OR LEFT FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Activate the rotation movement the mode Put the emergency lever in place
121. iring between switch SB3 or SB4 and the turntable Replace the relay See Fiche control box KA2 C062 The fault persists Check continuity of the electric wiring harness between relay KA2 terminal 103 of the turntable box and the starter solenoid YES Replace the defective electric wiring harness Replace the starter Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP017 Folio 1 1 THE MOTOR STARTS THEN STOPS AFTER 5 sec d motor starts then stops after 5 m Check the level of the diesel tank Fill the diesel tank Check the diesel supply circuit See motor manufacturer manual NO Restore the diesel supply circuit See motor manufacturer manual YES Check the state of the motor safety systems END motor oil pressure motor oil temperature air filter clogging and replace the defective component See motor manufacturer manual Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP018 NO TURNTABLE ROTATION MOVEMENT Folio 1 3 RIGHT AND OR LEFT FROM THE PLATFORM OR TURNTABLE CONTROL PANEL No turntable rotation movement right and or left from the platform or turntable control panel Place the key switch in the turntable or platform position Activate the lifting switch from the turntable control panel SA15 or the rotation man
122. it fuse Accessories circuit fuse YV1 circuit fuse SOS M4 engine circuit fuse 02 03 04 05 04 12 Load Sensing solenoid valve 05 16 On off control selection solenoid valve 05 14 Boom raising control solenoid valve 05 11 Arm lifting control solenoid valve 05 9 Slewing control solenoid valve Repair manual Pinguely Haulotte 7 4x2 differential lock control solenoid valve Telescoping control solenoid valve Compensation control solenoid valve Pendular control solenoid valve Platform rotation control solenoid valve Hour counter Horn Weighing buzzer Tilt warning Travel control solenoid valve Travel speeds combination solenoid valve Travel speeds combination solenoid valve Differential lock control solenoid valve FORWARD direction control solenoid valve REVERSE direction control solenoid valve M4 electropump contactor Engine cut out position switch Engine cut out position switch Movement cut out position switch Movement cut out position switch Air filter pressure controller Engine oil temperature pressure controller Engine oil pressure controller Hydraulic oil temperature pressure controller Gas pressure controller option BEACON OPTION Beacon Single pole switch 8 m CUT OUT OPTION 8 m cut out position switch 8 m cut out position switch Shunt travel 26 m tilt 3 Fault light i
123. ith the selector on high speed and check that malfunctions may occur movement speed is actually micro speed Lower the arm Lift the boom Make a travel movement with the selector on high speed and check that movement speed is actually micro speed Lower the boom Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C059 Folio 1 1 CHANGING A COIL 1 Preliminary operations Putthe machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph 2 Removing a coil Disconnect the electric connector 2 from the coil concerned Unscrew the nut 3 and remove the coil 1 3 Installing a coil Puta new coil into place 1 and fix with the nut 3 e Reconnect the electric connector 2 to the coil Putthe machine back into the operational configuration Check proper operation by making the movement corresponding to the replaced coil Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C062 Folio 1 1 CHANGING A RELAY 1 Preliminary operations Putthe machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Disconnect the then terminals of the starter battery 2 Removing a relay Openthe turntable electric box Markand disconnect the electric connections 1 of the relay 2 Remove the relay by removing the fixing bolt
124. lifting From the basket 30s 3s 40s 3s Boom lowering From the basket 30s 3s Rotation left From the basket 52s 4s per 1 2 turn Rotation right From the basket 52s 4s per 1 2 turn Micro micro speed travel forward From the basket 80s 2 10m Micro micro speed travel reverse From the basket 80s 25 10m Micro speed travel forward From the basket 356 2s 5m Micro speed travel reverse From the basket 35s 2s 5m HS travel forward From the basket 40s 3s 50m HS travel reverse From the basket 40s 3s 50m 19 Pinguely Haulotte Repair Manual 20 Repair manual Pinguely Haulotte 7 3 SAFETY SYSTEM 3 1 FUNCTIONS OF THE TURRET CABINET FUSES AND RELAYS see chap 4 page 25 KA2 Heat engine starting KP1 Heat engine stopping KT2 Acceleration of movements electromotor KMG Mains supply KM4 Electropump contactor FU1 10 A Engine stop circuit fuse FU3 80 A Accelerator circuit fuse FU4 30 A General circuit fuse FU5 3 A Fuse for circuit for controlling movements from turret FU6 3 A Fuse for circuit for controlling movements from platform FU7 20 A Solenoid valve supply circuit fuse FU8 5 A Turret platform control circuit fuse FU9 20 A Accessories circuit fuse FU10 3 A Circuit fuse FU11 250 A Engine circuit fuse 3 2 FUNCTION OF THE SAFETY
125. ll the brake washer 12 and counter nut 11 Block the counter nut 11 then raise the wings of the brake washer Put back the cap 10 Additional operations Put back the wheel see corresponding sheet Putthe machine back in the operational configuration Make several travel movements to check correct operation Lubricate the pins with the lubricators Pinguely Haulotte 4 kE I o O 2 lt 2 E lt lt 2 gt kE O O O CHANGING A STEERING PIVOT ON A Folio 2 2 Sheet C085 NON DRIVE WHEEL NE Js 2 SE eS ANS l Sheet C086 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET DISMANTLING AND RE ASSEMBLING Folio 1 2 THE STEERING SYSTEM Caution Ensure that the oil is not too hot Caution Use a container to collect oil to prevent pollution of the environment Caution It is essential to put the component in slings before dismantling re assembling it 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph 2 Removing a steering bar NB Remove the fixing screw 1 from th
126. ls Wear protective clothing suited to working conditions and current local legis lation in particular when working in hazardous areas Do not disable the safety system end of stroke contactors Avoid contact with fixed or mobile obstacles Do not increase working height by using ladders or other accessories Never use the hand rails as a means of access for getting onto and off the platform use the steps provided on the machine Never climb on the hand rails when the platform is raised Never drive the platform at high speed in narrow or cluttered areas Never use the machine without installing the platform protective bar or clo sing the safety barrier Never climb on the covers To avoid risks of tipping over operators must respect the following instructions NB Do not disable the safety system end of stroke contactors Avoid moving the steering control levers in the opposite direction without stopping in the O position to stop during a travel manoeuvre move the manipulator lever gradually Respect maximum load and maximum number of people authorised on the platform Distribute the load evenly and place in the centre of the platform if possible Check that the floor resists the pressure and load per wheel Avoid contact with fixed or mobile obstacles Do not drive the platform at high speed in narrow or cluttered areas Do not drive the platform in reverse inadequate visibility Do not use the machine if the plat
127. m control stations that the machine is being serviced If possible restrict access to the elevating platform to intervention personnel only 12 2 1 Specific tools Personnel should therefore be familiar with the use of the specific tools used measurement device torque tightening device lifting apparatus etc and respect the operating limits specified in the documentation that is supplied with the tools Incorrect use of a tool incorrect adjustment after a reading error may lead to premature deterioration of the elevating platform or more seriously an accident for which PINGUELY HAULOTTE cannot be held responsible 61 Pinguely Haulotte 4 12 3 MAINTENANCE SYSTEM Photo 1 62 Repair manual 12 2 2 Replacing an element Before replacing an element the machine must be put in the maintenance configuration see corresponding paragraph and the electric power supply cut off see corresponding paragraph All distributing valves are with open centre breaking the electric circuit therefore decreases pressure in the hydraulic circuits up to the non return valves flanged on the cylinders An element can be replaced safely if the procedures described in the maintenance sheets are respected unscrew hydraulic connectors slowly to release residual pressure To preserve the integrity of the safety systems and the technical characteristics of the elevating platform it is essential to use original parts and to respect the
128. m sufficiently to enable access to the turntable rotation hydrau Put the turntable rotation lic motor blocking pin into place Place wedges under the boom to bear its weight 5 5 Putthe machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Caution f necessary close the shut off valve or empty the hydraulic tank It is essential to put the component in slings before 2 Removing the hydraulic motor dismantling re assembling Mark and disconnect the two hoses 1 of the hydraulic motor 3 it _ NB Unscrew the hoses slowly to release residual hydraulic pressure Putcaps on the hoses Caution Place a wedge under the hydraulic motor Ensure that the oil is not too Remove its two fixing screws 2 hot Remove the hydraulic motor Remove the blocking screws from the keyed sleeve at the end of the motor shaft Remove and retain the keyed sleeve Caution Use a container to collect oil to prevent pollution of the Installing the hydraulic motor Put the keyed sleeve back at the end of the motor shaft coat the blocking screw with blue loctite environment Put a new hydraulic motor into place Fix the hydraulic motor with the two fixing screws equipped with new spring washers the hydraulic hoses according to the marks made during dis Q mantling 4 Additional ope
129. made during dis mantling see table of tightening torque values Put the machine back into the operational configuration Make several platform rotation movements to purge the hydraulic circuit and adjust rotation speed using the flow limiter adjustment buttons see Table of adjustment times Check the level ofthe hydraulic oil tank Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C053 Folio 1 3 CHANGING THE BASKET 1 Preliminary operations Caution Putthe machine in the maintenance configuration see corresponding It is essential to put the paragraph component in slings before Switch off electric power see corresponding paragraph dismantling re assembling Disconnect the then terminals of the starter battery it 2 Removing the platform Disconnect the platform control panel electric wiring harness Remove the control panel fixing screws 17 Remove the control panel and its silent blocks 18 Remove the platform s electric plug 19 if any by unscrewing its fixing bolts Putthe platform in slings Remove the pre stressing stop by unscrewing the screw 1 and nut 2 Upper part Remove the Nylstop nut 3 and its washer 4 on the platform side Remove the stop pad 5 on the platform side Remove the weighing articulation pin 6 Lower part Remove the lower pivot pin 7 by removing its fixing screws 8 and washer 9 Remove the platform and retain t
130. manual 14 1 3 Travel system ANOMALY PROBABLE CAUSE SOLUTION Pinguely Haulotte 4 No machine travel movement Connectors disconnected Manipulator 4 defective Wiring harness defective Electronic module U1 defective Coils of electrovalve YV6 or YV7 defective Electrovalves YV6 or YV7 defectives Fiche DP032 Only travel micro speed remains available on the machine regardless of the speed selected Machine unfolded Contactors 502 SQ3 504 incorrectly set or defective Wiring harness defective Electronic module U1 defective Printed circuit defective Fiche DP071 Machine travel speed does not correspond to the selec tor Electrovalve YV8 YV10 or YV12 defective Coil of electrovalve YV8 YV10 or YV12 de fective Wiring harness defective Printed circuit defective Speed selector SA11 defective Electronic module U1 defective Fiche DP069 Sudden stop of travel during a platform lifting operation Contactors SQ3 SQ4 SQ2 incorrectly set or defective Wiring harness defective Electronic module U1 defective Fiche DP070 No differential blocking during action on switch SA3 Switch SA3 or SA11 defective Electronic module U1 defective Wiring harness defective Contactors SQ3 SQ4 SQ2 incorrectly set or defective Printed circuit defective Coils of electrovalves YV9 or YV13 defective Electrovalves YV9 or YV13 defective Fiche DP036 No grip on a drive wh
131. mofy 1002 0 12 2 d9ZYH dOZYH 6661 70 80 wo a wem ALLO INVH A TENONId 1 101 VSIA NOILVOISIGOW auva 6 20 doe 10 218 899 10 euJayy Jeuejs AoueBieur3 d IN 1 0 DE 2 655 L 1 M lt 8 1 4 1 0 1 E z9 1 wa ys ys y va y erw y I 1 1 0 9 T 1 A A A 1 S 0 I o A MER e e sor 9 SOL A d N 0 1 81 90 61 0 0z p0 6 20 09 VIH H erzo al gt spe a 9 0 N 0 4 E o 3 D gt oz 0 a VOL 5 08 hee Ind 9 a ezo Tor e e v oz GL SL 21 OL SL FL EL AA LL ol 8 2 El v L Repair Manual Pinguely Haulotte 4 WIRING DIAGRAM E 448 FOLIO 02 05 4 2 20 SVIN3HOS SSL 19 ans yunys 1002 01 06 SPORE Sana a 5 eduiog dg 100 10 80 OLA lee bz bZ 62 LL AL S dIZVH dOZVH
132. n the frequency The symbol represents the consumable to use or the operation to be carried out ubricants used by PINGUELY HAULOTTE SHELL RIMULAX SYMBOL Gearbox oil SAE 90 SHELL SPIRAXA EP80W90 TRANSELF TM 80 W 90 Hydraulic oil AFNOR 48602 ISO VG 46 HYDRELF DS 46 EQUIVIS ZS 46 SHELL TELLUS T46 Organic hydraulic oil option HF E 46 SHELL Naturelle HF E46 Lithium extreme pressure grease Lead free grease Grade 2 ou 3 ESSO MULTIMOTIVE GP GREASE 2 MULTIS EP 2 Replacement or special operation Grease Ceplattyn KG 10 HMF Grease 64 Energrease LS EP2 500 Pinguely Haulotte 4 HOURS Repair manual Le 25 d X 5 4 x 5 0 25 5 0 252 25 m 5 5 5 2 e lt gt 5 0 x 2 050 SX eO 25 25 255 5 2 255 RL SN 25 2 RL SL 2505 SES 255 2505 RL SN d OO CER RKS 0 d i d d 5 dy 111595 t 00 di 25 50 500 1 000 2 000 ie Wl 10 50 65 250 500 1 000 2 000 25 Hr
133. n YV1 1 and YV5 1 Right if SA15b 1 then YV1 1 and YV5 1 Platform Left if HM31 1 and SM31ab 0 puis SM31ab 1 and SQ6 1 and then YV1 1 and YV5 1 Right if HM31 1 and SM31ab 0 puis SM31ab 1 and SQ6 1 and then YV1 1 and YV5 1 Turntable Up if SA14a 1 and SQ1 1 or machine folded then YV1 1 and YV4 1 Down if SA14b 1 then YV1 1 and YV4 1 if SQ4 1 then the end of the lowering movement is slowed down Platform Up if HM2 1 and SM2ab 0 puis SM2ab 1 and SQ6 1 and SQ1 1 or machine folded then YV1 1 and YV4 1 Down if HM2 1 and SM2ab 0 puis SM2ab 1 and SQ6 1 then YV1 1 and YV4 1 Repair manual 6 9 BOOM LIFTING 6 10 TELESCOPING 6 11 TRAVEL 6 12 STEERING Pinguely Haulotte Z Turntable Up if SA13a 1 and SQ1 1 or machine folded or SQ9 1 then YV1 1 and YV3 1 Down if SA13b 1 and SQ1 1 or machine folded or SQ9 1 then YV1 1 and YV3 1 Turntable Up if HM31 1 and SM1ab 0 then SM1ab 1 and SQ6 1 and SQ1 1 or machine folded or SQ9 1 then YV1 1 and YV3 1 Down if HM31 1 and SM1ab 0 puis SM1ab 1 and SQ6 1 and SQ1 1 or machine folded or SQ9 1 then YV1 1 and YV3 1 Input if SA8a 1 SA9a 1 and SQ6 1 or turntable position then YV14a 1 and YV2a 1 and YV1 1 Output if SA8b 1 or SA9b 1 and SQ1 1 or machine folded and SQ6 1 or turntable position then YV14b 1 and YV2a 1 and YV1 1 if unfolded machine then micro speed 1 if machine folded then micro speed 0 if SA11a 0 and SA11b 1 M
134. ndicator 29 Pinguely Haulotte Repair Manual 30 Repair manual 5 1 5 2 5 3 MOTOR FUSES INPUT Pinguely Haulotte 4 5 MACHINES ELEMENTS G2 M3 YA2 YA1 01 FU1 FU3 FU4 FU5 FU6 FU7 FU8 09 FU10 Generator Motor start Accelerator Motor stop Frequency module 10A Motor stop 80A Maintain accelerator 30A Main 3A 212 turntable 211 Platform 20A 201 if an electrovlve is supplied permanently FU7 is destroyed 5A 242 Permanent 20A Accessories 3A Load Sensing valve 5 3 1 Control inputs SB3 SB4 SB5 5 2 SA3 SA4 SA5 SA6 SA7 SA8 SAQ Turntable start 117A Platform start 117B Buzzer 901 Accelerator 605 Differential blocking 807 Platform basket rotation SA4a right 311 SA4b left310 Platform compensation SA5a up 401 SA5b down 402 Turntable jib SA6a down 405 SA6b up 406 Platform jib SA7a down 409 SA7b up 410 Turntable telescope SA8a input 411 SA8b output 412 Platform telescope SA9a input 418 SA9b output 419 31 Pinguely Haulotte 2 SA11 Speed selection LS 805 1 804 0 5 805 0 804 0 HS 805 0 804 1 SA12 Front steering SA12a left708 SA12b right 707 SA13 Turntable liftig SA13a up 504 SA13b down 505 SA14 Turntable lifting SA14a up 510 SA14b down 511 SA15 Turntable rotation SA15a left 516 SA15b right 517 SA17 Platform electrical thermical
135. nel and check the wiring of the FRONT steering switch SA12 Replace the U1 module See Fiche NO Repair wiring C058 YES END Check the electric continuity of the switch contacts when closed NO The fault persists END the See Fiche pe printed circuit C063 5 Replace the FRONT See Fiche END steering switch SA12 C043 Repair the connection or replace the wiring END harness between the FRONT steering switch SA12 and the printed circuit of the turntable control panel Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP038 Folio 1 4 NO STEERING MOVEMENT RIGHT AND OR LEFT ON THE REAR AXLE No steering movement right and or left on the rear axle Place the key switch in the platform position Put the emergency lever into place on the manual control of the ON OFF distributor YV2 Press the pedal and make a travel movement Activate the REAR steering switch SM4 while activating the emergency lever of distributor YV2 direction YV2b Steering movement oK Y Open the turntable control panel and check that the LEDs associated with electrovalve YV21A left YV21B right and YV2B are off YES Put the machine on wedges so that the wheels are not touching the ground Press the pedal and make a travel movement Activate the R
136. ng or replace the wiring harness between the NO platform control panel and the turntable control panel YES END Replace the U1 module See Fiche C058 or C107 The fault NO persists YES END Replace the printed circuit See Fiche C063 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP020 THE MOTOR DOES NOT START Folio 1 1 FROM THE TURNTABLE CONTROL PANEL BUT DOES START FROM THE PLATFORM CONTROL PANEL The motor does not start from the turntable control panel but does start from the platform control panel Open the turntable control panel Activate switch SB3 and check continuity between the two terminals of the switch See Fiche Replace the switch SB3 NO C044 YES END Activate SB3 and check for 12V voltage at terminal 117A of the printed circuit Repair wiring of switch SB3 NO connection or replacement of electric wires Replace the U1 module See Fiche C058 or C107 NO The fault persists Replace the printed circuit See Fiche C063 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP021 MOTOR ACCELERATION FOR ANY MOVEMENT CONTROLLED Folio 1 1 FROM THE PLATFORM ACCELERATION TRAVEL LIFTING TURNTABLE ROTATION TELESCOPE No motor acceleration regardless of the movement controlled from the platform acceleration tr
137. ngs before dismantling re assembling it Equip the unions with new O rings Screw the hydraulic unions on the pump Check that the circlips and spacer and in good condition and in position inside the split spined hub Lubricate then fit the split spined hub onto a new pump until the pump shaft comes up agains the spacer Tighten to a torque of 83 N m 61 21 Ib ft Coat the hub s tightening screws with normal blue loctite 243 Install the pump on the flange and fix using fixing screws previously coated with normal blue loctite 243 and equipped with new grower washers Tighten to a torque of 86 N m 63 43 Ib ft Reconnect the hydraulic hoses according to the marks made during dismant ling Open the shut off valve if any Checkthe level of the hydraulic tank and fill if necessary Before starting fill tne pump pan with hydraulic oil hole L engraved on the pump 14 Additional operations Putthe machine back in the operational configuration Make several extension movements to purge the hydraulic circuit Checkthe level of the hydraulic oil tank Adjust pump flow the load sensing pressure limiter and the main pressure limiter see corresponding sheet Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 091 Folio 2 2 CHANGING THE HYDRAULIC PUMP Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C092 CHANGING THE HYDRAULIC BLOCK Folio 1 1 TRAVEL ON OFF MOVEMENT STEERIN
138. ns and pre operation inspections have been performed Pinguely Haulotte 2 Repair manual 1 5 REPAIRS AND ADJUSTMENTS These cover major repairs and work on or adjustments to safety systems or devices of a mechanical hydraulic or electrical nature These must be performed by personnel from or working for PINGUELY HAULOTTE who will use only original parts Any modification not controlled by PINGUELY HAULOTTE is unauthorised The manufacturer cannot be held responsible if non original parts are used or if the work specified above is not performed by PINGUELY HAULOTTE approved personnel 1 6 VERIFICATIONS WHEN RETURNING TO SERVICE To be performed after extensive disassembly reassembly operation repair affecting the essential components of the machine any accident caused by the failure of an essential component It is necessary to perform a suitability examination a state of conservation examination a static test a dynamic test see coefficient in paragraph see Chap 1 4 2 page 9 Caution These test must be performed by a competent person 1 7 BEAUFORT SCALE The Beaufort Scale of wind force is accepted internationally and is used when communicating weather conditions It consists of number O 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
139. ntrol of the boom lifting distributor YV3 Activate the lever up down while pressing the emergency control of the safety valve YV1 Movement OK Activate the lifting switch SA13 of the turntable control panel and check for 3V or 9V voltage depending on movement direction on the connector of electrovalve YV3 Maintain the control activated and check for 3V or 9V depending on movement direction on terminal 403A of the printed circuit Voltage OK See Fiche C077 Replace PVG electrovalve YV3 NO Voltage y OK Replace the U1 See Fiche module C058 YES END Repair the connection or replace the wiring harness between the turntable control panel and electrovalve YV3 Voltage OK Replace the See Fiche printed circuit C063 Pinguely Haulotte 4 Sheet DP068 BREAKDOWN DETECTION FLOW CHART NO BOOM LIFTING MOVEMENT UP AND OR DOWN FROM THE PLATFORM OR TURNTABLE CONTROL PANEL mode tion distributor YV5 Activate the rotation movement in the emergency Put the emergency lever into place or activate the emergency unit on the manual control of the rota Activate the lever right left while pressing the emergency control of the safety valve YV1 Movement OK _ NO see Fiche DP023 Folio 4 4 Replace PVG electrovalve YV3 See Fiche
140. ntrolled If an electrovalve is not connected the corresponding LED is permanently on Instructions Identify the defective function Machine power on but not started check the presence of the electro valves LED off No electrovalve should be controlled LED on Check that the outputs corresponding to the function are active using the LEDs and directly on the electrovalve heads If they are not active check which inputs create the function Test the inputs with a voltmeter 83 Pinguely Haulotte 4 14 1 1 General operation Repair manual ANOMALY PROBABLE CAUSE SOLUTION The motor does not start the starter is activated Diesel tank empty Fuse FU1 defective Diesel supply circuit defective Wiring defective Module U1 defective Stop motor solenoid YA1 defective Fiche DP066 The motor does not start the starter is not activated Emergency stop locked Generator defective Batteries defective Fuses FU1 FUA FU8 defective Wiring defective Switch SB3 or SB4 defective Relay KA2 defective Fiche DP016 The motor starts then stops after 55 Diesel tank empty Diesel supply circuit defective Fiche DP017 The motor does not start from the platform station but does start from the turntable station Fuse FU6 defective Defective connection of switch SB4 Switch SB4 defective Wiring harness defective Fiche DP019 The motor does not start from the
141. of the platform control panel is defective Repair cabling or replace the NO platform control panel a YES END See Fiche C064 Replace the pedal Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART NO AVAILABLE 22 FROM THE PLATFORM CONTROL PANEL Open the turntable control panel Check for 12V voltage on terminal 211 NO YES Check wiring of wire 211 inside the platform control panel Replace the wiring harness between the turntable control panel and the platform control panel Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP025 Folio 1 2 NOISY HYDRAULIC PUMP The hydraulic pump makes a noise Check the oil level in the circuit Oil level Top up with oil See Fiche P005 or P008 END Check that the oil used is the recommended oil problem of oil viscosity being too high NO Change the hydraulic oil YES END Check that the hydraulic tank air vent is not blocked NO Clean the hydraulic tank air vent YES END On certain platforms check that the suction valves are open Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP025 Folio 2 2 NOISY HYDRAULIC PUMP Open the suction valves Check the state of the suction pipes clogging etc
142. on pins Block the pins with new M canindus pins Install the four pin stop rings and fix using their fixing bolts Pass the hydraulic hoses and electric cables along the jib according to the marks made during dismantling and reconnect Install the two cable passage collars on the platform and the three collars along the length of the jib Install and set the contactor SQ2 see corresponding sheet Put the machine back into the operational configuration Make several jib lifting boom lifting and platform rotation movements to purge the hydraulic circuit Check the level of the hydraulic oil tank Sheet C079 Caution Ensure that the oil is not too hot Caution Use a container to collect oil to prevent pollution of the environment Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Folio 1 1 CHANGING A FLOW SEPARATOR 1 Preliminary operations the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph 2 Removing a flow separator Remove the flow separator 1 by unscrewing it 3 Installing a flow separator Screw a new flow separator whose characteristics correspond to the machine in question into the hydraulic block Tighten to the recommended torque Flow separator ref FDC1 10 47 to 54 Nm 34 to 39 8 Ib ft Flow separator ref FDC1 16 108 to 122 Nm 79 6 to 89 9 Ib ft
143. on reducing gear 1 Put in slings then remove the turntable rotaton reducing gear 1 Remove and retain the adjustment screws 2 with their counter nuts Installing the turntable rotation reducing gear Put back the adjustment screws 2 and 3 with their counter nuts on the new reducing gear without blocking them so that the heads are as flush as possible Position the new reducing gear on the turntable Put back the reducing gear s four fixing screws 4 without blocking them Adjust the position of the reducing gear using the adjustment screws 2 and 3 Turn the reducing gear to position the ring teeth marked with a colour opposite the reducing gear pinion this coloured mark corresponds to the most excentric point of the ring Adjust the gap between the teeth to 300um with a set of flakes When the is set block the counter nuts of adjustment screws 2 and 3 Block the reducing gear s four fixing screws 4 to a torque of 196 N m 144 56 Ib ft Additional operations Put back the turntable rotation hydraulic motor 5 see corresponding sheet Remove the wedges from the boom Put the machine back in the operational configuration Make several turntable rotation movements to purge the hydraulic circuit and check reducing gear operation Check the level of the hydraulic oil tank Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C117 CHANGING THE TURNTABLE ROTATION REDUCING GEAR Folio
144. on the rotation distribu tion platform control YV5 Activate the lever to the right and left while pressing the emergency control of the safety valve YV1 Movement oK Activate the rotation switch SA15 from the turntable panel and check for 3V or 9V voltage depending on the movement direction at the terminals of electrovalve YV5 Maintain the control activated and check for 3V or 9V voltage depen ding on the movement direction on terminal 512A of the printed circuit Voltage OK See Fiche C077 NO Voltage Replace PVG electrovalve YV5 y OK Replace the U1 See Fiche module C058 END Repair the connection or replace the electric wiring harness between the turn table control panel and electrovalve YV5 Voltage OK Replace the See Fiche printed circuit C063 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP018 NO TURNTABLE ROTATION MOVEMENT Folio 3 3 RIGHT AND OR LEFT FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Activate the arm lifting movement in the emergency mode Putthe emergency lever on the manual control of the rotation distributor YV4 Activate the lever to the right and left while pressing the emergency control ofthe safety valve 1 Movement Fiche DP023 OK Replace PVG electrovalve YV
145. onal configuration Make several lifting travel steering and turntable rotation movements to purge the hydraulic circuit Check the level of the hydraulic oil tank Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C097 Folio 1 1 CHANGING A TURNTABLE COVER 1 Preliminary operations Putthe machine in the maintenance configuration see corresponding Caution paragraph Do not use the machine Switch off electric power see corresponding paragraph during maintenance operations 2 Removing a cover Openthe relevant cover 1 Putthe cover in slings Remove the nuts and washers 3 fixing the gas springs to the connecting rods 2 supporting the cover Remove the bolts 5 and 6 fixing the cover 1 to the two hinges 4 Retain the cover support connecting rods 2 Remove the cover Installing a cover Position a new cover and fix to the hinges 4 with screws 5 Put back the cover support connecting rods using their fixing screws 6 Fixthe gas springs to the cover connecting rods 2 using nuts and washers 3 Check that the cover opens and closes properly f necessary adjust the cover using screws 4 and 5 Putthe machine back in the operational configuration Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C099 CHANGING THE TURNTABLE ROTATION HYDRAULIC MOTOR 1 Preliminary operations A Caution Lift the boo
146. oom lifting manipulator SM31 Check that the LED associated with electrovalve YV1 is on NO YES Maintain activation of the controls and check connector YV1 for 12V voltage 1A to 1 6A current Replace the electric wiring YES harness between electrovalve YV1 and the turntable control panel 1A to 1 6A dis END 9 K YES Replace electrovalve Replace the coil of See Fiche YV1 electrovalve YV1 C077 or C108 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART un cee NO MOVEMENT AVAILABLE PS FROM TURNTABLE OR PLATFORM CONTROL PANELS Pressure NO 25 to 32 bars YES Adjust the load See Sheet sensing pressure 073 or C111 NO Pressure OK YES Check the coupling See Fiche between the hydraulic C042 or END pump and the thermal 091 motor Coupling NO OK Y Replace the hydraulic See Fiche Replace the See Fiche pump C042 or C091 coupling C042 or C091 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP023 Folio 4 5 NO MOVEMENT AVAILABLE FROM TURNTABLE OR PLATFORM CONTROL PANELS Replace the pressure limiter of the PVG input module Clean the protective filter screen The fault NO persists YES END Replace the PVG input See Fiche module C076 or C094 The fault NO persists
147. ovement electrovalve YV21 C067 control right 2 or left 1 ENDE A Put coils YV21A and YV21B back into their original positions Press the pedal make a travel movement and activate the REAR steering switch SM4 and check for 12V voltage at the terminals of the connector of YV21A or YV21B Open the turntable control panel Press the pedal and make a travel movement activate the REAR steering switch SM4 and check for 12V voltage on terminals 307 left and 308 right of the printed circuit 12V OK at terminals of electric connectors n NO Replace the See See Fiche Replace the U1 module C058 C059 defective coil Y YES The fault persists END Repair the connection or replace the wiring harness between the turntable control panel and electrovalve YV21 See Fiche C063 Replace the printed circuit END Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP038 Folio 4 4 NO STEERING MOVEMENT RIGHT AND OR LEFT ON THE REAR AXLE Maintain the control activated and check for 12V voltage at terminals 705 right and 703 left of the printed circuit Open the platform control panel and check the wiring of NO the REAR steering switch SM4 YES NO Replace the U1 module SeeFiche Repair wiring C058 YES END Check the electric continuity of the switch contacts when closed
148. ped with new toothed washers Reconnect the then terminals of the starter battery Putthe machine back into the operational configuration Adjust the weighing contactors see corresponding sheet SES SISSI N Zo 4 1 Sl us Figure 1 NN NN Cl NY TY FA 4 CT h A 4 222222222222272222277222222222222224 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C053 Folio 3 3 CHANGING THE BASKET vide 27 cote a IS 15 HA16 18PX HA46 51JRT 108 mm 4 25 in H21T HB62 103 mm 4 055 in H23T TP H25TP HB68J HB76J 108 mm 4 25 in Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C054 Folio 1 1 CHANGING A WEIGHING SYSTEM ROLLING BEARING 1 Preliminary operations Putthe machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Remove the basket see corresponding sheet 2 Removing the rolling bearing Remove the screws 1 from the rolling bearing track Remove the rolling bearing track 2 Remove the circlips 4 then the ball bearings 3 3 Installing the rolling bearing Putnew rolling elements on the bearing track Block in travel using the cir clips Lubricate th
149. peratures of less than 15 C in particular in cold rooms consult our service department if work is required in conditions below 15 C In an explosive atmosphere In an incorrectly ventilated area as exhaust fumes are toxic During storms risk of being struck by lightning At night if the machine is not equipped with an optional light In the presence of intense electromagnetic fields radar mobile and high current DO NOT DRIVE ON THE PUBLIC HIGHWAY 1 2 3 Using the machine It is important to ensure that in normal use i e platform operation the platform station selection key remains in the the platform position to enable control of the machine from the platform If a problem occurs on the platform a person present and trained in emergency standby manoeuvres can help by putting the key in the ground control position Never use the machine with aload 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 Caution Never use the platform as a crane goods lift or elevator Never use the platform or tow or haul 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 rai
150. pply output way to telescop output Telescop supply output way to telescop input Telescope input entry pressure regulator set at 200 Bars 2900 PSI Telescope outlet pressure regulator set at 150 Bars 2175 PSI Telescope output valve Telescopue input valve 56 Repair manual Pinguely Haulotte 7 10 6 STEERING BLOCK CONTROL 10 6 1 Location Description YV22 A Front right steering YV21 A Rear left steering YV22 B Front left steering YV21 B Rear right steering 10 6 2 Input and output Input of block feeding Output return to tank Output unbreaking supply when steering is stopped when no drive Front steering cylinder supply A1 big chamber B1 small chamber Rear steering cylinder supply A2 small chamber B1 big chamber 57 Pinguely Haulotte 2 Repair manual 58 Repair manual Pinguely Haulotte D 11 HYDRAULIC EQUATIONS 11 1 TRAVEL PV YV1 YV6 amp YV7 GV YV1 YV6 8 YV7 YV10 12 Differential blocking YV13 11 2 TURNTABLE ROTATION YV1 YV5AorB 11 3 ARM LIFTING YV1 YVA up A down 11 4 BOOM LIFTING YV1 YV 3 up down 11 5 TELESCOPING YV1 YV 2A YV 14 A out B in 11 6 OTHER MOVEMENT YV1 YV2B Jib YV 18 A up B down or Platform rotation YV 19 A or B or Manual compensation YV15 A or B or Steering front axle YV 21 A or B or Steering rear axle YV22 A or B 59
151. rations Remove the boom wedge Putthe machine back in the operational configuration Make several turntable rotation movements to purge the hydraulic circuit Checkthe level of the hydraulic oil tank Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C100 Folio 1 2 CHANGING THE SWING JOINT ASSEMBLY 1 Preliminary operations Caution Lift the boom sufficiently to enable access to the swing joint Put the turntable rotation Place wedges under the boom to bear its weight blocking pin into place Putthe machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph If necessary close the shut off valve or empty the hydraulic tank Caution It is essential to put the 2 Removing the swing joint component in slings before Open the chassis box mark and disconnect all electric connectors 5 dismantling re assembling Open the turntable box mark and disconnect all electric connectors 6 it from the swing joint wiring harness Free the two electric wiring harnesses 2 of the swing joint after marking their respective paths Markand disconnect the hydraulic caps and hoses 1 of the swing joint Caution 3 on the turntable and below the chassis Ensure that the oil is not too 5 hot NB Unscrew hoses slowly to release residual hydraulic pressure Putcaps on the hoses Putthe sw
152. re not touching the ground From the platform control panel select low speed Press the pedal and make a travel movement in the FOR direction Put the emergency lever on the manual control of the travel distributor YV6 and tilt the lever in the FOR operation direction The wheels turn Y Maintain action on the platform panel controls Putthe emergency lever into place on the manual travel distributor YV7 and tilt the lever in the FOR operation direction The wheels turn Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP032 Folio 2 4 NO MACHINE TRAVEL MOVEMENT Open the turntable control panel and check connection of PVG travel connectors 25 and 26 Y Connections oK YES Check operation of the travel manipulator SM4 Activate the fail safe HM4 alone and check for voltage at HM4 output and no voltage at SM4ab output Reconnect the connectors Y YES Check for setpoints at inputs 29 2 29 3 and 29 4 of the U1 electronic module Setpoints Replace the manipulator See Fiche HM4 12V C045 SMdab OV an END While maintaining the fail safe 4 activate the travel manipulator SM4 and check the setpoint at output Y ofthe manipulator SM4 Setpoints Forward 2 5 to 4 5V Replace t
153. rts 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 89 392 CEE dated June 14th 1989 modified by directives 91 368 CEE dated June 21st 1991 93 44 CEE dated June 14th 1993 93 68 CEE 98 37 CE dated July 22nd 1993 and 89 336 CEE dated May 3rd 1989 to directive 2000 14 CE and directive EMC 89 336 CE Pinguely Haulotte 7 Repair manual Repair Manual Pinguely Haulotte 7 SUMARY 612 257 A 1 1 GENERAL RECOMMENDATIONS SAFETY 2 1 1 5 Ms GENERAL E HE 5 talles Manual 5 1 12 EE 5 toko nn 5 1 2 GENERAL SAFETY 6 6 1 2 1 O TA 6 1 2 2 Emironment 6 1 2 3 Using the machine u an 6 To RESIDUAL RISAS zn ann 8 1 3 1 Risks of jerky movements and tipping over sien 8 1 3 2 Electrical riskieren been 8 1 3 3 Risk of explosion or UIT en ae ee 8 1 3 4 Risks of collision 8 14 E enne 9 1 4 1 Periodic inspections 9 1 4 2 Examination or ele ee 9 1 4 3 State of conservation 9 14 5 REPAIRS AND ADJUSIMEN Tr sa a 10 1 6 VERIFICATIONS WHEN RETURNING TO SERVICE 10 1 BEAUFOR
154. s 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 74 Repair manual Pinguely Haulotte 7 13 PREVENTIVE MAINTENANCE SHEET IList of maintenance preventive sheets Sheet no Description Checking filling the hydraulic oil tank Changing the hydraulic filter cartridge Checking changing the oil of a wheel reducing gear 75 Pinguely Haulotte 2 Repair manual 76 Sheet P005 HA16 18PX New Design HA46 51JRT Pinguely Haulotte 4 PREVENTIVE MAINTENANCE SHEET CHECKING FILLING Folio 1 1 THE HYDRAULIC OIL TANK 1 Preliminary operations the machine in the maintenance configuration see corresponding para graph Switch off electric power see corresponding paragraph 2 Checking filling the hydraulic oil tank NB This operation must be carried out when the oil is cold e before star ting the machine Check that the level of oil 1 in the tank is between the high and low levels when cold Top up if necessary by filling via the cap 2 NB Only use the oil recommended by the manufacturer Putthe machine back into the operational configuration Pinguely Haulotte 4 PREVENTIVE MAINTENANCE SHEET Sheet P006 CHANGING THE HYDRAULIC FILTER Folio 1 1 CARTRIDGE 2 Preliminary operations Putthe machine in
155. see 250 hour interval Drain the drive wheel reducers see 500 hour interval 2 points for 4x2 model 4 points for 4x4 model Check the tightness of the slewing ring screws torque 27 daNm Every 250 hours Engine see engine manufacturer s manual Grease the telescope s friction parts spatula Check the condition of the telescopic cylinder friction pads Check the tightness of the wheel nuts torque 32 daNm Change the hydraulic filter s cartridge Every 500 hours Engine see engine manufacturer s manual Drain the wheel reducers Fill up again capacity 4 x 1 4 Ring screw check tightness and tighten if necessary torque 27 daNm OPTION every 500 Empty the hydraulic oil tank completely if you have the organic hy hours or every 6 draulic oil option months Every 1000 hours or Engine see engine manufacturer s manual every year Drain the hydraulic oil reservoir Every 2000 hours Engine see engine manufacturer s manual Drain the hydraulic oil complete circuit and reservoir Drain and clean the diesel tank Grease rotation reducer 1 point REMINDER All these intervals must be reduced if working in difficult conditions refer to the After Sales Department if necessary 66 Repair manual Pinguely Haulotte 7 12 7 PRESENCE OF LABELS Make sure that the labels plates informing personnel of the various dangers related to machine use are in good condition The labels informing operators on the use and
156. ses NO Replace the defective harness es no 115A and 115B Check the setting of detectors 507 508 5010 and 5011 END Detector setting OK YES See Fiche Replace the U1 module 058 See Fiche Adjust the detectors CXXX Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP066 Folio 3 4 THE MOTOR DOES NOT START THE STARTER IS ACTIVATED Replace relay See Fiche Check the wiring between the motor start KP1 062 switch SB3 SB4 and the printed circuit of the turntable control box The fault persists NO Wiring END OK Check the continuity of the wiring harness between relay KP1 Repair wiring turntable box terminal 115 and the solenoid of the motor stop YA1 END NO Replace the U1 module See Fiche C058 Replace the defective YES wiring harness END Replace the motor stop solenoid END YA1 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP066 THE MOTOR DOES NOT START Folio 4 4 THE STARTER IS ACTIVATED Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP067 NO TELESCOPING MOVEMENT OUT AND OR IN FROM Folio 1 6 THE PLATFORM OR TURNTABLE CONTROL PANEL No telescoping movement in and or out from the platform or turntable control panel Place the key switch in the platform position Press th
157. t to test manipulator operation Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C046 Folio 1 1 CHANGING THE STARTER BATTERY ae 1 Preliminary operations Caution Put the machine in the maintenance configuration see corresponding Wear protective goggles and paragraph gloves for any operation on Switch off electric power see corresponding paragraph the batteries 2 Removing the starter battery Disconnect the then terminals 1 of the battery 3 Remove the fixing screws from the battery fixing tab and remove the fixing tab 2 Remove the battery 3 Installing the starter battery Puta new battery into place Putback the fixing tab and secure with the fixing screw equipped with a new toothed washer Re connect the then terminals of the battery and lubricate them to improve contact Putthe machine back into its operational configuration Start the machine to check that the battery works properly Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C047 Folio 1 1 CHANGING A COVER GAS SPRING 1 Preliminary operations Putthe machine in the maintenance configuration see corresponding N Caution paragraph S Switch off electric power see corresponding paragraph Do not use the machine during maintenance 2 Removing a gas spring operations Open the cover 1 concerned Putthe cover in slings Remove the fixing
158. the machine back in the operational configuration Lubricate the pins with lubricators Pinguely Haulotte 4 Folio 2 2 kE I o O 2 lt 2 m E lt lt 2 gt kE O O O DISMANTLING AND RE ASSEMBLING Sheet C086 THE STEERING SYSTEM Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 087 Folio 1 1 CHANGING THE STEERING CYLINDER 8 Preliminary operations Putthe machine in the maintenance configuration see corresponding para AN Caution graph Ensure that the oil is not too e Switch off electric power see corresponding paragraph hot 9 Removing the steering cylinder Open the upper cover of the chassis Caution Mark and disconnect the two hoses 2 of the steering cylinder 1 Use a container to collect oil to prevent pollution of the environment NB Unscrew the hoses slowly to release residual hydraulic pressure Put caps on the hoses Caution Put the cylinder in slings It is essential to put the Remove the Nylstop nuts 4 then remove the two fastening pins 3 from the component in slings before steering cylinder dismantling re assembling Remove the steering cylinder it 10 Installing the steering cylinder Puta new steering cylinder into place Putback the fastening pins and fix using new
159. the maintenance configuration see corresponding Ensure that the oil is not too paragraph hot Switch off electric power see corresponding paragraph 2 Removing a double balancing valve Mark disconnect the four hydraulic hoses 3 on the double balancing valve unit 1 NB Unscrew the hoses slowly to release residual hydraulic pressure Fit hoses with caps Remove the unit s 4 unions 2 Remove the unit 1 by unscrewing the 2 fixing bolts 4 1 Installing a double balancing valve Putanew unit into place and fix with the two bolts equipped with new too thed washers Putthe four unions equipped with new O rings back onto the unit Tighten to the recommended torque see corresponding paragraph Reconnect the hydraulic hoses according to the marks made during dis mantling Tighten to the recommended torque see corresponding para graph Putthe machine back into the operational configuration Caution Make several movement cycles using the replaced double balancing valve to purge the hydraulic circuit Balancing valves are safety e Check the level of the hydraulic oil tank elements They are calibrated in the plant and must not be re adjusted Sheet C069 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Folio 1 2 DISMANTLING RE ASSEMBLING THE JIB Caution Ensure that the oil is not too hot Make sure that the lifting eq
160. the maintenance configuration see corresponding para Caution graph Use a container to collect oil Switch off electric power see corresponding paragraph to prevent pollution of the environment 2 Replacing the hydraulic filter cartridge NB The filter has a clogging indicator Clogging should be checked when the machine is hot otherwise the indicator may be visible due to the viscosity of the cold oil Change the cartridge 1 if the clogging indicator appears 2 Unscrew the base nut 3 and remove the cartridge from the hydraulic filter Screw a new cartridge into place Putthe machine back into the operational configuration HA16 18 PX HA46 51JRT HA20 26 PX HA61 80JRT H14P H16TP 40 44 Pinguely Haulotte 4 PREVENTIVE MAINTENANCE SHEET Pinguely Haulotte 4 PREVENTIVE MAINTENANCE SHEET Sheet P007 Folio 1 1 CHECKING CHANGING THE OIL OF A WHEEL REDUCING GEAR 3 Preliminary operations Caution Putthe machine in the maintenance configuration see corresponding para Use a container to collect oil graph to prevent pollution of the Switch off electric power see corresponding paragraph environment 2 Checking the level Turn the wheel so that one cap 1 is on a horizontal line and the other 2 is on a vertical line Unscrew the cap 1 and check the level that should be up to the hole Top up Caution if necessary Make sure that the machine e Screw the cap
161. to conditions related to the ground traffic slope and movement of people or any other factor that may cause a collision When driving down the ramp of a truck ensure sufficient space is available for safe unloading Check brake pad wear regularly to avoid all risk of collision Repair manual 1 4 INSPECTIONS Pinguely Haulotte 4 Comply with the national regulations in force in the country of machine use For FRANCE Order dated 9 June 1993 circular DRT 93 dated 22 September 1993 which specify 1 4 1 Periodic inspections The machine must be inspected every 6 months in order to detect any defects liable to cause an accident These inspections are performed by an organisation or personnel specially designated by the site manager and under his responsibility whether or not they belong to the company Articles R 233 5 and R 233 11 of the French Labour Code The results of these inspections are recorded in a safety register kept by the site manager and constantly available to the labour inspector and the site safety committee if one exists and the list of specially designated personnel Article R 233 5 of the French Labour Code Moreover before each use check the following the operator s manual is in the storage compartment on the platform the stickers are placed according to the section concerning Labels and their positions oil level and any elements the mainteance operation table look out for
162. ts of the jib 2 and 3 and the cylinder 1 4 Removing the jib link part 9 Put the jib link part into slings 9 Put the receiver compensation cylinder into slings 10 Remove the M canindus pin blocking the pin then remove the pin 11 of the receiver compensation cylinder 10 Remove the male clevis blocking the link part rotation pin 12 by remo ving its fixing screw Remove the rotation pin 12 then remove the jib link part 9 5 Installing the jib link part NB Lubricate all bores before re installing the pins Only use lubricants recommended by the manufacturer Check the condition of the rings of the different jib pins and replace if necessary Put the jib link part back into place Install the link part rotation pin Install the clevis and block using the screw previously coated with normal blue loctite 243 Install the receiver compensation cylinder pin and block with a new M ca nindus pin Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C069 Folio 2 2 DISMANTLING RE ASSEMBLING THE JIB 6 Installing the jib Put the jib and its cylinder into place and install the articulation pins Fix the pins with M canindus pins Install the 3 stop rings and the contactor SQ2 cam in the positions marked during dismantling and fix with their bolts 7 Installing the platform support assembly Put the platform support assembly into place and install the two articula ti
163. uipment is in good condition and of sufficient capacity Caution Use a container to collect oil to prevent pollution of the environment Jb Caution It is essential to put the component in slings before dismantling re assembling it 1 Preliminary operations Put the machine in the maintenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph Remove contactor SQ2 see corresponding sheet 2 Removing the platform support assembly NB 1 Mark and disconnect the electric connections at the platform box Mark and disconnect the hydraulic hoses of the platform rotation motor and the jib cylinder 1 Unscrew the hoses slowly to release residual hydraulic pressure Fit caps to the hoses Open the two cable passage collars on the platform and the three collars along the jib Mark the path of the electric cables and hoses then remove all cables passing along the length of the jib Put the platform into slings Put the jib cylinder 1 and vertical elements 2 and 3 into slings Remove the four bolts and pin stop rings 5 fixing the platform assembly 4 Remove the two M canindus pins blocking the pins 5 Remove the two pins 5 and remove the platform assembly Removing the jib Mark the position of the cam 6 of sensor SQ2 7 Remove the two pins 8 fixing the jib to the jib link part as described above then remove the vertical par
164. uld be audible from the basket Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C043 CHANGING AN ELECTRIC COMPONENT Folio 1 1 ON THE TOP CONTROL PANEL 1 Preliminary operations Putthe machine in the maintenance configuration see corresponding ZN Caution Em Switch off electric power see corresponding paragraph De the machme Disconnect the then terminals of the starter battery during maintenance operations 2 Removing a component from the top control panel Remove the closing plate 1 by removing the four fixing screws 4 Mark and disconect the electric connections 3 of the component to be replaced 2 Remove the component 3 Installing a component in the top control panel Put a new component and seal into place on the front panel of the top con trol panel NB In the case of a lever switch adjust the position of the fixing nut and counter nut so that the switch lever s articulation pin is at the same level as the seal to ensure tightness Reconnect the electric connections according to the marks made during dismantling Fixthe closing plate using the four fixing screws Reconnectthe then terminals of the battery Putthe machine back into the operational configuration Perform the function corresponding to the replaced component to check that it works properly Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C04
165. witch in the platform position Do not press the pedal Open the turntable control panel and check that the LEDs associated with electovalves YV9 and YV13 are off All the LEDs are Note the LED that is on off Put the machine on wedges so that the wheels are not touching the ground Place switch SA3 in the differential blocked position Press the pedal and make a forward travel movement Check that the LEDs associated with electrovalves YV9 and YV13 are on Allthe LEDs are on NO e Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP036 Folio 2 3 NO DIFFERENTIAL BLOCKING WHEN SWITCH SA3 IS ACTIVATED Press the pedal and make a forward travel movement Check for 12V voltage at the terminals of the connector of the electrovalve in question YV9 and YV13 NO YES Open the turntable control panel Press the pedal and make a forward SeeFiche Replace the coil of the travel movement C059 electrovalve Check for 12V voltage at the terminals of the printed circuit associated with the electrovalve in question e 807A for YV9 END e 807B for YV13 NO YES Replace the U1 module 22 107 Replace the wiring harness between the turntable control panel and the electrovalve in question YV9 and YV13 The fault persists END Replace the printed

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