Home

STAR 8 GB.book

1. A15007 39 Repair manual Pinguely Haulotte Z HYDRAULIC DIAGRAM B17085 9 2 980219 1 HMIOAEISHH air AMIVINONAd ONISAAALS NOILOSTAIAG NOILVLNIIHO These diagrams also be found the parts manual along with the list of their components 40 Pinguely Haulotte 10 HYDRAULIC FUNCTIONING B17085 DIAGRAM 10 1 MAST RAISING ORIENTATION DIRECTION SS PENDULAIRE 10 2 MAST LOWERING C Sese ORIENTATION DIRECTION Sg PENDULATRE E 41 Pinguely Haulotte Z 10 3 JIB LIFTING 10 4 JIB LOWERING 42 Repair manual Pinguely Haulotte 2 10 5 TURNTABLE ROTATION Position el Sens du valve direc Fini distributeur 4 tion l
2. 5 8 STAR 10 Load Indoor Outdoor 200 kg 2 people 230 kg 2 people 160 kg 1 person 120 kg 1 person Maximum side force Indoor Outdoor 40 kg 20kg Working height 8 73 m 10 m Floor height 6 73 m 8m Maximum reach 2 6 m 2 6 m Turntable rotation 360 not continuous Maximum slope and tilt during operation 3 approx 5 2 Platform floor dimensions 670 x 920 mm Maximum slope during travel 25 Low travel speed 0 7 km h High travel speed 4 5 km h Traction batteries 24V in 2trays Floor clearance 100 mm max 40 mm Tyres Solid tyres Turning radius Internal 440 mm External 1875 mm Mast telescoping stoke 3700 mm 4900 mm Max wind speed in operation indoor outdoor 0 km h 45 km h Max pressure on the ground with useful load concrete 16 5 kg cm 17 kg cm Max force on one wheel 1200 kg 1240 kg Movement time with one person Turntable rotation 360 60s 60s Mast telescoping extend retract approx 40s 27s 46 5130 5 Jib lifting up down 265 365 265 365 Engine separate energising Voltage 24V Power 1 2 kW Consumption 63A Hydraulic pump in operation volume 1 5 5 cm3 tr Hydraulic oil tank capacity 25 litres Hydraulic operating pressure max steering pressure 160 bars 160 bars max orientation pressure 50 bars 50 bars max mast extension telescoping pressure 45 bars 45 bars
3. H1 Platform buzzer 4 1 9 Light indicators PV Hourmeter battery indicator HA Weighing or tilt light indicator HPh Work headlight Pinguely Haulotte 5 WEIGHING DEVICE Weighing system including Electronic card ref 244 030 9330 Angle sensor ref 244 030 9350 Pressure sensor ref 244 030 9340 Training control ref 244 030 9320 Electronic card able to detect a single and only threshold at 11596 of nominal charge gt Vi sual and sound signalling cut off of all movements transmit a piece of information to the chopper in order to slow down jib raising on reaching the upper stop so as to avoid abrupt stops 5 1 FUNCTIONING PRINCIPLE This device measures non stop 2 physical values the pressure in the jib cylinder s chamber the chassis jib angle It determines during a training test the pressure normal value according to the jib angle without load and loaded at 11596 When detecting a pressure value which is too high compared to the one reported during the first test with105 load the system interprets it as an overload and gives the alarm to inform the user 5 2 WEIGHING CARD 5 2 1 Characteristics oll 410 JD A ES 6 5 4 4 ASE 2 outputs in order to obtain logical combinations 95 iso uss 151 interpreted by the chopper 2 J 4 3 UE D10 O O J11 pressure sensor connection J1
4. CNA 8 0V idle CNA 8 0V at 4V CNA 10 5V amp CNA 9 0V UP CNA 10 0V 8 CNA 9 5V down NO Follow the same wire colours and measure voltage at the terminals of manipulator SM1 Measure voltage at CNB S OV lt cursor lt 4V FOR contact 5V or NO NO REV contact 5V Replace manipulator See sheet YES 5 1 143 Repair the wiring Replace the Serial See sheet board C063 END Measure voltage at 586 output 586 24 V NO YES See sheet Replace the button Repair the wiring P C004 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DPO78 NO UP OR DOWN MAST MOVEMENT Folio 3 6 FROM THE TURNTABLE No down movement No up movement Measure voltage at terminal 24 of the chopper oltage measured NO 24 V Check if the mast has reached its max height gt ax height YES Lower the mast Measure voltage at 5010 NO Replace the sensor See sheet C200 Repair the wiring END Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP078 Folio 4 6 NO UP OR DOWN MAST MOVEMENT FROM THE TURNTABLE No down movement No up movement Check battery charge Battery charge NO i YES See sheet
5. 61 1 1 al lt 0 3 D 61 8 v lF 5 po E N N lo 9 9 0 E 1 TF ole 5 3 a 3 RIS 2 i lmotado S EIE m i Jneyoung uondQ d 1 1 4 3 N 12 10 na 2 i 1 i 12X 885 Ei ve M i A evs zus eas 1685 SH i A x 22 2 mod a ENS ZNS REPE i 8 J 2 EI sor lt a 9 ONILAIT THAVIL 1 NOILVLNSIHO e 01 10 NOILVA373 NOILVISNVAL 1 NOLLO3IG NOLLV LN3IHO 1 ad be be x bei 1 SOL SOL v 6L SL ZL OL SL FL EL LL OL 6 8 L 9 S v L Repair manual Pinguely Haulotte Z 3 3 3 555 03 ben SYW3H S oynay SWUOH 1 29 27 8 dOL 8 UVLS NOLLVOIJIN3A See EEN e 69 devanvat nof vooz vo r o 1002 90 62 er 30 101 VSIA NOLLVOIJIGON aiva 9999
6. AN Caution e Put the machine into the maintenance configuration see relevant sec Do notuse the machine during maintenance Switch off the electric power supply see relevant section operations 2 Removing an end of travel contactor e Mark the position of the end of travel contactor 1 Remove the end of travel contactor Open the end of travel contactor mark and disconnect the electric con nections 3 Reinstalling an end of travel contactor Open the new end of travel contactor reconnect the electric connections and close the contactor again e Put the end of travel contactor into place according to the position marked during dismantling and fix onto its support Do not tighten the bolts before adjusting 4 Adjustment and test Put machine back into the operational configuration Make the movement using the contactor in question and check that it works properly Adjust the position of the contactor if necessary and tighten the fixing bolts SQ4 mast down 5010 high position caisson 5012 jib up 504 5012 Pinguely Haulotte Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C201 Sheet 1 1 REPLACING THE HYDRAULIC FILTER Attention 4 1 Preliminary operations Ensure that the oil is not too Put the machine into the maintenance configuration see relevant sec hot tion Switch off the electric power supply see relevant section d 2 Removin
7. DIRECTION STEERING ORIENTATION BRANCHEMENT SUR PRISE 37 VOIES CONNECTION ON 37 PIN SOCKET EMBASE REP P20027d The above diagrams along with the list of their components are included in the spare parts manual 14 Repair manual Pinguely Haulotte 3 2 BUNDLE DIAGRAM 16209 MARQUAGE JET 0 ENCRE Wi NN zonsouaun S 10 1 DELECTRO PG livr e non mont e attach sur faisceau m i 2442009180 9 4 EMBOUT DE CABLAGE 8 CABLE 2 1mm2 SUIVANT SPECIF N5074 1 COSSE DOUILLE CYUNDRIQUE 6 1 FICHE METALIQUE 16 VOIES 5 1 ADAPTATEUR 1 3 16 18 UNEF 4 PIM THERMORETRACTABLE 3 GAINE POLYFLEX 17 2 8 EMBOUT DE CABLAGE 1 1 CABLE SPIRALE SUIVANT SPECIF 5292 d MN REr Ne DESIGNATION FAISCEAU CABLE SPIRALE emana Ces Wi a FAISCEAUX 0702 MONTAGE PRISE __ E Daneze STAR 8 HM10P me Description Haulotte reference Electro head delivered not fitted tied on YV5 bundle 2442009180 Cabling end fittings 2440502250 Cable 2 1mm2 according to specification N5074 2440311480 Cylindrical socket lug 2440305560 16 pin metal plug 2440603870 Adaptor 1 3 16 18 UNEF 2440106380 Thermoretractable she
8. RL1 Security relay fitted on the U2 card Control of the overload pressure switch circuit RL2 Security relay fitted on the U2 card Control of the chassis insulation from the machine e SA1 Ignition key selector command selection either by the upside console or by the downside console 581 Electric eguipment main switch 585 Push button to command the jib Input of the serial card 5 6 Push button to command mast lifting Input 5 of the serial card 587 Push button to command the rotary motion Input R ofthe serial card SM1 Orientation lifting jib joystick 501 Tilt sensor 100 2 4 25A 2A5 42 2 4 5010 Upper end oftravel 42A 2A7 24A 2A8 504 Jib lower end of travel tilt resetting 5012 Mast lower end of travel tilt resetting U2 Interface card of the downside console 03 ofthe upside console e YV1 Steering solenoid valve A Right 204 17 Left 19 common 18 2 YV2 e Mast rotation solenoid valve A left 7A 20 8A 3A22 common 3A21X2 YV3 Up Down Selection of the jib or mast lowering 18A 3A16 3815 B mast telescoping 12A 28 3827 YV4 Mast telescoping 9A 3A23 3A24 YV5 Jib lifting or lowering 19A 2 18 YV6 Mast lowering solenoid valve17A 3A14 3A15 Repair manual Pinguely Haulotte 2 6 2 PLATFORM CO
9. max jib lifting pressure 160 bars 160 bars Tightening torgue of steering wheel nuts 29 daNm Tightening torgue of drive wheel nuts 29 daNm Tightening torgue of slew ring nuts 13 5 daNm Weight 2515kg 2575 kg Pinguely Haulotte Z Fig 1 Dimensions 10 Repair manual pressures can be checked by means of a tap Jib movement lifting telescoping orientation hydraulic electro pump Steering by electro distributing valve Two drive wheels with braked reducing gears and electric motors controlled by choppers 2 1 1 Dimensions Repair manual Pinguely Haulotte 2 2 TIGHTENING TORQUE 2 2 1 Tightening torque for large thread screws Tightening torque in N M Nominal diameter M 6 1 9 11 10 9 13 14 15 17 M 771 15 19 21 24 26 28 M 8 1 25 22 27 31 34 37 41 M 10 1 5 43 45 61 67 73 81 12 1 75 75 94 110 120 130 140 14 2 120 150 170 190 200 220 M 16 2 190 230 260 290 320 350 18 2 5 260 320 360 400 440 480 M 20 2 5 370 450 520 570 620 680 M 22 2 5 500 620 700 770 840 930 M 24 3 3 630 790 890 990 1070 1180 M 27 3 930 1150 1300 1400 1560 1730 M 30 3 5 1260 1570 1770 1960 2200 2350 2 2 2 Tightening torque for f
10. not available at present Machine retracted gt SQ4 1 and 5012 1 7 7 1 Platform 7 7 1 1 Left If SA1 platform and 5 8 1 and SA2 travel and SM2 1 and 501 1 machine retracted and overload 0 then M1 1 and YV1b 1 overload 1 if inputs 26 0 and 38 0 Machine retracted gt 504 1 and 5012 1 7 7 1 2 Right If SA1 turntable and SB8 1 and SA2 travel and SM2 1 and SQ1 1 machine retracted and overload 0 then M1 1 and YV1a 1 overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and 5012 1 If SA1 platform and SB9 1 then H1 1 7 9 1 Without option If SA 1 0 and machine extended or overload 1 then buzzer 1 7 9 2 With option on console If travel option 1 and Travel 1 or movement option 1 and mast 1 or jib 1 or rotation 1 then buzzer 1 7 10 WORKING LIGHT OPTION LIGHT INDICATOR 7 11 The working light is electrically wired To use it activate the switch WEIGHING OR TILT ALARM LIGHT INDICATOR If overload 1 501 0 and machine extended then HA 1 available for Europe 35 Pinguely Haulotte Z Repair manual 7 12 HOUR METER AND BATTERY CHARGE LIGHT INDICATOR Shows the number of hours of use for the machine and remaining battery charge 7 13 OTHER FUNCTIONS 7 13 1 Platform movement validation button Pressing the button validates platform movements for 5 seconds This duration is renewed as soon as a movement is made 36 Pinguely Haulott
11. Connect a pressure gauge to the pressure tapping at small pump output Make a jib up down movement Replace electrovalve See sheet YV5 C067 NO Pressure zero See sheet Replace electrovalve 067 Test or replace the ibis 2320 PSI 160 bars gt Sheet i C218 pressure limite Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DPO75 NO UP OR DOWN JIB MOVEMENT Folio 6 6 FROM THE PLATFORM Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheel OR DOWN JIB MOVEMENT Folio 1 6 FROM THE TURNTABLE QUE up or down movement from ui turntable Put the key switch in the Platform position Activate jib movement he jib move up or down YES Put the key switch in the Turntable position Activate jib movement Open the Turntable box and measure voltage on CNA 10 CNA 8 and CNA 9 of the turntable board Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP076 Folio 2 6 NO UP OR DOWN JIB MOVEMENT FROM THE TURNTABLE 8 0 idle CNA 8 0V at 4V 10 5 amp CNA 9 0V NO Follow the same wire colours and measure voltage at the terminals of manipulator SM1 Measure voltage at CNB Q OV lt cursor lt 4V
12. See sheet C145 Replace the coil The problem persists Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Dare UP OR DOWN JIB MOVEMENT Folio 5 6 FROM THE TURNTABLE Connect a pressure gauge on the pressure tapping at small pump output Make a jib up down movement Pressure 2320 PSI 160 bars YES NO See sheet Replace electrovalve C067 YV5 NO Pressure zero Replace electrovalve See sheet YV3 067 Test or replace the 2320 PSI 160 bars pressure limiters See sheet C218 Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART UP OR DOWN JIB MOVEMENT Folio 6 6 FROM THE TURNTABLE Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP077 Folio 1 6 NO UP OR DOWN MAST MOVEMENT FROM THE PLATFORM No mast up or down movement from the platform Put the key switch in the Turntable position Activate mast up down movement up or down Put the key switch in Platform position Activate mast up down movement YES Open the Platform box and mea sure voltage on CN23 and CNB6 of the platform board CN23 OV NO CNB6 OV Measure voltage at the terminals of selector switch SA2 SA2a 29A NO SA2b OV Replace See shee
13. sufficient capacity Remove the reducer motor assembly by removing the fixing bolts 4 Unscrew the screws 3 fixing the hydraulic motor to the wheel reducer Replace the hydraulic motor or defective reducer 1 Reinstalling a wheel reducer or hydraulic motor Assemble the hydraulic motor on the reducer using the fixing screws equipped with new grower washers Photo 1 Putback the reducer motor assembly and secure with fixing screws Tighten to a torque of 33 ft lb 45Nm Inthe case of a steering axle couple the steering connecting rod with the pivot Reconnect the hydraulic hoses of the hydraulic motor and that of the reducer equipped with a new seal according to the marks made during dismantling Photo 2 Reconnectthe electric brake release cables leaving from the cable sleeve Photo 3 Photo 3 Pinguely Haulotte MAINTENANCE SHEET Sheet C217 A WHEEL REDUCER OR Sheet 2 2 A HYDRAULIC TRAVEL MOTOR 2 n tt EE s SE 71 Vm GH Figure 1 Figure 2 4 Additional operations e Top up the wheel reducer with oil Reinstall the wheel see relevant sheet Put the machine back into the operational configuration Make several travel movements to purge the hydraulic circuit Check the level of the hydraulic oil tank Pinguely Haulotte CORRECTIVE MAINTENANCE SHEE
14. 1 Preliminary operations Putthe machine in the low configuration Switch off the electric power supply see relevant section 2 Removing the steering cylinder Mark and disconnect the two hoses ofthe steering cylinder 1 NB Unscrew the hoses slowly to release residual hydraulic pressure Putcaps onthe hoses Put the cylinder into slings Unscrew the fixing screws of the steering cylinder 2 Remove the steering cylinder 1 Reinstalling the steering cylinder Puta new steering cylinder into place with the fixing screws 4 Reconnect the hydraulic hoses according to the marks made during dis mantling 1 Putthe machine back into the operational configuration Make several steering movements to purge the hydraulic circuit Check the level of the hydraulic oil tank Pinguely Haulotte Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C213 1 2 1 REPLACING THE COUNTERWEIGHTS Sheet 1 1 Preliminary operations Putthe machine into the maintenance configuration see relevant sec tion Switch off the electric power supply see relevant section Removing the counterweights Putthe counterweights 1 fixed on the battery trays into slings Unscrew their fixing screws 2 Remove the counterweights Remove the bottom battery tray by unscrewing the fixing plates on either side of the tray see relevant sheet Slacken all the fix
15. BACK Possible reasons E RICE joystick Mistake in wiring Working microswitch stuck Wrong operation by the user Stepping down of the traction current and blocking Fix the problem selecting of the pump functions The battery alarm switches the ADJUSTMENT on when there is 10 of residual load left function It is essential to 18 BATTERY LOW If the alarm is on with unloaded batteries control 4 test the travel movements the battery value read in the TESTER menu ofthe RENTE BEFORE replacing the console If incorrect adjust it in the menu CONFIG chopper MENU ADJUSTMENT This alarm is on when there is a problem on the electrobrake driver Possible reasons BRAKE DRIVER Short circuitin the driver nile al e 19 the chopper QH20 driver KO Defect in the driver unable to command the Replace the chopper electrobrake The measure circuit on the voltage on the electro brake coil is defective CONTACTOR control microprocessor is broken or has 20 identified a dangerous situation that has not been Replace the chopper OPEN nee detected by the main microprocessor 21 MICRO CONTROL The pP of the logic control is broken or several KO connections have been damaged pper e Servicing request programmed interval of the last maintenance operation gt 300h This alarm Cancel the servicing CHECK UP 22 NEEDED does not stop the mach
16. C139 Charge the batteries Put the key swith in the Turntable position and activate mast movement No down movement Y No up movement The pump works SO Check pump wiring Measure voltage at terminals 9 12 17 18 of the chopper Wiring is correc NO 17 18 24V 104 down 9 12 24V 104 up down See sheet C003 See sheet Replace the chopper C003 Y YES Replace the chopper Repair the wiring Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DPO78 NO UP OR DOWN MAST MOVEMENT Folio 5 6 FROM THE TURNTABLE Measure voltage at the terminals of electrovalves YV3a YV3b YV4 amp YV6 V3a and YV4 24 V up and YV3b and YV6 24 V down Repair the wiring between the chopper and the electrovalves See sheet C145 Replace the coil The problem persists Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP078 Folio 6 6 NO UP OR DOWN MAST MOVEMENT FROM THE TURNTABLE Connect a pressure gauge to the pressure tapping at small pump output Make a mast up down movement Pressure 1450 PSI 100 down movement YES Replace electrovalve YV4 See sheet C067 YES Test or replace the 1450 PS
17. 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 nominal load more people than the authorised number lateral force in the platform greater than the level permitted wind speed higher than the permitted level Repair manual Caution Never use the platform as a crane goods lift or elevator Never use the platform or tow or haul Pinguely Haulotte 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 an
18. PLATE CODE HAULOTTE Sr CODE LC Se RESET wat Le 0 28955 OISLUNN 5 5 5 WEEK YEAR v 51004 0894 48 CC Pinguely Haulotte 12 2 1 List of components Position Description Auantity 1 Entry 3 8 gas UMD1025 SB RIT 1 2 Closing cap with P T 3 8 gas 1 3 Mod Solenoid valve ED1 3 8 2 4 Mod Solenoid valve ED1 3 8 1 5 Mod Solenoid valve ED2 3 8 1 6 Modular element ED VM2 A 2 7 O ring 10 8 O ring 4 9 Tie rod M8x245 3 10 Nut 8 10 3 11 Knurled washer 8 3 12 Kit screws and modular elements 1 EL N 4 M5x60 2 13 Push button manual overrride ED1 6 14 Plug DIN 908 3 8 gas 1 15 Washer 3 8 gas 1 16 Push button manual override ED2 1 17 Washer 34 gas 1 18 Pressure inlet 4 BSPP 1 19 Union piece male 3 83 1 20 Union piece male 3 83 G 5 21 Union piece male 3 83 G 2 22 Union piece male 3 83 G 2 49 Pinguely Haulotte Z 50 Repair manual Repair manual Pinguely Haulotte Z 13 MAINTENANCE 13 1 GENERAL RECOMMENDATIONS AN Caution Do not use the machine as welding earth Do not weld without disconnecting the and terminals of the batteries Do not start other vehicles with the batteries connected Servicing operation described in this manual are given for normal conditions of use In difficult conditions extreme temperatures high hygrometry polluted atmosphere high altitude etc certains operati
19. Pinguely Haulotte AN Caution The technical data in this manual is not binding and we reserve the right to make or modifications without altering this manual GENERAL This manual gives the information required for you to perform servicing and repair operations on certain pieces of equipment yourself However we would like to bring your attention to the importance of respecting the safety instructions concerning the machine itself its use and its environment use within the limits of its performance correct servicing to ensure long service life During and after the guarantee period our After Sales service is available to perform any servicing operations you may require In this case contact our local agency or our Plant After Sales service specifying the exact type of machine and its serial number To order consumables or spare parts use the Instructions for use and maintenace manual and the Spare parts catalogue to order original parts the only guarantee of interchangability and perfect operation REMINDER We would like to remind you that our machines comply with the clauses of the Machines Directive 89 392 CEE dated June 14th 1989 modified by directives 91 368 CEE dated June 21st 1991 93 44 CEE dated June 14th 1993 93 68 CEE 98 37 CE dated July 22nd 1993 and 89 336 CEE dated May 3rd 1989 to directive 2000 14 CE and directive EMC 89 336 CE Pinguely Haulotte Repa
20. Pinguely Haulotte Z 12 55682 HYDRAULIC BLOCK CHARACTERISTICS Description Movement block STAR 8 10 Haulotte ref 242 021 2860 12 1 1 Technical characteristics Maximum pressure 160bar Max flow 22l mm on the P and T line useful load for mast raising Max flow 10l mm for all other movements Temperature range ambient 20 C to 50 C hydraulic 20 C to 80 C Hydraulic characteristics Mineral oil viscosity grade 32cSt 45cSt and 68cSt With biodegradable oil option SHELL NATUREL HFE Ports cylindric gas Connectors ISO 4400 24V continuous current Hydraulic components will be delivered washed and rinsed following 55093 Pinguely Haulotte specification 12 1 2 Fttings Connections should comply with 55470 Haulotte specification The block must be delivered equipped with fittings tightened to the appropriate torque The supplier selected for supplying fittings must be approved by Pinguely Haulotte Extract from R amp D FQ 01 15 A 47 Pinguely Haulotte 4 Repair manual 12 2 DIAGRAMS S s e S 8 wo 6 28955 CIQUINN NOILV314193dS 2 B E 2 a gt 002 0V eq snoineg Ajanbuid Le max 160 bar hi ES kl 0 max 20 lit nin gt TOM 20 C are TEST COMPLETE ASSEreLr PROJECTION PLASTIC PLUGS AFTER TEST INDICATE ON ASSEMBLY CODE OF CUSTOMER PE _ 20 21
21. gt ver na E E 62 or m 1 a d 2 E 8 o 02 zo CER 2 5 99 8555 SE SE HS SS 29 ag 58 lt d 0040 5 2 zn 5 2 5 95 Ho H D BB om oes 8 85 8595 22 023 o DS 8 3 20 DO 2 S Hc 9 85 De n a 2085 UE o LS oS Bog D Ugo 3 D 2 28 B S 1 0 ol 95 8 n e 5 H 0 19 5 8 Aaa 2 5 25 D at M za 3 82 8 _ NE WE T te SE gne DA ge Revue ER VI BR fo co SE 33 9922189 amp 95 NE 5 jawinewopu 88 85 EI Bag rf eM g ve zz ES E ve Be n E aig 2 gt ala a F g EPA 81818 s p 6 AE Brei D 1 gt gt nei 219 gt gt 2 pelz 40792 6 0 0 d pos 7 H ITT s Cp 0 E OO gt gt 9 1 VL peaunus e ver ver L 9 QIUNUS ee ee 5 55 OOL e DS WEL p i GOL vi 1 97 oor 1 ws ti i 3 3 SE 2 8 0 E o 5 Ind a 4 Js 9 10 K LONO ONO Z INI 4o p ND eTqequany c tao ajle no joues aue l LENI l 485 1 Ld JO nn MANI A DUNN m PIS 91011 no 2340 01 6181219 l S H asen un JO o
22. 4 page 49 If necessary close the shut off valve or empty the hydraulic tank 2 Removing a hydraulic hose NB Disconnect hose from the equipment to which it is connected Unscrew the hose slowly to release residual hydraulic pressure Protect the eguipment holes with caps 3 Remounting a hydraulic hose Reconnect a new hydraulic hose 8 2 3 4 Tightening torgue of hydraulic hoses page 16 Put the machine back in the operational configuration Make a few movements implementing the hose in guestion to purge the hydraulic circuit Check the level of the hydraulic oil tank Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C040 Sheet 1 1 CHANGING THE HORN AN Caution 1 Preliminary operations Switch off electric power see corresponding paragraph Do notuse the machine during maintenance 2 Removing the operations Mark disconnect the electric connections from the horn 1 Remove the horn by unscrewing the fixing bolts 2 3 Installing the horn Putthe horn back into place and fix with the fixing bolt Reconnect the electric connections according to the marks made during dismantling 4 Test Select the top control panel and switch on machine power Putthe machine back into the operational configuration Activate the horn switch from the platform control panel and check that the horn sounds Star 22J Star 8 AN Caution The horn sho
23. ALLOINVH ATANONId PNR ee ena 1 NOILOALONA i NOILdO 4415004 NOIL9310 d 1444409 YNALIOAYNS NOILdO pu IN i 17 270 1 l D EE Dae rd T HR PERS IN SCH 4 00 21 2 lt p n MES passed 1 12 gt CN E d NO 00H 10 T RU t LISE 3 21 10 ri af a CE MEER r 2784 I 3j9VvSdd ALYVO le L 4 L 4 v S 9 H Sur 22 wr Lo Je ble VI Sor etr A Lor 0 N 3 7 a N 9 3 9 OSNES S IONV d N N EN FE i N i 0 Zor lt ere N 1 0 ATONV C YNILdVI OOL lt 1 10 ca HOSNSS DNIHOIEM Y y 4 440 21 10 I9VSFI4 zu NOISS3Hd 3a unaiavo La 2 6L 8L 21 9L SL vL L ZL LL OL 6 8 2 9 6 2 L 18 Repair manual Pinguely Haulotte 77 Pinguely Haulotte Z 20 Repair manual Repair manual Pinguely Haulotte 4 SAFETY SYSTEMS 4 1 MACHINE ELEMENTS 4 1 1 Motors M1 Motorpump MD Right traction motor MG Left traction motor EFG Left electro brake EFD Right electro brake ED Left energising ED Right energising 4 1 2 Power supplies and fuses FU1 1A Overload protection FU2 5A Control protection FU3 10A Electrovalve protection FU4 250A Power suppl
24. END Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP077 Folio 4 6 NO UP OR DOWN MAST MOVEMENT FROM THE PLATFORM No down movement No up movement Check battery charge Battery charge NO i YES See sheet C139 Charge the batteries Put the key switch in the Platform position and activate mast movement No down movement Y No up movement The pump works SO Check pump cabling Measure voltage at terminals 9 12 17 and 18 of the chopper NO 17 18 24V 104 down 9 12 24V 104 up down S heet YES Replace the chopper C003 See sheet Replace the chopper C003 Repair the wiring Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet 077 NO UP OR DOWN MAST MOVEMENT Folio 5 6 FROM THE PLATFORM Measure voltage at the terminals of electrovalves YV3a YV3b YV4 8 YV6 V3a and YV4 24 V up and YV3b and YV6 24 V down Repair the wiring between the and the electrovalves See sheet C145 Replace the coil The problem persists Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP077 Folio 6 6 NO UP OR DOWN MAST MOVEMENT FROM THE PLATFORM Connect a pressure gauge to the pressure tap
25. FOR contact 5V or NO 24 VS NO REV contact 5V YES Replace manipulator See sheet SM1 C1 Repair the wiring Replace the Serial See sheet board C063 END Measure voltage at 585 output NO ension measured 24 V YES See sheet Replace the butt Repair the wiring C004 Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP076 Folio 3 6 NO UP OR DOWN JIB MOVEMENT FROM THE TURNTABLE No down movement No up movement Check battery charge Battery charge NO OK WES See sheet Charge the batteries C139 Put the key switch in the Turntable position and activate jib movement No down movement Y No up movement The pump works SO Check pump wiring Measure voltage at terminals 18 and 19 of the chopper Wiring is correc NO 18 24V 104 up 19 24V 104 up down 5 heet Replace the chopper ui See sheet Replace the chopper C003 Repair the wiring Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART UP OR DOWN JIB MOVEMENT Folio 4 6 FROM THE TURNTABLE Measure voltage at the terminals of electrovalves YV3a and YV5 24 V u and YV5 24 V up down NO Repair the wiring be tween the chopper and the electrovalves
26. MAN INTERIEUR COFFRET BOX INSIDE to vers38 43 to vers 26145 EN TO CNA CONTROL POST SWI 985 1svn 985 on O OO CONTROL POST SWITCH SELECTEUR DE POSTE SA1 LESNOILVLOH Xo g sasa r gas 3uIvINGNad 7 10 PORTE COFFRET BOX DOOR NOIR BLAGK ROSE PINI JAUNE YELOW ROUGE RED CH D 9 0 0 O N D 13 Pinguely Haulotte Z Repair manual 3 1 2 Platform box wiring diagram P20027d H O O TRANSLATION TRAVEL A ORANGE B GRIS GREY C BLEU BLUE O OO OO 5 HA INDICATOR LOL YyoUMs uonoejes LOL bal O A ORANGE GRIS GREY C BLEU BLUE D JAUNE YELLOW E ROSE PINK F NORI BLACK G ROUGE RED Jezzng jnessnieAv 0000000
27. Remove the tilt sensor 2 by unscrewing the fixing bolts 1 3 Re installing the tilt sensor Puta new tilt sensor into place and secure with the fixing bolts 1 Reconnect the electric connections according to the marks made during dismantling Setthe adjusting screw 4 so that the tilt sensor level is set Putthe machine back into the operational configuration 4 Tilt sensor operating test e Extend the machine Tilt the tilt sensor and check that an audible alarm is sounded Make mast up and jib lifting movements to the safety contacts Pinguely Haulotte Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C141 Sheet 1 1 CHANGING THE JIB CYLINDER 1 Preliminary operations Putthe machine in the maintenance configuration see relevant section AN Caution Switch off the electric power supply Putthe basket in slings to ensure it does not fall Photo 1 and secure it Slightly lift the drum to facilitate access to the cylinder Ensure that the oil is not too hot 2 Removing the jib cylinder Putthe cylinder 1 and the vertical parts 2 and 3 of the jib into slings e Mark disconnect the 2 hydraulic hoses of the jib cylinder NB Unscrew the hoses slowly to release residual hydraulic pressure Putcaps on the hoses Remove the 2 bolts of the cylinder pin 4 on the cylinder body side Remove the pin 4 Remove the 2 bolts of the cylinder pin 5 on the rod s
28. Replacing the battery charger Replacing the slew ring Replacing a steering pivot Replacing a steering cylinder Replacing the counterweights Replacing the electric plate Replacing the jib platform assembly 65 Pinguely Haulotte Z Repair manual Sheet no Description Removing reinstalling the cable sleeve Replacing a wheel reducer or a hydraulic travel motor Adjusting a pressure limiter 66 Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET SHEET C003 Sheet 1 2 REPLACING THE SPEED VARIATOR 1 Preliminary operations Put the machine in the low position off the electric power supply see 8 6 3 page 26 Disconnect the and terminals of the batteries to isolate the electric circuit Removing the speed variator Disconnect the speed variator s electric connections Remove the speed variator 1 Replacing the speed variator Put the speed variator back into place and secure with the fixing screws Reconnect the speed variator s electric connections Compact Reconnect the and terminals of the batteries Put the machine back in the operational configuration Optimum Optimum Compact Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET SHEET C003 Sheet 2 2 REPLACING THE SPEED VARIATOR p LE D INI HA12IP HA33JE Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET SHEET C004 S
29. SA1 turntable and SB7 1 SM1 1 and SQ1 1 or machine retracted and overload 0 then YV2a 1 and M1 1 overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and SQ12 1 7 5 1 2 Right If SA1 turntable and SB5 1 SM1 1 SQ1 1 or machine retracted and overload 0 then YV2b 1 and M1 1 overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and SQ12 1 7 5 2 Platform 7 5 2 1 Left If SA1 platform SB8 1 and SA2 rotation andSM2 1 and SQ1 1 or machine retracted and overload 0 then YV2a 1 and M1 1 overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and SQ12 1 7 5 2 2 Right If SA1 turntable and SB8 1 and SA2 rotation and SM2 1 and SQ1 1 or machine retracted and overload 0 then YV2b 1 and M1 1 overload 1 if inputs 26 0 and 38 0 Machine retracted gt 504 1 and 5012 1 Repair manual 7 6 7 7 7 8 7 9 TRAVEL STEERING HORN BUZZER Pinguely Haulotte Z 7 6 1 Platform If SQ4 0 5012 0 then Microspeed 1 7 6 1 1 Forward If SA1 platform and SB8 1 and SA2 travel and SM3 1 and 501 1 or machine retracted and overload 0 then MD 1 and MG 1 full setpoint overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and 5012 1 7 6 1 2 Reverse If SA1 turntable and SB8 1 and SA2 travel and SM3 1 and SQ1 1 machine retracted and overload 0 then MD 1 and MG 1 full setpoint overload 1 if inputs 26 0 and 38 0
30. WHEEL 1 Preliminary operations Putthe machine in the low configuration Switch off the electric power supply see relevant section 2 Removing a wheel e Slacken without completely unscrewing the nuts of the wheel to be removed Raise the machine using a jack or hoist Remove the 5 wheel nuts 1 and remove the wheel 3 Reinstalling a wheel Puta new wheel into place and put back the nuts 1 Lower the machine back to the ground e Tighten the nuts Tightening torque for wheel nuts 213 ft lb 29 m dNm Putthe machine back into the operational configuration Pinguely Haulotte Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET SHEET C145 Sheet 1 1 REPLACING A COIL 1 Preliminary operations e Put the machine into the maintenance configuration see relevant sec tion Switch off the electric power supply see relevant section 2 Removing a coil Disconnect the electric connector 1 of the coil in question Unscrew the nut 2 and remove the coil 3 3 Reinstalling a coil Puta new coil into place 3 and secure with the nut 2 Reconnect the electric connector 1 on the coil Putthe machine back into the operational configuration Check correct operation by making the movement corresponding to the replaced coil Pinguely Haulotte Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C146 Sheet 1 1 REPLACING AND SETTING THE STEERING POTENTIOMET
31. chap 4 3 3 1 each start of opera i tions electrolyte level in the batteries See chap 4 3 3 2 Grease 4 wheel pivot pins 5 ring bearing ring teeth 6 CAUTION Every 50 hours after first 50 hours Change the hydraulic filter cartridge 3 See 5 3 1 see 250 hours periodicity Check tightness of slew ring screws see 500 hour periodicity 7 Change the hydraulic filter cartridge 10 Every 500 hours dabei Check the tightness of the If using organic oil empty the hydrau lic oil tank ring 12 Every 1000 hours Empty the hydraulic oil tank capacity 25 l See chap 5 3 3 13 Every 2000 hours Empty the hydraulic oil tank and the whole circuit See chap 5 3 3 14 AN Caution It is essential to use the lubricants mentioned in the consumables table Chap 2 2 1 page 49 as dust sticks to standard grease 13 6 PRESENCE OF LABELS Make sure that the labels and plates informing personnel of the various dangers related to machine use are in good condition The labels also inform operators on the use and maintenance of the machine An illegible label may result in incorrect or dangerous use of the machine Instructions Check that the labels are present Check that all the labels described in the operator s manual are legible and in place Replace if necessary additional copies can be supplied on request 55 Pinguely Haulotte Z Repair manu
32. cycles to purge the hydraulic circuit e Check the level of the hydraulic oil tank Pinguely Haulotte Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C206 Sheet 1 1 REPLACING A DRIVE WHEEL 1 Preliminary operations Putthe machine into the maintenance configuration see relevant sec tion Switch off the electric power supply see relevant section Raise the machine with a jack or hoist 2 Removing a drive wheel Push back the tab 1 of the toothed washer 2 Unscrew the wheel s fixing nut 3 Remove the toothed washer 2 then the flat washer 4 Remove the wheel 3 Reinstalling a drive wheel Replace the key 5 if necessary Puta new wheel into place and secure with the fixing nut 6 After tightening block the nut with the KM washer Putthe machine back into the operational configuration Pinguely Haulotte Sheet 207 AN Caution Ensure that the oil is not too hot AN Caution Use a container to collect the oil to prevent pollution of the environment Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet 1 1 REPLACING THE HYDRAULIC TANK 1 Preliminary operations Putthe machine into the maintenance configuration see relevant sec tion Switch off the electric power supply see relevant section 2 Removing the hydraulic tank 1 Empty the tank by removing the plug 2 Disconnect the hydraulic hoses 3 and remove the
33. hours in the three directions of an orthostandardized system at 5 58 g 50Hz to 200 HZ Shocks DIN IEC 68 2 27 50g for 11m 3 shocks in each direction of an orthostandardized system for a total of 18 shocks 17 7 Pinguely Haulotte 5 3 CABLING Top pe Card power supply J4 connectors J4 1 power supply Voyant HA 65 J4 2 321 J4 3 chopper n 38 dii a 1 input J4 4 Weighing card o panel J11 Terminal Meaning Terminal Meaning 5 Positive 5 Positive Negative 4 20 mA White Sensor signal White signal 5 4 SENSORS 5 4 1 Pressure sensor Operating pressure 250 bars Maximum pressure 1500 bars e Output 4 20mA Power supply voltage rating 9 34 Vdc Precision 9 34Vdc Tolerated temperature range 40 C 85 C Protection grade IP 67 Construction material stainless steel 5 4 2 Angle sensor Power supply 5 to 30 Maximum angle measured 320 Linearity 2 0 FS Maximum power draw 0 18 W Resistance 5 k Ohm Working temperature 20 C 70 Standard connecting cable approx 4 m Standard protection grade IP 65 Weight 0 25 kg 25 Pinguely Haulotte Z 5 5 J4 5 OV OV OV 24V 24V 24V 5 6 26 OUTPUTS FUNCTIONING J4 3 OV 16V 24V OV 16V
34. hub 1 NB Grease the parts added evenly and insert them using a mallet Place the bearing in the hub 2 Push in completely 1 Insert seal 5 Push in completely Position the hub after turning it on the pivot Photo 5 Lower the pivot e Install the conical roller bearing 6 Photo 4 Lower it Install a flat washer 8 on the bearing Photo 6 Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C211 Sheet 2 2 REPLACING A STEERING PIVOT Place the wheel on the pivot Screw the fixing nuts 12 without tightening them too far to avoid blocking the bearings e Fix the stud 9 on the nut 10 Photo 6 Put the cap on the wheel and secure 11 Photo 7 Grease generously NB The brake washer must be changed whenever the wheel is replaced 4 Additional operations Remove the slings Put the machine back into the operational configuration Make several travel movements to purge the hydraulic circuit Check the level of oil in the wheel reducer Check the level of the hydraulic oil tank Sheet 212 AN Caution Ensure thatthe oil is not too hot AN Caution Use a container to collect the oil to prevent pollution ofthe environment AN Caution It is essential to put the component into slings before dismantling reassembling it Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET REPLACING A STEERING CYLINDER Sheet 1 1
35. i SIANO 2321 sa ae a ida ayones no ejueose us e ND SE SS HO 3 pl er pu Es L 6L SL LL 9L L LL OL 6 8 L 9 S L 16 Pinguely Haulotte Z 3 3 2 E555C 02 Repair manual 17 1002 10 10 XNOSAVIN JOH eS bee C AdOYNI SVINIHOS Terenspsieuguondo eooz z0 12 v M HM d EV 48 3OVSId 2002 90 92 a dOL 8 YVLS 69 dnof asiw vo0Z vO vL 9 002 60 6 2 4 FOH BA WIOL HYEN VSIA NOILVOISIGOW ANI 9999 30 31VO uvd ANISS3O 3LLOTNVH A13 Id IN oor oor E oor 1 d ex VU T uorado ATOM ida ep uondo WS M erg 29 KOE Ter sg o IUGS eue 9 0 UOTIeQUETIO 1 IN 0 0 H o 5 0 N uonoeurq 5 9 9 9 2 2 2 9 9 9 9 9 9 9 9 22 2 2 9 9 9 5 5 5 5 5 8 g g 88 5 a 2 8 sa 28 etc det a i o o
36. 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 Repair manual Pinguely Haulotte 2 PRESENTATION Self propelled platforms models STAR 8 HM10P STAR 10 designed for all types of overhead work within the limits of their characteristics and provided all the safety recommendations specific to the eguipment and operating environment are respected The main control panel is situated in the platform The control panel situated on the tunrtable is to be used in emergencies or cases of machine failure technical characteristics 2 1 STAR 8 10 TECHNICAL CHARACTERISTICS
37. 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 Z Repair manual 1 2 GENERAL SAFETY RECOMMENDATIONS AN Caution Only trained operators may use Haulotte self propelled platforms 1 2 1 Operators Operators must be aged 18 or over and hold an operating permit issued by the employer after verification of medical aptitude and the practical platform operation test There must be at least two operators present so that one of them can intervene rapidly if necessary take over the controls in the case of accident or breakdown monitor and prevent machines or people from circulating around the plat form guide the platform operator if necessary 1 2 2 Environment Never use the machine On soft unstable or cluttered floors Ona 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
38. table look out for any danaged incorrectly installed modified or missing parts NOTE This register can be obtained from trade organisations and in some cases from the OPPBTP or private prevention agencies The designated persons must be experienced in risk prevention Articles R 233 11 or order n 93 41 No member of personnel is allowed to perform any check whatsoever during machine operation Article R 233 11 of the French Labour Code 1 4 2 Examination of machine suitability The manager of the site where the machine is operated must ensure the machine is suitable i e capable of performing the work in complete safety and in compliance with the operating manual Furthermore the French order of 9 June 1993 addresses problems relative to leasing examination of the state of conservation checking upon operation after repairs and test conditions static test coefficient 1 25 dynamic test coefficient 1 1 All users must consult this order s requirements and comply with them 1 4 3 State of conservation Detect any deterioration liable to cause hazardous situations concerning safety devices load limiters tilt sensor cylinder leaks deformation welds bolt tightness hoses electrical connections tyre state excessive mechanical gaps NOTE If the machine is rented leased the user responsible for the machine must examine its state of conservation and suitability He must ob tain assurance from the leaser that g
39. to prevent pollution of the environment AN Caution 3 It is essential to put the component into slings before dismantling reassembling it Reinstalling the motorpump unit Reinstall the suction and discharge flanges 4 equipped with new seals on the motorpump unit Put the motorpump unit into place and secure with the fixing collar 3 Reconnect the hydraulic hoses 2 on the pumps according to the marks made during dismantling e Reconnect the electric connections 1 on the motor according to the marks made during dismantling Put the machine back into the operational configuration Check motor rotation direction Make several lifting cycles to purge the hydraulic circuit Checkthe level of the hydraulic oil tank Pinguely Haulotte Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C204 Sheet 1 1 REPLACING THE HYDRAULIC PUMP 1 Preliminary operations Putthe machine into maintenance configuration see relevant section AN Caution Switch off the electric power supply see relevant section Ensure that the oil is not too hot 2 Removing the hydraulic pump Remove the motorpump unit see relevant sheet Remove the screws fixing the pumps 2 to the motor and remove the AN Caution pumps 1 Use a container to collect the 3 Reinstalling the hydraulic pump Put new pumps equipped with new seals into place on the electric motor and secure with fixing screws AN
40. 24V TRAINING Repair manual J4 3 3 state output gt gt OV 16V 24V J4 5 2 state output gt gt OV 24V Overload gt 115 Impossible Low position end of travel lowering forbidden Top position end of travel raising forbidden Raising at low speed ramp slow down threshold is reached Normal functioning Overload always has priority 1 Read all the paragraphs listed below before starting the procedure 2 Cut off the card s supply 3 Set the J14 adjustment jump 4 Remove all load from the platform 5 Switch the card on and wait for at least 15 seconds 6 Starting the adjustment phase Press the SW2 button for at least 3 seconds the D20 red led comes on 7 Perform at least one complete raising lowering cycle so as to bring the oil to the normal temperature ie as during operation 8 Activate the lowering control every now and then in order to comple tely discharge the hydraulic pressure 9 Sensors zero Press the SW3 button Meanwhile the green led comes on as confirmation 10 Maximum height acquisition Activate the raising command and reach the top height never stop activating the raising control in the mean time 11 Press the SW1 rapidly no longer than one second so as to me morise the maximum height The yellow led comes on as confirmation while you press the button 12 Pression acquisition unloaded Activate the lowering control up to the rest position The system must stop at mid height approx
41. 5 angle sensor connection Dimensions 128x86x26 8 Card supply 24Vdc Supplied power 4 20mA loop for pressure angle 5Vdc for angle sensor 23 Pinguely Haulotte Z Repair manual 5 2 2 Environment Varnished card welding points are insulated Radiated emissions Radiated emissions must comply with the 95 54 CE European directive Radiated sensitivity Radiated sensitivity must comply with ISO 11452 5 and ISO 11452 2 5 2 2 1 Climatic environment The new system s protective treatment must at least comply with the most demanding features defined by the TH indicator or Pinguely Haulotte s demands Temperature during use 40 C 85 C negotiable Store temperature 40 C 90 C Maximum specific humidity 39g water kg dry air 40 C 80 HR Useful specific humidity 30 C 5 C 60 10 HR Atmospheric pressure 95000 Pa 10000 Pa Saline fog Must resist saline fog as defined by 5 NaCl for 72 hours 41002 Protection indicator IP67 Chemical aggression 24 The device must resist the following agents Oil ga soil standard acids solvents and stain removers standard industrial cleaning products acetone whit spirit human perspiration etc 5 2 2 2 Mechanical environment Vibrations DIN IEC 68 2 34 random vibrations 2
42. ACC NOT OK The alarm shows that the traction accelerator voltage received by the serial card is more than 1V at rest without any operation request Possible reasons to look for in the serial card One of the potentiometer s wires is cut The potentiometer is improperly connected The potentiometer is defective Incorrect serial card programming The code checks the potentiometer voltage value at rest Replace the serial card or the joystick Repair manual Pinguely Haulotte Z CODE ALARM PROBABLE CAUSES REMEDIES testis executed at rest In this condition the voltage on the 2 connections of the field should be about half of the batteries The alarm is given if N Check the travel motor s voltage is different from this value Possibl f It diff inductors and check the F1 8 VFIELD NOT OK eir and F2 outputs resistance Motor current leakage to the ground The field of th tor i t ted t compared to positive and The field of the motor is not connected to negative outputs the chopper Default in the section of the power unit related to the field P maintains that the signal of the steering STEER SENSOR potentiometer is not out of the programmed range Check the potentiometer 9 KO Possible reasons for failure wiring chopper data steer Incorrect programming sensor adjusting Steering potentiometer needs readj
43. ATIONAL MAST MOVEMENT FROM THE PLATFORM Measure voltage at CN1 4 CN1 5 and CN1 3 on the platform board CN1 3 0V idle CN1 3 0V at 4V CN1 5 5V amp CN1 4 0V up CN1 5 0V amp CN1 4 5V down NO Follow the same wire colours and measure voltage at the terminals of manipulator SM2 Measure voltage at CNB4 OV lt cursor lt 4V FOR contact 5V or REV contact CNB4 24 V NO 5V Replace manipulator See sheet YES SM2 C142 Repair the wiring Replace the Serial See sheet board C063 END voltage at output oltage measured NO 24 V YES See sheet Repl th Repair the wiring REE C064 BREAKDOWN DETECTION FLOW CHART Pinguely Haulotte Sheet DP079 Put the key switch in the Platform position and activate right left rotation movement NO The pump works Check pump wiring Measure voltage at terminals 7 and 8 of the chopper NO NO RIGHT OR LEFT ROTATIONAL MAST MOVEMENT FROM THE PLATFORM Folio 3 6 Wiring is correc YES 7 24V 104 left 8 24V 104 right Replace the chopper YES See sheet Replace the chopper See sheet C003 C003 Repair the wiring Pinguely Haulotte
44. BREAKDOWN DETECTION FLOW CHART Sheet DP079 NO RIGHT OR LEFT ROTATIONAL MAST MOVEMENT Folio 4 6 FROM THE PLATFORM Measure voltage at the terminals of electrovalves YV2a and YV2b 2a 24 V le and YV2b 24 V right Repair the wiring between the chopper and the electrovalves See sheet C145 Replace the coil The problem persists Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP079 NO RIGHT OR LEFT ROTATIONAL MAST MOVEMENT Folio 5 6 FROM THE PLATFORM Connect a pressure gauge to the pressure tapping at small pump output Make a right left rotation movement Pressure 1450 PSI NO 100 bars YES Test or replace the 1450 PSI 100 bars See sheet See sheet and 2320 PSI 160 C218 or C067 bars pressure limiters sheet Replace the rotation C205 motor Replace electrovalve YV2 Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP079 NO RIGHT OR LEFT ROTATIONAL MAST MOVEMENT Folio 6 6 FROM THE PLATFORM Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP080 NO RIGHT OR LEFT ROTATIONAL MAST MOVEMENT Folio 1 6 FROM THE TURNTABLE mast right or left rotation mu from the turntable Put the key switch in the Platform position Activate mast right left rotation movement Right left YES Put the key switch in the T
45. CTION FLOW CHART Sheet DP082 NO MOVEMENT AVAILABLE FROM THE TURNTABLE Folio 3 4 Measure voltage atthe terminals of contactor SB1 L3 NO p Check the wiring and See sheet the batteries C149 If necessary repair the wiring and or YES replace the batteries Replace contactor SB See sheet C200 Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP082 vo MOVEMENT AVAILABLE FROM THE TURNTABLE Folio 4 4 Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP083 Folio 1 4 NO FORWARD OR REVERSE TRAVEL MOVEMENT No forward or reverse travel movement from the platform Put the key switch in the Platform position Activate FOR and REV travel Open the Platform box and measure voltage at CN23 and CNB6 of the platform board CN23 24V NO CNB6 Measure voltage at the YES terminals of selector switch SA2 SA2a 29A 24V SA2b OV Replace the See sheet selector C143 Repair the wiring Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP083 Folio 2 4 NO FORWARD OR REVERSE TRAVEL MOVEMENT Measure voltage at CN1 8 CN1 9 CN1 10 on the platform board CN1 8 OV idle CN1 8 OV at 4V CN1 10 5V 8 CN1 9 0V UP CN1 10 0V 8 CN1 9 5 down NO Follow the same wire colors and measure voltage atthe terminals of ma
46. Caution e Put back the motorpump unit see relevant sheet e Put the machine back into the operational configuration Make several lifting cycles to purge the hydraulic circuit e Check the level of the hydraulic oil tank It is essential to put the component into slings before dismantling and reassembling it HA12IP HA33JE STAR 8 STAR 22J Pinguely Haulotte Sheet C205 AN Caution Ensure that the oil is not too hot AN Caution Use a container to collect the oil to prevent pollution of the environment AN Caution It is essential to put the component into slings before dismantling reassembling it Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet 1 1 REPLACING THE ROTATION MOTOR 1 Preliminary operations Put the machine into the maintenance configuration see relevant sec tion Switch off the electric power supply see relevant section Close the shut off valve or empty the hydraulic tank 2 Removing the rotation motor Mark and disconnect the hoses 1 of the rotation motor Puta on the hose Unscrew the four fixing screws 2 of the rotation motor Remove the rotation motor 3 Reinstalling the rotation motor Puta new motor filled with oil into place Reinstall the screws with loctite Reconnect the hydraulic hoses equipped with new seals Put the machine back into the operational configuration Make several operating
47. E SHEET Sheet P005 CHECKING FILLING Folio 1 1 THE HYDRAULIC OIL TANK 1 Preliminary operations Putthe machine in the maintenance configuration see corresponding para graph Switch off electric power see corresponding paragraph 2 Checking filling the hydraulic oil tank NB This operation must be carried out when the oil is cold i e before star ting the machine Check that the level of oil 1 in the tank is between the high and low levels when cold Top up if necessary by filling via the cap 2 NB Only use the oil recommended by the manufacturer Putthe machine back into the operational configuration HA16 18PX HA46 51JRT Star 22 J Star 8 HA16 18PX New Design HA46 51JRT New Design Pinguely Haulotte PREVENTIVE MAINTENANCE SHEET Pinguely Haulotte 77 PREVENTIVE MAINTENANCE SHEET Sheet CHANGING THE HYDRAULIC FILTER Folio 1 1 CARTRIDGE 2 Preliminary operations Putthe machine in the maintenance configuration see corresponding para AN Caution graph Usea container to collect oil Switch off electric power see corresponding paragraph to prevent pollution of the environment 2 Replacing the hydraulic filter cartridge NB The filter has a clogging indicator Clogging should be checked when the machine is hot otherwise the indicator may be visible due to the viscosity of the cold oil Change the cartridge 1 if the cloggin
48. EIGHING DEVICE ungeEe 23 Dd FUNCTIONING PRINCIPLE seen ne 23 oe iz tal sic T T 23 5 2 1 en E 23 22 EI le E ten aa 24 dee cise crc 25 Repair Manual Pinguely Haulotte A 5 4 SENSORS 25 eg Da ENER GITT 25 54 2 Angle eege 25 5 5 OUTRBUTGEUNCTIONING 26 5 6 26 5 7 ERRORS 8 27 5 7 1 Sensors errors D19 green LEE a aan a aa ERE M RR evi m da ai 27 5 7 2 Card related errors 021 yellow LED 27 5 8 STARS 8 AND STARS 10 0 0 27 5 9 ALARM SYSTEM 28 6 ELECTRIC COMPONENTS 2 1 3 29 6 1 TURNTABLE CONTROL PANEL 8 29 6 2 PLATFORM 31 6 3 JB 31 6 4 CHASSIS 32 7 OPERATING 65 22 1 1 4 5 33 7 1 NIE CAE LEER 33 7 2 SHUTDOWN P 33 7 3 MAGTUIETING 33 e Ga E UIA Serpette aces aN Dee 33 Ke GEN diea TETTE 33 y ME ee s p
49. ER Caution 1 Preliminary operations Before final reinstallation of Putthe machine into the maintenance configuration see relevant sec the steering potentiometer it tion must be set with a zapi Switch off the electric power supply see relevant section console by a Pinguely Remove the covers see relevant sheet Haulotte technician 2 Removing the potentiometer Disconnect the electric connection 1 Slightly unscrew the screw 5 fixing the potentiometer support 3 Slacken the 2 BTR screws 2 Liftthe potentiometer support 3 to remove the potentiometer from the fix ing flat 4 of the wheel pivot Unscrew the nut 6 keeping the potentiometer on its support 3 Remove the potentiometer 7 3 Reinstalling the potentiometer before setting Connect the electric connection 1 Fixthe new potentiometer on its support 3 by screwing the fixing nut 6 Connect the calibrater 9 to the MDI socket 8 on the mother board 10 4 Adjusting and reinstalling the potentiometer Switch on the machine in the platform station Using the Roll buttons 11 find the Tester menu Press Enter 12 Find the Steer Angle parameter The angular value of the potentiometer is displayed on the console Adjust the potentiometer so that the value 0 is displayed on the console 13 From the platform station place the wheels perfectly straight Position the potenti
50. FORM Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP082 Folio 1 4 NO MOVEMENT AVAILABLE FROM THE TURNTABLE No movement available from the turntable Put the key switch in the Turntable position Activate a movement No movement is made NO Check EM FU2 FUA and 205 Y YES NO Replace any defective fuses YES END Check that the emergency stop and station selection buttons are operational NO Replace any See sheet Buttons defective buttons C004 Measure voltage at terminals 5 and 42 of the chopper END NO See sheet Replace the chopper C003 YES END Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP082 NO MOVEMENT AVAILABLE FROM THE TURNTABLE Open the Turntable box and measure voltage at CNA 10 CNA 9 and CNA8 of the turntable board 8 0 idle CNA 8 0V at 4V CNA 10 5V and CNA 9 0V NO up CNA 10 0V and CNA 9 5 down See sheet C063 Replace the Serial board Follow the same wire colors and measure voltage at the terminals of manipulator SM1 OV lt cursor lt 4V FOR contact 5V or REV contact 5V YES Repair the wiring NO Folio 2 4 Replace manipulator SM1 See sheet C143 Pinguely Haulotte BREAKDOWN DETE
51. 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 39 05 17 80 813 Fax Fax 39 05 16 05 33 28 Haulotte Scandinavia AB u b T l Phone 46 31 744 32 90 Fax Fax 46 31 744 32 99 Haulotte Portugal T l Phone 351 21 955 98 10 Fax Fax 351 21 995 98 19 Repair Manual Pinguely Haulotte A SUMMARY GENERAL palace 1 1 GENERAL RECOMMENDATIONS SAFETY iii 3 Wie GENERAL WARNING aaa 3 li Manual A 3 1 12 Labels ee ee ae nani 3 3 1 2 GENERAL SAFETY 4 1 2 1 Operators AEREA FARRER RAE EAEn Dai 4 1 2 2 4 1 2 3 Using the machine eccidi 4 is RESIDUAL RISKS Lr 6 1 3 1 Risks of jerky movements and tipping Over 1100000 enne 6 1 3 2 Electrical air 6 1 3 3 Risk of explosion or ONG ud e ate 6 IT RISKS OT COMBO OS 6 D EE 7 enge eTp 7 1 4 1 Periodic inspections 7 1 4 2 Examination ee 7 1 4 3 State of conservation PR 7 Loe REPAIRS AND ADJIUSINIEN TS dessous ee 8 1 6 VERIFICATIONS WHEN RETURNING TO SERVICE 8 BEAUFORT SCALE p
52. I 100 bars See sheet No down movement and 2320 PSI 160 C218 bars pressure limiters Manually test electrovalve YV3 Replace electrovalve See Sheet Operation correct NO Manually test electrovalve Test or replace the eo sheet pressure limiters Replace electrovalve See sheet YV3 067 Operation correct NO Replace electrovalve See sheet YV6 C067 Replace electrovalve See sheet 067 YV5 Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP079 Folio 1 6 NO RIGHT OR LEFT ROTATIONAL MAST MOVEMENT FROM THE PLATFORM No mast right or left rotation movement from the platform Put the key switch in the Turntable position Activate the right left rotation movement Right left rotation ovement O gt 5 Put the key switch in the Platform position Activate mast right left rotation movement Open the Platform box and measure voltage at CN23 and CNB6 of the platform board CN23 OV NO CNB6 OV Measure voltage terminals of selector switch SA2 SA2a 29A NO SA2b OV Replace the See sheet selector 004 Repair the wiring Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP079 Folio 2 6 NO RIGHT OR LEFT ROT
53. NTROL PANEL 5 9 5 2 5 8 SA2 Motion selector CNB3 29 6 583 Platform emergency stop 37A 105 588 Motion selection CNB4 CNB7 SM2 Orientation steering joystick SM3 Travel lifting joystick 589 Warning signal push button 6 3 JIB P2 B2 B2 Angle sensor weighing P2 Pressure sensor weighing 31 Pinguely Haulotte Z Repair manual 6 4 CHASSIS EQUIPMENT EFG EFD MD ED MD Right handside travel motor MG Left handside travel motor EFD Right travel motor electrobrake EFG Left travel motor electrobrake EG Left handside travel motor inductor ED Right handside travel motor inductor 1 Steering potentiometer Brakes connections 15A 3A6 7 32 Pinguely Haulotte OPERATING EQUATIONS 7 1 START UP If SB1 1 and RCH 0 and SA1 turntable or SA1 platform and SB3 1 then chopper active 7 2 SHUTDOWN If SB1 0 or RCH 1 or SA1 0 or SA1 platform and SB3 0 then chopper inactive 7 3 MAST LIFTING 7 3 1 Turntable 7 3 1 1 Up If SA1 turntable and 5 6 1 and SM1 1 and SA1 1 or machine retracted and overload 0 then YV3b 1 and YV4 1 M1 1 overload 1 if inputs 26 0 and 38 0 26 and 38 ZAPI chopper inputs 26 jib up blocking 38 jib down blocking Machine retracted gt SQ4 1 and 5012 1 7 3 1 2 Down If SA1 turntable and SB6 1 an
54. ON essen ee ilo 43 QU NN LEE 43 11 POSITION OF HYDRAULIC 4 45 12 55682 HYDRAULIC BLOCK ea ae RUNE 47 CHARAGCIERISTICS aineol eee een 47 Repair Manual Pinguely Haulotte A 12 1 1 Technical characteristics see 47 cM EET 47 122 DIAGRAMS mi niti MU eu a RE 48 12 2 1 Uistofcomponents sise 49 MAINTENANCE ee 51 13 1 GENERAL 65 4 288444 51 13 2 PARTICULAR RECOMMENDAT IONS 51 13 2 1 e ele e reddo ______________ 51 13 2 2 Replacing an element sc 51 13 2 3 LOCAUING bre oor M 52 13 3 MAINTENANCE SYS TEM pente ic ax ia 52 13 4 ELECTRIC POWER SUPPLY lella 52 13 5 MAINTENANCE PLAN sense a u 53 13 5 1 Consumables _____ ________ 53 13 5 2 Maintenance 54 13 5 3 OPERALIONS E 55 13 6 PRESENCE OF LABELS aan ee 55 13 7 PRESENCE OF tihedamaid a 55 14 PREVENTIVE MAINTENANCE 8 2 1111 55 15 OPERATING INCIDENTS 12 aan 57 TROUBLE SHOO en 58 16 CORRECTIVE MAINTENANCE PROCEDURE 24 4 42111 65 Pinguely Haulotte 7 Repair Manual Repair manual
55. PLAN Pinguely Haulotte device and consumables to be used The plan on the following page gives the freguency servicing operations The reference in the symbol indicates the servicing point according to freguency The symbole represents the consumable to be used 13 5 1 Consumable Lubricants INGREDIENT SPECIFICATION SYMBOL used by ELF TOTAL HAULOTTE E AFNOR 48 602ISO V HYDRELFDS EQUI Hydraulic oil G 46 lt gt BPSHF 25 46 46 VISZS 46 pressure li ISO 2 As CARDREXA thium grease Vl DC 1 ESSOGP MULTIMOTIVE MULTIS Lead free grease Grade 2 or 3 O GREASE 2 EP 2 Exchange or specific operation BARDAHL High pressure SUPER lubricant a TEFLUBE 2 ORGANIC hydraulic oil OPTION lt gt Extreme cold AFNOR 48 602150 V SHELL G 32 TELLUS T 32 OPTION 53 Pinguely Haulotte Z Repair manual 13 5 2 Maintenance plan o EL j N AA 54 Repair manual Pinguely Haulotte Z 13 5 3 OPERATIONS IMPORTANT IF ORGANIC OR EXTREME COLD OILS ARE USED THE PERIODICITIES IN THE TABLE BELOW ARE REDUCED BY HALF Every 250 hours See chap 5 3 1 Grease the friction parts of the mast 8 check pad wear Check the tightness of wheel nuts upper clevis screws PERIODICITY OPERATION REFERENCE Check Everyday or hydraulic tank level See
56. Pinguely Haulotte REPAIR MANUAL SELF PROPELLED PLATFORM STAR 8 HM10P STAR 10 242 031 9680 07 04 GB 150 9001 GROUPE 4 7 TELESCOPIQUES GSEAUX TRACTEES ARTICULEES MATS 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 KEE bow 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 Haulotte Iberica Sevilla T l Phone 34 95 493 44 75 Fax Fax 34 95 463 69 44 Centre Mondial Pieces de Rechange Spare Parts International Centre T l Phone 33 0 4 77 29 24 51 Fax Fax 33 0 4 77 29 98 88 Haulotte Portugal T l Phone 351 21 955 98 10 Fax Fax 351 21 995 98 19 Haulotte U S Inc Main tool free 1 877
57. Platform position Activate a movement NO No movement is made YES Check fuses FU1 FU2 FUA and 205 defective fuses YES END Make sure that the emergency stop and station selection buttons are operational NO Replace an See sheet Butt OK dd if y ERA defective buttons C004 YES Measure voltage at terminals 5 END and 42 of the chopper NO See sheet Replace the chopper C003 YES END Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet 081 NO MOVEMENT AVAILABLE FROM THE Folio 2 4 PLATFORM Measure voltage at CNB4 CNB4 24 V SC YES See sheet C063 Replace the Serial board Measure voltage at output Voltage measured NO 24 YES Repair the wiring See sheet C064 Replace the pedal Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP081 NO MOVEMENT AVAILABLE FROM THE Folio 3 4 PLATFORM Measure voltage terminals of contactor SB1 L3 NO Check the wiring and sheet batteries C149 If necessary repair the wiring and or YES replace the batteries Replace contactor SB See sheet C200 Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DEE NO MOVEMENT AVAILABLE FROM THE Folio 4 4 PLAT
58. See sheet Replace the coil C145 The problem persists Connect a pressure gauge on the pressure tapping at small pump output Make a steering movement Pressure 1450 PSI 100 bars NO Test or replace the 1450 PSI 100 bars See sheet and 2320 PSI 160 C218 bars pressure limiters Replace electrovalve See sheet YV1 067 Repair manual Pinguely Haulotte 16 CORRECTIVE MAINTENANCE PROCEDURE List of corrective maintenance sheets Sheet no Description Replacing the chopper Replacing a component of the platform control station Replacing a hose Replacing the horn Replacing the hand pump Replacing the printed circuit Replacing an electrovalve Charging the traction batteries Replacing the tilt sensor Replacing the jib cylinder Replacing the top panel manipulator Replacing the bottom panel manipulator Replacing a steering wheel Replacing a coil Replacing the steering potentiometer Replacing the covers Replacing the hydraulic winder Replacing the batteries Dismantling reassembling the mast Replacing an end of travel contactor Replacing the hydraulic filter Replacing the hydraulic block Replacing the motor pump unit Replacing the hydraulic pump Replacing the rotation motor Replacing a drive wheel Replacing the hydraulic tank Replacing the turntable emergency stop button
59. T Sheet C218 ADJUSTING A HYDRAULIC PRESSURE LIMITER Sheet 1 2 AN Caution 1 Preliminary operations Ensure that the oil is not too Putthe machine into the low position hot e Switch off the electric power supply see relevant section 2 Adjusting the main pressure limiter Photo 3 ref 1 Unscrew the cap of the hydraulic pressure tapping marked MX on the N Caution hydraulic block and connect a pressure gauge of sufficient range to mea A sure the overall pressure Photo 1 Use a container to collect the oil to prevent pollution of the environment AN Caution It is essential to put the component into slings before dismantling reassembling it Restore the electric power supply see relevant section Requesta steering rotation or jib lifting movement Photo 2 and measure the main pressure at 2320 PSI 160 bar on the pressure gauge Photo 2 Switch off the electric power supply see relevant section Unscrew the pressure gauge and put back the hydraulic pressure tapping cap Photo 1 Putthe machine back into the operational configuration Make several movements to check correct machine operation NB Steering is disabled after a certain time when the machine is at its limit in one direction Only steering in the opposite direction is poosible and may re authorise steering in the initial direction The steering pressure measurement time is therefore limited 3 Adjusting the mast lifti
60. achine back into the operational configuration Make several rotation movements to test correct operation of the slew ring and to purge the hydraulic circuit Check the level of the hydraulic tank Pinguely Haulotte MAINTENANCE SHEET Sheet C210 Sheet 4 4 REPLACING THE SLEW RING Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C211 Sheet 1 2 REPLACING A STEERING PIVOT AN Caution 1 Preliminary operations pan Put the machine into the maintenance configuration see relevant sec Ensure that the oil is not too tion hot Disonnect the batteries Switch off the electric power supply see relevant section Remove the chassis covers see relevant sheet AN Caution Remove the wheel in question see relevant sheet Use a container to collect the Liftthe chassis with a jack or hoist oil to prevent pollution of the environment 2 Removing a steering pivot Remove the pin and washer Photo 1 Unscrew the steering pivot fixing plates Photo 2 AN Caution It is essential to put the FERN component into slings before dismantling reassembling it AN Caution Check that the lifting means are in good condition and of sufficient capacity Photo 1 Photo 2 Liftthe chassis pivot comes down Hit the pin near the stud on the pivot with a mallet Remove the pivot 3 Reinstalling a steering pivot Grease the steering pivot Grease the
61. al 13 7 PRESENCE OF MANUALS Itis 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 ofthe machine Instructions Check that the manuals are present Check that the manuals are legible complete and stored in the document holder provided on the platform Replace if necessary extra copies can be supplied on reguest by the manufacturer 56 Repair manual Pinguely Haulotte A 14 PREVENTIVE MAINTENANCE SHEETS List of preventive maintenance sheets Sheet no Description Lubricating the steering wheel pivots Checking filling the hydraulic oil tank Changing the hydraulic filter cartridge Checking servicing the traction batteries Lubricating the mast 55 Pinguely Haulotte Z Repair manual 56 Pinguely Haulotte PREVENTIVE MAINTENANCE SHEET Sheet 1 1 SHEET P003 GREASING THE STEERING WHEEL PIVOTS 1 Greasing the steering wheel pivots Cut off the electric power supply see S 6 3 page 26 Grease the pivots NOTA Only use the grease recommended by the manufacturer 5 KI Compact optimum previous design Put the machine back into the operational configuration Compact optimum current design Star 22J Star 8 Pinguely Haulotte PREVENTIVE MAINTENANCE SHEET Pinguely Haulotte PREVENTIVE MAINTENANC
62. al Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP075 Folio 1 6 NO UP OR DOWN JIB MOVEMENT FROM THE PLATFORM No jib up or down movement from the platform Put the key switch in the Turntable position Activate jib movement he jib move up or down Put the key switch in the Platform position Activate jib movement YES Open the Platform box and measure voltage on CN23 and CNB6 of the platform board NO CN23 0 V CNB6 24 V Measure voltage at the terminals of selector switch SA2 SA2a 29A N Replace the See sheet selector C004 Repair wiring Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART NO UP OR DOWN JIB MOVEMENT Folio 2 6 FROM THE PLATFORM Measure voltage on CN1 9 CN1 10 and CN1 8 on the platform board CN1 8 0V idle CN1 8 0V at 4V CN1 10 5V CN1 9 0V up CN1 10 0V CN1 9 5V down NO Follow the same wire colours and measure voltage at the terminals of manipulator SM3 Measure voltage at CNB4 OV lt cursor lt 4V FOR contact 5V or NO NO REV contact CNB4 24V 5V Replace manipulator See sheet Mey YES SM3 142 Repair the wiring Replace the Serial See sheet board C063 voltage a
63. angle value through the RS232C series connection via PC parameter LIMSUP Jib instruction speed Jib deceleration speed 2 27 Pinguely Haulotte Z Repair manual Deceleration threshold Mechani aAA stops Deceleration threshold e o Electrical stops 5 9 ALARM SYSTEM MANAGEMENT EUROPE Tilt Overload Red light indicator Flashes Buzzer Continuous Irregular NB The overload alarm has priority before the tilt alarm The functioning of the machine along with the weighing device is possible through the following chopper software version European version TRIPLATB HU 1 06 gt gt TRI106B 28 6 ELECTRIC COMPONENTS POSITION 6 1 TURNTABLE CONTROL PANEL SA1 MDI Serial card 1A 1B 2 2B 29 Pinguely Haulotte Z Repair manual 30 FU1 protection of the 02 202 5A Protection of the U2 card controls FU3 10A Protection of the solenoid valve on U2 card FUA 250A power fuse e FU5 5A Work headlight protection option HA1 Warning signal 100 2 10 200 2 11 1 Pump motor Multifunction indicator 21 5 Steering potentiometer 2 5 e RCH Battery charger internal relay
64. ath 0 31m 2440701720 Polyflex 17 sheath 2440701940 Cabling end fittings 2440502250 Spiral cable according to specification N 5292 2440315300 2 A 0l OM O 15 Repair manual Pinguely Haulotte WIRING DIAGRAMS E555C 3 3 3 3 1 E555C 01 IWUOH 1 29127 0 2d04N3 SVW3H9Sesna v op ejeud uondO cO0Z ZO IZ V aae una 39vVsad 002 50 92 dOL 8 AVLS EE 69 inof esi 002 0 0 2 1002 90 61 4 AILLOINVH A1SNONId W101 VSIA NOILVOISIGOW 3iva Ava 3NISS30 vez 01 S 4 s 10 S Love SIVE eve 1288 siae zae Leve 818 sive Set NL 5 5 XC XL XO XO XL XL 2 0 1 XO 2 HS S5 re 5 TAA BENA PCNA qL EIN IN d a n N gt save 3 N 0 cw seve owe 0 ozve N N avc 0
65. ce the 194 F The alarm stops if T lt 70 C 167 F chopper P 61 Pinguely Haulotte Z Repair manual ANOMALY PROBABLE CAUSE SOLUTION No jib up down movement from the platform Defective wiring Defective serial board Defective manipulator SM3 Defective fail safe pedal Defective SB5 Defective or discharged batteries Defective chopper Defective coil Sheet DP075 No jib up down movement fromthe turntable Defective wiring Defective selector switch Defective serial board Defective manipulator SM1 Defective fail safe pedal Defective or discharged batteries Defective chopper Defective coil Defective 5 5 Sheet DP076 No mast up down movement from the platform Defective wiring Defective selector switch Defective serial board Defective manipulator SM3 Defective fail safe pedal Defective 5010 Defective or discharged batteries Defective chopper Defective coil Sheet DP077 No mast up down movement from the turntable Defective wiring Defective serial board Defective manipulator SM1 Defective 586 Defective 5010 Defective or discharged batteries Defective chopper Defective coil Sheet DP078 No right left rotation movement from the platform Defective wiring Defective selector switch Defective serial board Defective manipulator SM2 Defective fail safe pedal Defective chopper Defective coil Sheet DP079 No right left rotation movement from the tu
66. d SM1 1 and overload 0 then YV3a 1 YV6 1 and M1 1 overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and 5012 1 7 3 2 Platform 7 3 2 1 Up If SA1 platform and SB3 1 and SB8 1 and SA2 Mast and SM3 1 and SA1 1 or machine retracted and overload 0 then YV3b 1 and YV4 1 and M1 1 overload 1 if inputs 26 0 38 0 Machine retracted gt SQ4 1 and 5012 1 7 3 2 2 Down Overload 0 then YV3a 1 and YV6 1 and M1 1 Overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and 5012 1 7 4 JIB 7 4 1 Turntable 7 4 1 1 Up If SA1 turntable and SB5 1 and SM1 1 and SQ1 1 or machine retracted and overload 0 then YV3a 1 and YV5 1 and M1 1 Overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and SQ12 1 33 Pinguely Haulotte Z 7 5 34 ROTATION Repair manual 7 4 1 2 Down If SA1 turntable and SB5 1 and SM1 1 and overload 0 then YV5 1 overload 1 ifinputs 26 0 and 38 0 Machine retracted gt 504 1 and 5012 1 7 4 2 Platform 7 4 2 1 Up If SA1 platform and SB8 1 and SA2 jib and SM3 1 and SQ1 1 or machine retracted and overload 0 then YV3a 1 and YV5 1 and M1 1 overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and SQ12 1 7 4 2 2 Down If SA1 turntable and SB8 1 and SA2 jib and SM3 1 overload 0 then YV5 1 overload 1 if inputs 26 0 and 38 0 Machine retracted gt SQ4 1 and SQ12 1 7 5 1 Turntable 7 5 1 1 Left If
67. d hand rails Wear protective clothing suited to working conditions and current local legis lation in particular when working in hazardous areas Do not disable the safety system end of stroke contactors Avoid contact with fixed or mobile obstacles Do not increase working height by using ladders or other accessories Never use the hand rails as a means of access for getting onto and off the platform use the steps provided on the machine Never climb on the hand rails when the platform is raised Never drive the platform at high speed in narrow or cluttered areas Never use the machine without installing the platform protective bar or clo sing the safety barrier Never climb on the covers To avoid risks of tipping over operators must respect the following instructions NB Do not disable the safety system end of stroke contactors Avoid moving the steering control levers in the opposite direction without stopping in the O position to stop during a travel manoeuvre move the manipulator lever gradually Respect maximum load and 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 i
68. e 7 8 MDI CONSOLE PROGRAMING PARAMETERS AccELERATION 59 112 3 4 5 8 7 9 peeemmov EH RRE EA 09 1 2 3 4 5 6 7 819 mea KI EE ER EAR EA See NN LC CUTBACK accel cenom pepee je jo prp MAX SPEED FWD FLD NOM 100 90 82 75 69 64 60 56 52 48 SPEED REV FLD NOM 100 90 82 75 69 64 60 56 52 48 9 e ss or 91 9 os 100 WEAK DROPOUT ARMA NOM 35 40 45 50 55 60 65 70 75 80 MAXFLD FLDMAX rmt FLD NOM MAXFLD 34 38 41 44 47 50 53 56 60 peor E 3 5 0 5 0 5 1 6 1 6 emm E ps pss for a pre 2 100 SPEED CE ss for oo 72 rs 00 STEER SP accel aj ja spe pe per jj ERR emer p p AK LES pem en 4 fo 2 2 3 r 3 4 27 4 6 9 2 5 7 10 3 6 8 WREVP p m Tee pe pp 55 37 Pinguely Haulotte Z 38 Repair manual Pinguely Haulotte 9 HYDRAULIC DIAGRAMS 9 1 HYDRAULIC INSTALLATION 415007
69. e high in the following situations Sudden action on the controls Overloading of the platform Uneven ground Be careful during thaw periods in winter Gusts of wind Contact with an obstacle on the ground or at a height Working on platforms pavements etc Allow sufficient stopping distances 3 meters at high speed 1 meter at low speed Allow sufficient stopping distances 3 metres at high speed and 1 metre at low speed Do not alter or neutralise any components connected in any way to the machine s safety or stability Do not place or fasten a load so that it overhangs the machine s parts Do not touch adjacent structures with the elevator arm 1 3 2 Electrical risk Electrical risks are high in the following situations Contact with a live line check safety distances before operation near electricity lines Use during storms 1 3 3 Risk of explosion or burning The risks of explosion or burning are high in the following situations Working in explosive or inflammable atmosphere Filling the fuel tank near naked flames Contact with the hot parts of the motor Use of a machine generating hydraulic leakage 1 3 4 Risks of collision Risk of crushing people in the machine operation zone when travelling or manoeuvring equipment The operator must assess the risks above him before using the machine Pay attention to the position of the arms during turntable rotation Adapt mov
70. e the screws systematically to reassemble 8 8c class screws 14 x 65 34 then tighten to a torque of 99 ft lb 135 Nm Put the mast into slings approx 94 stones 600 kg Photo 2 Place the mast on trestles Photo 3 Photo 3 Unscrew the 3 screws from the cylinder plate at the bottom of the mast and remove the plate Unscrew the two elbow unions at the bottom ofthe mast Photo 4 4 Photo 5 Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C198 Sheet 2 6 DISMANTLING REASSEMBLING THE MAST Photo 4 8 Photo 5 Put the ring support Photo 6 into slings Unscrew the 12 bolts class 8 8 HM16x100 38 of the ring support Photo 7 and remove the ring with an overhead crane Take the circlips off the upper part of the cylinder Photo 8 Put the cylinder into slings and remove it with an overhead crane Put the smallest caisson into slings and remove it with an overhead crane Unscrew the 6 fixing screws on each stop of the 1st elevation caisson and remove the stops Unscrew the 6 screws of the next stop and remove it Putthe 3rd caisson into slings and remove it with an overhead crane Putthe 2nd caisson into slings and remove it with an overhead crane Putthe 1st caisson into slings and remove it with an overhead crane Photo 7 Photo 8 Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C198 Sheet 3 6 DISMANTLING REASSEMBLING THE MAST 3 Reinstalli
71. ecans 33 Ke ME dn E EE EE 33 A EB Ie MERITI 34 7 5 ROTATION 34 FAERIT 34 1 93 25 34 TRAVEL si ae ia ela M E UM alata 35 AN PA EE LC 35 Pinguely Haulotte Repair Manual TEE cm 9 35 HE EM LM 35 MON M 35 120 BUZZER 35 7 9 1 Without 35 7 9 2 With option on console 35 7 10 WORKING LIGHT OPTION LIGHT 35 7 11 WEIGHING TILT ALARM LIGHT 35 7 12 HOUR METER AND BATTERY CHARGE LIGHT INDICATOR 36 Als FUNCTIONSS 36 7 13 1 Platform movement validation button an 36 8 MDI CONSOLE PROGRAMING PARAMETERS nennnnnnennnnnnns 37 9 HYDRAULIC DIAGRAMS 2 e eae Ca enn ilaria 39 9 1 HYDRAULIC INSTALLATION 15007 39 9 2 HYDRAULIC DIAGRAM B17089 a 40 10 HYDRAULIC FUNCTIONING B17085 41 10 1 MAST RAISING E ee 41 192 MAST LOWERING ass een 41 10e JB LUFTING sus te ea 42 104 5 ELOWERINS gala 42 10 5 TURNTABLE ROTATI
72. electric connections according to the marks made during dismantling Putback the closing place and secure with the four fixing screws Putthe machine back into the operational configuration Make several up and down movements from the platform control panel to test manipulator operation Pinguely Haulotte Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET SHEET C143 Sheet1 1 REPLACING THE BOTTOM PANEL MANIPULATOR 1 Preliminary operations Putthe machine in the maintenance configuration see relevant section Caution Switch off the electric power supply see relevant section Do not use the machine during maintenance opera 2 Removing the manipulator 2 tions Remove the closing plate 1 by taking out the four fixing screws e Mark and disconnect the electric connections of the manipulator Remove the manipulator by taking out its fixing screws 3 Reinstalling the manipulator Fixa manipulator equipped with new seals on the turntable control panel Reconnect the electric connections according to the marks made during dismantling Putthe closing plate back into place and secure with the four fixing Screws Putthe machine back into the operational configuration Make several up and down movements from the turntable control panel to test manipulator operation Pinguely Haulotte Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET SHEET C144 Sheet 1 1 REPLACING A STEERING
73. ely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C067 Sheet 1 2 CHANGING AN ELECTROVALVE 1 Preliminary operations AN Caution Putthe machine in the maintenance configuration see corresponding Ensure that the oil is not too paragraph hot Switch off electric power see corresponding paragraph 2 Removing an electrovalve Markand disconnect the electric connections 1 of the coils e Mark the installation position of the electrovalve on the block Caution Unscrew the four fixing screws 3 of the electrovalve 2 and remove i 3 Installing an electrovalve Use a container to collect oil Puta new electrovalve equipped with its seals into place and fix using the to prevent pollution of the 4 screws in the position of the electrovalve on the block Tighten to the environment recommended torque see corresponding paragraph Reconnect the electrovalve s electric connections according to the marks made during dismantling Putthe machine back into the operational configuration Make several movement cycles using the replaced electrovalve to purge the hydraulic circuit Checkthe level of the hydraulic oil tank 4 Dismantling reassembling an Oil Control coil Markand disconnect the electric connections of the coils 4 Remove the protection 5 plastic cap from the end of the coil Unscrew the nut 6 holding the coil and remove Puta new coil into place Put back the nut protectio
74. ement speed to conditions related to the ground traffic slope and movement of people or any other factor that may cause a collision When driving down the ramp of a truck ensure sufficient space is available for safe unloading Check brake pad wear regularly to avoid all risk of collision Repair manual 1 4 INSPECTIONS Pinguely Haulotte Z with the national regulations in force in the country of machine use For FRANCE Order dated 9 June 1993 circular DRT 93 dated 22 September 1993 which specify 1 4 1 Periodic inspections The machine must be inspected every 6 months in order to detect any defects liable to cause an accident These inspections are performed by an organisation or personnel specially designated by the site manager and under his responsibility whether or not they belong to the company Articles R 233 5 and R 233 11 of the French Labour Code The results of these inspections are recorded in a safety register kept by the site manager and constantly available to the labour inspector and the site safety committee if one exists and the list of specially designated personnel Article R 233 5 ofthe French Labour Code Moreover before each use check the following the operator s manual is in the storage compartment on the platform the stickers are placed according to the section concerning Labels and their positions oil level and any elements the mainteance operation
75. eneral periodic inspections and pre operation inspections have been performed Pinguely Haulotte 2 Repair manual 1 5 REPAIRS AND ADJUSTMENTS These cover major repairs and work on or adjustments to safety systems or devices of a mechanical hydraulic or electrical nature These must be performed by personnel from or working for PINGUELY HAULOTTE who will use only original parts Any modification not controlled by PINGUELY HAULOTTE is unauthorised The manufacturer cannot be held responsible if non original parts are used or if the work specified above is not performed by PINGUELY HAULOTTE approved personnel 1 6 VERIFICATIONS WHEN RETURNING TO SERVICE To be performed after extensive disassembly reassembly operation repair affecting the essential components of the machine any accident caused by the failure of an essential component It is necessary to perform a suitability examination a state of conservation examination a static test a dynamic test see coefficient in paragraph see Chap 1 4 2 page 7 AN Caution These test must be performed by a competent person 1 7 BEAUFORT SCALE The Beaufort Scale of wind force is accepted internationally and is used when communicating weather conditions It consists of number 0 17 each representing a certain strength or velocity of wind at 10m 33 ft above ground level in the open Description of Wind Specifications for use
76. equire safety precautions Remove the standby pump 1 by removing the 3 fixing nuts 2 wear gloves and protective Removing the hoses 6 is not necessary goggles Disconnect the and then terminals of the batteries 2 Removing the upper battery 3 Release the lock 4 of the battery support Putthe battery support into slings using the lifting rings 5 Pivot the support around its axis Using an overhead crane remove the battery 3 Removing the lower battery 6 Unscrew the 2 nuts 7 Putthe battery support into slings using the lifting rings 8 Using an overhead crane remove the battery 4 Re installing the batteries Perform the dismantling operations in reverse order to reassembly starting with re installation of the lower battery 6 Additional operations Reconnect the then terminals of the batteries Putthe standby pump back into place Putthe machine back into the operational configuration Pinguely Haulotte Sheet 198 Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet 1 6 DISMANTLING REASSEMBLING THE MAST AN Caution Ensure that the oil is not too hot AN Caution Use a container to collect the oil to prevent pollution of the environment AN Caution Make sure the lifting means are in good condition and of sufficient capacity Photo 1 Photo 2 1 Preliminary operations Put the machine in the ma
77. ervention it is essential to consult table 6 1 If the incident is listed simply follow the instructions Only common incidents whose solutions can be implemented by an operator are listed For all other incidents contact your PINGUELY HAULOTTE representative or the plant s After sales service Before diagnosing a failure check that the emergency stop palm buttons on the turntable and platform are unlocked the circuit breakers on the turntable panel are pushed in The speed chopper has a failure indication system on the timer display To diagnose a failure consult the table below note the alarm code and pass it onto the After sales service who will given you the instructions to follow 57 Pinguely Haulotte Z 15 1 TROUBLE SHOOTING Repair manual CODE ALARM PROBABLE CAUSES REMEDIES POWER FAILURE Short circuit on an on off valve proportional electrovalve coil main contactor 581 or electrobrake EEPROM KO Failure in the memory area in which the configured parameters are stored If the failure remains when the ignition key has been turned on and then off change the EEPROM If the alarm stops the stored parameters may have been cancelled and replaced by default parameters Replace the chopper INCORRECT START Forward reverse gear jib lowering or lifting platform lifting or lowering left right steering traction authorization is are ON when the ignition key i
78. f the platform is cluttered Do not use the machine with equipment or objects hanging from the hand rails Do not use the machine with elements that may increase the wind load e g panels Do not perform machine maintenance operations when the machine is raised without setting up the required safety means gantry crane crane Make daily checks and monitor proper operation during periods of use Preserve the machine from any uncontrolled operation when it is not in ser vice Do not tow the platform it is not designed to be towed and must be transported on a trailer Pinguely Haulotte Z 1 3 RESIDUAL RISKS AN Caution The direction of travel can be reversed after 180 turntable rotation Take account of the colour of the arrows on the chassis compared with the direction of travel green forward red reverse Thus moving the manipulator in the direction of the green arrow on the control panel will move the machine according to the direction indicated by the green arrow on the chassis Similarly moving a manipulator in the direction of the red arrow on the control panel will move the machine in the direction of the red arrow on the chassis AN Caution If the machine has 220 V 16A max plug the extension must be connected to a mains socket protected by a 30 mA differential circuit breaker Repair manual 1 3 1 Risks of jerky movements and tipping over Risks of jerky movement and tipping over ar
79. g indicator appears 2 Unscrew the base nut 3 and remove the cartridge from the hydraulic filter Screw a new cartridge into place Putthe machine back into the operational configuration HA16 18 PX HA46 51JRT HA20 26 PX HA61 80JRT 2 HA33JE H14P H16TP HA15I HA43E HB40 44J Pinguely Haulotte PREVENTIVE MAINTENANCE SHEET Pinguely Haulotte PREVENTIVE MAINTENANCE SHEET Sheet 1 Folio 1 2 CHECKING SERVICING THE TRACTION BATTERIES AN Caution 1 Preliminary operations These operations reguire Putthe machine into the maintenance configuration see relevant section safety precautions wear 2 gloves and protective 2 Battery servicing Check the electrolyte levels before charging once a week in normal use e If necessary top up with distilled or de mineralised water A Caution after charging kohti No not add acid in the event of spillage contact our After sales department ae no are We Do not leave discharged batteries idle machine without first di Gan the bellam Avoid overflow HIS DANBNES Clean the batteries to avoid salt formation and current deviation Wash the top without removing the caps Dry with compressed air or clean cloths AN Caution Grease the lugs goggles Do not use the batteries to Jump start another vehicle NB To enable rapid diagnosis of the state of your bat
80. g the hydraulic filter Attention Unscrew the bowl 1 of the hydraulic filter Use a container to collect the Place a bowl under the hydraulic filter to collect the oil oil to prevent pollution of the Take the filtration element out of the base environment 3 Reinstalling the hydraulic filter Clean the filtration element support Replace the filter Screw the base back onto the fixed part of the hydraulic filter 2 Putthe machine back into the operational configuration Make several lifting cycles to purge the hydraulic circuit Pinguely Haulotte Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C202 Sheet 1 1 REPLACING A HYDRAULIC BLOCK 1 Preliminary operations AN Caution Putthe machine into the maintenance configuration see relevant sec Ensure that the oil is not too tion hot Switch off the electric power supply see relevant section 2 Removing the hydraulic block Open the covers to access the components e Mark and disconnect the electrovalves 2 of the hydraulic block 1 Mark and disconnect the hoses 3 of the hydraulic block NB Unscrew the hoses slowly to release residual hydraulic pressure Put caps the hoses Remove the union connectors from the hydraulic block Remove the hydraulic block by removing the fixing screws and washers 1 Reinstalling the hydraulic block Putthe hydraulic block into place and fix with screws equipped
81. heet 1 1 REPLACING A COMPONENT ON THE PLATFORM CONTROL PANEL 1 Preliminary operations Cut off the electric power supply see S 6 3 page 26 Caution 2 Removing a component from the platform control panel Do not use the machine Remove the closing plate 1 by unscrewing the four fixing screws during maintenance Mark and disconnect the electric connections of the component to be operations replaced Remove the component 3 Replacing a component on the platform control panel Puta new component and seal into place on the front of the platform con trol panel NB If itis a lever switch adjust the position of the fixing nut and counter nut so that the switch lever joint axle is on the same level as the seal to ensure tightness Reconnectthe electric connections according to the marks made when dismantling Fixthe closing plate with the four fixing screws Perform the function corresponding to the replaced component to check that it works properly Star 8 HM10P star 10 Pinguely Haulotte Sheet C010 AN Caution Ensure that the oil is not too hot AN Caution Use a container to collect the oil to avoid pollution of the environment Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Folio 1 1 REPLACING A HYDRAULIC HOSE 1 Preliminary operations Put the machine in the maintenance configuration see 8 6 3 page 48 Switch off the electric power supply see 8 6
82. hydraulic connectors Putcaps on the hoses Remove the tank 1 by removing its fixing nuts 4 3 Reinstalling the hydraulic tank Reinstall the tank and secure with its nuts NB Take care with hydraulic hoses passing behind the tank Putthe connectors back into place and connect the hoses see table of tightening torque values Fill the hydraulic oil tank use the oil recommended by Pinguely Haulotte Putthe machine back into the operational configuration Make several lifting cycles to purge the hydraulic circuit Checkthe level of the hydraulic circuit Pinguely Haulotte Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET SHEET C208 Sheet1 1 REPLACING THE TURNTABLE EMERGENCY STOP BUTTON 1 Preliminary operations Putthe machine into the maintenance configuraiton see relevant sec tion Switch off the electric power supply see relevant section e Disconnect the then terminals of the batteries to isolate the electric circuit Caution Do not use the machine during maintenance operations 2 Removing the emergency stop button 2 Mark and disconnect the electric connections 1 of the emergency stop button Remove the head of the emergency stop button 2 by unscrewing it hav ing blocked its pin by inserting a rod into the hole 3 provided Remove the emergency stop button by unscrewing its two fixing screws 4 3 Reinstalling the emergency stop butt
83. i mately Keep activating the lowering control even during the momen tary interruption 13 Load the adjustement weight 115 nominal charge 14 Static pressure values acquisition Activate the raising control up to the maximum height The system will automatically perform in termediate stops Caution Never activate the lowering control before reaching the maximum height 15 Activate the lowering control and bring once more the platform back to the maximum height 16 Activate the descent control every now and then in order to com pletely discharge the hydraulic pressure 17 Dynamic pressure values acquisition during lifting Activate the raising control up to the maximum height Caution Do not inter rupt this phase 18 Dynamic pressure values acquisition during lowering Activa te the lowering control and bring once more the platform back to the maximum height Caution Do not interrupt this phase 19 Towards the end of the lowering phase the system automatically gets out of the previous adjustements and the LD20 red led goes out 20 Switch the card off Pinguely Haulotte 21 Remove the adjustment jump 22 Switch the system back on and check that it functions correctly bring the system to give the alarm and check that the state of J4 3 J4 4 or J4 5 J4 6 changes Also check that the system stops before the top and the low position end of travel 5 7 ERRORS SIGNALLING 5 7 1 Sensors errors D19 g
84. ide Remove the pin 5 Remove jib cylinder 1 3 Reinstalling the jib cylinder NB Before reassembly check the condition of all articulated pin rings and replace if necessary Lubricate all bores before reinstalling the pins Only use lubricants recommended by the manufacturer Photo 1 Putthe jib cylinder into place and reinstall the 2 articulation pins on the cylinder rod and body sides Secure the pins with their bolts Remove the slings 4 Additional operations Putthe machine back into the operational configuration Make several jib movements to test operation and purge the hydraulic cir cuit e Check the hydraulic circuit level Pinguely Haulotte Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET SHEET C142 Sheet 1 1 REPLACING THE TOP PANEL MANIPULATOR 1 Preliminary operations Putthe machine into the maintenance configuration see relevant sec Caution tion Do not use the machine Switch off the electric power supply see relevant section during maintenance opera tions 2 Removing the manipulator 2 Remove the closing plate 1 by taking out the four fixing screws e Mark disconnect the electric connections of the manipulator Remove the manipulator by taking out the fixing screws 3 Reinstalling the manipulator Fixa new manipulator equipped with new seals on the platform control panel Reconnect the
85. in switch driver is not in short circuit Possible reasons for failure Main switch alarm usually Driverin short circuit overridden by the POWER DRIVER o X 14 Malfunction in the measure circuit of the FAILURE alarm SHORTED contactor voltage Machine related problem Incorrect wiring contact After Sales Service Faulty hardware circuit protection Nota Bene This alarm is normally overridden by alarm 1 POWER FAILURE 59 Pinguely Haulotte Z Repair manual 60 CODE ALARM PROBABLE CAUSES REMEDIES test is executed while the main switch is closed It checks that the driver is not open Alarm given on 581 driver 15 CONTACTOR Possible reasons for failure main switch short DRIVER Short circuit in the driver circuit Malfunction in the circuit of the contactor Replace the chopper coil voltage Alarm given due to a The test is executed each time before the main BR problem on the SB1 power switch is closed It checks that the switch is actually contact 16 CONTACTOR p Replace the power sensor CLOSED Possible reasons for failure or the chopper The switch contacts are stuck Check F1 and F2 th A malfunction in the power unit Se NIE chopper test is performed non stop The alarm is on if two requests for different operations are simultaneously activated SEE EURO 17 FORW
86. ine but signals the problem reguest reset or service the Select the option CHECK UP DONE ON to erase machine if needed the message Check the circuit and the Maintains that the chassis is not on short circuit MODO pup 23 NO ISOLATION 2 insulation with the BATT or connected to the ground e Repair the damaged circuit Repair manual Pinguely Haulotte Z CODE ALARM PROBABLE CAUSES REMEDIES pressure switch can be damaged or Check the shunt on the 24 PRESSURE disconnected the emergency stop could serial card and that the OK been damaged it cuts the positive charge at the voltage on the chopper pressure switch but not at the logic input is positive 25 CHOPPER NOT A valid model for the chopper has not been oe Ha ae CONFIGURATED configured See the model selection board the serial that the controller proportional electrovalve is open at rest has been correcti 26 EVP NOT OK While working the electrovalve is too open or too 3 f configured with absent closed compared to the PVM applied EVP SERIAL ERROR Incomplete or lack of reception by the selected Check the serial card 27 1 serial card selection by SA1 o Lr 3 the choppers THERMAL Heat alarm gt 75 C 167 F the maximum current temperature using 28 PROTECTION on inductors is linearly stepped down to 0 at 90 C console or repla
87. ine thread screws Tightening torque in N M Nominal diameter 10 9 M 8 1 24 29 33 37 40 44 M 10 1 25 46 57 64 71 77 85 M 12 1 25 83 100 120 130 140 150 M 14 1 5 130 160 180 200 220 240 M 16 1 5 200 250 280 310 340 370 M 18 1 5 290 360 410 450 490 540 M 20 1 5 410 510 570 630 690 760 M 22 1 5 550 680 780 870 920 1000 M 24 1 5 690 860 970 1070 1160 1290 M 27 2 1000 1300 1400 1560 1690 1880 30 2 1400 1700 1960 2180 2350 2610 11 Pinguely Haulotte Z Repair manual 2 2 3 Tightening torgue for hydraulic hoses Torgue to apply Nm min max Description Drawing N A14706 Ref 7 Hose SP 5238 Lg 2060 Ref 8 Hose SP 5008 Lg 530 Ref 9 Hose SP 5238 Lg 1640 Ref 10 Hose SP 2361 Lg 1450 Ref 11 Hose SP 449 Lg 670 Ref 12 Hose SP 5025 Lg 400 Ref 13 Hose SP 5008 Lg 1300 Ref 14 Hose SP 5008 Lg 550 Ref 47 Hose SP 5028 Lg 500 Ref 53 Hose SP 2361 Lg 700 Ref 54 Hose SP 1663 Lg 610 Ref 68 Hose SP 1786 Lg 500 Ref 69 Hose SP 1756 Lg 350 2 3 PRESSURE TABLE IN BARS General Steering Rotation Lifting 160 160 50 45 2 4 TABLE OF ADJUSTMENT TIMES Movement Movement duration Micro speed Mast up 50 s 2s for 10m Forward gear High speed Mast and jib lowered 8 s 1s for 10
88. ing screws 4 of the hydraulic tank 3 Unscrew the closing plate fixed to the electric plate to access the fixing screws at the back of the main counterweight Putthe main counterweight into slings Unscrew the screws at the back of the 86 stone 550 kg counterweight Remove the counterweight Reinstalling the counterweights Vacuum clean the holes drilled on the fixing plate of the main counter weight e Put each counterweight into slings Tighten the screws and grower washers at the back of the main counter weight Screw the closing plate for the electric part back onto the electric plate e Position the 68 Ib 31kg counterweight opposite each battery tray Insert the battery tray pilot points into the counterbores Fix the counterweights with the fixing screws Pinguely Haulotte Sheet C214 AN Caution Ensure thatthe oil is not too hot AN Caution Use a container to collect the oil to prevent pollution of the environment AN Caution It is essential to put the component into slings before dismantling reassembling it AN Caution Make sure that the lifting means in good condition and of sufficient capacity Photo 3 Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET REPLACING THE ELECTRIC PLATE 1 1 Sheet 1 2 Preliminary operations Put the machine into the maintenance configuration see relevant sec tion Disconnect the battery terminal
89. intenance configuration see relevant section Switch off the electric power supply see relevant section Remove the right and left side covers see relevant sheet Remove the motor cover see relevant sheet Remove the lower right and left covers see relevant sheet Disconnect and remove the batteries see relevant sheet Disconnect the pump power supply after marking the supply wires see relevant sheet Remove the plate covering the end of travel contactors SQ3 and 504 and remove them see relevant sheet Remove the hydraulic winder see relevant sheet Remove the end oftravel contactor 5012 see relevant sheet Remove the hydraulic supply hose at top of the mast Remove the jib see relevant sheet Remove the circuit breaker see relevant sheet Remove the charger see relevant sheet Remove the end of travel contactor SQ10 see relevant sheet Remove the electric plate see relevant sheet Remove the hydraulic plate see relevant sheet Remove the hydraulic filter see relevant sheet Remove the pump see relevant sheet Remove the hydraulic tank see relevant sheet Remove the hydraulic block assembly see relevant sheet Remove the rotation motor see relevant sheet Remove the counterweight see relevant sheet Remove the cable sleeve support see relevant sheet 2 Removing the mast Remove the trapdoor in the middle of the mast ref 1 Photo 1 Unscrew the 12 screws on the ring replac
90. ir manual Repair manual Pinguely Haulotte A 1 GENERAL RECOMMENDATIONS SAFETY 1 1 GENERAL WARNING 1 1 1 Manual This manual aims to help maintenance personnel service and repair the machine It cannot however replace the basic training required by any person working on the site eguipment 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 eguipment safety 1 1 2 Labels Potential dangers and recommendations for the machine are indicated on labels and plates Read the instructions on them All labels conform to the following colour code Red indicates a potentially fatal danger Orange indicates a danger that may cause serious injury Yellow indicates a danger that may cause material damage or slight injury Maintenance pesrsonnel must ensure that these labels and plates are in good conditions and keep them legible Spare labels and plates can be supplied by the manufacturer on request 1 1 3 Safety Ensure that any person entrusted with the machine is take the safety measures implied by its use Avoid any working mode that may affect safety Any use that does not comply with the recommendations may generate risks and damage to
91. k pump wiring NO Wiring is correc See sheet Replace the chopper C003 Repair the wiring Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP080 RIGHT OR LEFT ROTATIONAL MAST MOVEMENT Folio 4 6 FROM THE TURNTABLE Measure voltage at the terminals of electrovalves YV2a and YV2b V2a 24 V left and YV2b 24 V right Repair the wiring between the chopper and the electrovalves See sheet C145 Replace the coil The problem persists Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP080 NO RIGHT OR LEFT ROTATIONAL MAST MOVEMENT Folio 5 6 FROM THE TURNTABLE Connect a pressure gauge to the pressure tapping at small pump output Make a left right rotation movement Pressure NO 1450 PSI 100 bars YES Test or replace the 1450 PSI 100 bars See sheet See sheet and 2320 PSI 160 C218 or C067 bars pressure limiters sheet Replace the rotation C205 motor Replace electrovalve YV2 Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP080 RIGHT OR LEFT ROTATIONAL MAST MOVEMENT Folio 6 6 FROM THE TURNTABLE Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP081 Folio 1 4 NO MOVEMENT AVAILABLE FROM THE PLATFORM No movement available from the platform Put the key switch in the
92. l configuration Pinguely Haulotte Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET sheets REMOVING REPLACING THE SuSE HYDRAULIC WINDER AN Caution 1 Preliminary operations Ensure that the oil is not too e Put the machine into the maintenance configuration see relevant section hot Switch off the electric power supply see relevant section NB Unscrew the hoses slowly to release residual hydraulic pressure ion AN 2 Removing the hydraulic winder 1 Use a container to collect the oil to prevent pollution of the environment Disconnect the hydraulic hoses 2 and 3 Put caps on the hoses Unscrew the two fixing nuts 4 to free the hose 5 Remove the winder by taking the fixing nuts 6 off the support 3 Reinstalling the hydraulic winder Perform dismantling operations in reverse order to reassemble 4 Additional operations Putthe machine back into the operational configuration Make several movements using the replaced hydraulic winder to purge the hydraulic circuit e Check the hydraulic oil tank level Pinguely Haulotte Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C149 Sheet 1 1 REMOVING REPLACING THE BATTERIES 1 Preliminary operations AN Caution Putthe machine into the maintenance configuration see relevant section Battery servicing operations Switch off the electric power supply see relevant section r
93. lana irta 8 2 PRESENTATION 9 2 1 STAR8 10 TECHNICAL CHARACTERISTICS iii 9 RTE EE 10 TIGHTENING TORQUE Distance 11 2 2 1 Tightening torque for large thread screws ii 11 Pinguely Haulotte 7 Repair Manual 2 2 2 Tightening torque for fine thread SCrewSs 1 11 2 2 3 Tightening torque for hydraulic 12 2562 PRESSURE TABLE IN BARS een 12 2 44 TABLE OF ADJUSTMENT TIMES aan 12 3 WIRING DIAGRAMS 2 222 13 3 1 ELECTRIC CASINGS WIRING DIACGHRAMS nnne nnne 13 3 1 1 Turntable box wiring diagram 20503 13 3 1 2 Platform box wiring diagram P200270 naeh kiida 14 32 BUNDLE DIAGRAM C 16209 ne ee 15 Ge WIRING DIAGRAMS E5550 see 16 D le 331518 1 TT TTE 16 CR Ediz edic C M age 17 3 39 34 PR 18 4 SAFETY SYSTEMS eu einen 21 41 MACHINE ELEMENTS ae ennemies 21 dis Em 21 4 1 2 Power supplies and fuses 8 nenne nennen 21 4 1 3 ee n nnn nennen 21 SEE CI LR Tn NE 21 4 15 EE 21 4 1 6 mM 22 4 1 7 Management Ac 22 5 i lella 22 210 Light let EC 22 5 W
94. linder 6 Operate the machine to stretch the cable sleeve and check its escape limit Pinguely Haulotte MAINTENANCE SHEET Sheet C216 REINSTALLING THE CABLE SLEEVE Sheet2 2 Escape limit Escape points Pinguely Haulotte MAINTENANCE SHEET Sheet C217 REPLACING A WHEEL REDUCER OR Sheet 1 2 A HYDRAULIC TRAVEL MOTOR 1 Preliminary operations AN Caution Putthe machine into the maintenance configuration see relevant sec Ensure that the oil is not too tion hot Switch off the electric power supply see relevant section Raise the chassis with a jack or hoist Remove the wheel corresponding to the element to be removed AN Caution left motor remove the left wheel right motor remove both wheels oil to prevent pollution of the environment 2 Removing a wheel reducer or hydraulic motor NB Figure 1 steering axle AN Caution fixed axle It is essential to put the component into slings before dismantling reassembling it Inthe case of a steering axle uncouple the steering connecting rod from the pivot e Mark and disconnect the hoses then the connectors of the hydraulic motor Photo 1 and reducing gear Photo 2 NB Unscrew the hose slowly to release residual hydraulic pressure AN Caution DUNS Check that the lifting means Putcaps on the hoses are in good condition and of Place a wedge under the wheel reducer
95. lotte CORRECTIVE MAINTENANCE SHEET Sheet C216 REINSTALLING THE CABLE SLEEVE Sheet 1 2 1 Preliminary operations Putthe machine into the maintenance configuration see relevant sec tion AN Switch off the electric power supply see relevant section Check that the cable sleeve Disconnect the two electric cables of the brake control is properly positioned and Disconnect the 6 cables of the electric motor secured each time the Disconnect the 2 hoses of the steering cylinder machine s systems are Disconnect the steering potentiometer connectors removed 2 Removing the cable sleeve Unscrew the collars around the support 3 near the rotation motor 5 and the steering cylinder 6 Unscrew the rizlans 2 and the collar 4 fixing the cables to the cable sleeve support Remove the cable sleeve from its support 3 Remove the cable sleeve 3 Installing the cable sleeve The cables inserted into the cable sleeve include 2 hydraulic hoses on the second row from the top 1 2 brake cables 2 travel motor inducer circuits 2 travel motor induced circuits 3 steering potentiometer cables Tape the cables and tighten with a rizlan 2 Fixthese cables on the cable sleeve support guide 3 Putthe cable sleeve back around the cables and at the top of the support guide Fixthe cable sleeve with a fixing collar near the rotation motor on the rod guide 5 near the steering cy
96. ly is connect ed For information charging time for a battery discharged by 80 is approximately 15 hours AN Caution Connect the plug 2 to the mains 110 for USA Safety precautions are Check the charge state on the light 3 on the bottom control panel reguired for battery Red zone machine charging servicing operations wear Yellow zone 80 of charging complete gloves and protective Green zone batteries charged goggles Star 8 Star 22J Star 8 Star 22J Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C139 CHARGING THE TRACTION BATTERIES Sheet 2 2 HA12IP HA33JE 3 During charging Do not remove or close the element caps Ensure that element temperature does not exceed 45 C be careful in sum mer or in rooms with high ambient temperature 4 After charging Top up the electrolyte level if necessary 4 Additional operations Putthe machine back into the operational configuration Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C140 Sheet 1 1 REPLACING THE TILT SENSOR 1 Preliminary operations Putthe machine on a flat level surface Caution Putthe machine in the maintenance configuration see relevant section Switch off the electric power supply see relevant section Do not use the machine during maintenance 2 Removing the tilt sensor operations Markand disconnect the electric connections of the tilt sensor
97. m Reverse gear High speed Mast and jib lowered 8s 1s for 10m Braking distance High speed Mast and jib lowered 70cm 20cm Slew ring orientation Right to left Mast and jib lowered 60s 2s Right to left steering Mast and jib lowered 4s 15 Mast lifting with useful load on platform STAR 8 425 Mast lifting with useful load on platform STAR 10 46s 25 3s Jib lifting with useful load on platform 26s 25 3s 12 3 WIRING DIAGRAMS 3 1 ELECTRIC CASINGS WIRING DIAGRAMS 3 1 1 Turntable box wiring diagram P20593a 2 KA2 RELAIS SURVOLTEUR BOOSTER RELAY 5 5 5 5 5 5 O 8 8 8 e uj 8 S 8 ur E 23 5 a s a Sp 5 8 z a 33 33 55 BI 38 88 O VERS SURVOLTEUR 2 5 TOBOOSTER 1 AVERTISSEUR BUZZER HAT 616202 am an 2 CoD cha
98. n and then reconnect the electric connections 5 Dismantling reassembling an Oil Control slide valve The whole section 7 must be replaced not just the slide valve mark the defective sections in the stack Disconnect the wiring harnesses and the hydraulic hoses plug them to prevent contamination Remove the nuts 8 from the end of the three assembling tie rods 9 Remove the sections 7 one by one until the defective section is reached Puta new section into place then reassemble all sections Star 8 Star 22J Putthe nuts back into place tightening torque 20 21 N m or 14 75 15 49 Ib ft Throughout the dismantling reassembly operation take great care to preserve cleanliness and place the seals correctly at the interfaces between sections Star 22 J Star 8 Pinguely Haulotte Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C139 Sheet 1 2 CHARGING THE TRACTION BATTERIES 1 Preliminary operations AN Caution Ensure that the mains supply is suitable for the charger s consumption and Do not use the machine voltage during the charging process Fill to the minimum electrolyte level if an element s level is below this mini mum e Work in a clean ventilated area away from naked flames AN Caution Use the machine s on board charger Its charge output is suited to the machine 2 Charging the batteries NB Charging starts automatically as soons as the mains supp
99. ng pressure limiter Photo 3 ref 2 Place a load corresponding to nominal load 10 in the platform Unscrew the lifting pressure limiter adjusting screw and connect a pres sure gauge of sufficient range to measure the lifting pressure which should not exceed 652 PSI 45 bar Liftthe mast and tighten the pressure limiter adjusting screw until the movements are disabled by nominal load 10 Placeaload corresponding to nominal load in the platform e Check that the lifting movement is not disabled for this load Putthe machine back into the operational configuration Switch the electric power supply back on again see relevant section Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C218 Sheet 2 2 ADJUSTING A HYDRAULIC PRESSURE LIMITER Photo 3 4 Adjusting the steering pressure limiter Photo 3 ref 3 Unscrew the cap of the hydraulic pressure tapping marked MX on the hydraulic block and connect a pressure gauge of sufficient range to measure steering pressure which should not exceed 1450 PSI 100 bar Switch the electric power supply back on again see relevant section Activate the steering control to its left or right limit Maintain the steering control and measure steering pressure on the pressure gauge NB Steering is disabled after a certain time when the machine is at its limit in one direction Only steering in the opposite direction is poosible and may re authorise
100. ng the mast Placethe caissons trestles Insert the 1st caisson in the bottom of the mast e Check the clearance between the 1st caisson and the bottom of the mast the gap should be between 1 and 2 mm at each end of the mast Adjust the gap with a set of adjustment wedges Check that the caisson works properly by sliding it manually Insert the 2nd caisson into the 1st Check the gap and adjust if necessary Check that the caisson works properly by sliding it manually Put stops back on the 1st caisson making it protrude by approxi mately 5 cm Insert the 3rd caisson in the 2nd Checkthe gap and adjust if necessary Check that the caisson works properly by sliding it manually Putthe stop back on the 2nd caisson making it protrude by approximately 5 cm e Check the gap between the 4th and 3rd caissons the gap should be between 1 and 2 mm at each end of the mast Adjust the gap with a set of adjustment wedges Check that the caisson works properly by sliding it manually Gap adjustment at reassembly Photo 10 Bottom of the mast 1st elevation 2nd elevation a Gap adjustment at reassembly Gap adjustment at reassembly 3rd elevation Photo 9 Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C198 Sheet 4 6 DISMANTLING REASSEMBLING THE MAST AN Caution THEN PERFORM THE DISMANTLING OPERATIONS SECTION 2 IN REVERSE After assembling the mast i
101. nipulator SM3 Measure voltage at CNB4 OV lt cursor lt 4V FOR contact 5V or REV contact 5V NO CNB4 24 V SC YES Replace manipulator See sheet C143 Repair the wiring SMS Measure voltage at output Measured voltage 24V es Replace the pedal See sheet 064 Repair the wiring Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART VASE DES NO FORWARD OR REVERSE TRAVEL MOVEMENT Measure voltage at terminals 1 and 15 of the chopper NO 1 24V and 15 24 V Replace the Serial board See sheet C063 Measure voltage directly on the brakes Repair the wiring between the brakes and the chopper Replace the chopper See sheet C003 Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART olle6tDFUG2 NO FORWARD OR REVERSE TRAVEL MOVEMENT Folio 4 4 Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP084 Folio 1 2 TRAVEL MOVEMENT IN MICROSPEED ONLY Travel movement microspeed Put the key switch in the Platform position Retract the mast and jib completely Measure voltage at terminal 36 of the chopper NO Measure voltage atthe terminals of SQ12 wire 36A YES Replace the See Sheet cho
102. notice Ger machine into the maintenance configuration see relevant sec ll Switch off the electric power supply see relevant section Remove the jib end of travel contactor ref 1 Disconnect the hydraulic distributor ref 2 of the jib cylinder bg Caution Disconnect the hoses of the steering cylinder Use a container to collect the Put caps the hoses oil to prevent pollution of the environmen 2 Removing the jib platform assembly Put the jib platform assembly into slings Unscrew the 7 screws ref 3 of the top cover ref 4 of the jib platform N Caution assembly It is essential to put the component into slings before dismantling reassembling it AN Caution Check that the lifting means are in good condition and of sufficient capacity Remove the assembly using a hoist 3 Reinstalling the jib platform assembly Put the jib platform assembly into slings Reinstall the assembly on the mast in order to secure the top cover ref 4 Screw the 7 screws of the jib platform top cover Reinstall the jib end of travel contactor Reconnect the hydraulic distributor of the jib cylinder ref 2 Reconnect the hoses to the jib cylinder ref 5 4 Additional operations Putthe machine back into the operational configuration Make several jib lifting movements to purge the hydraulic circuit Checkthe level of the hydraulic oil tank Pinguely Haulotte Pinguely Hau
103. nuts from the electric plate closing plate Photo 3 ref 3 Unscrew the other screws on the edge ofthe electric plate Photo 4 Pinguely Haulotte Sheet C214 Photo 6 Photo 7 CORRECTIVE MAINTENANCE SHEET REPLACING THE ELECTRIC PLATE Sheet 2 2 3 Reinstalling the electric plate Put back the electric plate checking the cable routes via the plate Fix the various elements horn 1 chopper 2 battery charger 3 tilt sensor 4 fuse holder 5 turntable box 6 collar and polypropylene tube 7 mast end of travel contactor support 8 on the plate Photo 5 Screw the stop collar of the spiral cable back into place Photo 7 ref 9 Screw the electric plate at its various fixing points Photo 6 Sa Photo 5 4 Additional operations Reconnect the charger to the socket Reconnect the hydraulic distribution block connections Reconnect the battery terminals Fix all the cables on the platform and jib Tighten all the cable clamps of all cables in the sleeve Tighten the cable sleeve with the fixing collars Reconnect the top panel plug Reconnect the travel motor cables Reconnect the steering cylinder hoses Reconnect the steering potentiometer plug Reconnect the plug of the electrovalve near the rotation motor Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C215 REPLACING THE JIB PLATFORM ASSEMBLY Sheet 1 1 AN Caution 1 Preliminary operations Ensure thatthe oll Is
104. ometer leaving a gap of 0 07 to 0 19 in 2 to 5 mm 14 between the potentiometer fixing nut and the wheel pivot fixing flat and fix the potentiometer support so that the head of the fixing screw does not touch the support Fixthe potentiometer using the BTR screws 2 Pinguely Haulotte Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET SHEET C147 Sheet 1 1 REMOVING REPLACING THE COVERS 1 Preliminary operations e Put the machine into the maintenance configuration see relevant sec tion Switch off the electric power supply see relevant section 2 Removing the motor cover 2 Unscrew the fixing screws 1 Remove the cover 2 3 Reinstalling the motor cover 2 Reinstall a cover 2 Tighten the fixing screws 1 4 Removing a side cover 3 First remove the motor cover 2 Manually unscrew the fins 4 Unscrew the screws 5 Remove the cover 3 5 Reinstalling a side cover 3 Puta new side cover into place 3 Screw the screws 5 and fins 4 back into place Reinstall the motor cover 2 6 Removing a pivoting turntable cover 6 Open the cover 6 and put it into slings Take the cover off its hinges 8 and remove 7 Reinstalling a pivoting turntable cover 6 Puta new cover into place 6 Remove the slings 8 Additional operations Check that the cover is properly anchored on the machine Putthe machine back into the operationa
105. on Puta new emergency stop button into place Reconnect the electric connections according to the marks made during dismantling 4 Test Reconnect the then terminals of the batteries Put machine back into the operational configuration Check that the emergency stop button works properly STAR 8 STAR 22 J HA12IP HA33JE HA15I HA43E Pinguely Haulotte Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET Sheet C209 Sheet 1 1 REPLACING THE BATTERY CHARGER A Preliminary operations AN Caution e Put the machine into the maintenance configuration see relevant section Battery servicing operations Switch off the electric power supply see relevant section reguire safety precautions wear gloves and protective 2 Removing the charger 1 goggles Mark and disconnect the electric connections 2 DF Remove the charger by removing its fixing screws and nuts 3 3 Reinstalling the charger 1 Perform the dismantling operations in reverse order to reassemble 4 Additional operations Putthe machine back into the operational configuration Pinguely Haulotte Sheet 210 AN Caution It is essential to put the component into slings before dismantling reassembling it Caution Ensure that the lifting means are in good condition and of sufficient capacity AN Caution Ensure that the oil is not too hot AN Caution Use a container
106. ons must be carried out more frequently and specific precautions must be taken consult PINGUELY HAULOTYTE After Sales Service for information Only authorised and competent personel may operate on the machine and must comply with the safety instructions related to Personnel and Environment protection Regularly check that the safety systems work properly IMPORTANT REMOVE ALL COVERS BEFORE WORKING ON THE TURNTABLE COMPONENTS 13 2 PARTICULAR RECOMMENDATIONS Before any maintenance intervention on the elevating platform indicate on the turntable and platform control stations that the machine is being serviced if possible restrict access to the elevating platform to intervention personnel only 13 2 1 Specific tools Personnel should therefore be familiar with the use of the specific tools used measurement device torque tightening device lifting apparatus etc and respect the operating limits specified in the documentation that is supplied with the tools Incorrect use of a tool incorrect adjusment after a reading error may lead to premature deterioration of the elevating platform or more seruously an accident for which PINGUELY HAULOTTE cannot be held responsible 13 2 2 Replacing an element Before replacing an element the machine must be put in the maintenance configuration see corresponding paragraph and the electric power supply cut off see corresponding paragraph All distributing valves are with open cen
107. ping at small pump output Make a mast up down movement Pressure 1450 PSI NO 100 bars down movement YES Pressure Zero NO See sheet Replace electrovalve 067 YV4 Test or replace the 1450 PSI 100 bars See sheet and 2320 PSI 160 C218 bars pressure limiters No down movement Manually test electrovalve YV3 Replace electrovalve See Sheet Operation correct NO Manually test electrovalve Test or replace the eo sheet pressure Replace electrovalve See sheet YV3 067 Operation correct NO Replace electrovalve See sheet YV6 C067 Replace electrovalve See sheet 067 YV5 Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP078 NO UP OR DOWN MAST MOVEMENT Folio 1 6 FROM THE TURNTABLE mastup or down movement from gt turntable Put the key switch in the Platform position Activate mast up down movement up or down YES Put the key switch in the Turntable position Activate mast up down movement Open the Turntable box and measure voltage at CNA 8 CNA 9 and CNA 10 of the turntable board Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP078 Folio 2 6 NO UP OR DOWN MAST MOVEMENT FROM THE TURNTABLE
108. point marked by a red spot on the ring Photo 4 Put the mast into slings 2 m slings to put it in the vertical position Photo 5 Photo 5 Prepare planks where the mast will be placed to protect the slew ring Position the mast in the vertical position Move the whole assembly forwards by lifting the mast with the hoist control Position the mast using the guides fixed on the chassis Photo 6 so that the trempe point Photo 4 is as close as possible to the mechanical stop of the chassis Photo 6 Tighten the screws in diagonally opposite pairs Prepare the screws to fix the ring to the chassis and apply loctite check ing that the thread is clean and totally grease free Insert two pins in two diagonally opposite screws threads of the chassis Tighten the screws one by one turning th mast from right to left Replace the pins with screws to fix to the ring to the chassis Photo 7 ref 1 Sheet 210 AN Caution After reinstalling the mast it is essential to have static and dynamic load tests performed by a certified organisation Pinguely Haulotte 77 CORRECTIVE MAINTENANCE SHEET NB Sheet 3 4 REPLACING THE SLEW RING Photo 7 Tighten to a torque of 99 Ibf ft 135Nm Tighten the screws in diago nally opposite pairs Check that the mast turns properly from stop to stop 4 Additional operations Remove the slings Check that the counterweights are properly secured to the machine Put the m
109. pper C003 YES NO Repair wiring between 5012 and chopper Visually check that 5012 is closed END NO 5012 is closed 5 Adjust or replace the See sheet C200 sensor Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP084 Folio 2 2 TRAVEL MOVEMENT IN MICROSPEED ONLY Measure voltage terminals of SQ4 wire 106 Visually check that 504 Repair the 2 504 is closed an NO END 504 is closed YES Adjust or replace the See sheet sensor C200 Repair the wiring between 504 and 42 Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP085 Folio 1 4 NO LEFT OR RIGHT STEERING MOVEMENT No left or right steering movement from the platform Put the key switch in the Platform position Activate left or right steering Open the Platform box and measure voltage at CN23 and of the platform board CN23 24V bas CNB6 0V Measure voltage at the terminals of selector switch SA2 SA2a 29A 24V SA2b OV Replace See sheet selector C004 Repair the wiring Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP085 Folio 2 4 NO LEFT OR RIGHT STEERING MOVEMENT Measure voltage at CN1 3 CN1 4 and CN1 5 ofthe pla
110. reen LED Number of flashes Meaning No error 1 Sensor n 1 line error pressure transducer J11 terminal block Sensor n 2 line error angle transducer J15 terminal block Pressure value is too low 2 3 4 Angle value is too low 5 Pressure value too low compared to the angle 6 Pressure value too high at zero angle 5 7 2 Card related errors D21 yellow LED Number of flashes Meaning 5 No error 1 Card related error Contact Pinguely Haulotte Card related error Contact Pinguely Haulotte Check the connections polarity round the relays Angle value is too low N Check that all the card s inputs are connected to service positive inlets and not directly to the batteries positive Replace the card 5 8 STARS 8 AND STARS 10 FUNCTIONING Load lt 115 Load gt 115 Deceleration Upper stop end Lower stop end of threshold of travel travel before upper stop The system works All movements as well as Lifting is performed at Jib lifting is Jib lowering is properly lifting and lowering are cut low speed from this deactivated deactivated off The buzzer sounds at threshold up to the regular intervals The red top position end of light indicator flashes travel A few degrees 5 to 10 before the upper stop a logical combination on the chopper s inlets reports the deceleration for the jib raising instruction It is possible to adjust the threshold
111. rntable 62 Defective wiring Defective serial board Defective manipulator SM1 Defective SB7 Defective SQ10 Defective chopper Defective coil Sheet DP080 Repair manual Pinguely Haulotte Z ANOMALY PROBABLE CAUSE SOLUTION Defective fuses Defective wiring Defective emergency stop button or station selection Defective chopper Defective serial board Sheet DP081 Defective manipulator SM2 Defective fail safe pedal Defective SB contactor Defective or discharged batteries No movement available from the platform Defective fuses Defective emergency stop button or station selection Defective chopper Defective serial board Defective manipulator SM1 Defective SB contactor Defective wiring Defective or discharged batteries No movement available from the turntable Sheet DP082 Defective wiring Defective selector switch Defective manipulator SM3 Defective fail safe pedal Defective serial board Defective chopper No forward or back travel Sheet DP083 movement Defective wiring Defective chopper 5012 incorrectly set or defective 504 incorrectly set defective Travel only in microspeed Sheet DP084 Defective wiring Defective selector switch Defective manipulator SM2 Defective fail safe Defective chopper Defective No right or left steering movement Sheet DP085 63 Pinguely Haulotte Z 64 Repair manu
112. rresponding paragraph Switch off electric power see corresponding paragraph Disconnect the then terminals of the starter battery 2 Removing the printed circuit Openthe turntable electric box Carefully mark and disconnect all the electric connections 1 of the prin ted circuit 2 e Remove the U1 electronic module 4 except STAR HA12IP and HA33JE see corresponding sheet Remove the bolts 3 fixing the board to the box and their sealing washers Remove the printed circuit and silent blocks equipping the fixing bolts STAR only disconnect the printed circuit s serial card 3 Installing the printed circuit Puta new printed circuit into place and fix using the bolts equipped with silent blocks sealing rings and new toothed washers STAR only Install the printed circuit s serial card Install the U1 electronic module except STAR HA12IP and HA33JE see corresponding sheet Reconnect the electric connections according to the marks made during dismantling Close the turntable box Reconnectthe then terminals of the starter battery Putthe machine back into the operational configuration Testthe printed circuit 4 Testing the printed circuit Perform the computer operating test see changing the U1 electronic module sheet except STAR HA121P and HA33JE HA12IP HA33JE HA15I HA43E Star 22J Star 8 Pinguely Haulotte Pingu
113. s top and bottom trays Switch off the electric power supply see relevant section Disconnect the two hoses of the steering cylinder see relevant sheet Disconnect the plug of the steering potentiometer see corresponding sheet Disconnect the travel motor connections see relevant sheet Unscrew the cable clamp of the cables inside the sleeve see relevant sheet Unscrew the cable sleeve fixing cables see relevant sheet Disconnect the mast lowering electrovalve plug near the rotation motor see relevant sheet Mark the position of the cables on the electric onnections of the hydraulic distribution block Unscrew the connections and remove the wires see relevant sheet Disconnect the electric connections of the pump see relevant sheet Disconnect the mast end of travel contactor see relevant sheet Disconnect the jib cylinder distribution block see relevant sheet Disconnect the jib end of travel contactor see relevant sheet Disconnect the top panel plug see relevant sheet Unscrew all the cable clamps on the platform Unscrew the collars on the jib Dismount the two bolts above the electric plate Unscrew the spiral cable stop collar Photo 7 ref 9 2 Removing the electric plate Unscrew the two fixing screws of the push button Photo 1 ref 1 with a BTR key Photo 1 Photo 2 Pull the wire of the charger s 220V plug Photo 2 ref 2 Unscrew the horn screw Photo 3 ref 2 Unscrew and remove the 4
114. s turned off or traction is required before traction authorization occurs Machine problem contact After Sales service CAPACITOR CHARGE The test is executed during the initial diagnosis The alarm switches on if 500 m after the ignition key has been turned off condensers have not started to load A probable reason for that is a default in the power unit Replace the chopper R VMN NOT OK The test is executed at rest main switch off and during operation If the VMN is inferior to the battery voltage and the machine is at rest then the chop per switches to an alarm state While working the alarm switches ON if the VMN does not follow the duty cycle of the chopper Possible reasons Incorrect motor connection Current leakage to the ground Default in the power unit Check the right travel motor and its wiring sock If they are correct replace the chopper L VMN NOT OK The test is executed at rest main switch off and during operation If the VMN is inferior to the battery voltage and the machine is at rest then the chop per switches to an alarm state While working the alarm switches ON if the VMN does not follow the duty cycle of the chopper Possible reasons Incorrect motor connection Current leakage to the ground Default in the power unit Check the left travel motor and its wiring sock If they are correct replace the chopper 58 V
115. steering in the initial direction The steering pressure measurement time is therefore limited Putthe machine into the maintenance configuration see relevant sec tion Switch off the electric power supply see relevant section Unscrew the pressure gauge and put back the hydraulic pressure tapping cap Putthe machine back into the operational configuration Make several steering movements to check that the machine works properly
116. t output See sheet C064 Replace the pedal Repair the wiring Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP075 Folio 3 6 NO UP OR DOWN JIB MOVEMENT FROM THE PLATFORM No down movement No up movement Check battery charge Battery charge NO OK WES See sheet Charge the batteries C139 Put the key switch in the Platform position and activate jib movement No down movement Y No up movement The pump works SO Check pump wiring Measure voltage at termi nals 18 and 19 of the chopper Wiring is correc NO 18 24V 104 19 24V 104 up down 5 heet YES Replace the chopper ui See sheet Replace the chopper C003 Repair the wiring Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART NO UP OR DOWN JIB MOVEMENT Folio 4 6 FROM THE PLATFORM Measure voltage at the terminals of electrovalves YV3a and YV5 24 V u and YV5 24 V up down NO Repair the wiring between the chopper and the electrovalves See sheet C145 Replace the coil The problem persists Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheel Dre NO UP OR DOWN JIB MOVEMENT Folio 5 6 FROM THE PLATFORM
117. t see relevant sheet Reinstall the rotation motor see relevant sheet Reinstall the hydraulic block assembly see relevant sheet Reinstall the hydraulic tank see relevant sheet e Reinstall the pump see relevant sheet Reinstall the hydraulic filter see relevant sheet Reinstall the hydraulic plate see relevant sheet Reinstall the electric plate see relevant sheet Reinstall the end of travel contactor 5010 see relevant sheet Reinstall the charger see relevant sheet Reinstall the circuit breaker see relevant sheet Reinstall the jib see relevant sheet Reinstall the end of travel contactor 5012 see relevant sheet Reinstall the hydraulic supply hose at the top of the mast Reinstall the hydraulic winder see relevant sheet Reinstall the end of travel contactors SQ3 and 504 and the sheet covering them see relevant sheet Reconnect pump supply Reinstall and reconnect the batteries see relevant sheets Reinstall the bottom right and left covers see relevant sheet Reinstall the motor cover see relevant sheet Reinstall the right and left side covers see relevant sheet Putthe machine back into the operational configuration Make several movements to check correct machine operation and safety Systems Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C200 Sheet 1 1 REPLACING AN END OF TRAVEL CONTACTOR 1 Preliminary operations
118. t selector C004 Repair the wiring Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP077 Folio 2 6 NO UP OR DOWN MAST MOVEMENT FROM THE PLATFORM Measure voltage at CN1 9 CN1 10 and CN1 8 on the platform board CN1 8 0V idle CN1 8 OV at 4V CN1 10 5V amp CN 1 9 0V UP CN1 10 0V CN1 9 5 NO Follow the same wire colours and measure voltage at the terminals of manipulator SM3 Measure voltage at CNB4 OV lt cursor lt 4V FOR contact 5V or NO CNB4 24 V NO REV contact 5V Replace manipulator See sheet YES SM3 142 Repair the wiring Replace the Serial See sheet board C063 END voltage at output oltage measured NO See sheet Replace the pedal Repair the wiring P P 064 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet 077 NO UP OR DOWN MAST MOVEMENT Folio 3 6 FROM THE PLATFORM No down movement No up movement Measure voltage at terminal 24 of the chopper Voltage measured NO 24 V Check if the mast is at its max height gt l ax height reached YES Lower the mast Measure voltage at SQ10 NO Replace the sensor See sheet C200 Repair the wiring
119. t suivant selection 10 6 STEERING Possible directions E right or left Sens possible droite ou gauthe 43 Pinguely Haulotte Z 44 Repair manual Pinguely Haulotte 11 POSITION OF HYDRAULIC COMPONENTS 1 YV1 Steering electrovalve 2 YV2 Turntable rotation motor electrovalve 3 YV3 Pump flow accumulation electrovalve 4 YV4 Electrovalve maintaining lifting or lowering movements At rest lowering if YV6 1 5 YV5 Electrovalve selecting power supply At rest powers the telescopic cylinder small chamber feeding the mast working powers the jib 6 Position valve 7 YV6 Electrovalve maintaining the lifting telescopic cylinder lowering movement 8 Main pressure regulating valve adjusted at 160 bars 9 Lifting pressure regulating valve adjusted at 45 bars 10 Emergency lowering manual tap 11 YV6 Emergency lowering electrovalve 12 Emergency pump 13 Steering pressure regulating valve adjusted at 100 bars 2 Orientation YV2a and YVb T Steering YV1a and YV1b Pump coupling selec tion and winder feed ing control Jib mast lowering control 3 YV3 a amp YV3 b maxi mum pressure 100 bars Mast raising YV4 Lifting pressure regulating valve 45 Pinguely Haulotte Repair manual 46 Repair manual 12 1
120. t ORDER TO REASSEMBLE is essential to have static and dynamic load tests facilitate caisson sliding use a synthetic lubricant spray see section listing carried out by a certified Consumables recommended by Pinguely Haulotte organisation 4 Adjustment of pads after assembling the mast Raise the mast to the start of the 3rd caisson Check the gap between the 4th and 3rd caissons between 1 and 2 mm using thickness wedges on the front side and right and left sides of the mast Photo 11 4th caisson 3rd caisson Gap check be tween 1 and 2 mm REAR Bottom of the mast Adjusting screws Side gap right and left between 1 and 2 mm Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C198 Sheet 5 6 DISMANTLING REASSEMBLING THE MAST If necessary adjust this gap using the two adjusting screws on the side NB Repeat this operation between the 3rd and 2nd caisson between the 2nd and 1st caisson and finally between the 1st caisson and the bottom of the mast NB If the side gap is less than 1 mm there must be a blockage The mast must be dismantled and reassembled Adjusting screws Photo 12 Gap adjusting screw for assembled mast Photo 13 Pinguely Haulotte MAINTENANCE SHEET Sheet C198 Sheet 6 6 DISMANTLING REASSEMBLING THE MAST 5 Additional operations Reinstall the cable sleeve support see relevant sheet Reinstall the counterweigh
121. teries note the density m of each element once a month using a battery hydrometer as a func tion of temperature using the graph below do not measure directly af ter filling STOP Do not recharge Recharge RECHARGE IMMEDIATELY 1 30 59 Fahrenheit 15 86 Fahrenheit 3 113 Fahrenheit 4 p o o oe oe OY o N oe o oe Electrolyte freezing point in Fahrenheit C for densities noted at 86 Fahrenheit 30 State of charge of a battery as a function of density and temperature Pinguely Haulotte PREVENTIVE MAINTENANCE SHEET Sheet P010 Folio 2 2 CHECKING SERVICING THE TRACTION BATTERIES Pinguely Haulotte 77 PREVENTIVE MAINTENANCE SHEET SHEET P011 Folio 1 1 LUBRICATING THE MAST 1 Lubricating the mast Extend the mast Switch off the electric power supply see relevant section Grease the slides at pad level using a spatula Grease the pads at the back of the machine NB Only use lubricants recommended by the manufacturer Putthe machine back into the operational configuration Pinguely Haulotte PREVENTIVE MAINTENANCE SHEET Repair manual Pinguely Haulotte Z 15 OPERATING INCIDENTS REMINDER Respecting the machine s operating and servicing instructions will enable you to avoid most incidents However certain incidents may arise and before any int
122. tform board NO CN1 3 0V idle CN1 3 0V at 4V CN1 5 5V amp CN1 4 0V up CN1 5 0V amp CN1 4 5V down Follow the same wire colors and measure voltage at the terminals of manipulator SM2 OV lt cursor lt 4V FOR contact 5V or REV contact 5V Measure voltage at CNB4 Replace manipulator See sheet SM2 C14 CNB4 24 V NO Repair the wiring YES END Measure voltage at pedal output Voltage measured NO 24 YES Repair the wiring Seesheet C064 Replace the pedal Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP085 NO LEFT OR RIGHT Folio 3 4 STEERING MOVEMENT NO The pump works Check pump wiring Measure voltage at terminals 6 12 and 20 of the chopper 24V 104 right 12 24V 104 left right 20 24V 104 left See sheet Replace the chopper C003 See sheet Replace the chopper C003 Repair the wiring Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP085 Folio 4 4 NO LEFT OR RIGHT STEERING MOVEMENT Measure voltage at the terminals of electrovalves YV1a YV1b and YB3b YV1a 24 right YV1b 24 left and YV3a 24 V left right Repair the wiring between the chopper and the electrovalves
123. to collect the oil to prevent pollution of the environment Photo 1 Photo 2 Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet 1 4 REPLACING THE SLEW RING 1 Preliminary operations Putthe machine into the maintenance configuration see relevant sec tion Switch off the electric power supply see relevant section Disconnect and remove the batteries see relevant sheet Remove the covers see relevant sheet Remove the hand pump see relevant sheet Remove the end of travel contactors see relevant sheet Remove the hydraulic winder see relevant sheet Remove the hydraulic supply hose from the top of the mast Remove the jib plus basket assembly see relevant sheet Remove the circuit breaker see relevant sheet Remove the charger see relevant sheet Remove the electric plate see relevant sheet Remove the hydraulic filter see relevant sheet Remove the pump see relevant sheet Remove the hydraulic tank see relevant sheet Remove the hydraulic unit see relevant sheet Remove the rotation motor see relevant sheet Remove the counterweights see relevant sheet Remove the cable sleeve support see relevant sheet Remove the mast see sheet 198 and place on trestles Photo 1 NB Unscrew the hydraulic hoses slowly to release residual pressure NB Put caps on the hoses NB Only use greases and lubricants recommended by the manufac
124. tre breaking the electric circuit therefore decreases pressure in the hydraulic circuits up to the non return valves flanged on the cylinders An element van be replaced safely if the procedures described in the maintenance sheets are respected unscrew hydraulic connectors slowly to release residual pressure To preserve the integrity of the safety systems ans the technical characteristics of the elevating platform it is essential to use original parts and to respect the initial setting and tightening torque value see correspondning paragraph 51 Pinguely Haulotte Z Repair manual 13 2 3 Locating the breakdown certains checks reguire the elevating platform to be switch on In this case personnel must ensure thatthe measurement devices used are properly insluated thatthey do not touch the live parts thatthey not wearing or carriyng metal objects that may deterio rate the live components e g dropping a spanner during an interven tion on the batteries 13 3 MAINTENANCE SYSTEM Maintenance configuration Position the elevating platform on a firm horizontal surface f possible fold the machine completely 13 4 ELECTRIC POWER SUPPLY Instructions Cutting off the electric power supply Press the turntable emergency stop ref 1 Photo 1 page 52 Photo 1 Restoring the electric power supply Reset the emergency stop Photo 1 page 52 52 Repair manual 13 5 MAINTENANCE
125. turer see relevant section 2 Removing the slew ring Unscrew the 12 screws fixing the ring to the mast Photo 2 Separate the ring assembly from the main mast caisson 3 Reinstalling a new slew ring Screw the slew ring onto its support using new screws class 8 8 14 65 34 and loctite to a torque of 99 ft lb 135Nm photo 3 ref 1 Photo 3 Grease generously Photo 3 ref 2 Putthe assembled slew ring and its support into slings Position the assembly opposite the mast cylinder e Screw the fixing plate to the centre of the slew ring Photo ref 3 Make sure there is no grease on the threads Re secure the support ring assembly to the mast with 12 screws class 8 8 HM16x100 38 and loctite Photo 2 Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C210 Sheet 2 4 REPLACING THE SLEW RING NB Photo 4 Caution Before reassembling the mast rotation motor check that the cable sleeve is free to move around the whole rotation Caution If safety parts are replaced they must be validated with NB static tests CE 1 25 x nominal USA 1 5 x nominal Start by putting in the screws on one side and adjust the mast posi tion with the sling to adjust the position ofthe ring assembly Tighten to torque of 143 Ibf ft 195Nm for the ring mast fixture and 99 ft lb 135Nm for the ring support fixture using a torque wrench Turn the ring to the Trempe
126. uld be audible from the basket HA12IP HA33JE Pinguely Haulotte Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C060 Sheet 1 1 CHANGING THE HAND PUMP 1 Preliminary operations AN Caution e machine in the maintenance configuration Use a container to collect oil to prevent pollution of the 2 Removing the hand pump environment Mark and disconnect the hydraulic hoses 2 from the hand pump 1 NB Unscrew the hoses slowly to release residual hydraulic pressure Fitcaps to the hoses Remove the union pieces 3 from the hand pump Remove the hand pump by removing its fixing bolts 5 1 Installing the hand pump Puta new hand pump into place and fix using the fixing bolts Replace the non return valve 6 if necessary Install the union pieces on the pump Reconnect the hydraulic hoses according to the marks made during dis mantling e Put machine back into the operational configuration Close the decompression valve 4 Perform an emergency operation to check that the hand pump works perly see Operation and Maintenance Instructions manual Open the decompression valve Star 22 J Star 8 HAT2IP Pinguely Haulotte Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C063 Sheet 1 1 CHANGING THE PRINTED CIRCUIT 1 Preliminary operations Putthe machine in the maintenance configuration see co
127. urntable position Activate mast right left rotation movement Open the Turntable box and measure voltage at CNA 8 CNA 9 and CNA 10 ofthe turntable board Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP080 NO RIGHT OR LEFT ROTATIONAL MAST MOVEMENT CNA 8 0V idle CNA 8 0V at 4V down CNA 10 5V amp CNA 9 0V up CNA 10 0V amp CNA 9 5V Folio 2 6 FROM THE TURNTABLE NO Follow the same wire colours and measure voltage at the terminals of manipulator SM1 Measure voltage at CNB R CNB R 24 V YES OV lt cursor lt 4V FOR contact 5V or REV contact 5V Replace the Serial board NO Replace manipulator See sheet SM1 C143 Repair the wiring See sheet C063 END Measure voltage at 587 output era NO YES See sheet Replace the button Repair the wiring P C004 Pinguely Haulotte BREAKDOWN DETECTION FLOW CHART Sheet DP080 NO RIGHT OR LEFT ROTATIONAL MAST MOVEMENT Folio 3 6 FROM THE TURNTABLE Put the key switch in the Turntable position and activate mast movement NO The pump works Measure voltage at terminals 7 and 8 of the chopper 7 24V 104 left 8 24V 104 right YES See sheet Replace the chopper C003 Chec
128. usting test is executed during the initial diagnosis at rest It maintains that the current is superior to a RIGHT STBY minimum threshold In the opposite case the HIGH chopper switches the alarm ON while blocking the Induction current problem 10 machine detected on ignition LEFT STBY Possible reasons for failure Replace the chopper HIGH Sensor is out of order Fault in the measure circuit the logic circuit or in the power test is executed while working It checks that the current is superior to a threshold value In the Induction current problem RIGHT 0 EVER i 11 opposite case the chopper switches the alarm ON detected during operation LEFT 0 EVER i i while blocking the machine e Replace the chopper Possible reasons see STBY HIGH e Malfunction in the field current The field current at pestis e Inductor current problem HIGH FIELD Possible reasons for failure to indicate nil field 12 detected on ignition CURRENT current the chabbar Malfunction in the current detector Faultin the power unit of the field Malfunction in the field current While working the NO FIELD field curent is nil Inductor current problem 13 CURRENT Possible reasons detected on ignition Malfunction in the current detector Replace the chopper Fault in the power unit e The test is executed with the main switch SB1 open Check that the ma
129. with new toothed washers Putback the union connectors Reconnect the hydraulic hoses according to the marks made during dis mantling Reconnectthe electrovalves of the hydraulic block according to the marks made during dismantling Putthe machine back into the operational configuration Make several movement cycles using the hydraulic block in question to purge the hydraulic circuit Checkthe level in the hydraulic oil tank see relevant sheet Close the covers again NB Check the chopper software version when changing the block up to version 1 03 for blocks with two pressure limiters from version 1 05 for blocks with three pressure limiters For US machines version from 1 04 US Pinguely Haulotte Pinguely Haulotte CORRECTIVE MAINTENANCE SHEET Sheet C203 Sheet 1 1 REPLACING THE MOTORPUMP UNIT 1 Preliminary operations AN Caution e Put the machine into the maintenance configuration see relevant sec Ensure that the oil is not too tion hot Switch off the electric power supply see relevant section 2 Removing the motorpump unit AN Caution Mark and disconnect the electric connections of the motor pump unit 1 Mark and disconnect the four hoses 2 of the hydraulic pumps Put caps on the hoses Remove the fixing collar 3 of the motorpump unit and remove the unit Remove the suction and discharge flanges 4 of the large pump Use a container to collect the oil
130. y fuse 05 5A Work headlight protection option 4 1 3 Control inputs SA1 Station selection switch turntable panel SA2 Movement selection switch platform panel SB1 Emergency stop line contactor SB3 Emergency stop platform SB5 Jib control turntable panel SB6 Mast control turntable SB7 Turntable rotation control SB8 Platform movement validation SB9 Horn platform SM1 Turntable up down orientation manipulator SM2 Platform orientation steering manipulator SM3 Platform travel manipulator Brake release control option 4 1 4 Safety inputs SQ1 Tilt SQ4 Tilt reset jib safety system gt 0 5010 end oftravel safety sensor mast 5012 Tilt reset Bottom end of travel safety sensor mast B2 Pressure sensor weighing P1 Steering potentiometer P2 Angle sensor weighing 4 1 5 Relays Overload relay inactive RL2 Insulation relay RCH Internal charger relay 21 22 Pinguely Haulotte Z Repair manual 4 1 6 Electrovalve logic outputs YVia Right steer YV1b Left steer YV2a Left orientation YV2b Right orientation YV3a Jib up or mast down YV3b Mast up YV4 Mast up YV5 Jib down or jib up YV6 Mast down 4 1 7 Management elements U1 Charger U2 Chopper U3 Turntable serial card U4 Platform serial card 4 1 8 Sound indicator

STAR 8 GB.book

Contents

Download Pdf Manuals

Related Search

Related Contents