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1. AZ NENNEN _ A Ha n 4 3 S Euh NE 32 Repair manual 10 50 14 250 500 1 000 2 000 10 50 500 1 000 2 000 3 000 Repair manual 6 5 OPERATIONS FREQUENCY Pinguely Haulotte Z 6 5 1 Summary table OPERATIONS Every day or before each start of operation Check the levels hydraulic oil see paragraph 7 sheet P001 electric batteries battery charge using the indicator Check cleanliness machine in particular check the tightness of connections and hoses also check the condition of tyres cables and all accessories and equipment platform slide for extension Check hydraulic oil filter clogging Every 50 hours Pay attention for the first 50 hours Change the hydraulic oil cartridge see 250 hours frequency Check the condition of battery cables replace if worn Check the tightness screws in general front motor fixing screw 9 daNm rear brake fixing screws 9 daNm wheel nuts torque 110 daNm Every 250 hours Change the hydraulic filter cartridge see sheet P002 Grease steering wheel pivots see paragraph 7 sheet P003 the friction parts of the slides with a spatula see paragraph 7 sheet P004 Check battery charger connection battery level
2. Reduce load END Make a lifting movement from the chassis he latf No movement is See SHEET porn available rises YES Make a lifting movement from the platform lifting control panel he platform No movement is available from the See SHEET rises platform DP014 Make a lowering move ment from the platform The platform goes See SHEET DP014 down YES Lower the platform below 1 5m or 4ft92in Pinguely Haulotte FAILURE DETECTION FLOW CHART SHEET DP006 Sheet 2 4 NO TRAVEL MOVEMENT IN BOTH DIRECTIONS FORWARD AND BACKWARD Reguest a travel movement Disconnect the two coils a and b of m The electrovalve YV2 rave movemen Request a travel movement and check for operates 24V Raise the platform above Ke 1 5m or 4ft92in and check that the othole sys tem extends See SHEET DP013 Check for 24V on input 24 of the speed variator 24V present Check electric continuity of the wiring harness between the pothole end of stoke contactor 595 and 506 and the variator Replace the See SHEE Continuit variator U1 T C003 Re y Replace a wiring END END See SHEET C018 Adjust or replace the defective pothole end of stroke contac
3. 27 Pinguely Haulotte 2 Repair manual 28 Repair manual Pinguely Haulotte 4 6 MAINTENANCE 6 1 GENERAL RECOMMENDATIONS AN Caution Do not use the machine asa Servicing oprations described in this manual are given for normal conditions of welding earth use Do not weld without In difficult conditions extreme temperatures high hygrometry polluted disconnecting the and atmosphere high altitude etc certain operations must be carried out more battery terminals frequently and specific precautions must be taken consult the PINGUELY Do not start other vehicles HAULOTTE After Sales Service for information Only authorised and competent personnel may operate on the machine and must comply with the safety instructions related to Personnel and Environment protection Regularly check that the safety systems work properly 1 Tilt buzzer stop travel and lifting disabled 2 Platform overload load 6 2 MAINTENANCE DEVICE The maintenance stand enables the operator to work under the machine in total safety Instructions for the COMPACT 8 10N see Photo 1 page 29 Installing the maintenance stand Position the elevation platform on a firm horizontal floor Ensure that the two emergency stop buttons are ON Turn the chassis ignition key to the Chassis position Move the chassis lifting switch up to raise the platform Turn the maintenance stand
4. Load setting for disabling movements H8SN outdoor use 120kg outdoor use 120kg indoor use 350kg indoor use 350kg H8SW outdoor use 120kg outdoor use 120kg indoor use 450kg indoor use 450kg H10S outdoor use 120kg outdoor use 120kg indoor use 450kg indoor use 450kg H12SN outdoor use 120kg outdoor use 120kg indoor use 300kg indoor use 300kg Optimum 6 outdoor use 115kg outdoor use 115kg indoor use 270kg indoor use 270kg Optimum 8 indoor use 230kg indoor use 230kg tolerance or 10 Pinguely Haulotte 4
5. 1 86 m 2 48 m gt 2 2 2 Compact 8W size 2 29 m 81 cm 1 20 m 2 2 3 Compact 10N size 2 48m 2 29 m 1 20 m 81 cm 2 18 m Q AM ER i i al d lt OI ES 9 a Ls _ e o i 1 86 m 81 cm 2 48 m Pinguely Haulotte 2 Repair manual 2 2 4 Compact 10 size 2 31 m 1 20 m 2 2 5 Compact 12 size 2 31m 2 38 m olololo 1 20 m 16 Repair manual Pinguely
6. 27 6 6 PRESENCE OF cares de 28 6 7 PRESENCE OF MANUALS nenne 35 7 PREVENTIVE MAINTENANCE SHEETS eese nnne 37 8 OPERATING INCIDENTS unse 47 8 1 TABLE OP INGO EIN EE 47 8 2 DETECTION FLOW CHARTS ann 52 9 CORRECTIVE MAINTENANCE PROCEDURES 1 eene 91 Operating and maintenance instructions Pinguely Haulotte GENERAL AN Caution The technical data contained in this manual cannot involve our responsibility and we reserve the right to proceed with improvements or modifications without amending this manual You have just taken delivery of your mobile elevating work platform It will give you complete satisfaction if you follow the operating and maintenance instructions exactly The purpose of this instruction manual is to help you in this We stress the importance of complying with the safety instructions relating to the machine itself its use and its environment of using it within the limits of its performances of proper maintenance upon which its service life depends During and beyond the warranty period our After Sales Department is at your disposal for any service you might need Contact in this case our Local Agent or our Factory After Sales Department specifying the exact type of machine and its serial number When ordering consumables or spares use this documentation together with the Spares catalogue
7. Sgan 07 ZE e NOIL9341Q e er AE O Cms ic wt GI Paa S BAA 3 gt sa E SR SAA o5 M E EAA ka wa ale age elev af 8 ANA 8 L wn 8769 3NnvT 8 d v a a v alll CR 28191 23 Repair manual Pinguely Haulotte 4 HYDRAULIC INSTALLATION DIAGRAM FOR COMPACT 8 A14562B 5 2 YACNITAO ATOHLOd LH9TH 3 1OH LOd NIH3A YOLOW LNOH4J LHOIX LNVAV HNILON 085 duum peu uo JBUSEM pue 1225 au e ouuai peu BUNA UO e ad np e P enbuo3 quiofa Jeuuuddns Gp da np 5107 VION YACNITAO SNIHS3IS NOIL9341Q NIH3A uwggg 0 15 ag rs ots 2 7126 1 122 HIOAH3S3H 32018 3OHOJVHGOAH 9 E Divag dvd LHOIH NIS GAH a ole ud ese YOLOW LNOUJ 1331 3HOn V9
8. Pinguely Haulotte FAILURE DETECTION FLOW CHART SHEET DP012 Sheet 1 2 ONLY MICRO SPEED IS AVAILABLE BELOW 1 5M OR 4FT92IN Only micro speed is available below 1 5m or 4ft92in Raise the platform above 1 5m or 4ft92in Lower the platform below 1 5 or 4ft92in Check that the lowering movement stops normal procedure with lowering restarted after releasing the manipulator for 3s Check electric continuity of the wiring harness between the end of stroke contactor SP1 1 5m or Aft92in and speed variator U1 The platform stops its descent at 1 5m or Aft92in YES Replace the speed See SHEET variator U1 C003 ne harness END es END Adjust or replace the See SHEET end of stroke contac C018 tor SQ1 1 5m or Aft92in END Pinguely Haulotte FAILURE DETECTION FLOW CHART SHEET DP012 Sheet 2 2 ONLY MICRO SPEED IS AVAILABLE BELOW 1 5M OR 4FT92IN Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP013 Sheet 1 2 THE POTHOLE SYSTEM IS NOT EXTENDED WHEN THE PLATFORM IS LIFTED The pothole system is not extended when the platform is lifted Disconnect the electric connector of electrovalve YV6 Check 24V supply to the electrovalve t Replace the See SHEET 24V t ON Q
9. No down movement from the platform or chassis controls Defective wiring harness Badly adjusted or defective pressure contact SP1 Defective electrovalve YV7 coil Defective electrovalve YV7 Defective speed variator SHEET DP004 The platform above 1 5m comes down slowly by platform or chassis controls Defective electrovalve YV8 or YV9 coil Defective electrovalve YV8 or YV9 Defective electric wiring harness Defective speed variator SHEET DP005 The platform moves up and down with a jerky movement 50 Insufficient oil in the hydraulic circuit Top up with oil as ne cessary Repair manual Pinguely Haulotte A 8 1 3 Travel system ANOMALY CHECK PROBABLE CAUSE SOLUTION No movement available Defective pothole cylinder Defective wiring harness Defective pothole end of stroke con SHEET DP006 tactor Defective brake Defective motor No travel movement in either direction FORWARD or BACKWARD No travel in one Defective speed variator direction FORWARD Defective wiring harness SHEET DP010 or BACKWARD Defective YV2a or YV2b coil Defective electrovalve YV3 or YV4 High d coil igh spee unavailable below ee u SHEET DP011 1 5m Defective wiring harness Defective printed circuit U2 Defective speed selector switch SA3 Defective speed variator Defective electric wiring harness SHEET DP012 Defective contactor SQ1 Only micro speed is available below 1 5m The machi
10. Remove the pin 3 and nut 4 fixing the wheel and remove the wheel 1 Place a wedge under the vacuum brake Disconnect the vacuum brake s hose Fit a cap to the hose Remove the vacuum brake 2 by removing its fixing bolts 5 6 7 Replacing a vacuum brake Put the new vacuum brake 2 into place Secure the vacuum brake using the fixing bolts equipped with new elastic washers 5 Reconnect the hydraulic hose Put the wheel 1 into place and secure using the fixing nut and pin Put the machine back into the operational configuration Perform several brake release operations to purge the hydraulic circuit Check the oil level in the hydraulic oil tank Wheel nut tightening torgue 25 N m To fix the pin the slot must be in front of an hole at this time we can screw until 30 N m Fig 1 Pinguely Haulotte 4 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C012 Sheet 1 1 REPLACING A PRESSURE LIMITER ON THE HYDRAULIC BLOCK 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 2 page 25 Caution Cutoff the electric power supply see S 6 3 page 26 Ensure that oil temperature 2 Removing a pressure limiter from the hydraulic block is not too high f necessary unscrew the two fixing screws 1 from the fixing lug and remove the hydraulic block Unscrew the pressure limiter 2 and take it out of the hydraulic block 3 R
11. Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP010 Sheet 1 2 NO TRAVEL IN JUST ONE DIRECTION No travel in just one travel direction Disconnect the connector YV2a or YV2b B concerned by the fault Request the defective travel movement and check for 24V at the connector s terminals Check for 24V between outputs 8 and 34 for FORWARD 9 and 34 for BACKWARD Voltage present 24V present Invert coils YV2a and YV2b NO Replace the See SHEET speed variator C003 he faultis still o the same travel direction NO Replace the wiring harness between the electrovalve and the speed variator YES Replace See SHEE electrovalve YV2 T C008 Replace coil YV2a or See SHEET YV2b corresponding to C007 the defective travel direction Pinguely Haulotte FAILURE DETECTION FLOW CHART SHEET DP010 Sheet 2 2 NO TRAVEL IN JUST ONE DIRECTION FORWARD or BACKWARD Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP011 Sheet 1 2 HIGH SPEED UNAVAILBLE BELOW 1 5M OR 4FT92IN High speed unavailable below 1 5m or 4ft 92 in Disconnect the connector of electrovalve YV3 Request a high speed travel movement and check for 24V on the disconnected wiring harness connector Check electric continuity of the coil of el
12. 3o Hydraulic tank Total mass 1730 Kg 1950 Kg Max load on one wheel 1350 daN 1600 daN Maximum pressure on the floor 6 7 daN cm 7 9daN cm Number of drive wheels 2 2 Number of steering wheels 2 2 Tyres Solid rubber 38x13x5 cm Wheel diameter 380 mm Freewheel YES Movements Proportional controls Batteries 24 V 180 Amp h C5 24 V 250 Amp h C5 General hydraulic pressure Travel Steering Lifting 200 bars 200 bars 150 bars 165 bars Raising time Lowering time CE standards 12 Repair manual 2 1 2 Compact 10N Compact 10 technical data Pinguely Haulotte Z Description Compact 10N Compact 10 Load indoor use 230 kg including persons 450 kg including 3 persons Load outdoor use forbidden 120 kg including 1 person Manual lateral force indoor use 40 daN 40 daN Manual lateral force outdoor use forbidden 20 daN Maximum wind speed indoor use 0 km h 0 Km h Maximum wind speed outdoor use forbidden 45 km h Floor height 8 08 m 8 14 m Working height 10 08 m 10 14 m Folded length 2 31 m Folded length with steps 2 48 m Overall width 1 20 m Folded height hand rails 2 18 m 2 26 m Folded height platform 1 07 m 1 14 m Wheel base 1 86 m Floor clearance 130 mm Floor clearance with pothole syst
13. No movement Check battery charge Recharge or replace defective batteries Check the oil level in the hydraulic tank NO Top up with oil See SHEET P001 YES Check the state of fuses END FU1 FU2 FU3 and FU4 NO Replace defective fuses YES END Request a platform lifting movement and check motor pump operation audible Maintain the activated lifting control and check for setpoint voltage between terminals B and VMNP of the speed variator The motor pump set works YES Pinguely Haulotte FAILURE DETECTION FLOW CHART SHEET DP007 Sheet 2 4 NO MOVEMENT Check electric continuity of chassis emergency stop contacts SB1 NO Replace the chassis See SHEET emergency stop C031 YES Check for 24V at key switch SA1 END input on the chassis control panel Check electric continuity of plat form emergency stop contacts SB2 24V present Wa UJ N YES Place the chassis control panel key NO switch SA1 in the chassis position and check for 24V between terminals 13 and 2 4 YES and 2 34 and 2 of the speed variator U1 Replace the wiring harness between the platform control panel and the chassis Y See END Replace the platform SHEET emergency
14. Tiltthe tilt detector see photo and check that a signal is given the signal should be audible from the platform e Check that after 1 2 seconds it is no longer possible to raise the platform by activating the manipulator Pinguely Haulotte 4 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C007 Sheet 1 1 REPLACING A COIL 1 Preliminary operations Putthe machine in the maintenance configuration see 8 6 2 page 25 Cut off the electric power supply see 8 6 3 page 26 4 5 2 Removing a coil Unscrew the two fixing screws 1 from the fixing lug and take out the hydraulic block Disconnect the relevant coil s electric connector 2 Unscrew the nut 3 or 4 and remove the coil 5 3 Replacing a coil Puta new coil 5 into place and secure with the nut 3 or 4 Reconnect the electric connector 2 on the coil Putthe hydraulic block back into place and secure with the screws 1 equipped with new flat and toothed washers Putthe machine back into the operational configuration Check that the coil works properly by performing the movement corresponding to N the replaced coil Pinguely Haulotte 4 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C008 Sheet 1 1 REPLACING THE TRAVEL ELECTROVALVE Caution 1 Preliminary operations Ensure that oil temperature Putthe machine in the maintenance configuration see S 6 2 page 25 is not too high
15. paragraph 7 Every 500 hours or every 6 months If using organic hydraulic oil empty the hydraulic tank Every 1000 hours or every year Empty the hydraulic oil tank Clean the motor pump set carbon Every 2000 hours Empty the hydraulic tank and whole hydraulic circuit Every 3000 hours or every 4 years Check condition of the slides condition of the electric cables hydraulic hoses etc REMINDER AII these frequencies must be reduced if working in difficult condi tions consult After Sales if necessary 33 Pinguely Haulotte 2 Repair manual 6 6 34 PRESENCE OF LABELS It is important to check that the labels and plates warning personnel of the various dangers associated with using the machine are in good condition The labels providing operators with information on machine use and maintenance must also be checked An illegible label may lead to incorrect or dangerous use of the machine Operating instructions Check the presence of the labels Check that all the labels described below are legible and in the correct place Replace if necessary spare parts can be supplied on request if necessary 6 6 1 Common yellow labels 7814 354a ATTHE END OFTHE LOWERING OPERATION 3 SECOND AUTOMATIC DELAY IS NECESSARY TO AVOID THE RISK OF CRUSHING 7814471
16. working on quays pavements etc Allow sufficient stopping distances 3 metres at high speed 1 metre at low speed Pinguely Haulotte 2 Repair manual AN Caution If the machihe has a 220 V plug with max 16A the extension must be connected to a mains socket protected by a 30mA differential circuit 1 4 breaker VERIFICATIONS 1 3 2 Electric risks Electric risks are high in the following situations contact with a live line use during stormy weather 1 3 3 Risks of explosion or burning The risks of explosion or burning are high in the following situations work in an explosive or inflammable atmosphere filling the fuel tank near a naked flame contact with the hot parts of the motor use of a machine with hydraulic leaks 1 3 4 Risks of collision Risks of crushing people present in the machine s movement area travel or when manoeuvring the equipment The operator must assess any overhead risks before use Comply with current national legislation in the country of use In FRANCE Order dated June 9th 1993 circular DRT 93 22 dated September 1993 specifying 1 4 1 Regular checks The devices must be regularly inspected every 6 months to detect any defect liable to cause an accident These inspections are to be carried out by an organisation or person specially appointed by the site manager and under his responsibility company personnel or otherwise Articles R 2
17. 3 Replacing a component on the platform control panel Puta new component and seal into place on the front of the platform con trol panel NB If itis a lever switch adjust the position of the fixing nut and counter nut so that the switch lever joint axle is on the same level as the seal to ensure tightness Reconnectthe electric connections according to the marks made when dismantling Fixthe closing plate with the four fixing screws Perform the function corresponding to the replaced component to check that it works properly Star 8 HM10P star 10 Pinguely Haulotte 4 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C005 REPLACING A COMPONENT ON THE hier t CHASSIS CONTROL PANEL 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 2 page 25 Cut off the electric power supply see 8 6 3 page 26 Caution Do not use the machine 2 Removing a component from the chassis control panel 1 during maintenance Remove the protective plate 2 from the chassis control panel operations Mark and disconnect the electric connections of the component requiring replacement Remove the component 3 Replacing a component in the chassis control panel Putthe new component and seal on the front of the chassis control panel NB If itis a lever switch adjust the position of the fixing nut and counter nut so that the switch lever joint axle is on the same lev
18. 5 Except neutral 1 E SGT S Lowering gt N fr x E 8 Homme mort A T Dead man i 2 PV GV u u 1 2 9 ir TES le 1 LS HS gt ES SS Consigne Ve 1 rg lt 1 39 Droite MN 4 a TO Toe etre a SE Sad Right 9 2 N e o HS gt 6 55 wr 5 1 er a l J E F i Gauche bees g 9 o 2 1 9 1 Left 2 Ble 8 cig e mt 5 TE Movement 0 A 5 GIS EE o LI o gt Descente 8 Klaxon u N 51555 Hom 99 l Lowering FOS ida 501 Z 0 ei 0 8 USE 0 0 E 1 8 8 GV ke P Bad gt 9 9 HS a ojs je o GES gt a ya LL 1 Ze Egy Pothole gt i hh GV 7 amp sl Coupure 10m 12 HS I 8 e 8 C12 10 m cut off 2 z i Tr 8 o TS OF a MAR i a i Reverse gear PO 2 T OQ B 1 ei 1 bas 2 al J i 2 Bottom d 1 MAV d i b FW gear PGE 5 2 Surcharge 9 5 5 3 E Overload 3 i Monte m e PF CH e Q ge 3 Lifting z 2 0 al o lo u Sr Descente Contacteur gt 1 M o DOWN Switch B 5 PT z UP Lib S T 5 z ro e E d T Devers Free 5 D i AN FE 0 r gt Klaxon 5 A
19. Remove the screws 3 and blocking yokes 4 then remove the steering cylinder s two axles 2 Remove the steering cylinder 1 Replacing the steering cylinder Puta new steering cylinder into place Replace the axles and blocking yokes and secure with screws equipped with new toothed washers Reconnect the hydraulic hoses according to the marks made when dismant ling Putthe machine back into the operational configuration Make several steering movements to purge the hydraulic circuit Check the oil level in the hydraulic oil tank Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 SHEET C024 Caution Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet 1 2 REPLACING A POTHOLE CYLINDER 1 Preliminary operations Put the machine into the maintenance configuration see S 6 2 page 25 Cut off the electric power supply see S 6 3 page 26 Ensure that oil temperature 23 Removing a pothole cylinder is not too high Mark and disconnect the two hoses 2 of the pothole cylinder 1 Fit caps to the hoses Remove the special screw 5 washer 6 and nut 7 from the lower axle Remove the pin 3 and washer 4 from the cylinder s upper joint and remove the pothole cylinder 3 Replacing a pothole cylinder Put a new pothole cylinder into place on the upper axle Put the washer into place and secure a new pin Fix the pothole cylinder rod yoke with the
20. plaform on the scissors Putthe four fixed and moving platform axles into place and secure with the axle stop bolts Fit the bolts so that the screw is on the outside of the platform and the nut on the inside see diagram Remount the electric plug if applicable on the platform Put back the platform control panel Grease the slides using a spatula Only use the grease recommended by the manufacturer Putthe machine back into the operational configuration Perform several lifting cycles to check that the machine works properly ES e E ut Nut lt Screw Scre Screw 7 Nut UE Screw Nut ECROU Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET SHEET C027 Sheet 1 2 REPLACING THE SCISSORS 1 Preliminary operations Put the machine in the low position Cut off the electric power supply see S 6 3 page 26 2 Remove the scissors Remove the platform see SHEET C025 Remove the lifting cylinder s see SHEET C001 Mark and remove the hydraulic hoses and electric wiring harness routed along the scissors Fit caps on the hoses and hydraulic equipment Put the scissors into slings Remove the two axle stop bolts 8 on the two fixed chassis axles Remove the two fixed chassis axles u
21. Cut off the electric power supply see 8 6 3 page 26 2 Removing the travel electrovalve Unscrew the two screws 1 on the fixing lug and take out the hydraulic block Markand disconnect the coil s electric connections Remove the coils of the electrovalve 2 and remove it 3 Replacing the travel electrovalve Puta new electrovalve equipped with its seal into place Reconnect the electric connections on the coils Putback the hydraulic block and secure using the screws 1 equipped with new flat and toothed washers Putthe machine back into the operational configuration Make several travel movements to check that it works properly Compact Optimum Pinguely Haulotte 4 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C009 Sheet 1 1 REPLACING THE HYDRAULIC FILTER 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 2 page 25 Cut off the electric power supply see 6 3 page 26 Caution Ensure that oil temperature 2 Removing the hydraulic filter is not too high Disconnect the two hydraulic filter hoses Fitcaps on the hoses Unscrew the fixing screws 1 and remove the hydraulic filter Remove the two hydraulic filter connections 2 3 Replacing the hydraulic filter Putthe two connections 2 on a new hydraulic filter Putthe equipped hydraulic filter into place respecting the oil flow direc tion secure with the fixing s
22. 2 38m Folded height platform 1 26 m Wheel base 1 86 m Floor clearance 130 mm Floor clearance with pothole system extended 25 mm Platform dimension 2 3mx1 2m Extension dimension 0 92 m Extension capacity 150 kg Travel speed machine folded 0 2 17 mph variable Travel speed machine raised 0 62 mph Interior turning radius 0 2 m Exterior turning radius 2 5 m Maximum slope during travel 23 Maximum tilt permitted 3 Hydraulic tank 251 Total mass 2630 kg Max load on one wheel 1600 daN Maximum pressure on the floor 10 15 daN cm Number of drive wheels 2 Number of steering wheels 2 Tyres Solid rubber 38x13x5 cm Wheel diameter 380 mm Freewheel YES Movements Proportional controls Batteries 24 V 250 Amp h C5 General hydraulic pressure Travel Steering Lifting 240 bars 240 bars 150 bars 155 bars Raising time 85s Lowering time 50s CE standards 14 YES Repair manual 2 2 SIZE 2 2 1 Compact 8 size 2 29 m 1 99 Pinguely Haulotte Z 81 cm
23. 2 Repair manual Repair manual Pinguely Haulotte A 3 SAFETY SYSTEMS 3 1 RELAY AND FUSE FUNCTIONS FU1 Motor pump fuse FU2 Speed variator output protective fuse FU3 Speed variator intput protective fuse FUA Flashing light and working light optional protective fuse 3 2 SAFETY CONTACT FUNCTIONS Reference Description Line contactor Chassis emergency stop button Platform emergency stop button Tilt reset position switch Top position switch 8 meter breaking position switch Pothole extension Tilt indicator Speed variator fault light indicator Speed variator fault numeric indicator Pinguely Haulotte 2 Repair manual 20 Repair manual Pinguely Haulotte D 4 WIRING DIAGRAMS 4 1 WIRING DIAGRAM E 501 D sch BT SEES sers m 5 i d A 4 1 a gt 1 Descente C121 5 D Er et 1 Pera Lowering C12 lt __ Steering 1 _ Paras or ezvuszsts i 255 Hors neutre H Descente peet m 2 14 po
24. 27 i Cut off the electric power supply see S 6 3 page 28 Ensure that oil temperature is not too high 2 Replacing the hydraulic filter cartridge Unscrew the body and remove the hydrualic filter cartridge Screw a new cartridge into place Put the machine back into the operational configuration Optimum Pinguely Haulotte PREVENTIVE MAINTENANCE SHEET Pinguely Haulotte 77 PREVENTIVE MAINTENANCE SHEET SHEET P003 GREASING THE STEERING WHEEL PIVOTS 1 Greasing the steering wheel pivots Cut off the electric power supply see S 6 3 page 26 Grease the pivots NOTA Only use the grease recommended by the manufacturer Put the machine back into the operational configuration Compact optimum previous design D e Compact optimum current design Star 22J Star 8 Pinguely Haulotte PREVENTIVE MAINTENANCE SHEET Pinguely Haulotte 77 PREVENTIVE MAINTENANCE SHEET SHEET P004 GREASING THE SLIDES 1 Preliminary operations Put the machine in the maintenance configuration see S 6 2 page 25 Cut off the electric power supply see 8 6 3 page 26 2 Greasing the slides Grease the slides using a spatula NOTA Only use the grease recommended by the manufacturer Put the machine back into the operational configuration Pinguely Haulotte PREVENTIVE MAINTENANCE SHEET Repair manual Pinguely Haulotte 4 6 OPERATING INCIDENTS
25. 3100 mm E99 V ev H3ONITAO 1411 39VA313QG NIH3A Bes E deosrr iNv 33 V8 LHOIH NI383 OLET 91 86755 ING AdWOd vaga uvas 1481 AHONVS J aldaVNI JAA 25 Repair manual MNVL 122 eeerora 4 m 972 6 3 T g amp azAXA EDR egas 3 v 0 12 0 9 8 0 J 8 Kid 52 8 a zii ja 1 EN gt asst A 4 42 pe 4 E Like ra BEI PIER len Up ud 18 Iw BEIEN 18 IEN 8 41 2 e ex ANN L 8 4 8 4 ANN EL 8 4 ANA tL 8 4 v a 8 v Es 02 91 4 E cam Angera 37XV LNO34 N Tt LNVAV naissa 2 xj XV HV eu NAISSA gt 4 N osanoo oz ze LQ esanoo gz og ONIAJALS NOIL2 AIG HYDRAULIC DIAGRAM FOR COMPACT 12 MODEL B16188A Pinguely Haulotte 4
26. 5 4 26 Pinguely Haulotte 2 Repair manual HYDRAULIC INSTALLATION DIAGRAM FOR COMPACT 12 A14564C 5 5 YOLOW LHOIX LNVAV XN LOW FIOHLOd LHOIU 3 1OHLOd NIH3A VLON Pr 8 126 ANVIL 122 YlIOAYASSY LHOId 343144v 29 UELL uo pue Fos ay Gp peu BUY UO Galadai np e enbuo3 qutof Jeuuuddrs gp d np ebequouu np 5107 VION H3GONITAO SNIHS3IS e NOILI 3410 NIH3A 29074 3OHOJVHGAH 3OHOJVHOAH 20718 iuuross ogesjai enoi ud enuew oyes jonuew ep 5 w Jeu s nssaud wel ieJgugb uoisseid ep eansseid Buueeis uoissed p 69 Vua uva 1481 AHONVS J aldav gt 22 L47 MR 1411 os LAVH NIS3A sva FANA e e YOLOW LNOHJ 1331 AHONVS LNVAV AN ALONW 68 e
27. 77 CORRECTIVE MAINTENANCE SHEET SHEET C022 Sheet 1 2 REPLACING THE BRAKE RELEASE HAND PUMP 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 2 page 25 Cut off the electric power supply see S 6 3 page 26 Caution e Check that the brake release valve is open Ensure that oil temperature is not too high 2 Removing the brake release hand pump Unscrew the brake release hand pump 1 and take it out of the hydraulic block Put a cap on the hydraulic block hole to protect it 3 Replacing the manual brake hand pump Screw a new brake release hand pump into place Putthe machine back in the operational configuration Apply and release the brakes manually several times to purge the hydraulic circuit Compact 9 Optimum Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C023 Sheet 1 2 REPLACING THE STEERING CYLINDER 1 Preliminary operations Caution Putthe machine in the low configuration Ensure that oil temperature Cut off the electric power supply see S 6 3 page 26 is not too high Raise the machine with a jack or hoist 2 Removing the steering cylinder Mark and disconnect the two steering cylinder hoses 1 NB Unscrew the hose slowly to allow residual hydraulic pressure to dissipate Fit caps to the hoses Putthe cylinder into slings
28. BEER Replace the See Fiche correct coil CUT speed variator Replace See END electrovanne SHEET YV7 C030 Pinguely Haulotte FAILURE DETECTION FLOW CHART SHEET DP005 PLATFORM ABOVE 1 5M OR 4FT92IN DESCENT Sheet 1 4 IS SLOW FROM THE PLATFORM OR CHASSIS CONTROL Platform above 1 5m or 4ft92in descent is slow from the platform or chassis controls Compact 12 NO Compact 3747E YES Disconnect the coil connector of electrovalve YV9 and request platform descent NO Check for 24V at the terminals of the coil Platform descent Supply connector of electrovalve YV9 is even slower 24V present Disconnect the coil connector of electrovalve YV8 request platform lowe ring and check for 24V at the connector s terminals Check electrovalve YV9 coil continuity NO Continuity correct YES Y Change electrovalve See SHEET YV9 coil C007 Y Change See SHEET electrovalve YV9 C030 END Pinguely Haulotte FAILURE DETECTION FLOW CHART SHEET 05 PLATFORM ABOVE 1 5M OR 4FT92IN DESCENT Sheet 2 4 IS SLOW FROM THE PLATFORM OR CHASSIS CONTROL Check for 24V absence on input 25 of the speed variator 24V NO Check absence of short circuit in the absent gt wiring harness between pressure contact 5 1 and
29. Pinguely Haulotte 2 9 CORRECTIVE MAINTENANCE PROCEDURES List of corrective maintenance sheets Sheet no Description FICHE C001 Replacing a lifting cylinder FICHE C002 Adjusting a hydraulic block pressure limiter FICHE C003 Replacing a variable speed drive FICHE C004 Replacing a component on the platform control station FICHE C005 Replacing a component on the chassis control station FICHE C006 Replacing the tilt detector FICHE C007 Replacing a coil FICHE C008 Replacing the travel eletrovalve FICHE C009 Replacing the hydraulic filter FICHE C010 Replacing a hose FICHE C011 Replacing a vacuum brake FICHE C012 Replacing a hydraulic block pressure limiter FICHE C013 Replacing a manipulator FICHE C014 Replacing a hydraulic travel motor FICHE C015 Replacing the buzzer FICHE C016 Replacing the distribution block FICHE C017 Replacing the remote control system FICHE C018 Replacing the end of stroke sensor FICHE C019 Replacing the motor pump set FICHE C020 Replacing a hydraulic block valve FICHE C021 Replacing a wheel FICHE C022 Replacing the brake release pull FICHE C023 Replacing the steering cylinder FICHE C024 Replacing a pothole cylinder FICHE C025 Replacing the platform extension FICHE C026 Replacing the platform FICHE C027 Replacing the scissors and pads FICHE C028 Replacing a scissor ring or axle FICHE C029 Replacing the balancing valves FICHE C030 Replacing a cartridge electrovalve FICHE C031 Replacing the
30. chassis emergency stop button FICHE C032 Replacing the hydraulic pump FICHE C033 Replacing and adjusting the pressure switch 93 Pinguely Haulotte 2 Repair manual 94 SHEET C001 Caution Ensure that oil temperature is not too high Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 1 1 REPLACING A LIFTING CYLINDER 1 Preliminary operations Put the machine in the maintenance configuration see S 6 2 page 25 Cut off the electric power supply see S 6 3 page 26 2 Removing the cylinder Remove the cylinder remote control if any see SHEET C017 Mark and disconnect the cylinder pressure switch s electric connections Mark and disconnect the cylinder s hydraulic hoses Fit caps to the hoses Put the cylinder into slings Remove the two cylinder axle stop bolts 1 on the rod and body side Remove the two axles 2 also see figure 1 and remove the cylinder 3 Replacing the cylinder Put the new cylinder into place using slings Put back the cylinder axle on the cylinder body side and secure using the axle stop bolt Fit so that the screw is above the axle and the nut underneath see figure 2 Reconnect the cylinder s hydraulic hoses according to the marks made when dismantling Reconect the pressure switches electric connections according to th
31. speed variator U1 YES Check electric continuity of the wiring NO harness between electrovalve YV9 and the speed variator Replace the electric NO wiring harness Continuity correct END See SHEET C003 Replace the speed variator Replace the speed Replace the wiring 2 See SHEET harness C003 END Pinguely Haulotte Z FAILURE DETECTION FLOW CHART SHEET DP005 PLATFORM ABOVE 1 5M OR 4FT92IN DESCENT Sheet 3 4 IS SLOW FROM THE PLATFORM OR CHASSIS CONTROL NO Check electric continuity of the wiring harness between electrovalve YV8 and the speed variator 24V present YES Check continuity of electrovalve NO Continuity YV8 coil correct NO Continuity Replace the wiring correct harness END See SHEE Replace the T C003 speed variator Replace See SHEET electrovalve YV8 C030 END END Y Replace See SHEET the coil C007 Pinguely Haulotte FAILURE DETECTION FLOW CHART SHEET DP005 PLATFORM ABOVE 1 5M OR 4FT92IN DESCENT Sheet 4 4 IS SLOW FROM THE PLATFORM OR CHASSIS CONTROL SHEET DP006 Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART Sheet 1 4 NO TRAVEL MOVEMENT IN BOTH DIRECTIONS FORWARD AND BACKWARD No travel movement in either forward or backward direction Y Check platform load
32. 33 5 and R 233 11 of the Labour Code The result of these inspections is recorded in a safety register updated by the site manager and constantly available to the Works Inspector and the company s safety committee if any and the list of specially appointed personnel Article R 233 5 of the Labour Code NB This register can be obtained from professional organisations and for some from the OPPBTP or private prevention organisations The appointed people must be experienced in the field of risk prevention Article R 233 11 of decree no 93 41 It is forbidden to allow anyone to perform any checks during machine operation Article R 233 11 of the Labour Code 1 4 2 Examination of device suitability The manager of the site on which the equipment is used must ensure that the machine is suitable i e appropriate to the work to be carried out safely and that it is used in accordance with the instruction manual Moreover the French order dated June 9th 1993 refers to problems asosciated with rental examination of the condition verifications before starting work after repair and conditions of static test coefficient 1 25 and dynamic test coefficient 1 1 All responsible users should find out about and respect the requirements of this decree 1 4 3 Condition Detect any deterioration liable to cause dangerous situations safety devices load limiters tilt detector cylinder leaks deformation weld condition tightness of bolts ho
33. 8 1 TABLE OF INCIDENTS Before anything else check that the batteries are charged the green light indicators should be on the two palm button emergency stops on the chassis control box and on the platform control box are unlocked the oil level in the tank is OK AN Caution Bubbles pressure Cavitation emulsified oil may cause incorrect operation of hydraulic unacceptable situation components It takes approximately 4 hours for oil that has been Risk of explosion emulsified under the effects of cavitation to get back to its normal condition 8 1 1 General operation CHECK PROBABLE CAUSE Defective batteries Oil level low Defective fuses Defective chassis emergency stop Defective platform emergency stop Defective wiring harness Defective motorpump set Defective printed circuit Defective control unit SOLUTION ANOMALY No movement SHEET DP007 Insufficient oil in the tank SHEET DP009 Defective pump Hydraulic pump noisy Defective speed variator Pothole system does not extend when the platform is raised Defective wiring harness Defective electrovalve YV6 coil Defective electrovalve YV6 Defective pothole cylinders SHEET DP013 No movement from the platform control station Defective key switch SA1 Defective electric wiring harness Defective speed variator Defective manipulator Defective printer circuit U2 SHEET DP014 Hydraulic pump cavitation Vacuu
34. 9 05 17 80 813 Fax Fax 39 05 16 05 33 28 Haulotte Scandinavia AB u b T l Phone 46 31 744 32 90 Fax Fax 46 31 744 32 99 Haulotte Iberica Sevilla T l Phone 34 95 493 44 75 Fax Fax 34 95 463 69 44 Repair Manual 2 1 2 2 2 3 Pinguely Haulotte Z SUMMARY GENERAL susanne 1 GENERAL RECOMMENDATIONS SAFETY 4 5 GENERAL si te V 5 GENERAL SAFETY RECOMMENDATIONS eene eene 6 RESIDUAL RISKS een 8 VERIFICATIONS EE 8 REPAIRS AND EEN Eege ei ue 9 VERIFICATIONS BEFORE RESTARTING WORK 9 SPEEGIFIGATION ER 11 TECHNICAL CHARATTERISTIES 2 12 14 er 16 SAFETY SYSTEMS ae 17 RELAY AND FUSE ING et LE 17 SAFETY CONTACT FUNCTIONS 22a un 17 WIRING NIE 19 WIRING DIAGRAM E 501 KEE 19 HYDRAULIC DIAGRAMS nu ne 21 HYDRAULIC DIAGRAM FOR COMPACT 8 8W 10N AND 10 MODELS B16187A 21 HYDRAULIC DIAGRAM FOR COMPACT 12 MODEL B16188A 22 5555 M 23 Pinguely Haulotte 7 Repair Manual 6 1 GENERAL RECOMMENDATIONS eene nnnm nennen nnn 23 6 2 MAINTENANCE DEVICE ects cp sete cet na een 23 6 3 ELECIRICITY SUPPE E 24 64 MAINTENANCE PEAN EE 25 69 OPERATIONS P
35. EET C002 Sheet 2 2 ADJUSTING A HYDRAULIC BLOCK PRESSURE LIMITER 3 Adjusting the lifting pressure limiter 3 Putthe platform in the low configuration Unscrew the lifting pressure limiter adjusting screw 3 Place aload corresponding to nominal load 1096 in the platform see table below Liftthe platform and tighten the pressure limiter adjustment screw until move ments are disabled for this load e Place a load corresponding to nominal load in the platform see table below Check that the lifting movement is not disabled for this load Putthe machine back into the operational configuration 4 Load and pressure table Nominal load OW al Steering Nominal load hydraulic 10 pressure pressure outdoor use 120kg outdoor use 132kg HOSE indoor use 350kg indoor use 385kg an Bats 190 bate outdoor use 120kg outdoor use 132kg indoor use 450kg indoor use 495kg SE ES Jonas outdoor use 120kg outdoor use 132kg puos indoor use 450kg indoor use 495kg 220 bats ToU haie outdoor use 120kg outdoor use 132kg indoor use 300kg indoor use 330kg AB 190 Pals outdoor use 115kg outdoor use Optimum 6 indoor use 270kg 126 5kg 230 bars 100 bars indoor use 297kg Optimum 8 indoor use 230kg indoor use 253kg 230 bars 100 bars tolerance or 1096 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C003 Sheet 1 4 REPLACING THE
36. Haulotte Z 2 3 TIGHTENING TORQUE 2 3 1 Tightening torque for large thread screws Nominal diameter M 6 1 9 to 11 Tightening torque in N M 10 9 13 to 14 15 to 17 M 7 1 15 to 19 21 to 24 26 to 28 M 8 1 25 22 to 27 31 to 34 37 to 41 M 10 1 5 43 to 45 61 to 67 73 to 81 M 12 1 75 75 to 94 110 to 120 130 to 140 M 14 2 120 to 150 170 to 190 200 to 220 M 1672 190 to 230 260 to 290 320 to 350 M 18 2 5 260 to 320 360 to 400 440 to 480 M 20 2 5 370 to 450 520 to 570 620 to 680 M 22 2 5 500 to 620 700 to 770 840 to 930 M 24 3 3 630 to 790 890 to 990 1070 to 1180 M 27 3 930 to 1150 1300 to 1400 1560 to 1730 M 30 3 5 1260 to 1570 1770 to 1960 2200 to 2350 2 3 2 Tightening torque for fine thread screws Tightening torque in N M Nominal diameter 10 9 M 8 1 24 to 29 331037 40 to 44 M 10 1 25 46 to 57 64 to 71 77 to 85 M 12 1 25 83 to 100 120 to 130 140 to 150 M 14 1 5 130 to 160 180 to 200 220 to 240 M 16 1 5 200 to 250 280 to 310 340 to 370 M 18 1 5 290 to 360 410 to 450 490 to 540 M 20 1 5 410 to 510 570 to 630 690 to 760 M 22 1 5 550 to 680 780 to 870 920 to 1000 M 24 1 5 690 to 860 970 to 1070 1160 to 1290 M 27 2 1000 to 1300 1400 to 1560 1690 to 1880 M 30 2 1400 to 1700 1960 to 2180 2350 to 2610 17 Pinguely Haulotte
37. LNVAV UNFLOIN H3ONITAO 1411 NIH3A ep Jeu uoisseud Joywij Buueeis uor uolsseid noyuur esiw ep qur N vaga VS 1481 A AHONVS 343144v NI344 24 Pinguely Haulotte 2 Repair manual HYDRAULIC INSTALLATION DIAGRAM FOR COMPACT 8W 10N AND 10 A14563B 5 3 3 1OH LOd 4 310H10d NIUFA PP ANA 18 4 YOLOW LNOYS LHOIX LNVAV YNALOW SNIHS3IS NOIL9341Q NIH3A 126 170 YlOAYASSAY 77 55 8 OPS 0115755 STNG 055 916vv5 STNG uuloost 914045 TOHI SRG U TOT OOET STOSZT OT NET TULU OST 570525 OT NT TRUEST TOSS UT NC ugs verso NT CHE Zn e e E OTLT DI 9525 9 WAUOLZLOTSScS9 NG OTSTSTSSeSNG Ais ON E EE Sch 95 LNOYS 1431 AHONVS 2 a LG
38. N Hom Bii T e X 2 E o z N 0 e E 0858 OT d we ios Hei o E e gn lt psum em 3 ro i 5 ja 2 9 2 21 W D 5 E we Wd agf d 5 a D 3 o L 0 x 1 v N L o Ld N v R 5 up N E 6 gt V 0 as u Pa 5 30 2 100 a oln lt m a m 0 I 5 Y 4 gt amy 21 Pinguely Haulotte 2 Repair manual 22 Pinguely Haulotte Z Repair manual D HYDRAULIC DIAGRAMS HYDRAULIC DIAGRAM FOR COMPACT 8 8W 10N AND 10 MODELS B16187A 5 1 MNVL HIOAHZSHNH 172 P XN i s eq ozz 32722 LOVdINOD DL AA8 LOVdlAOO ozz 324 2 LOVdWOO N OL IOVdIAOO LAA Jed 82202 LOWdINOD S LOVdlIAOO GAA BSNA por mE ET 6 oJ a H 2 io A Naissa 0 DAVEHOSTXV avad T9 2SINO 2 06 et en X nassa
39. Pinguely Haulotte REPAIR MANUAL SH _ ka SELF PROPELLED SCISSOR PLATFORM 242 031 8240 04 04 GB zvo 2250 c moo v2 o m 0 2 7 PINGUELY HAULOTTE LA PERONNIERE 9 42152 L HORME T l 33 0 4 77 29 24 24 Fax SAV 33 0 4 77 3128 11 email haulotte haulotte com Web www haulotte com Distribu par Distributed by Distribuito da KAKA 8 Haulotte France T l Phone 33 0 4 72 88 05 70 Fax Fax 33 0 4 72 88 01 43 Haulotte Hubarbeitsb hnen T l Phone 49 76 33 806 920 Fax Fax 49 76 33 806 82 18 Haulotte UK T l Phone 44 0 1952 292753 Fax Fax 44 0 1952 292758 Haulotte Asia T l Phone 65 6536 3989 Fax Fax 65 6536 3969 Haulotte Australia PTY Ltd T l Phone 61 3 9706 6787 Fax Fax 61 3 9706 6797 Haulotte Do Brazil T l Phone 55 11 3026 9177 Fax Fax 55 3026 9178 Haulotte Iberica Madrid T l Phone 34 91 656 97 77 Fax Fax 34 91 656 97 81 Centre Mondial Pi ces de Rechange Spare Parts International Centre T l Phone 33 0 4 77 29 24 51 Fax Fax 33 0 4 77 29 98 88 Haulotte Portugal T l Phone 351 21 955 98 10 Fax Fax 351 21 995 98 19 Haulotte U S Inc Main tool free 1 877 HAULOTTE Service tool free 1 87 7 HAULOT S Haulotte Netherlands BV T l Phone 31 162 670 707 Fax Fax 31 162 670 710 Haulotte Italia T l Phone 3
40. RECOMMENDATIONS FOR USE BEFORE USING THIS MACHINE THE OPERATOR MUST 1 Read and understand the information in the operators manual and the information marked on the machine and become familiar with the controls 2 Receive training and practical experience in operating the machine under the employer s supervision 3 Ensure that maintenance is performed according to the manufacturers instructions 4 Refrain from using the machine in the event of any malfunction 5 Not wash the electrical components with a washer pressure 6 Not remove any parts which might affect the stability 7 Not modify the machine without the manufacturer s approval 8 Not use the machine as a welding earth 9 Not weld on the machine without first disconnecting the battery terminals See the instructions in the maintenance manual DAILY INSPECTION 1 Check the level of diesel fuel for diesel engine platforms 2 Check that there are no apparent defects hydraulic leaks loose bolts loose electric connections 7814 383a AN 3 Check that the tilt indicator operates correctly by sounding the buzzer INSTRUCTIONS BEFORE USE 1 Remove the rotation locking pin if there is a turntable 2 IMPORTANT when using the AC power line to the work platform the power plug must be connected to an electrical installation protected by a 30 mA circuit breaker C15 100 standard START UP 1 Turn the battery isolater switch to the on p
41. SPEED VARIATOR 1 Preliminary operations Put the machine in the low position Cut off the electric power supply see 8 6 3 page 26 Disconnect the and terminals of the batteries to isolate the electric circuit 2 Removing the speed variator Disconnect the speed variator s electric connections Remove the speed variator 1 3 Replacing the speed variator Put the speed variator back into place and secure with the fixing screws Reconnect the speed variator s electric connections Compact Reconnect the and terminals of the batteries Put the machine back in the operational configuration Optimum Optimum Compact Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C003 Sheet 2 4 REPLACING THE SPEED VARIATOR STAR 6 STAR 13 Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET BEEN 7 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 4 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C004 Sheet 1 1 REPLACING A COMPONENT ON THE PLATFORM CONTROL PANEL 1 Preliminary operations Cut off the electric power supply see S 6 3 page 28 Caution 2 Removing a component from the platform control panel Do not use the machine Remove the closing plate 1 by unscrewing the four fixing screws during maintenance Mark and disconnect the electric connections of the component to be operations replaced Remove the component
42. Sheet 4 4 SHEET DP003 NO UP MOVEMENT FROM THE CHASSIS OR PLATFORM CONTROL Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP004 Sheet 1 2 NO DOWN MOVEMENT FROM THE PLATFORM OR CHASSIS CONTROL No down movement from the chassis or platform controls Y Check the allowed load on the platform Reduce load Load correct Disconnect the wiring harness from pressure contact SP1 on up cylinder Check for 24V on one of the two wiring harness terminals 24V t Replace wiring harness presen Place a shunt between the two terminals of the wiring harness NO The platform comes down Adjust or replace pressure See SHEET C033 Check for 24V on input 26 of contact SP1 the speed variator END Replace the wiring harness 24V present Pinguely Haulotte FAILURE DETECTION FLOW CHART SHEET DP004 Sheet 2 2 NO DOWN MOVEMENT FROM THE PLATFORM OR CHASSIS CONTROL Y Check supply to electrovalve YV7 disconnect the coil s electric connector and measure supply voltage 24V coil supply NO Check electric continuity of the wiring harness between the electro valve and speed variator YES Check continuity of the coil of electrovalveYV7 Replace wi ring harness oil continuit Replace the
43. URU variator C003 pre 18 of the speed em END Check coil continuity Replace the wiring harness ref 25 NO Replacer the coil of See SHEET electrovalve YV6 C007 YES Check electrovalve operation Electrovalve Replace See SHEET works properly electrovalve YV6 C030 Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP013 Sheet 2 2 THE POTHOLE SYSTEM IS NOT EXTENDED WHEN THE PLATFORM IS LIFTED Check operation of the pothole system cylinder s Cylinder s work properly Replace defective See SHEET cylinder s C024 Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP014 Sheet 1 4 NO MOVEMENT FROM THE PLATFORM CONTROL PANEL No movement from the platform control panel Place the key switch SA1 in the platform position and check for 24V at terminals 9 and 11 of SA1 Replace the key See 24V present switch SA1 SHEET C004 YES Check for 24V on wires 9 and 11 of B the platform control panel between the platform control panel 24V present and the chassis YES Check for 24V between terminals END C1B and C2B of printed circuit U2 24V present YES Replace the electric wiring harness Check for 24V between terminals 34 and 2 of the speed variator Request a travel or lifting 24V present Replace speed See SHEE movement from the
44. YES Check operation of switch SA2 Change SA2 up down 24V at terminals 37 or 38 of the speed variator Replace switch SA2 See SHEET C003 Replace speed See SHEET variator U1 C005 Pinguely Haulotte FAILURE DETECTION FLOW CHART NO UP AND DOWN MOVEMENT FROM THE CHASSIS CONTROL Pinguely Haulotte FAILURE DETECTION FLOW CHART Sheet 1 4 SHEET DP003 NO UP MOVEMENT FROM THE CHASSIS OR PLATFORM CONTROL No up movement from the chassis or platform control Y Check that there are no hydraulic leaks Repair the NO hydraulic links YES END Check supply of the electrovalve coil disconnect the coil connector and measure supply voltage NO 24V coil supply Check electrical continuity of the wiring harness betwen coil YV1 and the speed variator Check continuity of coil YV1 ontinuity NO Replace the correct gt wiring harness Continuity correct Replace the See SHEET coil C007 Check the speed variator s safety inputs Tilt SA10 input 27 High position contactor SQ3 input 29 Connect a pressure gauge to the hy Potholes SQ5 SQ6 input draulic block s minimess pressure tap 24 associated with position Activate the up movement and note switch SQ1 input 25 pressure Pingu
45. and elastic ring back into place Putthe platform back see SHEET C026 Putthe machine back into the operational configuration Make several lifting movements and check that the scissors work properly Ss ETT 5 Nuts Nut EX sii Nut E E ECROU Fig 1 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet 1 1 SHEET C029 REPLACING THE BALANCING VALVES 1 Preliminary operations AN Caution Putthe machine in the low position Ensure that oil temperature Cut off the electric power supply see 8 6 3 page 26 is not too high 9 2 Removing the balancing valves Disconnect the hydraulic brake hoses 2 and close the holes on the pipework and hydraulic block Unscrew the two screws 1 of the fixing lug and take out the hydraulic block Remove the balancing valves 3 by unscrewing them 3 Replacing the balancing valves Screw the new balancing valves whose characteristics correspond to the machine in question into the hydraulic block Putthe hydraulic block back into place and secure using the screws 1 equipped with new flat and toothed washers Reconnect the hydraulic brake hose onto the block Make several travel movements to purge the circuit Position the machine on a 4096 slope and check that th
46. ange indicates a danger that may cause serious injury Yellow indicates a danger that may cause material damage or slight injury Maintenance pesrsonnel must ensure that these labels and plates are in good conditions and keep them legible Spare labels and plates can be supplied by the manufacturer on request 1 1 3 Safety Ensure that any person entrusted with the machine is take the safety measures implied by its use Avoid any working mode that may affect safety Any use that does not comply with the recommendations may generate risks and damage to people and equipment After intervention maintenance personnel must check that the operator manual is present This must be kept by the user throughout the machine s service life even if it is loaned rented or sold Ensure that all the plates or labels related to safety and danger are complete and legible AN Caution To attract the reader s attention instructions are indicated by this standardised sign Pinguely Haulotte 2 Repair manual 1 2 GENERAL SAFETY RECOMMENDATIONS AN Caution Only trained operators may use Haulotte self propelled platforms SS 1 2 1 Operators Operators must be aged 18 or over and hold an operating permit issued by the employer after verification of medical aptitude and the practical platform operation test There must be at least two operators present so that one of them can intervene rapidly if necessary take
47. control 24V NO present zi panel 24V 24V NO present on present outputs 3 or 6 ofthe manipulator NO Check continuity of coils YES Y YES YV5a or YV5b See SHEET Replace printed C004 circuit U2 Repair cabling between the manipulator and the circuit NO imprim U2 END YES Replace the See SHEET END defective coil C007 Replace the See SHEE manipulator T C013 Pinguely Haulotte FAILURE DETECTION FLOW CHART SHEET DP008 Sheet 2 2 NO STEERING o Connect a pressure gauge to the minimess tapping on the hydraulic block Activate steering and note the pressure value value disappears after 5s Pressure 150 bars or ND 2175 psi YES Replace the steering See SHEET Replace See SHEE cylinder C023 electrovalveYV5 T C030 END END Y SeesHEET Adjust or replace the steering C012 pressure limiter Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP009 Sheet 1 2 NOISY HYDRAULIC PUMP The hydraulic pump makes a noise Check the oil level in the circuit Oil level up with oil See SHEET SE P001 Incorrect operation of the hydraulic See SHEET pump replace the pump C032 Pinguely Haulotte 7 FAILURE DETECTION FLOW CHART SHEET DP009 Sheet 2 2 NOISY HYDRAULIC PUMP
48. crew the hoses slowly to allow the residual hydraulic pressure to dissipate Fit caps to the hoses Remove the distribution block Replacing the distribution block Put the new distribution block into place Reconnect the hydraulic hoses according to the marks made when dis mantling Reconnect the distribution block s electric connections according to the marks made when dismantling Secure the distribution block to the chassis using the fixing lug screws and washers Put the machine back into the operational configuration Perform several lifting steering and travel cycles to purge the hydraulic circuit Check the oil level in the hydraulic oil tank Pinguely Haulotte 4 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C017 Sheet 1 2 REPLACING THE REMOTE CONTROL 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 2 page 25 Cut off the electric power supply see 8 6 3 page 26 2 Removing the remote control Remove the protective plate 1 of the chassis control station for Compact machines Release the manual control cable 2 of the covered distributing valve on the lifting cylinder Unscrew the plate sheath stop 3 supporting the cable Mark the cable route in the scissor ducts and remove the cable from the ducts Unscrew the blocking nut of the emergency pull 1 and remove the pull and cable assembly Compact Optimu
49. crews Reconnect the hydraulic hoses Putthe machine back into the operational configuration Perform several lifting cycles to purge the hydraulic circuit Compact Optimum Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C010 Sheet 1 1 REPLACING A HOSE 1 Preliminary operations Putthe machine in the maintenance configuration see corresponding Ser paragraph Caution e Cut off the electric power supply see corresponding paragraph Ensure that oil temperature is not too high 2 Removing a hose Disconnect the hose from the equipment it connects NB Unscrew the hose slowly to allow residual hydraulic pressure to dissipate Fit caps to the equipment holes to protect them 3 Replacing a hose Reconnect a new hydraulic hose Put the machine back into the operational configuration Make several movements using the replaced hose to purge the hydraulic circuit Check the oil level in the hydraulic oil tank Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet 2 2 SHEET C011 Caution Ensure that oil temperature is not too high Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 1 1 REPLACING A VACUUM BRAKE 1 Preliminary operations Put the machine in the low configuration Cut off the electric power supply see 8 6 3 page 26 Raise the machine using a jack or hoist 2 Removing a vacuum brake see figure 1 1
50. e marks made when dismantling Reconnect the cylinder s remote control if any see SHEET C017 Put the machine back into the operational configuration Perform several lifting cycles to purge the hydraulic circuit Check the oil level in the hydraulic oil tank Screw Fig 2 Pinguely Haulotte 4 Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET SHEET C002 Sheet 1 2 ADJUSTING A HYDRAULIC BLOCK PRESSURE LIMITER 1 Adjusting the general pressure limiter 1 Caution Ensure that oil temperature is not too high Optimum Put the machine in the low position Cut off the electric power supply see S 6 3 page 26 Unscrew the cap of the hydraulic pressure tap marked MX on the hydraulic block and connect a pressure gauge with sufficient range to measure overall pressure Restore the electric power suply see S 6 3 page 26 Bring the machine against a wall to block the travel movement Request a travel movement and measure overall pressure on the pressure gauge Adjust the hexagonal hollow head screw on the overall pressure limiter 1 so that movements are disabled at the pressure indicated in the table below Put the machine in the maintenance configuration see S 6 2 page 25 Cut off the electric power supply see S 6 3 page 26 Unscrew the pressure gauge and put the cap back on the hydraulic pre
51. e machine does not go into runaway during a travel movement Optimum AN Caution The balancing valves are safety elements They are calibrated in the plant and must not be re adjusted Pinguely Haulotte 4 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet 1 1 HEET C030 REPLACING A CARTRIDGE ELECTROVALVE 1 Preliminary operations Put the machine in the maintenance configuration see S 6 2 page 25 Cut off the electric power supply see 6 3 page 26 AN Caution 2 Removing a cartridge electrovalve Remove the coil s 2 of the electrovalve see SHEET C007 Unscrew the electrovalve 1 with the Allen key and remove from the hydraulic block Ensure that oil temperature is not too high 3 Replacing a cartridge electrovalve Screw a new electrovalve equipped with its seal into the hydraulic block Putthe coil s back into place on the electrovalve and put the hydraulic block back into place see SHEET C007 Putthe machine back into the operational configuration Perform several movements using the replaced electrovalve to check that it works properly Optimum Pinguely Haulotte 4 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet 1 1 SHEET C031 REPLACING THE CHASSIS EMERGENCY STOP BUTTON 1 Preliminary operations Caution Put machine in the maintenance configuration see S 6 2 page 25 2 Disconnectthe and terminals of
52. ectrovalve YV3 NO Replace the coil of See SHE electrovalve YV3 ET C007 YES Disconnect the connector of END electrovalve YV4 Request a high speed travel movement and check for 24V on the disconnected wiring harness connector 24V present YES Check electric continuity of the coil of electrovalve YV4 24V present Check for 24V between terminals 7 and 34 of the speed variator U1 24V present Replace the wiring harness between electrovalve YV3 and speed variator U1 Check for 24V between terminals 6 and 34 of speed variator U1 24V present Replace the wiring harness between electrovalve YV3 and speed variator U1 Replace the coil of See SHEET electrovalve YV4 C007 END Pinguely Haulotte FAILURE DETECTION FLOW CHART SHEET DP011 Sheet 2 2 HIGH SPEED UNAVAILBLE BELOW 1 5M OR 4FT92IN Check for 24V on input B2 of printed circuit U2 of the platform control Repair cabling between the speed selector switch SA3 and printed circuit U2 of the platform control or replace the speed selector switch SA3 see SHEET C004 24V present Replace printed See SHEET circuit U2 C004 END Replace See SHEET electrovalve YV4 C007 The fault persists Replace See SHEET electrovalve YV3 C007
53. el as the seal to ensure tightness Reconnectthe electric connections according to the marks made when dismantling e Put back the chassis control panel protective plate 4 Test Putthe machine back into the operational configuration Perform the function corresponding to the replaced component to check that it works properly Compact Optimum Pinguely Haulotte 4 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C006 Sheet 1 1 REPLACING THE TILT DETECTOR 1 Preliminary operations Place the platform on a flat level floor with no slope 5 Put machine the maintenance configuration see S 6 2 page 25 Caution e Cut off the electric power supply see 6 3 page 26 Do not use the machine du ENG 2 Removing the tilt detector tions Mark and disconnect the tilt detector s electric connections Remove the tilt detector by unscrewing the three fixing bolts 3 Replacing the tilt detector Puta new tilt detector into place and secure with the three fixing bolts Reconnect the electric connections according to the marks made when dismantling Place a spirit level on the top of the tilt detector and adjust the fixing screws to align the tilt detector NB A spirit level is built into certain tilt detectors Putthe machine back into the operational configuration 4 Operating test of the tilt detector Liftthe platform to a height of 2m
54. ely Haulotte FAILURE DETECTION FLOW CHART Sheet 2 4 SHEET DP003 NO UP MOVEMENT FROM THE CHASSIS OR PLATFORM CONTROL Pressure 165 bars or 150 bars compact 12 NO 2393 psi or 2175 psi compact 3347E Zero pressure YES See SHEET Replace the lifting C001 hydraulic cylinder s YES See SHEET Adjust or Ene replace the SHEET END limiter C012 Replace See electrovalve SHEET YV1 C030 END Pinguely Haulotte FAILURE DETECTION FLOW CHART Sheet 3 4 SHEET DP003 NO UP MOVEMENT FROM THE CHASSIS OR PLATFORM CONTROL Check operation of tilt detector 5010 Check supply connection Check operation NO Check the setting Input 27 at 24V Replace the See Input 29 NO connectororthe SHEET at 24V tilt detector C006 Input END 25 at 24V below 1 5m or 4ft92in Check operation ofthe end of stroke Input 24 at 24V contactor SA3 Check supply connection Check operation Check setting Y Y Replace the speed See SHEET variator U1 C003 Y Check operation of end of stroke contactors SQ1 SQ5 and SQ6 END Check supply connection Check operation Check setting Adjust or replace the See SHEET defective detector or its C018 wiring Pinguely Haulotte 77 FAILURE DETECTION FLOW CHART
55. ely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 1 1 SHEET C033 REPLACING AND ADJUSTING A PRESSURE SWITCH 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 2 page 29 Cut off the electric power supply see S 6 3 page 30 e Check low pressure with the emergency control Caution Ensure that oil temperature is not too high 2 Removing the pressure switch Disconnect the lifting electric connector 1 from the lifting cylinder s pres sure switch Disconnect the pressure switch s hydraulic hose 2 Fita cap to the hose Unscrew and remove the pressure switch fixing screws 3 Replacing the pressure switch Screw a new pressure switch equipped with its seal into place e Reconnect the pressure switch s hydraulic hose Reconnect the pressure switch s electric connector Putthe machine back into the operational configuration 4 Adjusting the pressure switch Place aload corresponding to movement disabling load in the platform see table below raise the platform until the small rod of the lifting cylin der is disengaged and adjust the pressure switch screw 3 located on the lifting cylinder so that the movements are disabled for this given load Check that the machine works properly in all positions with a load slightly less than nominal load on the platform
56. em extended 25 mm Platform dimension 2 3 m x 0 8 m 2 3mx1 2m Extension dimension 0 92 m Extension capacity 120 Kg 150 kg Travel speed machine folded 0 2 17 mph variable Travel speed machine raised 0 62 mph Interior turning radius 0 34 m 0 2m Exterior turning radius 2 38 m 2 5m Maximum slope during travel 23 Maximum tilt permitted 2 3 Hydraulic tank 251 Total mass 2160 Kg 2330 Kg Max load on one wheel 1355 daN 1350 daN Maximum pressure on the floor 8 daN cm 7 65 daN cm Number of drive wheels 2 2 Number of steering wheels 2 2 Tyres Solid rubber 38x13x5 cm Wheel diameter 380 mm Freewheel YES Movements Proportional controls Batteries 24 V 180 Amp h C5 24 V 250 Amp h C5 General hydraulic pressure 220 bars Travel 220 bars Steering 150 bars Lifting 165 bars Raising time 51s Lowering time 42s CE standards YES 13 Pinguely Haulotte 2 2 1 3 Compact 12 technical data Repair manual Description Compact 12 Load indoor use 300 kg including 3 persons Load outdoor use 120 kg including 1 person Manual lateral force indoor use 40 daN Manual lateral force outdoor use 20 daN Maximum wind speed indoor use 0 mph Maximum wind speed outdoor use 27 96 mph Floor height 10m Working height 12m Folded length 2 31m Folded length with steps 248m Overall width 1 20 m Folded height hand rails
57. eplacing a pressure limiter in the hydraulic block Screw a new pressure limiter equipped with its seal onto the hydraulic block Putthe hydraulic block back into place if applicable and secure with screws 1 equipped with new flat and toothed washers Putthe machine back into the operational configuration Setthe limiter to the required pressure Perform several movements using the replaced pressure limiter to check that it works properly Checkthe oil level in the hydraulic oil tank Compact Optimum Pinguely Haulotte 4 Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET SHEET C013 Sheet 1 1 REPLACING THE MANIPULATOR 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 2 page 25 Caution Cut off the electric power supply see 8 6 3 page 26 Do not use the machine du ring maintenance opera 2 Removing the manipulator 2 tions Remove the closing plate 1 by removing the four fixing screws e Mark and disconnect the manipulator s electric connections Remove the manipulator by removing its fixing screws 3 Replacing the manipulator e Fix a manipulator equipped with new seals to the platform control panel Reconnect the electric connections according to the marks made when dismantling Putthe closing plate back into place and secure with the four fixing Screws Putthe machine back into the operational configuration Make several u
58. est NB If no situation and red and green last light indicators are on SPEED VARIATOR is INOPERATIVE Alarm 01 if all the green light indicators are on speed variator ino perative Check YV7 connector Disconnect the plug on electrovalve YV7 Take YV1 coil for testing The fault disappears replace coil the fault does not disappear Disconnect the plug connecting with the chassis wiring harness Check the pin of wire 26 for incorrect connection Tests Alarm 98 when replacing the speed variator or MDI this code may appear when restarting the machine In this case leave the machine live for approximately 1 4 hour to allow the speed variator to re establish communication with the M D I 53 Pinguely Haulotte 2 Repair manual 8 2 FAILURE DETECTION FLOW CHARTS 54 SHEET DP001 Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART Sheet 1 2 NO UP AND DOWN MOVEMENT FROM THE PLATFORM CONTROL No up and down movement from the platform control Y Place the movement selector Switch SA3 in the position HS then in the up position Check that light indicators HL4 up and HL5 HS come on Open the plat form control panel and LEDs come check for 24V on between terminals 7 and 4 Open the platform control Y panel and activate NO 24V between 7 and 4 the fail safe and tilt the manipulator Check the prese
59. forwards and allow to hang vertically on the lower axle pivot tube Push the lifting switch down to gradually lower the platform until the mainte nance stand comes up against the lower pivot tube Removing the maintenance stand Push the chassis lifting switch up and gradually lift the platform until the maintenance stand is free of the lower pivot tube Turn the maintenance stand towards the back to bring it into its storage po sition on the cylinder fixture Push the chassis lifting switch down and lower the platform completely 29 Pinguely Haulotte 2 Repair manual Operating instructions for the COMPACT 8W 10 12 see Photo 2 page 29 These operations are to be carried out on both sides ofthe platform Putting the maintenance stand into place Position the platform on a firm horizontal floor Ensure that the two emergency stop buttons are ON Turn the chassis ignition key to the Chassis position Push the chassis lifting switch up to raise the platform Unscrew and turn the maintenance stand and allow to hang vertically Push the lifting switch down to lower the platform gradually until the mainte nance stand comes up against the two fixing points top and bottom Removing the maintenance stand Push the chassis lifting switch up and gradually raise the platform until the maintenance stand is free Turn the maintenance stand until it comes into its storage position and screw bac
60. gth or velocity of wind at 10m 33 ft above ground level in the open Description of Wind Specifications for use on land MPH m s 0 Calm Calm smoke rises vertically 0 1 0 0 2 1 Light Air Direction of wind shown by smoke 1 5 0 3 1 5 2 Light Breeze Wind felt on face leaves rustle ordinary vanes moved by 6 11 1 6 3 3 wind 3 Gentle Breeze Leaves and small twigs in constant motion wind extends 12 19 3 4 5 4 light flag 4 Moderate Breeze Raises dust and loose paper small Branches are moved 20 28 5 5 7 9 5 Fresh Breeze Small trees in leaf begin to sway crested wavelets form 29 38 8 0 10 7 on inland waterways 6 Strong Breeze Large branches in motion whistling heard in telephone 39 49 10 8 wires umbrellas used with difficulty 13 8 7 Near Gale Whole trees in motion inconvenience felt when walking 50 61 13 9 against wind 17 1 8 Gale Breaks twigs off trees generally impedes progress 62 74 17 2 20 7 9 Strong Gale Slight structural damage occurs chimney pots and slates 75 88 20 8 removed 24 4 Pinguely Haulotte 2 Repair manual Repair manual Pinguely Haulotte A 2 SPECIFICATION Self propelled platforms models Compact 8 8W 10 10N and 12 are designed for any overhead work within the limits of their characteristics see paragraph 2 1 page 12 and within the respect of all safety instructions specific to the equipment and places of use The main operating stat
61. he document holder provided on the platform Replace if necessary extra copies can be supplied on request by the manufacturer Repair manual Pinguely Haulotte A 7 PREVENTIVE MAINTENANCE SHEETS List of preventive maintenance sheets Sheet no Description Checking filling the hydraulic oil tank Replacing the hydraulic filter cartridge Greasing the steering wheel pivots Greasing the slides 39 Pinguely Haulotte 2 Repair manual 40 Pinguely Haulotte 77 PREVENTIVE MAINTENANCE SHEET Sheet 1 1 SHEET P001 CHECKING THE HYDRAULIC OIL TANK LEVEL 1 Preliminary operations Putthe machine in the low position and maintenance configuration see 8 6 2 page 27 AN Caution Ensure that oil temperature NOTA Do notuse the maintenance stands leave the platform in the low po is not too high sition Cut off the electric power supply see 8 6 3 page 28 2 Checking the hydraulic oil tank level Ensure that the oil level in the tank is sufficient Top upif necessary NOTA Only use the oil recommended by the manufacturer Putthe machine back into operational configuration MAX MIN OIL LEVEL Pinguely Haulotte PREVENTIVE MAINTENANCE SHEET Pinguely Haulotte 77 PREVENTIVE MAINTENANCE SHEET Sheet 1 1 SHEET P002 REPLACING THE HYDRAULIC FILTER CARTRIDGE 1 Preliminary operations Caution i Put the machine in the maintenance configuration see S 6 2 page
62. he user s manual 3078145100 DANGER direction of travel 3078144630 Risk of damage do not use the machine during battery charging 3078151230 Information Platform control panel label 3078143540 Information 240V plug 3078145120 Compact 8 sticker 3078145130 Compact 8W sticker 3078150900 Compact 10N sticker OO 3078145140 Compact 10 sticker 3078145150 Compact 12 sticker 3078149010 Risk of crushing of upper limbs hands fingers 3078145730 Information 240V plug 3078143610 Risk of injury wear protective clothing 3078145310 Risk of overturning Lock the battery tray before using the machine 3078143510 Risk of damage servicing of batteries 3078145110 Information Anchoring hook location 3078143830 Information Fork lift truck fork location 3078152020 Procedure freewheeling brake release 3078144670 Risk of crushing crushing of feet potholes 3078143520 Information Hydraulic oil 3078148890 Organic hydraulic oil option 3078148770 HAULOTTE logo 3078143800 Risk of crushing do not park in the machine s work area 3078143810 Electrical risk This machine is not isolated 3078143600 Electrical risk Do not use the machine as a welding earth Do not wash 3078145060 Information bottom pane
63. ion is on the platform The other operating station away from the platform is a standby or emergency station REMINDER For any information intervention of spare part requests please spe cify the machine type and serial number 11 Pinguely Haulotte 2 2 1 TECHNICAL CHARACTERISTICS Repair manual 2 1 1 Compact 8 Compact 8W technical data Description Load indoor use Compact 8 350 kg including 2 people Compact 8W 450 kg including 3 people Load outdoor use 120 kg including 1 person 120 kg including 1 person Manual lateral force indoor use 40 daN 40 daN Manual lateral force outdoor use 20 daN 20 daN Maximum wind speed indoor use 0 Km h 0 Km h Maximum wind speed outdoor use 45 km h 45 Km h Floor height 6 18 m 6 27 m Working height 8 18 m 8 27 m Folded length Folded length with steps Overall width Folded height hand rails Folded height platform Wheel base 1 86 m Floor clearance 130 mm Floor clearance with pothole system extended 25 mm Platform dimension 2 3m x0 8m 2 3mx1 2m Extension dimension 0 92 m Extension capacity 150 Kg Travel speed machine folded 0 2 17 mph Travel speed machine raised 0 0 62 mph Interior turning radius Exterior turning radius Maximum slope during travel Maximum tilt permitted 2
64. k into place Push the chassis lifting switch down and lower the platform completely 6 3 ELECTRICITY SUPPLY Photo 3 Operating instructions Cutting off the electricity supply Press the chassis emergency stop Starting the electricity supply Reset the emergency stop 30 Repair manual Pinguely Haulotte A 6 4 MAINTENANCE PLAN The plan overleaf indicates frequency servicing points device and the consumables to be used The reference in the symbol indicates the servicing point according to the frequency The symbol represents the consumable to be used or the operation to be performed 6 4 1 Consumables Consumable Specification Symbol Lubricants used by ELF TOTAL Pinguely Haulotte SHELL Gearbox oil SAE 15W40 RIMULA X Hydraulic 48602 HYDRELF EQUIVIS y ISO VG 46 lt gt 25 46 DS 46 ZS 46 Organic hydraulic oil ISO BIO 46 optional Lithium grease ISO XM 2 CN CARDRERA A DC1 Lithium grease ENS EP 700 us EPEXA 2 ESSO MS Multis Lead free grease Grade 2 or 3 C GP GREASE Multimotive 2 Exchange or specific operation 31 Pinguely Haulotte 2 6 4 2 Maintenance diagram N 1
65. l label 3078144650 Risk of overturning verification of tilt 3078144710 Stop time during lowering English 3078149610 Information operating instructions English 3078144590 8 floor height load capacity 3078149000 8W floor height load capacity 3078150950 10N floor height load capacity 3078144610 10 floor height load capacity 3078144620 1 1 1 1 1 2 2 2 2 2 4 1 1 1 1 4 4 1 2 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 12 floor height load capacity 37 Pinguely Haulotte 2 Repair manual 6 6 8 Label positioning on the machine ER oe 16 N e Bi 29 DAB BAND 23 39 C Positions communes tous pays Common positions all countries AN Positions suppl mentaires Australie et Hollande Extra positions Australia and Holland Positions suppl mentaires USA Extra positions USA D16106c 6 38 7 PRESENCE OF MANUALS It is important to ensure that the manuals supplied with the machine are in good condition and stored in the document holder provided on the platform An illegible manual may lead to incorrect or dangerous use of the machine Operating instructions Check presence of manuals Check that all the manuals are legible complete and stored in t
66. m 3 Replacing the remote control Putthe remote control cable back into place in the scissor ducts according to the route marked when dismantling Putthe emergency pull 1 in place on the chassis and secure with the bloc king nut Screw the sheath stop onto the cable support plate 3 at the distributing valve level Seoure the cable to the distributing valve manual control Putthe chassis control panel protective plate 4 back into place for Com pact machines Putthe machine back into the operational configuration Raise the platform to a height of 2m or 6ft56in and activate the emergency pull to check that it works properly Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 SHEET C018 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 1 1 REPLACING AN END OF STROKE CONTACTOR Caution Do not use the machine during maintenance operations 1 Preliminary operations Put the machine in the maintenance configuration see S 6 2 page 25 Cut off the electric power supply see S 6 3 page 26 2 Removing an end of stroke contactor Mark the position of the end of stroke contactor 1 and its lever 2 Remove the end of stroke contactor Open the end of stroke contactor mark and disconnect the electric connec tions 3 Replacing an end of stroke contactor Open the new end of stroke contactor reconnect the electric connections and close the end of stroke contacto
67. m in the pump due to insufficient oil The hydraulic oil becomes cloudy and white with bubbles Oil viscosity too high Empty the circuit and refill with the recom mended oil 49 Pinguely Haulotte 2 CHECK ANOMALY Overheating of the hydraulic circuit PROBABLE CAUSE Oil viscosity too high Insufficient hydraulic oil in the tank Repair manual SOLUTION Empty the circuit and replace with the re commended oil Top up with oil as neces sary The system works irregularly The hydraulic oil is not at optimum operating temperature 8 1 2 Platform lifting system CHECK ANOMALY No up or down movement from the platform control PROBABLE CAUSE Defective wiring harness Defective printed circuit U2 Defective manipulator Defective platform emergency stop button Defective speed variator Make some move ments without load to enable the oil to heat up SOLUTION SHEET DP001 No up or down movement from the chassis control Defective key switch Defective wire no 10 Defective switch SA2 Defective speed variator SHEET DP002 No up movement from the chassis or platform controls Hydraulic leak Defective wiring harness Defective electrovalve YV1 coil Defective lifting cylinder Defective electrovalve YV1 Defective or badly adjusted limiter Defective tilt detector Defective speed variator Defective end of stroke contactor SHEET DP003
68. nce of a set point value on input A9 of printed circuit U2 and the YES of setpoint at CA Repair cabling or replace switch SA3 presence of 24V on input B5 and B13 of printed circuit U2 output of printed Continuity between coils 1 and 2 of the platform control panel Change the control panel link END between terminal CA Renovate cabling A9 setpoi value and 24V on B5 and B13 NO and output 5 of the control panel or change the control panel link wiring harness See SHEET Replace printed END C004 circuit U2 Replace speed variator U1 END See SHEET Replace the END C013 manipulator wiring harness Renovate cabling or change PB SB2 END Pinguely Haulotte FAILURE DETECTION FLOW CHART NO UP AND DOWN MOVEMENT FROM THE PLATFORM CONTROL Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP002 Sheet 1 2 NO UP AND DOWN MOVEMENT FROM THE CHASSIS CONTROL No up and down movement from the chassis control Place the key switch in the chassis control position and check for 24V on its terminal connected to wire no 10 24V present Replace the See SHEET switch C005 END Check for voltage on switch SA2 wire no 10 24V present Replace wire no 10
69. ne goes into Balancing valve incorrectly set or not Replace the balan runaway downhill working properly cing valve 8 1 4 Steering system ANOMALY CHECK PROBABLE CAUSE SOLUTION Hydraulic leak No lifting Defective printed circuit U2 Defective electrovalve YV5a or YV5b coil Defective electrovalve YV5 EE Defective wiring harness Defective manipulator Defective steering cylinder Defective steering pressure limiter 51 Pinguely Haulotte 2 Repair manual Numeric indicator 8 1 5 List of MDI codes Flash Description M D I red led Battery below 5 or speed variator inoperative Supply voltage of YV7 YV9 and wire no 3 input B check that wires 100 8 3 are not inverted Incorrect connection of wire 26 if all light indicators are on and fault 01 speed variator inoperative Serial card or cable or supply plug of the top station wire no 58 MDI cabling or MDI T wire wiring harness 37 5 38 B5 39 A 3 40 B1 41 B12 51 A7 52 EEPROM problem Speed variator inoperative Low idle VMN or incoherent with the applied PWM speed variator inoperative Mains switch stuck auxilliary contact of the battery set open or inoperative Mains switch open by the control microswitch battery cut off inoperative I 0 A EVER Current always zero in operation speed variator inoperative High idle current speed variator inoperative The capacitors do
70. ne or fork lift truck 2 Removing the motor pump set Remove the upper inspection flap for Compact machines Mark and disconnect the motor s electric connections 1 Mark and disconnect the hydraulic pump s hoses 3 Fitcaps to the hoses Remove the fixing collars 2 from the motor pump set and remove the motor pump set Remove the hydraulic pump s suction and backflow flanges 4 3 Replacing the motor pump set Putthe suction and backflow flanges equipped with new seals on a motor pump set Putthe motor pump set into place and secure with the collars Reconnect the hydraulic hoses to the pump according to the marks made when dismantling Reconnectthe electric connections to the motor according to the marks made 4 when dismantling Close the inspection flap for Compact machines Putthe machine back into the operational configuration Perform several lifting cycles to purge the hydraulic circuit e Check the oil level in the hydraulic oil tank Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 SHEET C020 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet 1 2 REPLACING A HYDRAULIC BLOCK VALVE Caution Ensure that oil temperature is not too high Compact Optimum 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 2 page 25 Cut off the electric power supply see S 6 3 page 26 2 m a valve from the hydra
71. nominal load more people than the authorised number lateral force in the platform greater than the level permitted wind speed higher than the permitted level Repair manual AN Caution Never use the platform as a crane goods lift or elevator Never use the platform or tow 1 3 or haul RESIDUAL RISKS Pinguely Haulotte 2 To avoid all risk of serious fall operators must respect the following instructions Hold the hand rails firmly when climbing onto or operating the platform Wipe any traces of oil or grease off the steps floor and hand rails Wear protective clothing suited to working conditions and current local legis lation in particular when working in hazardous areas Do not disable the safety system end of stroke contactors Avoid contact with fixed or mobile obstacles Do not increase working height by using ladders or other accessories Never use the hand rails as a means of access for getting onto and off the platform use the steps provided on the machine Never climb on the hand rails when the platform is raised Never drive the platform at high speed in narrow or cluttered areas Never use the machine without installing the platform protective bar or clo sing the safety barrier Never climb on the covers To avoid risks of tipping over operators must respect the following instructions NB Do not disable the safety system end of stroke contactors Avoid moving the steering contr
72. not start to charge on key 250A fuse motor connections Speed variator temperature too high gt 75 speed variator inoperative Oli Om A Discharged battery Short circuit on electrovalve the mains switch or buzzer Mains switch pilot in short circuit switch coil or variator problem wire 19 on terminal 9 disconnected MAV on hydraulic block speed variator inoperative if the relay sticks immediately charger starter plug incorrectly connected Mains switch pilot does not close switch coil or speed variator problem Accelerator up when idle joystick problem Check the potentiometer supplied with 51 52 output 39 Incorrect start sequence joystick connection Double start request serial card or joystick YV6 coil inoperative or incorrectly connected wires 25 7 theoretical resistance 75 ohms inversion of wires 25 amp 27 at terminals 18 amp 18 Drivers 2KO SIC Problem with small wiring harness between MDI and bottom station control panel The control microswitch does not respond correctly to the SIEMENS micro speed variator inoperative If horn is quiet change the coil mains switch in DC 52 Pressure switch alarm Repair manual Pinguely Haulotte A Numeric T Flash Description Disagreement between the speed variator and MDI timers Auxililary contact of chassis emergency stop inoperative Programmed handling requ
73. ocking pedal and support assembly the two rollers and their axles back into place and secure with screws equipped with new toothed washers Install the electric plug support Putthe platform control panel back into place and reconnect the platform wiring harness Grease the friction parts of the slides Only use the grease recommended by the manufacturer Put the machine back into the operational configuration Check that the platform extension can be extended and retracted easily Optimum Compact Optimum Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET SHEET C026 Sheet 1 2 REPLACING THE PLATFORM 1 Preliminary operations Putthe machine in the low position Cut off the electric power supply see 8 6 3 page 26 2 Removing the platform Disconnect the wiring harness 1 from the platform control panel Remove the control panel and remove the wiring harnesses from the plat form Remove the electric plug and its support if any from the platform Putthe platform into slings Remove the axle stop bolts from the four platform axles two fixed axles 2 and two moving axles 3 and remove the four axles Remove the platform Remove the four pads and check their condition remove the adjustment wed ges if necessary Replacing the platform Putthe four pads into place fixed and moving on the platform 1
74. ol 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 platform is cluttered Do not use the machine with equipment or objects hanging from the hand rails Do not use the machine with elements that may increase the wind load e g panels Do not perform machine maintenance operations when the machine is raised without setting up the required safety means gantry crane crane Make daily checks and monitor proper operation during periods of use Preserve the machine from any uncontrolled operation when it is not in ser vice Do not tow the platform it is not designed to be towed and must be transported on a trailer 1 3 1 Risks of jolting tipping over The risks of jolting or tipping over are high in the following situations sudden action on the control levers platform overload uneven floor pay attention to thaw periods in winter gusts of wind contact with obstacles on the ground or in the air
75. osition 2 Unlock the emergency stop button then press the starter button 3 Ifthe machine does not start wait 10 seconds then repeat the operation THE MACHINE MUST NOT BE USED WHILE CHARGING THE BATTERIES 7814 345 Repair manual Pinguely Haulotte 2 6 6 3 Common red labels 18 7814 467 7814368a Haulotte 4 35 Pinguely Haulotte 2 Repair manual 6 6 5 Labels specific to models 6 6 5 1 Compact 8 3a m A INSIDE USE compacts OUTSIDE USE 125 m s t 45 km h 7814 459 c 3b 450 Kg gt 7814 900 6 6 5 3 Compact 10N 3c INSIDE USE ONLY 120Kg 230Kg fo aep p 3d HA 12 5 m s 45 km h 7814 461d 3e 400N 40 kg 125 m s 45 km 7814 462 d 36 Pinguely Haulotte 2 Repair manual 6 6 6 Labels specific Option 6 6 6 1 Organic hyaraulic oil D 19 d DIO x 6 6 7 References of the machine s labels Designation Refer to t
76. otte 4 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C015 Sheet 1 1 REPLACING THE BUZZER 1 Preliminary operations Cut off the electric power supply see 8 6 3 page 26 Caution Do not use the machine during maintenance operations 2 Remove the buzzer e Mark and disconnect the buzzer s electric connections 1 Remove the buzzer by unscrewing the fixing bolt 3 Replacing the buzzer Putthe new buzzer into place and secure with the fixing bolt Reconnectthe electric conections according to the marks made when dis mantling 4 Test Putthe machine back into the operational configuration e Check that the buzzer gives a signal below 1 5 metres or 4ft92in during lowering Compact Optimum Pinguely Haulotte 4 Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET SHEET C016 Sheet 1 1 REPLACING THE DISTRIBUTION BLOCK 1 Preliminary operations Caution Ensure that oil temperature is not too high NB N 1 Optimum Put the machine in the maintenance configuration see S 6 2 page 25 Cut off the electric power supply see 8 6 3 page 26 2 Removing the distribution block Remove the fixing lug 1 securing the distribution block to the chassis and take out the distribution block 2 to access its components Mark and disconnect the distribution block s electric connections Mark and disconnect the distribution block s hydraulic hoses Uns
77. over the controls in the case of accident or breakdown monitor and prevent machines or people from circulating around the plat form guide the platform operator if necessary 1 2 2 Environment Never use the machine On soft unstable or cluttered floors On a floor with a tilt greater than the allowed limit With a windspeed above the permitted level In case of outdoor use check that windspeed is lower or equal to the permitted level using an anemome ter Near electric lines find out about minimum distances according to current In temperatures of less than 15 C in particular in cold rooms consult our service department if work is required in conditions below 15 C In an explosive atmosphere In an incorrectly ventilated area as exhaust fumes are toxic During storms risk of being struck by lightning At night if the machine is not equipped with an optional light In the presence of intense electromagnetic fields radar mobile and high 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
78. p and down movements from the plaform to check that the manipulator works properly Pinguely Haulotte 4 SHEET C014 Caution Ensure that oil temperature is not too high Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 1 1 REPLACING A HYDRAULIC TRAVEL MOTOR 1 Preliminary operations Put the machine in the low configuration see S 6 2 page 25 Cut off the electric power supply see 8 6 3 page 26 Raise the machine using a jack or hoist 2 Removing a hydraulic travel motor see figure 1 1 Remove the pin 2 and nut 1 fixing the wheel and remove the wheel 7 Mark and disconnect the two hydraulic motor hoses Fit caps to the hoses Place a wedge under the hydraulic motor Remove the hydraulic motor 4 by removing its four fixing bolts 3 5 6 Replacing a hydraulic travel motor Put a new hydraulic motor into place Secure the hydraulic motor using the four fixing bolts equipped with new elastic washers Reconnect the hydraulic hoses according to the marks made when dis mantling Put the wheel back and secure with the fixing nut and pin Put the machine back into the operational configuration Make several travel movements to purge the hydraulic circuit Check the oil level in the hydraulic oil tank Wheel nut tightening torque 25 N m To fix the pin the slot must be in front of an hole at this time we can screw until 30 N m Pinguely Haul
79. platform and p variator U2 T C003 measure voltage at the manipulator s output terminals YES e 9 10V 11 10V END 10 between 10V and 10V Replace the electric wiring harness 5 24V between the platform control panel 140r1 24V and the chassis Pinguely Haulotte FAILURE DETECTION FLOW CHART SHEET DP014 Sheet 2 4 NO MOVEMENT FROM THE PLATFORM CONTROL PANEL Replace the See SHEET manipulator C013 END Check voltage on the inputs of printed circuit U2 A6 10V e AT 10V A9 between 10V and 10V 5 and B13 24V Repair cabling between the manipulator SM1 and printed circuit U2 Check for variable setpoint voltage between terminals C2B and C4 of printed circuit U2 Replace printed See SHEET circuit U2 C004 Presence of a setpoint voltage Check for setpoint voltage between terminals 2 and 21 ofthe speed variator U1 Pinguely Haulotte FAILURE DETECTION FLOW CHART SHEET DP014 Sheet 3 4 NO MOVEMENT FROM THE PLATFORM CONTROL PANEL Replace the wiring harness between the platform control panel and the speed variator Setpoint voltage present END Replace speed See SHEE variator U1 T C003 Pinguely Haulotte FAILURE DETECTION FLOW CHART SHEET DP014 Sheet 4 4 NO MOVEMENT FROM THE PLATFORM CONTROL PANEL Repair manual
80. r Move the end of stroke contactor s lever 2 back to the position marked when dismantling Put the end of stroke contactor into place in the position marked when dis mantling and secure with bolts 3 without tightening 4 Test Put the machine into the operational configuration Perform the movement using the contactor concerned see table and check that it works properly Adjust the contactor position if necessary and tighten the fixing bolts MOVEMENT TO CONTACTOR BE MADE CHECK Lifting end of stroke Liftin Lifting disabled in the high posi SQ3 9 tion Extension of the potholes T when the platform reaches Lifting 15m Pothole end of stroke Microspeed present 505 and 506 e Disconnect YV6 Lifting impossible beyond Lifting 1 5m Travel impossible beyond 1 5m Pr Check that the lowering move Pet end of Liting beyond ment is correct with interrup stroke SQ1 1 5m and lowering tion at 1 5m iu ene OI ur t Travel impossible microspeed switch 504 Lifting beyond Gm disabled H12SN only Pinguely Haulotte 4 Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET SHEET C019 Sheet 1 2 REPLACING THE MOTOR PUMP SET 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 2 page 25 JU Cut off the electric power supply see S 6 3 page 26 aution Ensure that oil temperature is not too high NB Lift the platform using a gantry cra
81. rease the slides using lead free grease Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C027 Sheet 2 2 REPLACING THE SCISSORS NB Only use the grease recommended by the manufacturer Perform several lifting cycles to check that the machine works properly ILS Nut 5 Screv SS s lui Ser 0 VAT ee 7 E SC eW L Nut ScrewNut Sie Nut TOT SS Mute Screws e screw Li Nut Nut Screw ECROU Fig 1 RON Fig 2 Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET SHEET C028 Sheet 1 2 REPLACING A SCISSOR RING OR AXLE 1 Preliminary operations Putthe machine in the low position Cut off the electric power supply see S 6 3 page 26 2 Removing a scissor axle 1 or ring 2 Remove the platform see SHEET C026 Remove the elastic ring and washer from the scissor axle in question Remove the axle stop bolt Take out the scissor axle Take out the two scissor rings 3 Replacing a scissor axle or ring Put new scissor rings into place Putthe scissor axle into place and secure using the axle stop bolt NB Fit the axle stop bolts so that the screw is above the axle and the nut underneath when the platform is in the high position see figure below Putthe washer
82. ses and electric connections tyre condition excessive mechanical play Repair manual Pinguely Haulotte Z NB In the case of rental responsible users of the rented machine must examine the condition and check suitability They must check with the rental company that the general regular checks and checks be fore starting work have been performed Major repairs interventions or adjustments on the safety systems or elements concerning mechanical hydraulic and electric systems must be carried out by PINGUELY HAULOTTE personnel or personnel working on behalf of PINGUELY HAULOTTE who will only use original spare parts Any modification outside PINGUELY HAULOTTE s control is unauthorised The manufacturer is not responsible if original spare parts are not used or if the work specified above is not performed by PINGUELY HAULOTTE approved personnel VERIFICATIONS BEFORE RESTARTING WORK To be performed after major dismantling reassembly operations repair of the machine s essential devices any accident caused by failure of an essential device A suitability examination examination of the condition static test and dynamic test must all be carried out see coefficient paragraph 1 4 2 page 8 1 5 REPAIRS AND ADJUSTMENTS 1 6 1 7 BEAUFORT SCALE The Beaufort Scale of wind force is accepted internationally and is used when communicating weather conditions It consists of number 0 17 each representing a certain stren
83. sing the threaded holes Remove the scissors and pads 3 Dismantling the scissors Carefully mark the equipment s assembly Remove the cable passage ducts 1 counterbore the eight rivets 2 at both ends of the duct and remove the straps remove the duct remove the upper duct stop bracket Put each element into slings and remove one after the other removing the elastic rings 3 and washers 4 from the articulation axles 5 Remove the scissor elements starting from the top 4 Reassembling the scissors Reassemble according to the dismantling procedure in reverse order respec ting the marks made when dismantling 5 Replacing the scissors NB Check the condition of the pads and replace if necessary Put the scissors into slings and into place on the chassis Check that the axial clearance between the chassis and the lower arm 6 does not exceed 1mm otherwise adjust the clearance using the adjustment wedges 7 provided see figure 2 Put the two fixed chassis axles into place and secure using the two axle stop bolts Fit the bolts so that the screw is on the top of the axle and the nut is un derneath see figure 1 Replace the hydraulic hoses and electric wiring harness routed along the scissors according to the marks made when dismantling Replace the lifting cylinder s see SHEET C001 Replace the platform see SHEET C025 Put the machine back into the operational configuration G
84. so as to receive original parts the only guarantee of interchangeability and perfect operation This manual is supplied with the machine and is included on the delivery note REMINDER You are reminded that our machines comply with the provisions of the Machines Directive 89 392 EEC of June 14th 1989 as amended by the directives 91 368 EEC of June 21st 1991 93 44 EEC of June 14th 1993 93 68 EEC of July 22nd 1993 and 89 336 EEC of May 3rd 19889 directive 2000 14 CE and directive EMC 89 336 CE Pinguely Haulotte A Operating and maintenance instructions Repair manual Pinguely Haulotte A 1 GENERAL RECOMMENDATIONS SAFETY 1 1 GENERAL WARNING 1 1 1 Manual This manual aims to help maintenance personnel service and repair the machine It cannot however replace the basic training required by any person working on the site equipment The site manager must inform operators of the recommendations in the instruction manual He is also 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 Or
85. special screw washer and a new nut Reconnect the hydraulic hoses according to the marks made when dismant ling Put the machine back into the operational configuration Perform several up down movements from the plaform above 1 5 meters or 4ft92in and travel movements with the platform lowered to purge the hydrau lic circuit Check that the pothole protective system extends and retracts correctly NOTA If counterweights are fitted with the potholes check that their position remains correct before replacing the cylinder Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C025 Sheet 1 2 REPLACING A PLATFORM EXTENSION 1 Preliminary operations Putthe machine in the low position Cut off the electric power supply see S 6 3 page 26 2 Removing the platform extension Remove the electric plug and its support if any from the platform Remove the control panel 1 and the platform wiring harness 2 Putthe platform extension 3 into slings Remove the locking pedal 4 and support 5 assembly Remove the two roller and roller axle assemblies at the back of the extension by unscrewing the fixing screws 6 Remove the two safety brackets 7 Remove the platform extension 3 Replacing the platform extension Putthe platform extension into place Secure the two safety brackets Putthe l
86. ssure tap Put the machine back in the operational configuration Make several travel movements to check that the machine works properly Adjusting the steering pressure limiter 2 Put the machine in the low configuration Cut off the electric power supply see S 6 3 page 26 Unscrew the cap of the hydraulic pressure tap marked MX on the hydraulic block and connect a pressure gauge with sufficient range to measure the steering pressure Restore the electric power supply see S 6 3 page 26 Activate the steering command as far as possible to the right or left Maintain the steering command and measure the steering pressure on the pressure gauge Steering is disabled after a certain period when at the maximum in one direction and only the other direction is possible and can re authorise steering in the initial direction The steering pressure measurement time is therefore limited If necessary adjust the hexagonal hollow head screw on the steering pres sure limiter 2 to disable movement at the pressure indicated in the table below Put the machine in the maintenance configuration see S 6 2 page 25 Cut off the electric power supply see S 6 3 page 26 Unscrew the pressure gauge and put the cap back on the hydraulic pressure tap Put the machine back in the operational configuration Make several steering movements to check that the machine works properly Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SH
87. stop C004 24V NO present Y END YES Repair electric cabling between key switch SA1 on the chassis control panel and the speed va riator U1 END Pinguely Haulotte FAILURE DETECTION FLOW CHART SHEET DP007 Sheet 3 4 NO MOVEMENT Check electric continuity of the motor pump set connection to the speed variator NO YES See SHEE Replace the motor T C019 pump set END Restore the electric connection between the motor pump set and the speed variator Pinguely Haulotte FAILURE DETECTION FLOW CHART SHEET DP007 Sheet 4 4 NO MOVEMENT Check cabling of the electrovalve supply line line 7 at fuse FU2 output Cabling NO OK YES See SHEE Replace speed T C003 variator U1 Replace cabling END Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP008 NO STEERING C No steering Y Check for absence of hydraulic leaks Absence of Sheet 1 2 leaks Make a lifting movement Lifting movement occurs Disconnect electrovalve YV5 electric connectors Activate steering and check for 24V on connector YV5a left or YV5b right NO gt Repair hydraulic connectors END NO SHEET DP007 Make a steering movement right and left and check for 24V on input B1 or B12 of printed circuit U2 ofthe platform
88. the batteries to isolate the electric cir Do not use the machine cuit during maintenance operations 2 Remove the emergency stop button Mark and disconnect the emergency stop button s electric connections 1 Remove the emergency stop button 2 3 Replacing the emergency stop button Puta new emergency stop button into place Reconnectthe electric connections according to the marks made when dismantling 4 Test Putthe machine back into the operational configuration e Check that the emergency stop button works properly Compact Optimum Optimum Compact Pinguely Haulotte 4 Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet 1 2 SHEET C032 REPLACING THE HYDRAULIC PUMP 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 2 page 25 Cut off the electric power supply see 8 6 3 page 26 AN Caution 2 Removing the hydraulic pump Ensure that oil temperature Remove the motorpump set see SHEET C019 is not too high Remove the screws securing the pump to the motor and remove the pump 3 Replacing the hydraulic pump Puta new pump equipped with seal onto the electric motor and secure with the fixing screws Remount the motor pump set see SHEET C019 Putthe machine back into the operational configuration Perform several lifting cycles to purge the hydraulic circuit e Check the oil level in the hydraulic oil tank Pingu
89. tor SQ5 or SQ6 Pinguely Haulotte FAILURE DETECTION FLOW CHART NO TRAVEL MOVEMENT IN BOTH DIRECTIONS SEET FORWARD AND BACKWARD Check for 24V on input 36 of the speed variator breaking at 8m or 26ft25in present Check continuity of the wiring harness between the top end of stroke contactor SQ4 and the speed variator breaking at 8m or 26ft25in Close valve NV1 of the hydraulic block and release the brakes manually Request a travel movement 24V present Continuity correct travel movemen Replace the See SHE occurs defective motor ET C014 Replace the wiring harness END Replace the See SHE Y defective brake ET C011 END Adjust or replace the See SHE top end of stroke ET C018 contactor SQ4 END Pinguely Haulotte FAILURE DETECTION FLOW CHART SHEET DP006 Sheet 4 4 NO TRAVEL MOVEMENT IN BOTH DIRECTIONS FORWARD AND BACKWARD Disconnect the movement selector switch on the platform control panel and activate the travel control rave occurs at low speed Replace printed See SHE circuit U2 ET C004 END Check cabling of the movement selector switch SA3 or replace it See SHEET C004 Pinguely Haulotte 4 FAILURE DETECTION FLOW CHART SHEET DP007 Sheet 1 4 NO MOVEMENT
90. ulic block Unscrew the fixing screws 3 and take out the hydraulic block 4 if neces sary to make access easier Open the valve concerned Unscrew the base 2 of the valve 1 and remove from the hydraulic block Fitacap to the hydraulic block hole to protect it 3 Replacing a valve in the hydraulic block Screw a new valve onto the hydraulic block Putthe valve back into its initial state Fixthe hydraulic block on with the fixing screws 3 Putthe machine back into the operational configuration Make several travel movements to purge the hydraulic circuit Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET SHEET C021 Sheet 1 2 REPLACING A WHEEL 1 Preliminary operations Putthe machine in the low configuration Cut off the electric power supply see S 6 3 page 26 Raise the machine using a jack or hoist 2 Removing a wheel Remove the pin 1 and fixing nut 2 from the wheel and remove the wheel 3 3 Replacing a wheel Replace the key 4 if necessary Puta new wheel into place and secure with the fixing nut and pin Putthe machine back into the operational configuration EH Wheel nut tightening torgue 25 N m To fix the pin the slot must be in front of an hole at this time we can screw until 30 N m Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet 2 2 Pinguely Haulotte

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