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repair manual - AJ Maskin AS

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1. EJ SVNAHOS 666L v0 0 HZ3Naa ugpgu4 SEK EEE d NOLLVOISINSA Hd SISA Z ve 62 LL v0 MEL erquuoigd 7 vaara 6661 70 80 pom ia wane IJLLOINVH ATINDNId d 1VLOL 3H8N VSIA NOILVOISIGOW dLScH E CH L NOLLV3YO Vd 3NISS30 4 10 IN 1 gt gt m g o i i z 2 2 E TE j a 2 2 E 8 2 9 E E E E E E o E a o E 8 3 g 3 E a 8 a 9 5 3 3 2 8 9 S 3 3 8 3 8 8 8 8 8 3 3 3 lt 9 zbz 0z 0 Los lt e e e 02 20 v cN Pinguely Haulotte 2 Repair manual FOLIO 05 05 r GO SVIN3HOS 666L 0 0 BAZINA ugp ta SNORT ES vesta NOILVOIJIMH3A 30 31vG UVd SU IIR VIEJO S 666L 0 0Z O18074 IG ISTE TV1O1 VSIA NOILVOISIGOW d1SCH ECH L L CH NOLLV3YO 31va SNISSSG 9 lt 11 10 ros 01 40 IN o o o Fb bede ez e ele N 1 AA I 4 4 EM YM GAA BA
2. 2m 12 pe dn 2 ET 2 7 Sheet C086 Caution Ensure that the oil is not too hot AN Caution Use a container to collect oil to prevent pollution of the environment A Caution It is essential to put the component in slings before dismantling re assembling it Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET DISMANTLING AND RE ASSEMBLING Folio 1 2 THE STEERING SYSTEM 1 Preliminary operations Put the machine in the maintenance configuration see 6 3 Switch off electric power see 6 4 2 Removing a steering bar NB Remove the fixing screw 1 from the two steering clevis pins 2 Remove the two steering clevis pins 2 Unscrew the counter nut 11 Remove the steering bar 3 Repeat the operation 2 for the other side 3 Removing the steering lever section B B Remove the Nylstop nut 4 and the washer 5 from the cylinder fastening pin Remove the cylinder fastening pin 6 Remove the male clevis 12 Remove the screws and washers 13 14 then the central steering pin 8 Remove the steering lever 9 4 Installing the steering lever NB When re installing the pins take the measures necessary to avoid damanging the pins rings and bores Replace the pins an
3. 5 he EL UN3143934 NOLLV LOM 13HSV4 Y3INVA NOLLV LOY Lor T3A31WHOdJ1V1d FON NOI LVSNIANOD NOISNHLXH WOO8 31V108 J19YLNYNL 3SVdOO9S3131 SATISYNOL NOLLVIN3IHO 3TXV3NION3 YNILON naissa NOLLVISNVHL NOILVISNVEL DIAGRAM H23TP H25TP REFERENCE B15330 3 Repair manual 5 33 Repair manua Pinguely Haulotte Z DIAGRAM H23TPX H25TPX REFERENCE B15331 5 4 7 6919 woog air SYIVINGNAd 15 15 o o E BZ ES d EZ NOLLVLOH 13HSV4 H3INVd NOLLVLOH GAK IZ UN314393U T3AFTWHOALVTId NOIIVSN3d NOI NOLIVISNVEL NOUVISNVEL aua La E 7
4. YV13 NO YES Open the turntable control panel Press the pedal and make a forward See Fiche Replace the coil of the travel movement C059 electrovalve Check for 12V voltage at the terminals of the printed circuit associated with the electrovalve in question 807A for YV9 END e 807B for YV13 NO YES Replace the U1 module 22 107 Replace the wiring harness between the turntable control panel and the electrovalve in question YV9 and YV13 The fault persists END Replace the printed circuit See Fiche C063 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP036 Folio 3 3 NO DIFFERENTIAL BLOCKING WHEN SWITCH SA3 IS ACTIVATED Open the platform control panel Press the pedal activate switch SA3 and check the setpoint at the output of switch SA3 807 Setpoint Replace See Fiche 12V switch SA3 C044 END Open the turntable control panel Maintain the pedal and switch SA3 activated Check for 12V voltage on terminal 807 of the printed circuit NO Replace wiring harness no 807 YES Make sure that switch SA11 is in the LS low speed or MS me dium speed position LS and MS not a See Fiche DP034 available Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP041 Folio 1 1 THE MOTOR STARTS THEN STOPS AFTER 5 SECS
5. 6 7 3 Red labels Composant sp cifique NE PAS INTERCHANGER Component specific GB to this machine DO NOT INTERCHANGE Komponenten nur f r diese maschine geeignet D BITTE AUF EINE ANDERE INE NIGHT MONTIEREN N MACHINE MASCHINE N 7814 518 400 N 40 kg Repair manual 400 N 40 kg 7814 432 400 N 40 Pinguely Haulotte 2 Repair manual 6 7 4 Other labels 7814 368 77 6 7 5 Option 76 B O 7814 889 45 Pinguely Haulotte 2 Repair manual 6 7 6 Positions of labels Ref Code Qty Description 3078143240a Manufacturer s plate French 3078143250a Manufacturer s plate Spanish 3078143260b Manufacturer s plate German 3078143270a Manufacturer s plate English 1 3078143280a 1 Manufacturer s plate Italian 3078143290a Manufacturer s plate Dutch 3078144960a Manufacturer s plate Danish 3078145550a Manufacturer s plate Finnish 3078145840a
6. Figure 3 Position of contacts Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C111 Folio 1 2 ADJUSTING A PRESSURE LIMITER A Caution NB Before an adjustment operation operate the machine so that the oil in the tank is at a t t f FR ER in the tank is at a temperature of around 50 hot 1 Adjusting the load sensing pressure 2 fig 1 standby pressure Putthe machine in the maintenance configuration see S 6 3 Switch off electric power see S 6 4 Caution Unscrew the minimess hydraulic pressure tapping cap 3 on the distribu Use a container to collect oil tion block and connect a pressure gauge of at least 0 to 300 bar to prevent pollution of the Switch electric power on again see S 6 4 and start the motor environment Without activating a movement measure pressure on the gauge Adjust the cup point hexagonal screw on the pressure limiter 2 of the hydraulic pump if necessary until the pressure gauge shows the pressure Figure 1 indicated in 8 5 Putthe machine in the maintenance configuration see S 6 3 Switch off electric power see S 6 4 Unscrew the pressure gauge and put back the hydraulic pressure tapping cap Putthe machine back in the operational configuration Make several machine extension movements to check operation 2 Adjusting the main pressure limiter 1 fig 1 flow cancellation Putthe machine in the maintenance configuration
7. BAA LA 9AA EA HILSYN YNALLAWA EE have NOLLVLOH LIMSVE H3INVd NOLIVLOH 3AVTS unaloadad TJA3 1 WHOAAV Id NOLIVSN3dWOO NOISNALX4 WOO8 i 39VdO09ST131 31V108 ATEVLNENL 3NIDN3 FIXV HOLO3HIG ATIAYNOL NOIIVINIIHO EN3LOMN 553 unaloa3ula N31SS3 NOLLWISNVEL NOLLWISNVEL DIAGRAM H21TX H23TX REFERENCE B15713 Pinguely Haulotte 2 5 2 32 9082519 15 NOI19341q TT e Pinguely Haulotte 2 215 oi 4 1 woog air YILSYW YNILLINI
8. The motor starts then stops after 5 seconds Check the level of the diesel tank Fill the diesel tank END Check the diesel supply circuit See motor manufacturer s manual NO Repair the diesel supply circuit See motor manufacturer s manual YES Check the state of the motor safety systems END motor oil pressure battery charge and replace the defective component See motor manufacturer s manual Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP042 NO TURNTABLE ROTATION MOVEMENT Folio 1 4 RIGHT AND OR LEFT FROM THE PLATFORM No turntable rotation movement right and or left from the platform or turntable control panel Place the key switch in the turntable or platform position Activate the rotation switch from the turntable control panel SA15 or the rotation manipulator SM31 from the platform con trol panel pedal activated Movement NO OK i YES Open the platform or turntable control panel and check the wiring of the rotation manipulator SM31 or rotation switch SA15 NO Repair wiring YES Turntable panel Platform panel END Y rotation fault rotation fault Place the key switch in the turntable Place the key switch in the platform position position Open the platform control panel Open the turntable control p
9. u a Su a alcista tos 45 6 7 6 Positions of labels 46 6 7 7 Positionnement des Giguet 47 6 8 PRESENCE OF MANYALS En re 48 7 PREVENTIVE MAINTENANCE SHEETS 49 Pinguely Haulotte Repair Manual 8 OPERATING Tel KC 57 Gils INCIDENT TABEE rnit nnd 57 8 1 1 General operation 58 Gte a ERING a aA PME OT a dell 60 MIU Ec EE 61 E SERGE uu e x mE MIDI MM DM DM M E 61 L Tumtable rotation Eau si 62 8 2 BREAKDOWN DETECTION FLOW CHARTS iii 62 9 CORRECTIVE MAINTENANCE 44 139 Operating and maintenance instructions Pinguely Haulotte 1 GENERAL RECOMMENDATIONS SAFETY 1 1 GENERAL WARNING 1 1 1 Manual This manual aims to help maintenance personnel service and repair the machine lt cannot however replace the basic training required by any person working on the site equipment The site manager must inform operators of the recommendations in the instruction manual He is also responsible for application of current user regulations in the country of use Before operating on the machine it is essential to be familiar with all the recommendations in this manual and the user manual to ensure personnel and equipment safety 1 1 2 Label Potential dangers and recommendations for the machine are i
10. 2 SPECIFICATION The self propelled elevating work platforms models H21T X H23T X H23TP X H25TP X are designed to carry out all kinds of overhead work within the limits imposed by their characteristics see Operation and maintenance instruction manual and Chapitre 2 1 page 8 and provided that all safety instructions relating to the equipment and environment of use are respected The main control panel is situated in the platform The control panel situated on the turntable is to be used in emergencies or cases of machine breakdown REMINDER When requesting information intervention or spare parts you will need to specify the machine type and serial number Repair manual Pinguely Haulotte 2 2 1 TECHNICAL DATA 2 1 1 H21T X and H23TP X technical data DESCRIPTION H21T H21TX H23TP H23TPX Load 360 kg including 3 people 250 kg including 2 people Maximum side manual force 40 kg Max wind speed 60 km h Floor height 18 8m 18 8 m 20 6 m 20 6 m Working height 20 8 m 20 8 m 22 6 m 22 6 Overall length 8 91 m 8 91 m 11 05 m 11 05 m Overall width 2 47 m Overall height 2 84 Wheelbase 2 49 m Floor clearance 340 mm Max reach 16 66 m 16 66 m 19 5 m 19 5 m Boom displacement 75 15 Telescoping stroke 4 76 m Turntable rotation Continuous Reducing gear 22 4 Max slope in travel 40 Tyr
11. Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP060 Folio 1 4 NO STEERING MOVEMENT RIGHT OR LEFT No steering movement right or left Place the key switch in the platform position Press the pedal and activate the basket rotation switch on the platform control panel he basket rotates Stop the movement and release the pedal Open the turntable control panel and check that the LED associated with electrovalve YV16A or YV16B is off NO Press the pedal and activate the REAR steering manipulator SM4 Check that the LED associated with electrovalve YV16A or YV16B is on YES YES Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP060 NO STEERING MOVEMENT RIGHT OR LEFT Press the pedal and activate the of the PVG YV2a connector REAR steering manipulator SM4 and check for 12V voltage at the terminals See Fiche C108 Replace the PVG YV2 control head Folio 2 4 Open the turntable control panel Press the pedal and activate the REAR steering manipulator SM4 and check for 12V voltage on terminal 305 of the printed circuit YES NO Repair the connection or replace the wiring harness between the turntable control panel and the PVG YV2 See Fiche C107 Replace the U1 module The fault NO persists Replace the See Fiche C063
12. Putback the pin 3 on the rod side and fix with its stop screw Reconnect the boom lifting cylinder s two hydraulic hoses 4 Additional operations Remove the slings from the boom Ensure that there is enough oil in the hydraulic tank Putthe machine back in the operational configuration Make several boom lifting movements to test operation and purge the hydraulic circuit Checkthe level of the hydraulic circuit Pinguely Haulotte 4 Sheet C116 CORRECTIVE MAINTENANCE SHEET Folio 2 2 CHANGING THE BOOM LIFTING CYLINDER FENN EEA 1 b Y i h 1 1 I b i 1 1 u 1 Ee wir 3 TN AEN D ul 1 att DI 72745 AAA 0 Sheet C117 Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Folio 1 2 CHANGING THE TURNTABLE ROTATION REDUCING GEAR 1 Preliminary operations N A 1 Lift the boom to enable access to the turntable rotation reducing gear 1 Wedge the boom to take its weight place on firm supports Put the machine in the maintenance configuration see S 6 3 Switch off electric power see 6 4 Remove the turntable rotation hydraulic motor 5 see corresponding sheet Removing the turntable rotation reducing gear Release then unscrew the counter nuts and screws 2 as far as possible Tighten the screws 2 as far as possible Release the counter
13. Switch off electric power see 6 4 If necessary close the shut off valve or empty the hydraulic tank 2 Removing the hydraulic motor NB Mark and disconnect the two hoses 1 of the hydraulic motor 3 Unscrew the hoses slowly to release residual hydraulic pressure Put caps on the hoses Place a wedge under the hydraulic motor Remove its two fixing screws 2 Remove the hydraulic motor Remove the blocking screws from the keyed sleeve at the end of the motor shaft Remove and retain the keyed sleeve Installing the hydraulic motor Put the keyed sleeve back at the end of the motor shaft coat the blocking screw with blue loctite Put a new hydraulic motor into place Fix the hydraulic motor with the two fixing screws equipped with new spring washers Reconnect the hydraulic hoses according to the marks made during dis mantling 4 Additional operations Remove the boom wedge Put the machine back in the operational configuration Make several turntable rotation movements to purge the hydraulic circuit Check the level of the hydraulic oil tank Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C099 CHANGING THE TURNTABLE ROTATION Folio 2 2 HYDRAULIC MOTOR Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C100 Folio 1 2 CHANGING THE SWING JOINT ASSEMBLY 1 Preliminary operations A Caution Lift the boom sufficiently to enable access to the swing joint
14. Haul ot t e b Bil 8 Y 2490 10777 12871 2478 2084 aut fot ta 340 13 Pinguely Haulotte Z 2 3 14 TIGHTENING TORQUE VALUES Nominal diameter M 6 1 Repair manual 2 3 1 Tightening torque values for large threading 9 to 11 Tightening torque in N M 10 9 13 to 14 15 to 17 M 7 1 15 to 19 21 to 24 26 to 28 M 8 1 25 22 to 27 31 to 34 37 to 41 M 10 1 5 43 to 45 61 to 67 73 to 81 M 12 1 75 75 to 94 110 to 120 130 to 140 M 14 2 120 to 150 170 to 190 200 to 220 M 16 2 190 to 230 260 to 290 320 to 350 M 18 2 5 260 to 320 360 to 400 440 to 480 M 20 2 5 370 to 450 520 to 570 620 to 680 M 22 2 5 500 to 620 700 to 770 840 to 930 M 24 3 3 630 to 790 890 to 990 1070 to 1180 M 27 3 930 to 1150 1300 to 1400 1560 to 1730 M 30 3 5 1260 to 1570 1770 to 1960 2200 to 2350 2 3 2 Tightening torque values for narrow threading Tightening torque in N M Nominal diameter 10 9 M 8 1 24 to 29 331037 40 to 44 M 10 1 25 46 to 57 64 to 71 77 to 85 12 1 25 83 to 100 120 to 130 140 to 150 M 14 1 5 130 to 160 180 to 200 220 to 240 M 16 1 5 200 to 250 280 to 310 340 to 370 M 18 1 5 290 to 360 410 to 450 490 to 540 M 20 1 5 410 t
15. lt gt E Open the turntable control panel YES Press the pedal and make a See Fiche forward travel movement C059 Replace the coil of Check for 12V voltage at terminal electrovalve YV10 814A of the printed circuit NO 12V OK YES Replace the U1 module See Fiche Replace the wiring harness between C058 or the turntable control panel and the electrovalve in question YV10 END The fault persists Replace the printed circuit See Fiche C063 END Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP034 Folio 4 4 MACHINE TRAVEL SPEED DOES NOT CORRESPOND TO THE SELECTOR SPEED Q Y Open the platform control panel Y Place the speed selector SA11 on low speed Place the speed selector SA11 on medium speed Check the setpoints at the terminals of selector SA11 Check the setpoints at the terminals of selector SA11 SA11a 0V 804 SA11b 12V 805 SA11a OV 804 SA11b OV 805 Y Place the speed selector SA11 on high speed Check the setpoints at the terminals of selector SA11 SA11a 12V 804 SA11b 0V 805 YES Replace the See Fiche YES speed selector C044 SA11 END Y Open the turntable control Replace the U1 See Fiche panel
16. y zva za mo e y eN i 1 q 8 gt E A DE ee I ee a e 1 D 0 21 10 lt 6 9 r OLL COL COL A d L 6 10 COL I 81 50 61 90 02 90 620 69 VIH GO Ilka EM zrz e 9 a 5 5 a a a o al a o 2 20 gt OZL a o DI a VOL V0S I Ind lle Ing 9 220 lt coi e e V 0 GL SL ZL 9r SL EL LL OL 6 8 9 s v E L Repair manual Pinguely Haulotte Z FOLIO 02 05 SWHOH 26126 6661 70 08 ZANAG ougpgi4 ZO SVIN3 HOS NOILVOIJIH3A Alva Vd Z VE 62 LL rO MIL Bee VSSVA 2 6661 0 80 18074 Id Mamme SONOS I JHON VSIA NOILVOISIGOW QNI dLSCH ECH LLCH 3NISS3a 31101 NVH ATINONId 14617330 NO 196111005 uoseag 01 20 10 1 0 lt e e e lt 02 10 IH amp Glen on vi hi 91H Lr i 1 0 H 0 7 9 0 21 10 2 EIWI UOJIMS 91 uen peeq 5 2 60 lt Jozvs eivs erro lt Soe N Li lt coc d z 0 e lt 027107 ve ve zo
17. Changing a control unit of the distribution block FICHE C109 Changing the emergency electropump unit FICHE C110 Changing a limit contact FICHE C111 Adjusting a pressure limiter FICHE C112 Changing a balancing block FICHE C114 Changing the pressure limiter on the emergency hydraulic circuit FICHE C115 Changing the jib cylinder FICHE C116 Changing the boom lifting cylinder FICHE C117 Changing the turntable rotation reducing gear FICHE C118 Changing a circuit selector travel hydraulic block 140 FICHE C119 Dismantling re assembling the boom Sheet C010 Caution Ensure that the oil is not too hot Caution Use a container to collect oil to prevent pollution of the environment Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Folio 1 1 CHANGING A HOSE 1 Preliminary operations Put the machine in the maintenance configuration see S 6 3 page 32 Switch off electric power see 6 4 page 32 Close the shut off valve if any if not empty the hydraulic tank 2 Removing a hose NB Disconnect the hose from the equipment to which it is connected Unscrew the hose slowly to release residual hydraulic pressure Protect the holes of the equipment using caps 3 Installing a hose Reconnect a new hydraulic hose Put the machine back into the operational configuration Make several movements using the hose to
18. INN N NH SEH 224446 SR q ANI Figure 1 Sheet Do not use the machine during maintenance operations HA16 18PX nouvelle g n ration HA46 51JRT New Design A Caution The buzzer should be audible from the basket Pinguely Haulotte 4 CORRECTIVE MAINTEANCE SHEET Folio 1 1 CHANGING THE TILT SENSOR 1 Preliminary operations Putthe machine on a flat surface with zero slope Putthe machine into the maintenance configuration see S 6 3 page 32 Switch off electric power see 6 4 page 32 2 Removing the tilt sensor Markand disconnect the electric connections of the tilt sensor Remove the tilt sensor 2 by unscrewing the fixing bolts 1 3 Installing the tilt sensor Puta new tilt sensor into place and fix using the fixing bolts 1 Reconnect the electric connections according to the marks made during dismantling Place a spirit level on the top surface of the tilt sensor and set the adjust ment screws 4 so that the tilt sensor is level NB The spirit level 3 is built into certain tilt sensors Putthe machine back into the operational configuration 4 Tilt sensor operating test Extend the machine Tiltthe tilt sensor and check that the buzzer sounds Check that after 1 or 2 seconds extension or travel movements have been disabled Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C040 Folio 1 1 CHANGING THE
19. Open the shut off valve if any Check the level of the hydraulic tank and fill if necessary Before starting fill the pump pan with hydraulic oil hole L engraved on the pump 4 Additional operations e Put the machine back in the operational configuration Make several extension movements to purge the hydraulic circuit Checkthe level of the hydraulic oil tank Adjust pump flow the load sensing pressure limiter and the main pressure limiter see corresponding sheet Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C091 Folio 2 2 CHANGING THE HYDRAULIC PUMP Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C092 CHANGING THE HYDRAULIC BLOCK Folio 1 2 TRAVEL ON OFF MOVEMENT STEERING A Caution 1 Preliminary operations Ensure that the oil is not too Put the machine in the maintenance configuration see 6 3 hot Switch off electric power see S 6 4 2 Removing the hydraulic block 2 Remove the chassis inspection enabling access to the hydraulic A Caution block Markand disconnect the electric connections 2 of the hydraulic block 1 Use a container to collect oil e Mark and disconnect the block s hoses 4 to prevent pollution of the Unscrew the hoses slowly to release residual hydraulic pressure Putcaps on the hoses Place a wedge under the hydraulic block if necessary Remove the hydraulic block by removi
20. Remove contact SQ10 see S 2 Putthe machine back in the operational configuration Liftthe boom between 0 and 40 Extend the telescope until SQ7 is activated Check that the motor stops Put SQ10 back see 3 6 Adjusting and testing SQ10 see chapter on positioning the safety ele ments Inthe telescope in position check that there is 2 mm between the contact lever and the telescope tube as shown in figure 2 Putthe machine back in the operational configuration Liftthe boom between 0 and 40 Extend the telescope until SQ10 is activated Check that telescope exten Sion is stopped and that only telescope retraction is possible Figure 2 7 Adjusting and testing SQ8 see chapter on positioning the safety ele ments Remove contact SQ11 see 2 Putthe machine back in the operational configuration Liftthe boom above 40 Extend the telescope as far as possible Lower the boom and check that 508 is activated at 40 and that it stops the motor Put SQ11 back see 3 8 Adjusting and testing SQ11 see chapter on positioning the safety ele ments Putthe machine back in the operational configuration e Lift the boom above 43 Extend the telescope as far as possible Lower the boom and check that SQ11 is activated at 43 and that boom lowering is stopped SQ11 SQ10 SQ9
21. YV3 Lifting403A YVA Telescoping 506A YV5 Rotation 512A YV6 Travel 612A YV7 Travel 612A 35 Pinguely Haulotte 2 Repair manual 36 Repair manual Pinguely Haulotte Z 6 MAINTENANCE 6 1 GENERAL RECOMMENDATIONS A Caution Do not use the machine as a welding earth Do not weld without disconnecting the then terminals of the batteries Do not use to jumpstart other vehicles The maintenance operations described in this manual apply when the machine is used in ordinary conditions Under difficult conditions extreme temperatures high humidity a polluted atmosphere high altitude etc some of these operations should be carried out more frequently and special precautions should be taken for more details check the motor manufacturer s manual and consult your local PINGUELY HAULOTTE agent Only qualified and competent personnel may carry out interventions on the machine and safety instructions relating to personnel and environment protection must be respected As far as the motor is concerned refer to the manufacturer s manual and instructions Regularly check proper operation of the safety mechanisms Tilt buzzer Passage to microspeed when the machine is extended 6 2 SPECIFIC RECOMMENDATIONS Before any maintenance intervention on the elevating platform indicate on the turntable and platform control panels that the machine is being serviced If possible restrict access to the eleva
22. printed circuit Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP060 Folio 3 4 NO STEERING MOVEMENT RIGHT OR LEFT Invert the coils of the jib electrovalve YV16A and YV16B Press the pedal and activate the REAR steering manipulator SM4 The defective movement right 1 or left 2 is made in response to a control for the opposite movement left 1 or right 2 See Fiche C067 Replace electrovalve YV16 Put coils YV16A and YV16B back in their original positions Press the pedal and activate the REAR steering manipulator SM4 and check for 12V voltage at the terminals of the YV16A or YV16B connector Open the turntable control panel Press the pedal and activate the jib switch and check NO for 12V voltage at terminals 304A or 306A ofthe printed 3r circuit YES cc co etta See Fiche Replace coil YV16A C059 or YV16B Y YES The fault persists Repair the connection or END replace the wiring harness between the turntable control panel and electrovalve YV16 See Fiche C063 Replace the printed circuit END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP060 Folio 4 4 NO STEERING MOVEMENT RIGHT OR LEFT G Maintain the control activated and check for 12V voltage at terminals 703 and 705 of the
23. Perform the function corresponding to the replaced component to check that it works properly Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C044 CHANGING AN ELECTRIC COMPONENT Folio 1 1 ON THE BOTTOM CONTROL PANEL 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 page 32 Caution Switch off electric power see 6 4 page 32 E e Disconnect the lt gt then terminals to isolate the circuit Do not use the machine during maintenance operations 2 Removing a component from the bottom control panel Open the door of the bottom control panel 1 Mark and disconect the electric connections 3 of the component to be replaced 2 Remove the component 3 Installing a component in the bottom control panel Put a new component and seal into place on the front panel of the bottom control panel NB In the case of a lever switch adjust the position of the fixing nut and counter nut so that the switch lever s articulation pin is at the same level as the seal to ensure tightness Reconnect the electric connections according to the marks made during dismantling Close the door of the bottom control panel Reconnectthe then terminals of the battery 4 Test Putthe machine back into the operational configuration Perform the function corresponding to the replaced component to check that it works properly Sheet
24. Put the turntable rotation Place wedges under the boom to bear its weight blocking pin into place Putthe machine in the maintenance configuration see S 6 3 Switch off electric power see S 6 4 fnecessary close the shut off valve or empty the hydraulic tank A Caution 2 Removing the swing joint It is essential to put the Open the chassis box mark and disconnect all electric connectors 5 component in slings before Open the turntable box mark and disconnect all electric connectors 6 dismantling re assembling from the swing joint wiring harness it Free the two electric wiring harnesses 2 of the swing joint after marking their respective paths Mark and disconnect the hydraulic caps and hoses 1 of the swing joint 3 on the turntable and below the chassis EO Caution Ensure that the oil is not too hot NB Unscrew hoses slowly to release residual hydraulic pressure Put caps on the hoses Put the swing joint in slings Remove the swing joint s stop screw 4 A Caution Remove the screws 7 fixing the swing joint to the chassis 8 Remove the swing joint from underneath the chassis Use a container to collect oil to prevent pollution of the 3 environment Installing the swing joint assembly Putthe swing joint into place from underneath the chassis and fix with fixing screws equipped with new nylstop nuts Put back the swing joint rotation stop screw 4 Reconne
25. Close the turntable box Reconnectthe then terminals of the starter battery Putthe machine back into the operational configuration Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C062 Folio 2 2 CHANGING A RELAY Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C063 Folio 1 1 CHANGING THE PRINTED CIRCUIT 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 page 32 Switch off electric power see 6 4 page 32 Disconnect the lt gt then lt gt terminals of the starter battery 2 Removing the printed circuit e Open the turntable electric box Carefully mark and disconnect all the electric connections 1 of the prin ted circuit 2 Remove the U1 electronic module 4 see corresponding sheet Remove the bolts 3 fixing the board to the box and their sealing washers Remove the printed circuit and silent blocks equipping the fixing bolts 3 Installing the printed circuit Puta new printed circuit into place and fix using the bolts equipped with silent blocks sealing rings and new toothed washers Install the U1 electronic module see corresponding sheet Reconnect the electric connections according to the marks made during dismantling Close the turntable box Reconnectthe then terminals of the starter battery Putthe machine back into the operational configuration Testthe printe
26. No telescoping movement out and or in from the plat form or turntable control panel Electrovalve YV4 defective Electronic module U1 defective Wiring harness defective Printed circuit defective Telescoping switch SA8 defective Telescoping manipulator SM2 defective Sheet DP053 No boom lifting movement up and or down from the platform or turntable con trol panel 60 Electrovalve YV3 defective Electronic module U1 defective Wiring harness defective Printed circuit defective Lifting switch SA13 defective Lifting manipulator SM31 defective Sheet DP054 Repair manual 8 1 3 Travel system Pinguely Haulotte Z ANOMALY PROBABLE CAUSE SOLUTION No machine travel movement Connectors disconnected Manipulator HM4 defective Wiring harness defective Electronic module U1 defective Coils of electrovalve YV6 or YV7 defective Electrovalves YV6 or YV7 defective Sheet DP032 Only travel micro speed remains available on the machine regardless of the speed selected Machine unfolded Contactors 502 SQ3 504 incorrectly set or defective Wiring harness defective Electronic module U1 defective Printed circuit defective Sheet DP056 Machine travel speed does not correspond to the selector Electrovalve YV8 YV10 or YV12 defective Coil of electrovalve YV8 YV10 or YV12 de fective Wiring harness defective Printed circuit defective Speed selector SA11 defective Electronic modu
27. Put the 2 stop washers into place on the large drum and install the large drum Put back the boom articulation pin and block with the slotted nut equipped with a new washer Put the emitting compensation cylinder into place and put back its two pins Put back the pin stop plate on the cylinder body side and the blocking clevis on the rod side Put the lifting cylinder into place and put back its two pins Put back the 3 blocking nuts and screws of the lifting cylinder pin on the body side and the two lubricators Check the condition of the lubricators and replace if necessary Put back the pin blocking washer and screw of the boom lifting cylinder on the rod side Reconnect the hydraulic hoses of the emitting compensation cylinder and boom lifting cylinder according to the marks made during dismantling Important Position of cables and hoses in the guide chain Insert the hoses and 42 wire cable in the chain the four hoses to gether arranged alternately without the connector caps To make it easier do not insert the cables and hoses in chain as semblies of more than 25 links high friction making sliding difficult In cold weather the chain is fragile and brittle Fasten the first link of the chain inside the head element 15 remo ve the upper spur on each side before assembly see Figure 7 Install the chain with the natural bowing downwards When installing the receiver compensation cylinder connect the ho ses bef
28. be bai B gt EE gt Eur ST E 1 001 SIONIL i W 1 1 NOILVLOY 13S VG ct act MaINVd NOLLV LOY i ATTE A 3AVIS E ls rt de UN3143934 13137 WsOALV Td NOLLVSN3ANOD ee 5 NOISN31X3 WOO8 FOVdOOSITIL EE FTEVINYNI YNALON NAISSE 3113801 NOLLVINIIHO NOLLWISNVELL 31 261 919 1081 HNVL 109 HIOAH3S3H ONIH331S NOILO3HIQ SO o E e Repair manual SC 1 S9 ni E
29. 1 25 dynamic test coefficient 1 1 All users must consult this order s requirements and comply with them 1 4 3 State of conservation Detect any deterioration liable to cause hazardous situations concerning safety devices load limiters tilt sensor cylinder leaks deformation welds bolt tightness hoses electrical connections tyre state excessive mechanical gaps NOTA In the case of rental the user of the rented device is respon sible for the machine condition and suitability inspection He must check with the renting party that the general periodic checks and checks prior to operation have been carried out Pinguely Haulotte Z 1 5 1 6 1 7 BEAUFORT SCALE Operating and maintenance instructions 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 ifthe work specified above is not performed by PINGUELY HAULOTTE approved personnel 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
30. 4 2 2 Positions of screws connectors and relays rss 27 4 2 3 Positions Of AAE 28 4 2 4 Positions of diagnosis coe renard runter ea 29 5 HYDRAULIC DIAGRAMS ne an 31 5 1 DIAGRAM H21T H23T REFERENCE B157 14 rreren 31 5 2 DIAGRAM H21TX H23TX REFERENCE B15713 reren 32 5 3 DIAGRAM H23TP H25TP REFERENCE B15330 33 5 4 DIAGRAM H23TPX H25TPX REFERENCE B15331 34 59 FUNCTIONS OF ELECTROVALVES soriana 35 Repair Manual Pinguely Haulotte Z 5 5 1 On off 35 5 5 2 Proportional electrovalves 35 6 MAINTENANCE ont 37 6 1 GENERAL 5 37 6 2 SPECIFIC RECOMMENDATIONS See un 37 NEE eh Le EE 37 6 2 2 Replacing an element ee een 37 6 2 3 Locating the a ze asle EE 38 6 2 4 Environment protection 38 6 3 MAINTENANCE SYSTEME a a aaa eie 38 64 ELECTRIC POWER SUPPLY 38 6 5 MAINTENANCE PLAN ana 39 Ge OPERATIONS Ss ee 41 6 6 1 Summary A A 41 Gr PRESENCE OF LABELS nee 42 6 7 1 Yellow E le uuu d c E OR E E E CE 43 6 7 2 Orange labels iee aaria be 43 6 7 3 GREG Biele 44 6 As Other Jabel u u uu u ae 45
31. 6 Tae BEAUFORTSERLE EN 6 2 SPECIFICATION Luana 7 2 1 TECHNICAL DATA aa da 8 2 1 1 H21T X and H23TP X technical data tacna dolia 8 2 1 2 H23T X and H25TP X technical data aroaren 9 22 BALA SA e LE 10 Pinguely Haulotte Repair Manual gilea e 10 222 A ni pali 11 2 2 3 H23T X dimensions ee 12 22 PAZ pC Em 13 23 TIGHTENING TORQUE VALUES a 14 2 3 1 Tightening torque values for large threading i 14 2 3 2 Tightening torque values for narrow threading 14 2 3 3 Tightening torque values for wheels ae kenne 14 2 3 4 Tightening torque values for hydraulic 15 2 3 5 Pressure values in bar b een r 16 2 3 6 Adjustment time 16 3 SAFETY SYSTEM ieii 17 3 1 FUNCTION OF RELAYS AND FUSES IN TURNTABLE 17 3 2 FUNCTION OF SAFETY CONTATTS aaa a a 17 23 POSITIONS OF ELECTRIC CONTACTS sisas 18 mde OPERATING EQUATION TE 19 4 WIRING ee 21 4 1 DIAGRAM E 455 POLIO NEE 21 4 2 POSITIONS OF ELECTRIC COMPONENTS ON THE MOTHER BOARD 26 4 2 1 Description 26
32. BSPP union MJIC 37 12 M1 4 BSPP union MJIC 37 18 M1 2 BSPP union MJIC 37 18 M3 4 BSPP union MJIC 37 25 M1 BSPP union MJIC 37 6 M1 4 BSPP 15 Pinguely Haulotte 2 Repair manual 2 3 5 Pressure values in bar Pump flow cancellation 240 b load sensing standby pressure 30b PVG Danfoss distributor entry pressure protection 270 b rotation pressure limiter 100 b Telescoping output pressure 100 b large chamber braking valve 210 b small chamber braking valve 210 b Lifting lowering pressure 100 b large chamber braking valve 210 b Compensation up down braking valve 210 b Jib large chamber braking valve 210 b Emergency unit 130 b 2 3 6 Adjustment time Movement HS decceleration Control Movement duration From the basket 1 30m 20cm HS travel forward and reverse From the basket 70s 100m Micro speed travel forward and reverse From the basket 22s 2s 5m Boom lifting lowering From the basket 60s 2s Telescope out in From the basket 30s 2s Rotation left right From the basket 60s 2s per 1 2 turn Boom lifting lowering From the turntable 60s 2s Telescope out in From the turntable 30s 2s Rotation left right 16 From the turntable 60s per 1 2 t
33. Certain checks require the elevating platform to be switched on In this case personnel must ensure that the measurement devices used are properly insulated that they do not touch the live parts that they are not wearing or carrying metal objects that may deterio rate the live components e g dropping a spanner during an interven tion on the batteries 6 2 4 Environment protection To protect the environment an oil collection tank must be used during interventions requiring hydraulic oil change or where there may be a hydraulic leak Instructions Maintenance configuration Position the elevating platform on a firm horizontal surface f possible fold the machine completely Otherwise for specific ope rations put the various components into slings Put the turntable rotation blocking pin into place ref 1 Photo 1 page 38 Restoring operational configuration Remove the blocking pin ref 1 Photo 1 page 38 6 4 ELECTRIC POWER SUPPLY Photo 2 38 Instructions Cutting off the electric power supply Press the turntable emergency stop ref 1 Photo 2 page 38 Restoring the electric power supply Reset the emergency stop ref 1 Photo 2 page 38 Repair manual Pinguely Haulotte Z 6 5 MAINTENANCE PLAN The plan shows the frequency area of maintenance device and the consumables to be used The reference shown in the symbol sho
34. HORN Caution 1 Preliminary operations pm Switch off electric power see 6 4 page 32 Do not use the machine during maintenance 2 Removing the horn operations Mark and disconnect the electric connections from the horn 1 Remove the horn by unscrewing the fixing bolts 2 3 Installing the horn Put the horn back into place and fix with the fixing bolt Reconnect the electric connections according to the marks made during dismantling 4 Test Select the top control panel and switch on machine power Putthe machine back into the operational configuration Activate the horn switch from the platform control panel and check that the horn sounds horn should audible from the basket Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C041 Folio 1 1 CHANGING THE TILT SENSOR BUZZER AN Caution 1 Preliminary operations Switch off electric power see 6 4 32 Do not use the machine during maintenance 2 Removing the buzzer operations Mark and disconnect the buzzer s electric connections 1 Remove the buzzer by unscrewing the fixing bolts 2 HA16 18PX HA46 51JRT 3 Installing the buzzer Putthe buzzer back into place and fix with the fixing bolts Reconnect the electric connections according to the marks made during dismantling 4 Test Putthe machine back into the operational configuration
35. Haulotte 4 PREVENTIVE MAINTENANCE SHEET Sheet P008 CHECKING FILLING Folio 1 1 THE HYDRAULIC OIL TANK 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 AN Caution Switch off electric power see 8 6 4 Put the machine in the folded position 2 Checking filling the hydraulic oil tank NB This operation must be carried out when the oil is cold i e before starting 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 Only use the oil recommended by the manufacturer Put the machine back into the operational configuration Pinguely Haulotte 4 PREVENTIVE MAINTENANCE SHEET Sheet P009 Folio 1 1 CHANGING THE HYDRAULIC FILTER CARTRIDGE 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 AN Caution Switch off electric power see 8 6 4 Use a container to collect oil to prevent pollution of the 2 Replacing the hydraulic filter cartridge environment NB The filter has a clogging indicator Clogging should be checked when the machine is hot otherwise the indicator may be visible due to the viscosity of the cold oil Change the cartridge 1 if the clogging indicator appears 2 Unscrew the base nut 3 and remove the cartridge from the hydraulic filter Screw a new cartridge into place Putthe machine back
36. Labour Code The results of these inspections are recorded in a safety register kept by the site manager and constantly available to the labour inspector and the site safety committee if one exists and the list of specially designated personnel Article R 233 5 of the French Labour Code Moreover before each use check the following the operator s manual is in the storage compartment on the platform the stickers are placed according to the section concerning Labels and their positions oil level and any elements in the mainteance operation table look out for any danaged incorrectly installed modified or missing parts NOTE This register can be obtained from trade organisations and in some cases from the OPPBTP or private prevention agen cies The designated persons must be experienced in risk prevention Articles R 233 11 or order 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
37. after undergoing a medical check and a practical test that prove they are apt to operate the machine There must always be at least two operators present so that one can always Take fast action if necessary Take over the controls in case of accident or malfunction Monitor and prevent movement of vehicles and people near the plat form Guide the platform operator if required 1 2 2 Environment Never use the machine On ground that is soft unstable congested On a ground that has a slope greater than permissible limit In winds greater than the permissible limit If used outside use an an emometer to ensure that the wind speed does not exceed the permis sible limit Near power lines check minimum safe approach distances according to voltage carried In temperatures less than 15 C especially in refrigerated chambers Consult us if it is necessary to work below 15 C In explosive atmospheres In poorly ventilated areas since the exhaust fumes are toxic During storms risk of lightning In the dark unless the optional floodlight is fitted In the presence of intense electromagnetic fields radar moving and high currents DRIVING ON PUBLIC ROADS IS PROHIBITED 1 2 3 Using the machine Do not use the machine with a load greater than allowed load if wind speed exceeds the maximum with more than maximum authorised number of occupants in platform with a side load in the platform great
38. collars 33 for hoses C2 R1 4 wire and 42 wire cables shown from F Figure 12 1 Shown from F hole at the front i Figure 11 Figure 12 Install the receiver compensation cylinder 2 after connecting the hoses excess of 300 mm The cylinder pin on the element is stopped by a Hc 7 screw Arrange and secure the 5 slings 10 Assembling the equipped head element with the intermediary element Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C119 Folio 9 13 DISMANTLING RE ASSEMBLING THE BOOM NB 2 operators required Preparation of the head element before insertion Attach the slings to the element with adhesive tape such as masking tape Figure 13 Prepare the slings on the head element Putthe pin into place 26 NB Hold the out sling 29 securely in the position shown to prevent the top strand passing under the bottom strand The top strand must pass above the pad 27 Leave the parachute cable 28 free Figure 13 e Insert the cable and hoses in the intermediary element previously aligned with the head element nsert the head element in the intermediary element assisting cables hoses and slings in their movement Stop movement before the head ele ment covers the back pulleys Place the in slings in the back pulley grooves and pass the strands through the outlet passages NB When passing the in slings 21 on the back pulleys make
39. electrovalve YV24 is on ESO Press the pedal and activate the compensation switch Check for 12V voltage at the terminals of connector YV24 YES Replace the coil of See sheet electrovalve YV24 C059 YES Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP051 Folio 2 2 THE COMPENSATION MOVEMENT IS MADE WHEN PLATFORM ROTATION IS ACTIVATED The fault NO persists See Fiche C067 Open the turntable control panel Press the pedal and activate the compensation switch and check for 12V voltage on terminal 399 of the printed circuit Replace electrovalve YV24 NO Replace the U1 See Fiche module C107 YES Repair the connection or The fault NO replace the wiring harness persists between the turntable control panel and electrovalve YV24 YES END END Replace the printed See Fiche circuit C063 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP053 Folio 1 5 NO TELESCOPING MOVEMENT IN AND OR OUT FROM THE PLATFORM OR TURNTABLE CONTROL PANEL No telescoping movement out and or in from the platform or turntable control panel Fold the machine except for the boom Place the key switch in the turntable or platform position Activate the telescoping switch from the turntable control panel SA8 or the telescoping manipulator SM2 from the platform con
40. essential component It is necessary to perform a suitability examination a state of conservation examination a static test a dynamic test see coefficient in paragraph 1 4 2 5 The Beaufort Scale of wind force is accepted internationally and is used when communicating weather conditions It consists of number 0 17 each representing a certain strength or velocity of wind at 10m 33 ft above ground level in the open Description of Wind Specifications for use on land MPH m s 0 Calm Calm smoke rises vertically 0 1 0 0 2 1 Light Air Direction of wind shown by smoke 1 5 0 3 1 5 2 Light Breeze Wind felt on face leaves rustle ordinary vanes moved by 6 11 1 6 3 3 wind 3 Gentle Breeze Leaves and small twigs in constant motion wind extends 12 19 3 4 5 4 light flag 4 Moderate Breeze Raises dust and loose paper small Branches are moved 20 28 5 5 7 9 5 Fresh Breeze Small trees in leaf begin to sway crested wavelets form 29 38 8 0 10 7 on inland waterways 6 Strong Breeze Large branches in motion whistling heard in telephone 39 49 10 8 wires umbrellas used with difficulty 13 8 7 Near Gale Whole trees in motion inconvenience felt when walking 50 61 13 9 against wind 17 1 8 Gale Breaks twigs off trees generally impedes progress 62 74 17 2 20 7 9 Strong Gale Slight structural damage occurs chimney pots and slates 75 88 20 8 removed 24 4 Repair manual Pinguely Haulotte D
41. gauge NB Check both rotation directions If measured pressure is not conform to the value in the table replace the pressure limiter Switch off electric power see S 6 4 Unscrew the pressure gauge and put back the hydraulic pressure tapping cap Pinguely Haulotte 4 Sheet C111 Figure 4 CORRECTIVE MAINTENANCE SHEET Folio 2 2 ADJUSTING A PRESSURE LIMITER Put the machine DacK in the Operational configuration Make several turntable rotation movements to check machine operation 4 Adjusting the emergency unit pressure limiter 5 fig 4 Put the machine in the maintenance configuration see 6 3 Switch off electric power see 6 4 Unscrew the minimess hydraulic pressure tapping cap 3 on the distribu tion block and connect a pressure gauge of sufficient range to measure the pressure of the emergency unit Switch electric power on again see 6 4 Stop the thermal motor Trip the emergency electropump unit from the bottom control panel Measure pressure on the gauge Adjust the cup point hexagonal screw on the emergency motorpump unit pressure limiter 5 if necessary so that movement is disabled at the pres sure indicated in 5 Switch off the emergency electropump unit Switch off electric power see 6 4 Unscrew the pressure gauge and put back the hydraulic pressure tapping cap Put the machine back in the operational configuration 5 Calibration pressure in
42. handle to O keeping your foot down on the pedal Do not exceed the maximum load or the number of occupants allowed in the platform Spread the load and if possible place in the centre of the platform Check that the ground resists the pressure and load per wheel Avoid contact with stationary or moving obstacles Do not drive the platform at high speed in narrow or congested areas Avoid contact with stationary or moving obstructions Do not drive the platform in reverse gear poor visibility Do not use the machine with a congested platform Do not use the machine with equipment or objects hanging from the guardrails or boom Do not use the machine with items liable to increase the wind load e g panels Never carry out maintenance on the machine with the platform raised without first installing the required safety provisions overhead crane crane Perform the daily checks and monitor the machine s good working or der during periods of use NOTA Do not tow the platform it is not designed to be towed and must be transported on a trailer Pinguely Haulotte 2 1 3 RESIDUAL RISKS Caution Operation direction inverted on a turntable machine after 180 rotation Bear in mind the colour of the arrows on the chassis in relation to the colour shown on the platform control panel green and red Thus moving the manipulator in the direction of the green arrow on the control panel
43. hydraulic hoses Reconnect the electric wires according to the marks made during dismant ling Reconnect the lt gt then lt gt terminals of the starter battery Put the machine back in the operational configuration Do not start the thermal motor and trip the emergency electropump unit Make several movements to purge the hydraulic circuit Put the machine back in the operational configuration Check the level of the hydraulic oil tank Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C109 Folio 2 2 CHANGING THE EMERGENCY ELECTROPUMP UNIT Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C110 Folio 1 2 CHANGING A LIMIT CONTACT 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 Switch off electric power see S 6 4 2 Removing a limit contact f necessary remove the protective plate 4 and its fixing screws 5 Mark the position of the limit contact 1 and its lever 2 Remove the limit contact Open the limit contact mark and disconnect the electric connections 3 Installing a limit contact Open the new limit contact reconnect the electric connections according to the marks made during dismantling of the defective contact then close the limit contact If necessary put the limit contact lever 2 back in the same position as that marked during dismantling Put back the limit contact in the positio
44. in the FOR operation direction The wheels turn Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP032 Folio 2 4 NO MACHINE TRAVEL MOVEMENT Open the turntable control panel and check connection of PVG travel connectors 25 and 26 Y Connections oK YES Check operation of the travel manipulator SM4 Activate the fail safe HM4 alone and check for voltage at HM4 output and no voltage at SM4ab output Reconnect the connectors Y YES Check for setpoints at inputs 29 2 29 3 and 29 4 of the U1 electronic module Setpoints Replace the manipulator See Fiche HM4 12V C045 SMdab OV an END While maintaining the fail safe HM4 activate the travel manipulator SM4 and check the setpoint at output Y of the manipulator SM4 Setpoints Forward 2 5 to 4 5V Replace the manipulator See Fiche Reverse 2 5 to 0 5V HM4 C045 SM4ab 12V END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP032 Folio 3 4 NO MACHINE TRAVEL MOVEMENT Check setpoint at output 26 3 and 25 3 of U1 electronic module Setpoint Output 26 3 and 25 3 Replace the U1 electronic See Fiche Forward 6 to 9V module C058 or C107 Reverse 6 to 3V YES Check for setpoint at input o
45. movements to purge the hydraulic circuit Checkthe level of the hydraulic tank Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C109 Folio 1 2 CHANGING THE EMERGENCY ELECTROPUMP UNIT 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 Caution Switch off electric power see S 6 4 that Dis o e parta Disconnect the lt gt then lt gt terminals of the starter battery PA 2 Removing the emergency electropump unit Mark the connections and path of the electric wires 1 of the electropump unit 2 AN Caution Disconnect the electropump unit s electric connections Di it i IsO area isconnect the electropump unit s hydraulic hoses 3 to prevent pollution of the NB Unscrew the hoses slowly to release residual hydraulic pressure environment Put caps on the hoses Remove the pressure limiter 4 of the emergency hydraulic circuit see corresponding sheet Unscrew the fixing screws and remove the electropump unit Mark and retain the hydraulic connectors and unions 5 screwed on the electropump unit Installing the electropump unit Putthe hydraulic unions and connectors retained from the removal opera tion in the same places on a new electropump unit Put back the pressure limiter see corresponding sheet Putthe back into place using the fixing screws Reconnect the
46. operational configuration Make several movements using the replaced balancing valve to purge the circuit Check that the corresponding movement is made correctly Pinguely Haulotte Z CORRECTIVE MAINTEANCE SHEET Sheet C083 CHANGING A DOUBLE FLOW LIMITER Folio 1 1 FOR THE COMPENSATION FUNCTION 1 Preliminary operations A Caution Putthe machine in the maintenance configuration see S 6 3 page 32 Ensure that the oil is not too Switch off electric power see S 6 4 page 32 hot 2 Removing a double flow limiter 1 Mark the installation position of the electrodistributor balancing valve and double flow limiter A Caution Remove the 4 fixing screws 2 then take out the electrovalve 3 balan Use a container to collect oil ging valve 4 double flow limiter 1 assembly to prevent pollution of the Remove the double flow limiter 1 environment 3 Installing the double flow limiter Replace the seals and put into place on the hydraulic block a new flow limiter 1 whose characteristics correspond to the machine in question then the balancing valve 4 and the electrovalve 3 Fixthe assembly with the 4 fixing screws 2 Tighten to the recommended torque see corresponding chapter Putthe machine back into the operational configuration Make several movements using the replaced double flow limiter to purge the circuit Adjust compensation up and down speeds see corresponding c
47. operations Put the machine in the maintenance configuration see 6 3 Switch off electric power see 6 4 Remove contactor 7 see corresponding sheet 2 Removing the platform support assembly NB Mark and disconnect the electric connections at the platform box Mark and disconnect the hydraulic hoses of the platform rotation motor and the jib cylinder hoses 1 Unscrew the hoses slowly to release residual hydraulic pressure Put caps on the hoses Open the cable passage collars on the platform and along the jib Mark the path of electric cables and hoses and remove all cables passing along the jib Put the platform in slings Put the jib cylinder 1 and vertical elements 2 and 3 in slings Remove the caps lower pin stop rings 5 screw and stop clevis from the upper pin 5 fixing the platform assembly 4 Remove the screw and pin stop clevis 6 Remove the pin 6 Remove the two pins 5 and remove the platform assembly 3 Removing the jib Remove the two pins 8 fixing the jib to the jib link part as described above then remove the jib s vertical elements 2 and 3 and the cylinder 1 4 Removing the jib link part 9 Put the jib link part in slings 9 Put the receiver compensation cylinder in slings 10 Remove the screw and pin stop clevis 11 then remove the pin 11 from the receiver compensation cylinder 10 Remove the screw and rotation pin stop clevis 12 fro
48. or YV18B up is on YES YES Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART NO JIB MOVEMENT UP AND OR DOWN Folio 2 5 Sheet DP028 FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Press the pedal and activate the jib switch Check for 12V at the terminals of the PVG connector YV2a Open the turntable control panel NO Press the pedal and activate the jib switch Check for 12V voltage on terminal 305 of the printed circuit See Fiche Replace the PVG C077 or YV2 control head C108 NO Replace the See Fiche P U4 module C058 or C107 YES Repair the connection or The fault NO replace the electric wiring persists harness between the turntable control panel and PVG YV2 END Replace the See Fiche printed circuit C063 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP028 NO JIB MOVEMENT UP AND OR DOWN Folio 3 5 FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Y Invert the coils of the jib electrovalve YV18A and YV18B Press the pedal and activate the platform or turntable jib switch The defective movement up 1 or down 2 is made in response to an opposite movement control down 1 or up 2 Put coils YV18A and YV18B back in their original positions Press the pedal and activate the jib switch Check for 12V voltage at the ter
49. printed circuit Open the platform or turntable control panel and NO check the wiring of the manipulator SM4 YES NO a Replace the U1 module See Fiche Repair wiring C107 YES END Check the electric continuity of the switch contacts when closed NO The fault 211A 703 and 211 705 persists END Replace the See Fiche NO printed circuit C063 YES Replace the See Sheet END manipulator SM4 C045 Repair the connection or replace the wiring END harness between the manipulator SM4 and the printed circuit of the turntable control panel Repair manual Pinguely Haulotte Z 9 CORRECTIVE MAINTENANCE PROCEDURE FICHE C010 List of corrective maintenance sheets Sheet no Description Changing a hose FICHE C034 Changing a wheel FICHE C035 Changing a wheel reducing gear or a hydraulic travel motor FICHE C036 Changing a steering pivot FICHE C039 Changing the tilt sensor FICHE C040 Changing the horn FICHE C041 Changing the tilt buzzer FICHE C043 Changing an electric component on the top control panel FICHE C044 Changing an electric component on the bottom control panel FICHE C045 Changing a manipulator FICHE C046 Changing the starter battery FICHE C047 Changing a cover gas spring FICHE C052 Changing the basket rotation hydraul
50. purge the hydraulic circuit Check the level in the hydraulic oil tank Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C034 Folio 1 1 CHANGING WHEEL 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 page 32 Switch off electric power see 6 4 page 32 1 2 2 Removing wheel Unblock without completely unscrewing the fixing screws 1 of the wheel to be removed Raise the machine using a jack or hoist Remove the fixing screws 1 from the wheel and remove the wheel 2 3 Installing a wheel Put a new wheel into place and put back the fixing screws Putthe machine on the ground Tighten the fixing screws to the recommended torque see tightening torque value table Putthe machine back into the operational configuration A Caution Use a container to collect oil to prevent pollution of the environment A Caution It is essential to put the component in slings before dismantling re assembling it Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C035 CHANGING A WHEEL REDUCING GEAR Folio 1 2 OR A TRAVEL HYDRAULIC MOTOR 1 Preliminary operations Put the machine in the maintenance configuration see S 6 3 page 32 Switch off electric power see 6 4 page 32 Remove the wheel corresponding to the element to be removed see cor Caution responding sheet Ensure that the oil is not too
51. removing its fixing screws 8 and washer 9 Remove the platform and retain the ball 10 the nylatron washer 11 and the stop 12 If necessary unscrew the pre stressing nut totally 13 as a safety measure before performing any operation on the platform 3 Installing the platform Checkthe condition of the elastic parts and wearing parts and replace if necessary spring washers 14 collar rings 15 ring 16 nylatron washer 11 control panel silent blocks circlips Lower part f necessary adjust the pre stressing system by tightening the pre stres sing nut 13 so that the washers are 108 mm high see figure 3 Putthe platform into place taking care to put the ball 10 nylatron washer 11 and stop 12 in the right places Lubricate the bore and put the lower pivot 7 into place Fix using the fixing screw 8 and washer 9 NB Only use lubricants recommended by the manufacturer Upper part Lubricate then put back the weighing articulation pin 6 Putback the stop tab 5 Install the Nylstop nut 3 and its washer 4 Adjust the stop for the pre stressing system by tightening the screw 1 and the nut 2 Putthe control panel into place on its silent blocks and fix using the screws equipped with new washers Reconnect the control panel wiring harness Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C053 Folio 2 3 CHANGING THE BASKET fnecess
52. sans d connecter les cosses des be e E DURMITE DELLA SATENE b batteries se r f rer la notice de conduite et d entretien DALY INSPECTION JSPEZIONE GUOTIDIANA INSPECTION JOURNALIERE 1 V rifier le niveau d huile hydraulique et le liquide des batteries INSTRUCCIONES DE UTILIZACI N BEDENUNGSANWEISUNGEN 2 V rifier s il n y a pas de signe apparent de d fectuosit fuite hydraulique PA OPERABOR DERE ur DER BEDIENER FOLGENDES ZU BEACHTEN boulonnerie liaisons lectriques ngao Trete gt 3 V rifier le fonctionnement de l indicateur de devers en faisant fonctionner 2 Tr l alarme sonore INSTRUCTION AVANT UTILISATION 1 Enlever la broche de blocage d orientation s il y a une tourelle 2 IMPORTANT La prise doit tre raccord e sur une installation lectrique prot g e par un disjoncteur diff rentiel 30 mA NORME C15 100 MISE EN ROUTE INSTRUCCIONES PREVIAS ALA UTILIZACI N VOR DEM EINSATZ ern ay na re ET 1 D verrouiller l arr t d urgence puis actionner le bouton de d marrage 2 En cas de non fonctionnement attendre 10 s et renouveler l op ration PUESTA EN MARCHA UNBETRIEBNAHWE INTERDICTION MOTZ pearen D UTILISER L APPAREIL DURANTE LA GANGA DE CAS BATERIAS und DIE AKKUS GELADEN WERDEN PENDANT LA CHARGE DES BATTERIES 7814 342 43 44 Pinguely Haulotte Z 120 Kg 3 250 Kg 90 Kg 2
53. see S 6 3 Switch off electric power see 6 4 Unscrew the minimess hydraulic pressure tapping cap 3 on the distribu tion block and connect a pressure gauge of at least to 300 bar Switch electric power on again see S 6 4 Extend the boom lifting cylinder fully to its stop to block the movement e Activate boom lifting and measure pressure on the pressure gauge Adjust the cup point hexagonal screw on the main pressure limiter 1 of the hydraulic pump if necessary so that movement is disabled at the pres sure indicated in 5 Putthe machine in the maintenance configuration see S 6 3 Switch off electric power see S 6 4 Unscrew the pressure gauge and put back the hydraulic pressure tapping cap Putthe machine back in the operational configuration Make several boom lifting movements to check operation of the machine 3 Checking the turntable rotation pressure limiter 4 fig 3 NB Turntable rotation pressure is pre set and must not be modified Putthe machine in the maintenance configuration see S 6 3 Switch off electric power see S 6 4 Unscrew the minimess hydraulic pressure tapping cap 3 on the distribu tion block and connect a pressure gauge of at least 0 to 300 bar 0 to 4351 PSI Switch electric power on again see S 6 4 Putthe turntable rotation pin into place to block movement e Activate turntable rotation and measure pressure on the
54. sheet Put the machine back in the operational configuration Make several jib lifting boom lifting and turntable rotation movements to purge the hydraulic circuit Check the level of the hydraulic oil tank Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C104 Folio 1 2 CHANGING THE BASKET ROTATION GEARING 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 Switch off electric power see 6 4 Remove the basket see corresponding sheet Remove the basket rotation hydraulic motor see corresponding sheet 2 Removing the gearing Remove the motor fixing flange 1 Remove the endless screw 2 and the adjusting washers 3 if any Caution Remove the screw 4 and the toothed washer 5 It is essential to put the Remove the end cap 8 then the platform link part 9 and the Nylatron component in slings before washer 10 dismantling re assembling it Remove the nylstop nut 11 bushing 12 elastic washers 13 plate 14 Remove the articulation pin assembly 15 then the disk 16 and pad 17 Remove the screws and washers 18 and 19 and remove the pin 15 wormwheel 6 keys 21 hub 20 key 7 Installing the gearing Change the rings pads and keys if necessary Put into place on the articulation pin 15 the key 7 hub 20 keys 21 wormwheel 6 and put back the screws and
55. to a torque of 27 m daN 199 Ib ft Place the turntable ring assembly on the chassis in the locking position Fix the ring 8 to the chassis 7 using the 24 screws 6 and washers without pre stressing Tighten in a star pattern see figure 2 to a torque of 27 m daN 199 Ib ft Remove the slings from the turntable Put back the rotation stop screw 5 of the swing joint 4 Reconnect the hoses of the swing joint 4 according to the marks made during dismantling Reconnect the electric connectors 2 of the chassis box 1 according to the marks made during dismantling Adjust the position of the reducing gear 11 using the adjusting screws 12 and 13 Turn the reducing gear to position the ring teeth marked with a colour opposite the reducing gear pinion this coloured mark corresponds to the most excentric point of the ring Adjust the gap between the teeth to 300um with a set of flakes When the gap is set block the counter nuts of the adjustment screws 12 and 13 4 Additional operations NB Put the machine back in the operational configuration Lubricate the ring Only use lubricants recommended by the manufacturer Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Fiche C106 Folio 2 3 CHANGING THE SLEW RING Make several turntable rotation steering and travel movements using a possible travel speeds to purge the hydraulic circuit Check that the electric controls work properl
56. 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 Z Repair manual Repair Manual Pinguely Haulotte Z SUMARY GENERAL 1 1 GENERAL RECOMMENDATIONS 4422 4 1 1 1 GENERAL WAR SING E 1 tiks Manual u s ee IS U OS 1 NEC q kawaq E 1 el GE 1 1 2 GENERAL SAFETY INSTRUCTIONS iii 2 1 2 1 Operators PP 2 1 2 2 o conn ss 2 1 2 3 Using the machine u nase an 2 VE KR TE UN RISKS PL 4 1 3 1 Risks of jerky movements and tipping over ss 4 1 3 2 Electrical rie 4 1 3 3 Risk of explosion or DIM 4 1 3 4 Risks of collision rrua 4 TAS INSPECTIONS contando rennen E 5 1 4 1 Periodic Imspechons ener nennen nnn nn 5 1 4 2 Examination of machine suitability ee ie 5 1 4 3 State of conservation 5 15 REPAIRS AND ADJUSTNEN iria ia 6 1 6 VERIFICATIONS WHEN RETURNING TO SERVICGE
57. 01 ED Ov HIONIL 7 so Bj ES NOISN31X3 WOO 3SVdOOSS3131 31V10H FTEVLNENL ZINK HOLOFHIA 31138N01 YNALOW NAISSA unaloaula N3 SS3 NOLLV TSNVHL NOLLIVISNVHL 34 Repair manual Pinguely Haulotte Z 5 5 FUNCTIONS ELECTROVALVES 5 5 1 On off electrovalves 12v electro controlled Ov electro not controlled YV1 Load Sensing 303 time delayed for 2 seconds YV2a Jib305 YV2b Compensation rotation steering 415 YV8 High speed vitesse 813 YV9 Differential blocking 807A YV10 MediumSpeed HighSpeed 814A YV12 MediumSpeed HighSpeed 814B YV13 Differential blocking 807B YV19a Compensation up 401A basket rotation L YV19b Compensation down 402A basket rotation R YV16a Left REAR steering in 4 4 304A YV16b Right REAR steering in 4 4 306A YV18a Jib down 407A YV18b Jib up 408A YV24 Basket rotation 399 5 5 2 Proportional electrovalves Supply voltage of proportional electrovalves varies from 6v to 3v in one direction and from to 9v in the other
58. 0b 3078144320 1 Floor height load capacity H23T X 20c 3078144330 1 Floor height load capacity H23TP X 20d 3078144340 1 Floor height load capacity H25TP X 21 3078143120 1 Turntable box label 22 3078143110 1 Platform box label 23 3078145180 1 Do not interchange multi language 24 3078145070 1 DANGER travel direction after rotation 25 3078148750 1 Acoustic power 16 3078148890 1 Biodegradable oil option 77 3078149220 1 Manual emergency assistance 46 Pinguely Haulotte Z Repair manual 47 Pinguely Haulotte 2 Repair manual 6 8 PRESENCE OF MANUALS Check 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 result in incorrect or dangerous use of the machine Instructions Check the presence of the manuals Check that all the manuals are legible complete and stored in the document holder on the platform Replace the manuals if necessary additional copies can be supplied on request by the manufacturer if necssary 48 Repair manual Pinguely Haulotte 7 PREVENTIVE MAINTENANCE SHEETS List of preventive maintenance sheets Sheet no Description FICHE P007 Checking changing the oil of a wheel reduci
59. 2V voltage at the terminals OK of connector YA2 YES See Fiche Replace relay KT2 NO C062 YES END Replace the coil of motor accelerator Y YA2 or adjust the motor accelerator system see motor manufacturer See Fiche Replace the U1 manual C058 or module C107 END END Repair replace the electric wiring harness between the accelerator elec trovalve YA2 and the turntable control panel Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP023 Folio 1 5 NO MOVEMENT AVAILABLE FROM TURNTABLE OR PLATFORM CONTROL PANELS No movement available from turntable or platform panels Check the level of hydraulic See Fiche oil P005 or P008 NO YES Open the turntable control Fill up See Fiche panel Check the state of fuses P005 or P008 FU4 FU7 and FU10 END NO YES Activate the boom lifting movement in the Replace the emergency mode defective fuse Put the emergency lever into place on the manual control of the boom lifting control distributor YV3 END Activate the lever up then down while pressing the emergency control of the safety valve YV1 or activate the emergency power unit Movement NO OK YES Connect a pressure gauge to the PVG pressure tap M on the turntable control Place the key switch in the platform position panel Pr
60. 3m 23m 23m Working height 23 3 m 23 3 m 25m 25m Overall length 11 05 m 11 05 m 12 87 m 12 87 m Overall width 2 48 m Overall height 3 10 Wheelbase 2 49m Floor clearance 340 mm Max reach 19 5m 19 5m 17 5m 17 5m Boom displacement 75 15 Telescoping stroke 4 76 m Turntable rotation Continuous Reducing gear 22 4 Max slope in travel 40 Tyre dimensions 15 R 22 External turning radius 6 15 m Tilt sensor 5 approx 996 Hydraulic tank 1501 Diesel tank 1501 Total weight 13750 kg 13750 kg 13850 kg 13850 kg Number of drive wheels 2 4 2 4 Number of steering whels 2 Differential blocking system YES Hydraulic brakes YES Freewheel YES Tightening torque wheel nuts 32 m daN slew ring nuts 27 m daN Vibrations at foot level 0 5 m s at hand level 2 5 m s DEUTZ diesel motor Type 3141 Power 43 6 CH 32 1 kW at 2400 rpm dling power 33 3 CH 22 9 kW at 1500 rpm Consumption 11 5 l h dling consumption 6 8 l h Hydraulic pump 45 cm rev 85 I min max LOADSENSING Hydraulic pressure 22 240 bars Steering 220 Dar 240 bars Rotation Equipment 100 bats 240 bars Travel speed LS 1 5 km h HS 5 km h Max force on one wheel 8000 daN Max pressure on the ground with 250 kg concrete 18 daN cm soft ground beaten earth 8 daN cm Starter battery 1x12V 95A h Supply voltage 12V Acoustic power 99 dB A Sound level at 10 m 66 5 dB A Pinguely Haulotte Z Re
61. BREAKDOWN DETECTION FLOW CHART Folio 1 5 NO COMPENSATION MOVEMENT UP AND OR DOWN No compensation movement up and or down Place the key switch in the platform position Press the pedal and activate the jib switch on the platform control panel movement OK Y YES Stop the movement and release the pedal Open the turntable control panel and check that the LED associated with electrovalve YV19A up or YV19B down is off TO Press the pedal and activate the compensation switch Check that the LED associated with electrovalve YV19A up or YV19B down is on YES YES Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP050 Folio 2 5 NO COMPENSATION MOVEMENT UP AND OR DOWN Press the pedal and activate the compensation switch and check for 12V voltage at the terminals of the PVG YV2a connector Open the turntable control panel Press the pedal and activate the compensation switch and check for 12V voltage on terminal 305 of the printed circuit See Fiche the 108 YV2 control head NO Replace the See Fiche U1 module C107 YES Repair the connection or The fault NO replace the wiring harness persists between the turntable control panel and PVG YV2 END Replace the See Fiche C063 printed circuit Pinguely Haulotte Z BREAKD
62. C045 AN Caution Do not use the machine during maintenance operations Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Folio 1 1 CHANGING A MANIPULATOR 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 page 32 Switch off electric power see 6 4 page 32 Disconnect the lt gt then terminals to isolate the circuit 2 Removing a manipulator 2 Remove the upper panel 4 of the top control box by removing its fixing screws 1 Using cutters remove the cable clamps from the defective manipulator wires Carefully mark the positions of the different manipulator wires 3 on the top control panel connector Disconnect the wires from the top control panel plug Disconnect the positive wires 211 from the switches and then the nega tive wire Remove the fixing screws 5 from the manipulator and take the manipula tor out of the box 3 Installing a manipulator Place the replacement manipulator in position and put back the fixing screws 5 Put back the wires 3 in the cable strand and fasten the strand using plas tic clamps Fit male reference contacts to the ends of the wires 3 Connect the wires in the plug according to the marks made during dis mantling e Re connect the supply wires 211 and then the negative wire Putback the upper panel 4 of the box and fix using screws 1 Re connectthe then te
63. DISTRIBUTION HYDRAULIC BLOCK 1 Preliminary operations Remove the distribution hydraulic block see corresponding sheet 2 Dismantling the distribution hydraulic block 1 Mark the assembly position of the input plate input module distribution elements and closing plate If necessary remove the control units see corresponding sheet Remove the fixing nuts and 3 tie rods 2 then separate the elements 3 Re assembling the distribution hydraulic block Replace the O ring seals If necessary put back the control units see corresponding sheet Remount the input plate input module distribution elements and closing plate Put back the fixing nuts and 3 tie rods 2 Tighten to 2 2 daN m 15 91 Ib ft Put back the distribution hydraulic block see corresponding sheet Check that there is sufficient oil in the hydraulic tank Put the machine back in the operational configuration Make several lifting travel steering and turntable rotation movements to purge the hydraulic circuit Check the level of the hydraulic oil tank Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C097 Folio 1 1 CHANGING A TURNTABLE COVER 1 Preliminary operations AN Caution Do not use the machine during maintenance operations Put the machine the maintenance configuration see S 6 3 Switch off electric power see S 6 4 2 Removing a cover Open the relevant cover 1 Put th
64. Extend the machine tilt the tilt sensor and check that the buzzer sounds HA16 18PX New design HA46 51JRT New Design A Caution The buzzer should be audible from the basket Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C043 CHANGING AN ELECTRIC COMPONENT Folio 1 1 ON THE TOP CONTROL PANEL 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 page 32 Caution Switch off electric power see 6 4 page 32 Disconnect the lt gt then terminals of the starter battery Do not use the machine during maintenance 2 Removing a component from the top control panel operations Remove the closing plate 1 by removing the four fixing screws 4 Mark and disconect the electric connections 3 of the component to be replaced 2 Remove the component 3 Installing a component in the top control panel Put a new component and seal into place on the front panel of the top con trol panel NB In the case of a lever switch adjust the position of the fixing nut and counter nut so that the switch lever s articulation pin is at the same level as the seal to ensure tightness Reconnect the electric connections according to the marks made during dismantling Fixthe closing plate using the four fixing screws Reconnect the lt then lt gt terminals of the battery Putthe machine back into the operational configuration
65. Manufacturer s plate Portuguese 3078145950a Manufacturer s plate Swedish 3078143420 Operating instructions French 3078143430 Operating instructions Spanish 3078143440 Operating instructions German 3078143450 Operating instructions English 3078143460 Operating instructions Italian 2 3078143470 1 Operating instructions Dutch 3078144940 Operating instructions Danish 3078145540 Operating instructions Finnish 3078145830 Operating instructions Portuguese 3078145940 Operating instructions Swedish 3078144560 Operating instructions Australia 3 3078143600 2 Do not use as a welding earth Do not wash 4 3078143540 1 The plug must be connected to 220 V 5 3078144130 2 Do not stop in the machine s work area 6 3078144140 1 This machine is not insulated Danger of electrocution 7 3078143620 2 Risk of crushing hands and fingers 8 3078143630 2 Risk of crushing body 9 3078143940 1 Red arrow reverse 10 3078143930 1 Green arrow forwards 11 3078143530 1 Remove the front turntable rotation pin 12 3078143570 1 Slew ring lubrication 13 3078143520 1 Hydraulic oil 14 3078143590 1 Hydraulic oil high and low level 15 3078143680 1 Read the operation and maintenance manual 3078138990 21 16 3078139000 2 23 3078140080 23 3078139010 25 17 1250127590 1 Haulotte 18 3070029541 2 Haulotte 19 3078136770 2 X 20a 3078144310 1 Floor height load capacity H21T X 2
66. N LMA I BSO Aouanbal4 7 lt 7255 KR EA lt Dr Glen en i ks se en ei ss a gei d I VELO N 5 b a d n a 1 Q 0 N Q gt gt gt Fe 22 474 Ko poz CH 6v 2 z 9 3 gt 3 2 El 2 3 s 8 E d o s s H o 3g z 9 z g Z g g Z E g p 9 58 3 3 3 8 a 2 8 E 2 a gt 3 5 3 5 8 5 S 9 gt 9 8 8 a E 3 B B 5 gt 5 o 5 A 3 5 a3 a a 9924 9 o lt L L e wA 029 v 25 Pinguely Haulotte Z Repair manual 4 2 POSITIONS OF ELECTRIC COMPONENTS ON THE MOTHER BOARD 4 2 1 Description A A SCREW Connector Battery Flashing light Bi energy machine option Bottom box door Main Top control panel Starter Bottom box door Accelerator control KMG main relay Main supply after contactor Emergency pump 4 contactor Emergency stop circuit Connector for console CO N OO P Emergency stop circuit Horn HA1 Battery Gas electrovalves option Gas petrol machine option Proportional valve output a O Gas petrol machine option Buzzer RELAY 5013 Starter Boom lifting PVG Motor stop Telescoping or arm lifting PVG Electric thermal power switching Rotation PVG Accelerator Travel PVG Emergency pump safety Travel PVG Convert
67. NOT ACTIVATED Activate the starter switch SB3 or SB4 and check for 12 V voltage between terminals 242 and 146 in the turntable control box NO YES Check wiring between switch SB3or SB4 and the turntable Replace the relay See Fiche control box KA2 C062 The fault persists Check continuity of the electric wiring harness between relay KA2 terminal 103 of the turntable box and the starter solenoid YES Replace the defective electric wiring harness Replace the starter Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP019 THE MOTOR DOES NOT START Folio 1 2 FROM THE PLATFORM PANEL BUT DOES START FROM THE TURNTABLE PANEL The motor does not start from the platform but does start from the turntable Place the key switch in the platform position Check that the platform panel power light indicator is on NO Open the turntable control panel and check the state of fuse FU6 YES NO Open the platform control panel and E check the connection continuity connector of switch SB4 YES Replace fuse FU6 Connection OK END In the turntable control panel Repair the YES check for 12V voltage on lines connection of 211 and 242 of the wiring switch SB4 Activate switch SB4 harness connection terminal and c
68. OWN DETECTION FLOW CHART Sheet DP050 Folio 3 5 NO COMPENSATION MOVEMENT UP AND OR DOWN Invert the coils of the compensation electrovalve YV19A and YV19B Press the pedal and activate the compensation switch The defective ovement up 1 or down 2 is made in response to a control for the opposite movement down 1 or up 2 Put coils YV19A and YV19B back in their original positions Press the pedal and activate the compensation switch and check for 12V voltage at the terminals of the YV19A up or YV19B down connector Open the turntable control panel Press the pedal and activate the compensation switch NO and check for 12V voltage at terminals 310 up SA4 311A down of the printed circuit YES NO Replace the See Fiche U1 module 107 See Fiche Replace the coil C059 YV19A up or Y YV19B down YES The fault persists Repair the connection or END replace the wiring harness between the turntable control panel and electrovalve YV19 See Fiche C063 Replace the printed circuit END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP050 Folio 4 5 NO COMPENSATION MOVEMENT UP AND OR DOWN G Maintain the control activated and check for 12V voltage at terminals 401 up and 402 down of the printed circuit Ope
69. P005 or P008 END Check that the oil used is the recommended oil problem of oil viscosity being too high NO Change the hydraulic oil YES END Check that the hydraulic tank air vent is not blocked NO Clean the hydraulic tank air vent YES END On certain platforms check that the suction valves are open Pinguely Haulotte 77 BREAKDOWN DETECTION FLOW CHART Sheet DP025 Folio 2 2 NOISY HYDRAULIC PUMP Open the suction valves Check the state ofthe suction pipes clogging etc Replace the hydraulic pump suction pipes Pipes NO OK YES See Fiche C042 or C091 Incorrect operation of the hydraulic pump replace it END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP028 NO JIB MOVEMENT UP AND OR DOWN Folio 1 5 FROM THE PLATFORM OR TURNTABLE CONTROL PANEL No jib movement up and or down from the platform or turntable control panel Place the key switch in the platform position Press the pedal and activate the basket rotation switch on the platform control panel he basket rotates Stop the movement and release the pedal Open the turntable control panel and check that the LED associated with electrovalve YV18A down or YV18B up is off TO Press the pedal and activate the platform or turntable jib switch Check that the LED associated with electrovalve YV18A down
70. PVG control head YV5 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP042 NO TURNTABLE ROTATION MOVEMENT Folio 3 4 RIGHT AND OR LEFT FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Maintain the control activated and check for 3V or 9V voltage depen ding on the movement direction on terminal 512A of the printed circuit Voltage OK Replace the PVG control head See Fiche YV5 C077 or C108 Voltage OK Y Replace the U1 See Sheet module C058 or C107 Repair the connection or replace the wiring harness between the turntable control panel and and the PVG control head YV5 The fault persists Replace the See Fiche printed circuit C063 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP042 NO TURNTABLE ROTATION MOVEMENT Folio 4 4 RIGHT AND OR LEFT FROM THE PLATFORM OR TURNTABLE CONTROL PANEL o Activate the boom lifting movement in manual Put the emergency lever into place on the manual control of the boom lifting distributor YV3 Activate the up down lever while pressing the emergency control of the safety valve YV1 or activate the emergency unit NO Movement See Fiche DP023 OK Replace the PVG distribution See Fiche element YV5 77 or C108 Sheet DP050 Pinguely Haulotte Z
71. Pinguely Haulotte 4 REPAIR MANUAL SELF PROPELLED TELESCOPIC PLATFORM H21T X H23T X H23TP X H25TP X Sa 242 031 9590 E 10 02 GB FAIA ISO 9001 PINGUELY e Haulotte PINGUELY HAULOTTE LA Cda BP 9 42152 L HORME e T l o 0 b 29 24 A Far bee Se a 4 es otte haulotte com e Web www haulotte co Repair manual Pinguely Haulotte Z Caution The technical data in this manualis not binding and we reserve the right to make improvements or modifications without altering this manual GENERAL This manual gives the information required for you to perform servicing and repair operations on certain pieces of equipment yourself However we would like to bring your attention to the importance of respecting the safety instructions concerning the machine itself its use and its environment use within the limits of its performance correct servicing to ensure long service life During and after the guarantee period our After Sales service is available to perform any servicing operations you may require In this case contact our local agency or our Plant After Sales service specifying the exact type of machine and its serial number To order consumables or spare parts use the Instructions for use and maintenace manual and the Spare parts catalogue to order original parts the only guarantee of interchangability and perfect operation REMINDER We would like to remind
72. Q9 1 Machine folded Fold the machine Check the setpoint at the output of sensors SQ2 SQ3 and SQ9 Adjust the sensor s or replace See Fiche Setpoint 19V the defective sensor s C110 YES END Check the continuity of wiring harnesses no 206 207 and 204 NO Replace the defective wiring harness es no 206 207 or 204 YES END Replace the U1 module See Fiche C107 Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP056 ONLY TRAVEL MICRO SPEED IS AVAILABLE Folio 2 2 ON THE MACHINE REGARDLESS OF THE SPEED SELECTED The fault NO persists Replace the printed circuit See Fiche C063 END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP058 Folio 1 1 SUDDEN STOP OF TRAVEL MOVEMENT DURING A PLATFORM LIFTING OPERATION Sudden stop of travel movement during a platform lifting operation Check the setpoint at the output of detectors SQ3 SQ2 and SQ9 Adjust the detector s See Fiche Setpoint replace the defective C110 12V detector s Check the continuity of wiring END harnesses no 207 206 and 204 Continuity of harn sses na 207 an NO Replace the defective harness es p 206 OK no 207 206 and 204 Check operation of the See Fiche electronic module U1 C107 and replace if necessary
73. ROBABLE CAUSE SOLUTION The motor does not start the starter is activated Diesel tank empty Fuse FU1 defective Diesel supply circuit defective Wiring defective Module U1 defective Stop motor solenoid YA1 defective Sheet DP015 The motor does not start the starter is not activated Emergency stop locked Generator defective Batteries defective Fuses FU1 FU4 or FU8 defective Wiring defective Switch SB3 or SB4 defective Relay KA2 defective U3 frequency module defective Sheet DP016 The motor starts then stops after 55 Diesel tank empty Diesel supply circuit defective Sheet DP041 The motor does not start from the platform panel but does start from the turntable panel Fuse FU6 defective Defective connection of switch SB4 Switch SB4 defective Wiring harness defective Sheet DP019 The motor does not start from the turntable panel but does start from the platform panel Switch SB3 defective Wiring harness defective Sheet DP020 No motor acceleration regar dless of the movement con trolled from the platform Electronic module U1 defective Wiring harness defective Sheet DP021 No motor acceleration by activating the accelerator switch SA2 on the turntable control panel Relay KT2 defective Electronic module U1 defective Wiring harness defective Accelerator switch SA2 defective Motor accelerator coil YA2 defective Sheet DP022 N
74. V2a 1 and YV1 1 Down If SA6a 1 or SA7a 1 then YV18a 1 and YV2a 1 and YV1 1 Rotation Turntable 1 Left If SA15a 1 then YV1 1 and YV5 1 2 Right If SA15b 1 then YV1 1 and YV5 1 Platform 1 Left If HM31 1 and SM31ab 0 followed by SM31ab 1 then YV1 1 and YV5 1 2 Right If HM31 1 and SM31ab 0 followed by SM31ab 1 then YV1 1 and YV5 1 Lifting Turntable 1 Up If SA13a 1 and SQ9 1 then YV1 1 and YV3 1 2 Down If SA13b 1 and SQ9 1 then YV1 1 and YV3 1 Platform 1 Up If HM31 1 and SM1ab 0 followed by SM1ab 1 and SQ9 1 then YV1 1 and YV3 1 2 Down If HM31 1 and SM1ab 0 followed by SM1ab 1 and SQ9 1 then YV1 1 and YV3 1 Telescoping Turntable 19 Pinguely Haulotte 2 20 Repair manual 1 Out If SA8a 1 then YV1 1 and YV4 1 2 Down If SA8b 1 then YV1 1 and YV4 1 Platform 1 Out If HM2 1 and SM2ab 0 followed by SM2ab 1 thenYV1 1 and YV4 1 2 In If HM2 1 and SM2ab 0 followed by SM2ab 1 then YV1 1 and YV4 1 Travel If machine extended then MicroSpeed 1 If machine folded then MicroSpeed 0 If SA11a 0 and SA11b 1 and MicroSpeed 0 then LowSpeed 1 YV1 1 If SA11a 0 and SA11b 0 and MicroSpeed 0 then MediumSpeed 1 YV1 1 and YV12 1 and YV10 1 If SA11a 1 and SA11b 0 and MicroSpeed 0 then HighSpeed 1 YV1 1 and YV12 1 and YV10 1 and YV8 1 If HM4 1 and SM4ab 0 followed by SM4ab 1 and SA9a 0 and SA9b 0 and SM31ab 0 and SM2ab 0 then YV6 1 and YV7 1 LowSpeed MediumSpeed HighSpeed full setpoint MicroSpeed low setpoi
75. able control panel SA13 or the lifting manipulator SM31 from the platform control panel Lifting movement OK Ki Open the platform or turntable control panel and check the wiring of the boom lifting mani pulator SM31 or boom lifting switch SA13 NO Repair wiring YES Turntable panel boom Platform panel boom END Y lifting fault lifting fault Place the key switch in the turntable Place the key switch in the platform position position Open the platform control panel Open the turntable control panel Tilt the boom lifting manipulator SM31 as far as possible Activate the boom lifting switch SA13 Check for 0 5V or 4 5V voltage depending on movement and check for 12V voltage on terminals direction on terminal 403 of the printed circuit 505 or 504 of the printed circuit Replace the boom lifting See Fiche manipulator SM31 or lifting switch C045 Fiche SA13 C044 Repair the connection or replace the wiring harness END between the boom lifting manipulator SM31 or boom lifting switch SA13 and the printed circuit of the turntable control panel END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet 54 NO BOOM LIFTING MOVEMENT Folio 2 5 UP AND OR DOWN FROM THE PLATFORM OR TURNTABLE CONTROL PANEL o Check the setpoint at the outputs of limit detectors SQ7 SQ8 and 5011 Set
76. anel Press the pedal and tilt the rotation manipulator as far as Activate the rotation switch SA15 and possible check for 12V voltage on terminals 517 or Check for 0 5V or 4 5V voltage depending on the move 516 of the printed circuit ment direction on terminal 512 of the printed circuit Replace the rotation See Fiche NO manipulator SM31 or the C045 Fiche rotation switch SA15 C044 YES Repair the connection or replace the wiring harness END between the rotation manipulator SM31 or the ro tation switch SA15 and the printed circuit of the turntable control panel END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP042 NO TURNTABLE ROTATION MOVEMENT Folio 2 4 RIGHT AND OR LEFT FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Activate the rotation movement in manual Put the emergency lever into place on the platform control of the rotation distributor YV5 Activate the lever right left while pressing the emergency control of the safety valve YV1 or activate the emergency unit Movement OK Place the key switch in the turntable position Activate the boom lifting switch on the turntable control panel SA13 Boom lifting movement OK See Fiche DP023 YES Activate the rotation switch SA15 of the turntable control panel and check for 3V or 9V voltage depending on the movement direction at the terminals of the
77. ary put the platform s electric plug back into place and fix using its fixing bolts equipped with new toothed washers Reconnect the lt then lt gt terminals of the starter battery Putthe machine back into the operational configuration Adjust the weighing contactors see corresponding sheet E E E EE N Zo ITI 4 1 Sl us Figure 1 HAN AMAA NN NN Cl NY TY 4 CT D b 4 4 222222222222272222277222222222222224 Figure 2 Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C053 Folio 3 3 CHANGING THE BASKET vide 27 cote o SOS SSS 15 I HA16 18PX HA46 51JRT 108 mm 4 25 in H21T HB62 103 mm 4 055 in H23T TP H25TP HB68J HB76J 108 mm 4 25 in Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C054 Folio 1 1 CHANGING A WEIGHING SYSTEM ROLLING BEARING 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 page 32 Switch off electric power see 6 4 page 32 Remove the basket see corresponding sheet 2 Removing the rolling bearing Remove the screws 1 from the rolling bearing track Remove the rolling bearing track 2 Remove the circlips 4 then the ball bearings 3 3 Installing the rolling bearing Putn
78. astic collars Onthe motor reconnect the battery connection wires 1 Additional operations Putback the cover see corresponding sheet Reconnectthe then terminals of the starter battery Putthe machine back in the operational configuration Start the motor and check that it works properly Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C098 Folio 2 2 CHANGING THE THERMAL MOTOR N caution Caution If the motor installed is new follow the first commissioning instructions see motor manufacturer s manual COUPLE SERRAGE 5 Nm Sheet C099 AN Caution Put the turntable rotation blocking pin into place A Caution It is essential to put the component slings before dismantling re assembling it A Caution Ensure that the oil is not too hot Caution Use a container to collect oil to prevent pollution of the environment Sd Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Folio 1 2 CHANGING THE TURNTABLE ROTATION HYDRAULIC MOTOR 1 Preliminary operations Lift the boom sufficiently to enable access to the turntable rotation hydrau lic motor Place wedges under the boom to bear its weight Put the machine in the maintenance configuration see S 6 3
79. ated front pad in place 30 Pass the sling 25 above the pad 30 by pulling from the back When passing the return slings 21 on the back pulleys make sure they are underneath Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C119 Folio 7 13 DISMANTLING RE ASSEMBLING THE BOOM Figure 9 9 Re assembling and adjusting a 3 element telescopic boom Head element equipment Bind together the two electric cables 31 Figure 10 with adhesive tape on the side on which they will be inserted Mark a length of 3m on the 42 wire cable Insert the 42 wire cable via the back of the head element passing first through a few links of the chain then in the chute Pull the cables out at the other end of the head element until the 3m mark is aligned with the collar fixing hole fig NB Align a mark tape at 3m with the screw hole Figure 10 Insert the 4 hoses 10 together along the same route as the 42 wire cable Figure 11 Atthe other end of the head element pull the hoses through Figure 10 NB Marks on the hoses C1 cylinder out Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C119 Folio 8 13 DISMANTLING RE ASSEMBLING THE BOOM C2 cylinder in R1 cylinder rotation R2 cylinder rotation NB Stick the ring 31 with loctite 648 Basket rotation Figure 11 Attach the cables and hoses inside the element with HB20 collars 32 for hoses C1 and R1 and HB33
80. bar and PSI Pump flow cancellation 240 b 3480 PSI load sensing standby pressure 30b 435 PSI PVG Danfoss distributor input pressure protection 270 b 3916 PSI rotation pressure limiter 100 b 1450 PSI Telescoping extension pressure 100 b 1450 PSI large chamber braking valve 210 b 3045 PSI small chamber braking valve 210 b 3045 PSI Lifting lowering pressure 100 b 1450 PSI large chamber braking valve 210 b 3045 PSI Compensation up down braking valve 210 b 3045 PSI Jib large chamber braking valve 210 b 3045 PSI Emergency unit 130 b 1885 PSI Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C112 Folio 1 1 CHANGING A BALANCING BLOCK BOOM LIFTING FUNCTION 3 1 Preliminary operations A Caution Lift the boom and wedge it The boom MUST be wedged Switch off electric power see 6 4 support the boom on wedges 2 Removing the balancing block Disconnect the cylinder hoses 1 Disconnect the rigid pipe 4 A Caution NB Unscrew the hoses slowly to release residual hydraulic pressure Ensure that the oil is not too hot Putcaps on the hoses Unscrew the fixing screws 2 and remove the balancing block 3 Remove the rigid pipe connector Installing the balancing block Check the condition and cleanliness of the cylinder bored block Put back the rigid pipe connector on the new balancing block Install t
81. ct the hydraulic hoses and caps on the swing joint according to the marks made during dismantling Passthe wiring harnesses in the machine along their original paths Reconnect the electric connections in the chassis box and turntable box according to the marks made during dismantling 4 Additional operations Putthe machine back in the operational configuration Remove the wedges from under the boom Make several steering and travel movements using all possible travel speeds to purge the hydraulic circuit Check that the electric controls work properly Checkthe level of the hydraulic oil tank Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C100 Folio 2 2 CHANGING THE SWING JOINT ASSEMBLY SS E i Eleak AAA Figure 1 Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C101 Folio 1 1 CHANGING A COUNTERWEIGHT Putthe machine in the maintenance configuration see S 6 3 Switch off electric power see 6 4 Putthe boom in slings 1 to prevent tipping when the counterweight s is are removed Screw the lifting rings on the counterweight and secure a lifting beam to them Fix a vehicle lift to the lifting beam and apply tension to the vehicle lift 2 Removing the counterweight Remove the 3 fixing screws and washers 3 Remove the counterweight 2 3 Removing the small counterweight H23TPX H25TPX HB68J HB76J R
82. d circuit 4 Testing the printed circuit Perform the computer operating test see changing the U1 electronic module sheet Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C064 Folio 1 1 CHANGING THE FAIL SAFE PEDAL 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 page 32 Switch off electric power see 6 4 page 32 Disconnect the lt gt then lt gt terminals of the starter battery 2 Removing the fail safe pedal Open the platform electric box Mark and disconnect the electric connections 1 of the fail safe pedal 2 in the box Mark the pedal cabling path 1 along the vertical platform parts and then cut the fixing collars 3 Remove the pedal by removing the pedal s fixing bolts 4 and their washers 3 Installing the fail safe pedal Puta new pedal into place and fix using the bolts and their washers Reconnect the electric connections in the box according to the marks made during dismantling Close the platform box Fixthe electric cable to the vertical platform parts using collars Reconnectthe then terminals of the starter battery Putthe machine back into the operational configuration e Check that movements from the platform are possible only if the fail safe pedal is pressed Sheet C067 A Caution Ensure that the oil is not too hot AN Caution Use a container to collect
83. d lubricators if necessary Put the steering lever into place Put back the central steering pin then the screws and new washers 13 14 Put back the male clevis and fix with its fixing screw equipped with a new washer Put back the cylinder fastening pin and fix with a new Nylstop nut and its washer 5 Installing a steering bar Replace the pins and lubricators if necessary Put the steering bar into place performing the removal operations in reverse order Adjust wheel alignment if necessary slacken the counter nut 10 on the steering bar Screw or unscrew the clevis 11 to adjust the length of the steering bar tighten the counter nut 10 Put back the two steering clevis pins Put back the fixing screws of the two steering clevis pins 6 Additional operations Put the machine back in the operational configuration Lubricate the pins with lubricators Pinguely Haulotte Z Folio 2 2 I o O 2 lt 2 m 2 lt gt gt D c O O DISMANTLING AND RE ASSEMBLING Sheet C086 THE STEERING SYSTEM SE Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C087 Folio 1 1 CHANGING THE STEERING CYLINDER 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 Caution Switch off electric po
84. ditional operations Checkthe level of oil in the wheel reducing gear see corresponding sheet Putthe wheel back see corresponding sheet Putthe machine back into the operational configuration Make several travel movements to purge the hydraulic circuit Checkthe level of the hydraulic oil tank Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C035 CHANGING A WHEEL REDUCING GEAR Folio 2 2 OR A TRAVEL HYDRAULIC MOTOR f 210 2 Figure 1 Figure 2 Sheet C036 A Caution Ensure that the oil is not too hot A Caution Use a container to collect oil to prevent pollution of the environment A Caution It is essential to put the component in slings before dismantling re assembling it Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Folio 1 2 CHANGING A STEERING PIVOT 1 Preliminary operations 2 Put the machine in the maintenance configuration see 6 3 page 32 Switch off electric power see 6 4 page 32 Remove the wheel corresponding to the element to be removed see cor responding sheet Remove the motor and reducing gear corresponding to the pivot to be removed see corresponding sheet Removing a pivot see figure 1 Place a wedge under the steering pivot 1 Remove the fixing screw 2 from the steering clevis pin Remove the steering clevis pin 3 Remove the two screws 4 f
85. e cover in slings Remove the nuts and washers 3 fixing the gas springs to the connecting rods 2 supporting the cover Remove the bolts 5 and 6 fixing the cover 1 to the two hinges 4 Retain the cover support connecting rods 2 Remove the cover Installing a cover Position a new cover and fix to the hinges 4 with screws 5 Put back the cover support connecting rods using their fixing screws 6 Fix the gas springs to the cover connecting rods 2 using nuts and washers 3 Check that the cover opens and closes properly If necessary adjust the cover using screws 4 and 5 Put the machine back in the operational configuration Sheet 98 A Caution Leave the motor and exhaust to cool sufficiently before performing any maintenance operation on these elements Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Folio 1 2 CHANGING THE THERMAL MOTOR 1 N A 1 8 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 Switch off electric power see S 6 4 Disconnect the then terminals of the starter battery Remove the cover on the motor side see corresponding sheet Removing the connections Onthe motor disconnect the battery connection wires 1 Disconnect the motor s electric connections 2 and free the trunking from its plastic collars Disconnect the fuel incoming 3 and outg
86. e cylinder pin 5 on the rod side AN Caution Remove the pin 5 It is essential to put the Remove the jib cylinder 1 component in slings before dismantling re assembling it 3 installin g the jib cylinder NB Before re installing check the condition of all articulation pin rings and replace if necessary Lubricate all bores before re installing the pins Only use lubricants recommended by the manufacturer Putthe jib cylinder into place and put back the two articulation pins on the rod and body side of the cylinder Putback the pin stop rings 4 and fix with their bolts Putback the pin stop clevis 5 Remove the slings Reconnect the cylinder s hydraulic hoses 1 4 Additional operations Free the basket Putthe machine back in the operational configuration Ensure that there is oil in the hydraulic tank Make several jib movements to test operation and purge the hydraulic cir cuit Checkthe level of the hydraulic circuit Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C115 Folio 2 2 CHANGING THE JIB CYLINDER Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C116 Folio 1 2 CHANGING THE BOOM LIFTING CYLINDER 1 Preliminary operations AN Caution Position the self propelled telescopic platform on a firm horizontal sur face e Put the turntable rotation blocking pin into place Lift the boom to access to the boom lifting cylinder fix
87. e dimensions 15 R 22 External turning radius 6 15 m Tilt sensor 5 approx 9 Hydraulic tank 1501 Diesel tank 1501 Total weight 13100 kg 13100 kg 13750 kg 13750 kg Number of drive wheels 2 4 2 4 Number of steering whels Differential blocking system YES Hydraulic brakes YES Freewheel YES Tightening torque wheel nuts 32 m daN slew ring nuts 27 m daN Vibrations at foot level lt 0 5 m s2 at hand level lt 2 5 m s DEUTZ diesel motor Type 3L41C Power 43 6 CH 32 1 kW to 2400 rpm Idling power 33 3 CH 22 9 kW to 1500 rpm Consumption 11 5 l h Idling consumption 6 8 l h Hydraulic pump 45 cm rev 85 l min max LOADSENSING Hydraulic pressure 2 240 Steering 20045 240 bars Rotation Equipment 189 bas 240 bars Travel speed LS 1 5 km h HS 5 km h Max force on one wheel 8000 daN Max pressure on the ground with 250 kg concrete 18 daN cm soft ground beaten earth 8 daN cm Starter battery 1x 12V 95A h Supply voltage 12V Acoustic power 99 dB A Sound level at 10 m 66 5 dB A Repair manual Pinguely Haulotte Z 2 1 2 H23T X and H25TP X technical data DESCRIPTION H23T H23TX H25TP H25TPX Nominal load 250 kg including 2 people Maximum side manual force 40 kg Max wind speed 60 km h Floor height 21 3m 21
88. eet P007 Fill up capacity 4 x 1 4 litres 26 Slew ring screws check tightness and tighten if necessary torque 27 daN m OPTION every 500 27 Change the oil of the hydraulic oil tank if using biodegradable oil hours or every 6 months Motor see Manufacturer s manual s Nours 27 Change the oil of the hydraulic tank or every year Check the tension of the telescope cables 41 Pinguely Haulotte 2 Repair manual Frequency Ref Operation 28 Change the oil of the hydraulic tank and whole circuit Every 2000 hours 29 Empty and clean the diesel tank 30 Lubricate the rotation reducing gear 1 point Check the condition of the safety cable the telescoping cables and friction pads Every 3000 hours On and the electric wires and hydraulic hoses REMINDER The above frequencies should be reduced if work is carried out in difficult conditions consult After Sales Service if necessary 6 7 PRESENCE OF LABELS 42 Make sure that the labels and plates informing personnel of the various dangers related to machine use are in good condition The labels informing operators on the use and maintenance of the machine must also be in good condition An illegible label may result in incorrect or dangerous use of the machine Instructions Check that the labels are present Check that all the labels described below are legible and in place Replace them if necessary additional copies can be supplied on req
89. emove the fixing screw from the small counterweight 4 and 6 Remove the small counterweight 5 4 Installing the small counterweight H23TPX H25TPX HB68J HB76J Place the small counterweight 5 on the turntable and secure with the screws 4 and washers provided see table of tightening torque values Caution Ensure that the lifting equipment is in good condition and of sufficient Installing the counterweight Put the counterweight 2 on the turntable Put back the 3 fixing screws and washers see table of tightening torque capacity values 6 Additional operations e Check that the counterweight is properly secured to the machine Remove the lifting rings from the counterweight Caution f Remove the sling from the boom It is essential to put the Put the machine back in the operational configuration component in slings before dismantling re assembling it Q Diameter M30 Figure 1 Sheet C103 Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Folio 1 2 DISMANTLING RE ASSEMBLING THE JIB AN Caution Ensure that the oil is not too hot A Caution Use a container to collect oil to prevent pollution of the environment Caution Ensure that the lifting equipment is in good condition and of sufficient capacity AN Caution It is essential to put the component in slings before dismantling re assembling it 1 Preliminary
90. en the cover 1 concerned Gilek Putthe cover in slings Remove the fixing nuts and washers 2 at both ends of the gas spring 3 HA16 18PX HA46 51JRT 3 Installing a gas spring Puta new gas spring into place and fix at both ends using the fixing nuts and washers Putthe machine back into the operational configuration Check that the cover opens and closes correctly HA16 18 PX New design HA46 51JRT New Design Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C052 Folio 1 1 CHANGING THE BASKET ROTATION HYDRAULIC MOTOR 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 page 32 Caution Switch off electric power see 6 4 page 32 Ensure that the oll Is not too 2 Removing the hydraulic motor GE Mark and disconnect the hoses 2 from the hydraulic motor 4 Unscrew the hoses slowly to release residual hydrualic pressure A Caution pri a Use a container to collect oil Fit caps to the hoses to prevent pollution of the Remove the flow limiters 1 by unscrewing the unions 5 and adapters environment 6 Remove the hydraulic motor by unscrewing its fixing screws 3 3 Installing the hydraulic motor Replace the flow limiters if necessary Puta new hydraulic motor into place Fixthe hydraulic motor using fixing screws equipped with new grower washers Screw the unions adapters and flow limiters onto the mo
91. ensation cylinder 35 and boom lif ting cylinder 36 in slings Mark and disconnect the hydraulic hoses of the emitting compensation cylinder and boom lifting cylinder Put caps on the hoses Remove the pin 37 from the boom lifting cylidner on the rod side by removing its blocking washer and screw Remove the 3 screws and nuts 39 blocking the pin 38 of the lifting cylinder on the body side and remove the two lubricators 40 Remove the pin then remove the lifting cylinder Remove the pin blocking clevis 41 of the emitting compensation cylinder 95 on the rod side and remove the pin Remove the pin stop plate 42 of the emitting compensation cylinder on the body side and remove the pin Remove the emitting compensation cylinder Remove the slotted nut 44 and washer from the boom articulation pin and remove the pin 43 Remove the large drum 16 and retain the 2 stop washers 45 Figure 6 Sheet C119 Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Folio 5 13 DISMANTLING RE ASSEMBLING THE BOOM 6 Installing the large drum NB NB NB Before re installing check the condition of all the articulation pin rings and replace if necessary Lubricate all bores before re instal ling the pins Only use lubricants recommended by the manufactu rer
92. er for bi energy machine Motor wiring harness Petrol gas switching Top control panel FUSE Top control panel Motor stop Top control panel Maintain acceleration SQ11 Main SQ10 Low position SQ6 Tilt High position Hydraulic tank temperature probe B4 Electrovalve SQ3 Permanent sensor supply SQ4 or SQ14 Accessories SQ7 Load Sensing valve for machine with PVG 508 26 509 Pinguely Haulotte Z Repair manual 4 2 2 Positions of screws connectors and relays 13 57 54 55 56 51 52 53 49 50 45 46 42 43 44 40 41 27 Pinguely Haulotte Z Repair manual 4 2 3 Positions of fuses 20 19 21 22 26 27 25 23 24 re E ub 2 STE 17 LIC t Ces T i H Za E EO LLRI Mie e eg T 28 Repair manual Pinguely Haulotte Z 4 2 4 Positions of diagnosis help LEDs d pue eka gr be 7 ES o YV16B ta YV16A YV19B YV19A 29 Pinguely Haulotte 2 Repair manual 30 Pinguely Haulotte Z 5 HYDRAULIC DIAGRAMS DIAGRAM H21T H23T REFERENCE B15714 Repair manual 5 1 2712619 7091 1091 HIOAH3S3H 9 092315 NOILLO3810 Seo TE el isst K A T BAA ana SAA EAA ei eg wel E p i ee LE d dl i i Tale saa o YILSYW i YNILLANI H i
93. er than permissible limit Operating and maintenance instructions Pinguely Haulotte To reduce the risks of serious falls operators must respect the following instructions Hold the guardrail firmly when lifting or driving the platform Remove any traces of oil or grease from the platform steps floor or guardrails Wear personal protective equipment suited to working conditions and conform to local regulations particularly when working in hazardous areas Never disable the limit switches of the safety devices Avoid contact with stationary or moving obstacles Do not increase the platform operating height by means of ladders or other accessories Never use the guardrails to climb into or out of the platform use the steps provided Never climb on the guardrails when the platform is up Avoid driving the machine at high speed in narrow or congested are as Never use the machine without putting in place the platform safety bar or closing the safety gate Never climb on the covers Caution Never use the platform as a crane To reduce the risks of tipping over operators must follow these hoist or lift instructions Never use the machine to pull or e Never disable the limit switches of the safety devices tow Never move the control handles from one direction to the other with Never use the boom as a ram or out stopping in the O position To stop when travelling gradually thruster or to lift the wheels move the
94. erminal 506A of the printed circuit Voltage OK Folio 4 5 Replace the PVG YV4 control See Fiche gt Voltage i C108 Y OK Replacethe U1 See Fiche YES module C107 END The fault persists head Replace the printed circuit See Fiche C063 Repair the connection or replace the wiring harness between the turntable control panel and the PVG YV4 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP053 NO TELESCOPING MOVEMENT Folio 5 5 IN AND OR OUT FROM THE PLATFORM OR TURNTABLE CONTROL PANEL 2 Activate the rotation movement in manual Put the emergency lever into place on the manual control of the rotation distributor YV5 Activate the lever right left while pressing the emergency control of the safety valve YV1 or activate the emergency unit NO Movement _ See Fiche DP047 OK Replace the PVG YV4 See Fiche distribution element C108 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP054 NO BOOM LIFTING MOVEMENT Folio 1 5 UP AND OR DOWN FROM THE PLATFORM OR TURNTABLE CONTROL PANEL No boom lifting movement up and or down from the platform or turntable control panel Y Fold the machine except for the boom Place the key switch in the turntable or platform position Activate the lifting switch from the turnt
95. ess the pedal and activate the boom lifting Start the platform start the thermal motor manipulator SM31 while pressing the emergency without making a movement control of the safety valve YV1 Check the lt load sensing gt pressure reading tap M 25 to 30 bars Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP023 i Folio 2 5 NO MOVEMENT AVAILABLE FROM TURNTABLE OR PLATFORM CONTROL PANELS Movement NO OK Open the turntable control panel Press the pedal and activate the boom lifting manipulator SM31 Check that the LED associated with electrovalve YV1 is on NO YES Maintain activation of the controls and check connector YV1 for 12V voltage 1A to 1 6A current Replace the electric wiring YES harness between electrovalve YV1 and the turntable control panel 1A to 1 6A END 9 K YES Replace electrovalve Replace the coil of See Fiche YV1 electrovalve YV1 C077 or C108 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART NO MOVEMENT AVAILABLE PS FROM TURNTABLE OR PLATFORM CONTROL PANELS Pressure NO 25 to 32 bars YES Adjust the lt load See Sheet sensing pressure 073 or C111 NO Pressure OK YES Check the coupling See Fiche between the hydraulic C042 or END pump and the thermal C091 motor Co
96. esses 115A 218A and 218B NO Replace the defective harness e YES Check the setting of the limit See Fiche detectors SQ7 SQ10 and 110 5011 Adjust or replace the limit NO detectors SQ7 SQ10 or See Fiche YES Replace the U1 module See Fiche END C107 END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP053 NO TELESCOPING MOVEMENT Folio 3 5 IN AND OR OUT FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Activate the telescoping movement in manual Put the emergency lever into place on the manual control of the telescoping distributor YV4 Activate the lever up down while pressing the emergency control of the safety valve YV1 or activate the emergency unit Movement OK Place the key switch in the turntable position Activate the turntable control panel rotation switch SA15 Rotation movement OK See Fiche DP023 YES Activate the telescoping switch SA8 of the turntable control panel and check for 3V or 9V voltage depending on movement direction at the terminals of the PVG YV4 control head Pinguely Haulotte Z Sheet DP053 BREAKDOWN DETECTION FLOW CHART NO TELESCOPING MOVEMENT IN AND OR OUT FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Maintain the control activated and check for 3V or 9V depending on movement direction on t
97. ew acting on the contactor motor stop so that the motor is cut out when the cable is pulled sharply The screw head should be about 1 cm from the contac tor caster 16 Checking the breaking actions after re assembling the boom on H25 Check that the range limiter cuts out when the boom is extended more than 16 m it cannot be lowered below 43 fthe first range limiter contactor fails there is a safety contactor at 40 that cuts out the motor In the case of a break action use the emergency unit to retract the boom Boom extension of 16m is detected by the contactor on the drum and a Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C119 Folio 13 13 DISMANTLING RE ASSEMBLING THE BOOM cam placed on the intermediary drum No adjustment is necessary Simply check that the contactor does not touch the intermediary drum and that contact with the cam is made correctly To adjust first act on the 40 break then on the range limiter 43
98. ew rolling elements on the bearing track Block in travel using the cir clips Lubricate the rolling bearings NB Only use lubricants recommended by the manufacturer Re install the basket see corresponding sheet Putthe machine back in the operational configuration Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C056 Folio 1 1 CHANGING THE HYDRAULIC FILTER A Canton 1 Preliminary operations Ensure that the oil is not too Put the machine in the maintenance configuration see 6 3 page 32 hot Switch off electric power see 6 4 page 32 Close the shut off valve if any Otherwise empty the hydraulic tank uri 2 Removing the hydraulic filter A Caution Disconnect the hydraulic filter hoses 1 Use a container to collect oil to prevent pollution ofthe NB Unscrew the hoses slowly to release residual hydraulic pressure environment Fit caps to the hoses Unscrew the fixing screws 2 and remove the hydraulic filter Remove the two connectors 3 from the hydraulic filter 3 Installing the hydraulic filter Install the two connectors on a new hydraulic filter see the table of tighte ning torque values Put the equipped hydraulic filter back into place respecting the oil flow direction and fix using the fixing screws Reconnect the hydraulic hoses e Put the machine back into the operational configuration Make several lifting cycles to purge the hydrau
99. explosion or burning The risks of explosion or burning are high in the following situations Working in explosive or inflammable atmosphere Filling the fuel tank near naked flames Contact with the hot parts of the motor Use of a machine generating hydraulic leakage 1 3 4 Risks of collision Risk of crushing people in the machine operation zone when travel ling or manoeuvring equipment The operator must assess the risks above him before using the ma chine Pay attention to the position of the arms during turntable rotation Adapt movement speed to conditions related to the ground traffic slope and movement of people or any other factor that may cause a collision When driving down the ramp of a truck ensure sufficient space is available for safe unloading Check brake pad wear regularly to avoid all risk of collision Operating and maintenance instructions Pinguely Haulotte Y 1 4 INSPECTIONS Comply with the national regulations in force in the country of machine use For FRANCE Order dated 9 June 1993 circular DRT 93 dated 22 September 1993 which specify 1 4 1 Periodic inspections The machine must be inspected every 6 months in order to detect any defects liable to cause an accident These inspections are performed by an organisation or personnel specially designated by the site manager and under his responsibility whether or not they belong to the company Articles R 233 5 and R 233 11 of the French
100. f The fault NO electrovalve YV6 and YV7 persists YES END Replace the printed See Fiche circuit C063 END Setpoint Output 26 3 and 25 3 Forward 6 to 9V Reverse 6 to 3V Replace wiring harness no 612A Replace PVG YV6 or YV7 See Fiche control head C077 or C108 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART un NO MACHINE TRAVEL MOVEMENT lioq Setpoints 29 2 exc neutral 29 3 12V 29 4 forward 2 5 to 4 5V Reverse 2 5 to 0 5V Replace defective wiring har nesses no 612 606 and 611A See Fiche C058 or C107 Replace the U1 module The fault NO persists YES Replace the printed circuit See Fiche C063 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP034 Folio 1 4 MACHINE TRAVEL SPEED DOES NOT CORRESPOND TO THE SELECTOR SPEED Machine travel speed does not correspond to the selector Do not press the pedal Open the turntable control panel and check that the LEDs associated with electovalves YV8 YV10 and YV12 are off All the LEDs are off Note the LED that is on Put the machine on wedges so that the wheels are not touching the ground Place the key switch in the platform position Place the speed selector in the High speed position Press the pedal and make a forward travel movement Check that the LED
101. h output so that you can check if an output is activated 8 2 BREAKDOWN DETECTION FLOW CHARTS 62 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP015 Folio 1 2 THE MOTOR DOES NOT START THE STARTER IS ACTIVATED The motor does not start the starter is activated Check the level of the diesel tank Diesel OK Fill the diesel tank END Open the turntable control panel and check the state of fuse FU1 NO Replace fuse FU1 YES END Check the diesel supply circuit See motor manufacturer manual NO YES Repair diesel supply circuit See motor manufacturer Activate the starter switch SB3 or m ual SB4 and check for 12V between terminals 242 and 150 of the turn table control box NO Z Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP015 Folio 2 2 SeeFiche Check wiring between the motor starter C062 switch SB3 or SB4 and the printed circuit of the turntable control box THE MOTOR DOES NOT START THE STARTER IS ACTIVATED Replace relay KP1 The fault NO persists NO END Check continuity of the electric wiring harness between relay KP1 Repair wiring terminal 115 of the turntable box and motor stop solenoid YA1 NO Replace module U1 See Fiche C058 Replace the defective YES wiring har
102. hapter Check that the corresponding movement is made correctly Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Folio 1 2 Sheet C085 CHANGING A STEERING PIVOT ON A NON DRIVE WHEEL 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 A Caution Switch off electric power see 8 6 4 Ensure that the oil is not too Remove the wheel corresponding to the element to be removed see cor hot responding sheet 2 Removing the bearings if necessary Remove the cap 10 Remove the counter nut 11 brake washer 12 and nut 13 A Caution Remove the hub 14 of the pivot 1 Use a container to collect oil Remove the bearings 16 to prevent pollution of the Remove the seal 15 environment 3 Removing a pivot see figure 1 Place a wedge under the steering pivot 1 Remove the fixing screw 2 from the steering clevis pin Remove the steering clevis pin 3 A Caution Remove the two screws 4 from the two caps on the pivot pin and remove the two caps 5 Take the M canindus pin from each pivot pin 6 and remove the pivot pin and support washer 7 Remove the steering pivot 1 4 Installing a pivot Putthe steering pivot into place Replace pins lubricators and support washers if necessary Putback the support washers and pivot pins and block using new M ca nindus pins Putback the pivot pin caps and fix using fixing screws a
103. he condition of the tyres wires and all accessories and equipment 7 Check clogging of the hydraulic oil filter Change the cartridge if the clogging indicator is visible see sheet P009 Check the degree of wear of the articulation pins 8 Change the hydraulic filter cartridge see sheet P009 see 250 hours frequency After the first 50 9 Change the oil of the drive wheels see sheet P007 hours see 500 hours frequency 2 points for model 4x2 4 points for model 4x4 10 Check the tightness of the slew ring screws torque 27 daN m 11 Motor see Manufacturer s manual 12 Check the level of the drive wheel reducing gears see sheet P007 Lubricate 14 jib articulation pin for H23TP and H25TP 2 points Every 50 hours 15 basket link part articulation pin 4 points 16 boom bottom pin 1 point 17 wheel pivot pins 8 points 18 steering axle central pivot and clevis pin 10 points 19 slew ring bearing 2 points Test the emergency electropump unit make a boom movement using the emergency electropump unit 20 Motor see Manufacturer s manual 21 Lubricate the friction parts of the telescope spatula Use this opportunity to check Every 250 hours the condition of the friction pads 21 Lubricate the telescoping cable 22 Check the tightness of the wheel nuts torque 32 daN m 23 Change the hydraulic filter cartridge see sheet P009 24 Motor see Manufacturer s manual Every 500 hours 25 Change the oil of the wheel reducing gears see sh
104. he control activated and check for 3V or 9V voltage depen ding on the movement direction on terminal 403A of the printed circuit Voltage OK Replace the PVG YV3 control See Fiche NO Voltage OK head C108 Replace the U1 See Fiche module C107 MES END Repair the connection or replace the wiring harness NO between the turntable control panel and the PVG YV3 control head Replace the See Fiche printed circuit CO63 The fault persists Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP054 NO BOOM LIFTING MOVEMENT Folio 5 5 UP AND OR DOWN FROM THE PLATFORM OR TURNTABLE CONTROL PANEL 2 Activate the rotation movement in manual Put the emergency lever into place on the manual control of the rotation distributor YV5 Activate the lever right left while pressing the emergency control of the safety valve YV1 or activate the emergency unit NO Movement _ See Fiche DP047 OK Replace the PVG YV3 See Fiche distribution element C108 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP056 ONLY TRAVEL MICRO SPEED IS AVAILABLE Folio 1 2 ON THE MACHINE REGARDLESS OF THE SPEED SELECTED Only travel micro speed remains available on the machine regardless of the selected speed Check that the machine is folded SQ2 1 SQ3 1 and S
105. he new balancing block with new seals on the cylinder body using A Caution 3 Use a container to collect oil to prevent pollution of the environment W the fixing screws and new grower washers Reconnect the rigid pipe Reconnect the hydraulic hoses e Put the machine back in the operational configuration AN Caution Make several movements using the cylinder concerned to purge the hydraulic Balancing valves are safety circuit elements They are calibrated in the plant and must not be modified Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C114 Folio 1 2 CHANGING THE EMERGENCY HYDRAULIC CIRCUIT PRESSURE LIMITER e 1 Preliminary operations AN Attention Putth hine in th int fi ti Duc teal E ut the machine in the maintenance configuration see 6 3 Switch off electric power see S 6 4 hot 2 Removing the emergency circuit pressure limiter Disconnect the return hose 1 of the emergency circuit at the pressure limiter 2 A Attention NB Unscrew the hoses slowly to release residual hydraulic pressure Use a container to collect oil to prevent pollution of the environment Put a cap on the hose Remove the pressure limiter 2 by unscrewing the adapter 3 Retain the pressure limiter s union and adapter Installing the emergency circuit pressure limiter Putthe union and adapter on a new pressure limiter Installthe pressure limiter by screwi
106. heck continuity block between the platform between the two control panel and the turntable terminals of the switch control panel NO gt NO Replace See Fiche YES YES Repair wiring of the switch SB4 C043 key switch SA1 or replace the switch END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP019 THE MOTOR DOES NOT START Folio 2 2 FROM THE PLATFORM PANEL BUT DOES START FROM THE TURNTABLE PANEL Activate SB4 and check for 12V voltage at terminal 117B of the printed circuit Repair wiring or replace the wiring harness between the NO platform control panel and the turntable control panel YES END Replace the U1 module See Fiche C058 or C107 The fault NO persists YES END Replace the printed circuit See Fiche C063 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP020 THE MOTOR DOES NOT START Folio 1 1 FROM THE TURNTABLE CONTROL PANEL BUT DOES START FROM THE PLATFORM CONTROL PANEL The motor does not start from the turntable control panel but does start from the platform control panel Open the turntable control panel Activate switch SB3 and check continuity between the two terminals of the switch See Fiche Replace the switch SB3 NO C044 YES END Activate SB3 and check for 12V voltage at terminal 117A of the printed circuit Repair wi
107. hot 2 Removing a wheel reducing gear or a hydraulic motor NB Figure 1 steering axle Figure 2 fixed axle AN Caution a Use a container to collect oil If working on a steering axle uncouple the steering connecting rod from to prevent pollution of the the pivot environment Mark and disconnect the hoses of the hydraulic motor 1 and reducing gear 2 NB Unscrew the hose slowly to release residual hydraulic pressure A Caution It is essential to put the Put caps on Me hoses component in slings before nn a the Wee EE dismantling re assembling SCH e reducing gear motor assembly by removing the fixing bolts Unscrew the screws 4 fixing the hydraulic motor to the wheel reducing gear Replace the defective hydraulic motor or reducing gear Installing a wheel reducing gear or a hydraulic motor Assemble the hydraulic motor to the reducing gear using fixing screws equipped with new grower washers Fix the hydraulic motor using the four fixing bolts equipped with new elas tic washers Re install the reducing gear motor assembly and secure with fixing screws Tighten to the torque recommended see tightening torque value table Inthe case of a steering axle couple the steering connecting rod to the pivot Reconnect the hydraulic hoses to the hydraulic motor and the reducing gear hose equipped with a new seal according to the marks made when dismantling A 1 Ad
108. ic motor FICHE C054 Changing the weighing rolling bearing FICHE C056 Changing the hydraulic filter FICHE C059 Changing a coil FICHE C062 Changing a relay FICHE C063 Changing the printed circuit FICHE C064 Changing the fail safe pedal FICHE C067 Changing an electrovalve FICHE C079 Changing a flow separator FICHE C082 Changing a balancing valve compensation function FICHE C083 Changing a double flow limiter compensation function FICHE C085 Changing a steering pivot FICHE C086 Dismantling and re assembling the steering system FICHE C087 Changing the steering cylinder FICHE C091 Changing the hydraulic pump FICHE C092 Changing the on off travel hydraulic block FICHE C093 Changing the distribution hydraulic block FICHE C094 Dismantling re assembling the distribution hydraulic block FICHE C097 Changing a cover FICHE C098 Changing the thermal motor 139 Pinguely Haulotte 4 Repair manual Sheet no Description FICHE C099 Changing the turntable rotation hydraulic motor FICHE C100 Changing the swing joint FICHE C101 Changing a counterweight FICHE C103 Dismantling re assembling the jib FICHE C104 Changing the basket rotation gearing FICHE C106 Changing the turntable slew ring FICHE C107 Changing the U1 electronic module FICHE C108
109. into the operational configuration Repair manual Pinguely Haulotte Z 8 OPERATING INCIDENTS 8 1 INCIDENT TABLE Before diagnosing failure check that the fuel tank is not empty the batteries are properly charged the turntable and platform palm button emergency stop buttons are unlocked the relays platform control panel turntable box are correctly pushed into their compartments see 4 2 the main tank oil level is OK the state of the fuses see 4 2 the electrovalves are working properly by checking the state of the LEDs in the turntable box Check the state of the LEDs see 4 2 The LEDs inside the turntable box indicate the state of the electrovalves NB LED off electrovalve present and not controlled LED on weak light electrovalve not connected LED on strong light electrovalve present and controlled If an electrovalve is not connected the corresponding LED is permanently on Instructions Identify the defective function Machine power on but not started check the presence of the electro valves LED off No electrovalve should be controlled LED on Check that the outputs corresponding to the function are active using the LEDs and directly on the electrovalve heads If they are not active check which inputs create the function Test the inputs with a voltmeter 57 Pinguely Haulotte 2 8 1 1 General operation Repair manual ANOMALY P
110. le U1 defective Sheet DP034 Sudden stop of travel during a platform lifting operation Contactors SQ3 SQ4 SQ2 incorrectly set or defective Wiring harness defective Electronic module U1 defective Sheet DP058 No differential blocking during action on switch SA3 ANOMALY No steering movement right and or left Switch SA3 or SA11 defective Electronic module U1 defective Wiring harness defective Contactors SQ3 SQ4 SQ2 incorrectly set or defective Printed circuit defective Coils of electrovalves YV9 or YV13 defective Electrovalves YV9 or YV13 defective 8 1 4 Steering system PROBABLE CAUSE Electrovalve YV18 or YV2 defective Coil defective Electronic module U1 defective Wiring harness defective Printed circuit defective Manipulator SM4 defective Sheet DP036 SOLUTION Sheet DP060 61 Pinguely Haulotte Z Repair manual 8 1 5 Turntable rotation system ANOMALY PROBABLE CAUSE SOLUTION Electrovalve YV5 defective No turntable rotation move Electronic module U1 defective ment right and or left from the platform or turntable Wiring harness defective Printed circuit defective SES Rotation switch SA15 defective Rotation manipulator SM31 defective The turntable does not turn The blocking pin has not been removed Remove the pin from the chassis control panel NB In the turntable box LEDs indicate the state of eac
111. lic circuit H14 16TPX HB40 44J Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Folio 2 2 Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C059 Folio 1 1 CHANGING A COIL 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 page 32 Switch off electric power see S 6 4 page 32 2 Removing a coil Disconnect the electric connector 2 from the coil concerned Unscrew the nut 3 and remove the coil 1 3 Installing a coil Puta new coil into place 1 and fix with the nut 3 e Reconnect the electric connector 2 to the coil Putthe machine back into the operational configuration Check proper operation by making the movement corresponding to the replaced coil Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C062 Folio 1 2 CHANGING A RELAY 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 page 32 Switch off electric power see 6 4 page 32 Disconnect the then terminals of the starter battery 2 Removing a relay Openthe turntable electric box Markand disconnect the electric connections 1 of the relay 2 Remove the relay by removing the fixing bolt 3 3 Installing a relay Puta new relay into place and fix using its bolt equipped with a new grower washer Reconnect the electric connections according to the marks made during dismantling
112. lt Non ZOL LYS E s S3 gs cor SLZ 02 10 a 01 20 SA ER Va jeun S3 9 oz e oz 0 GL SL ZL 9L SL rL L LL OL 6 8 2 9 r L 22 Pinguely Haulotte Z FOLIO 03 05 Repair manual NERA 6661 v0 0 ZINIO ougpgu4 boga GO swmwaros de e 2 1 vSSr4d FEH I S 6661 70 80 014014 IQ Jus neT Re SER SAIGON dLSZH EZH LIZH ne ALLOINVH ATININIA 1 10 e gt ee ee 9 9 A lt ww Fb LEZH LIH LSZH dLEZH HA AZ ES I6 Em 1 PESAS ae 7 if o gt Se F l 1 d 1 1 x XL LI x E x EX x JX x 1 1 1 BAA EUA OLAA 891AA VOLAA 961 VELMA EEIN VSLAM UA KEAK HEN 1 AR NN dE NN qu TENE 1 o 1 3 H o a I a d d gt lo la o lo o o 2 NO fa JN i gt gt gt gt quolsjieay 5 uonejoy uoll su duioo Jenpued uonejos Jejnpuad uonesu duioo uonejoy Anueg Jojejo ooo v 6 02 20 02 20 lt 02 20 6 02 20 oz 6L ZL 9L SL FL L ZL LL OL 6 8 2 2 6 v e L 23 Repair manual Pinguely Haulotte Z FOLIO 04 05
113. m the link part Remove the rotation pin 12 then remove the jib link part 9 5 Installing the jib link part NB Lubricate all bores before re installing the pins Only use lubricants recommended by the manufacturer Check the condition of the rings of the various jib pins and replace if necessary Put the jib link part back into place Put back the link part rotation pin 12 Put back the pin stop clevis and block with its screw previously coated in normal blue loctite 243 Put back the receiver compensation cylinder pin and block with the stop clevis Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C103 Folio 2 2 DISMANTLING RE ASSEMBLING THE JIB 6 Installing the jib Put the jib and its cylinder into place and put back the articulation pins Put back the upper pin stop clevis 8 Put back the two lower pin stop rings 8 and fix with their bolts 7 Installing the platform support assembly Put the platform support assembly back into place and put back the 2 arti culation pins 5 Put back the upper pin stop clevis Put back the two lower pin stop rings and fix with their fixing bolts Put back the pin 6 and its stop clevis Pass the hydraulic hoses and electric cables along the jib according to the marks made during dismantling and reconnect Put the cable passage collars back on the platform and along the jib Put back and adjust the contactor 7 see corresponding
114. minals of the YV18A down or YV18B up connector Open the turntable control panel Press the pedal and activate the jib switch Check for NO 12V voltage at terminals 407A down or 408A up of the printed circuit YES NO Replace the See Fiche ae ae C058 or C107 See Fiche Replace coil YV18A C059 down or YV18B Y up YES The fault persists Repair the connection or END replace the wiring harness between the turntable control panel and electrovalve YV18 See Fiche C063 Replace the printed circuit END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP028 NO JIB MOVEMENT UP AND OR DOWN Folio 4 5 FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Platform jib fault Turntable jib fault Y Maintain the control Maintain the control activated and check for activated and check for 12V voltage at terminals 12V voltage at terminals 410 up and 409 down of 406 up and 405 down of the printed circuit the printed circuit Open the platform control panel or turntable and check NO the wiring of jib switch SA7 or SA6 YES NO SE Replace the U1 module See Fiche Repair wiring C058 or C07 YES END Check the electric continuity of the switch contacts when closed NO The fault persi
115. module C058 or C107 Check for 12V voltage on terminal 805 harness 805 Replace wiring Open the turntable control panel Check for 12V voltage on terminal 804 The fault M persists YES Replace the printed See Fiche Ee circuit C063 Y Replace wiring harness 804 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP036 Folio 1 3 NO DIFFERENTIAL BLOCKING WHEN SWITCH SA3 IS ACTIVATED No differential blocking when switch SA3 is activated Place the key switch in the platform position Do not press the pedal Open the turntable control panel and check that the LEDs associated with electovalves YV9 and YV13 are off All the LEDs are Note the LED that is on off Put the machine on wedges so that the wheels are not touching the ground Place switch SA3 in the differential blocked position Press the pedal and make a forward travel movement Check that the LEDs associated with electrovalves YV9 and YV13 are on All the LEDs are on NO e Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP036 Folio 2 3 NO DIFFERENTIAL BLOCKING WHEN SWITCH SA3 IS ACTIVATED Press the pedal and make a forward travel movement Check for 12V voltage at the terminals of the connector of the electrovalve in question YV9 and
116. motor accelerates Y Open the turntable control Le NO The motor panel and check the state of accelerates fuse FU3 Open the turntable control panel Place the key switch in the turntable position and activate the accelerator switch SA2 from the turntable control panel Check for 12V voltage on terminal 605 of the printed circuit Fuse NO OK YES Replace fuse FU3 Y Open the turntable control panel Place the key switch in the turntable position and activate the accelerator switch SA2 from the turntable control panel Check for 12V voltage on terminal 118 of the Replace the See Fiche printed circuit accelerator switch C044 SA2 Y Repair the connection or replace the electric wiring harness between the accelerator switch SA2 and the printed circuit of the turntable control panel END END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP022 NO MOTOR ACCELERATION ON ACTIVATING THE Folio 2 2 ACCELERATOR SWITCH SA2 FROM THE TURNTABLE CONTROL PANEL Voltage NO OK YES Maintain activation of the accelerator switch SA2 of the turntable control panel Check for 12V voltage on terminal 605A of the printed circuit Y Place the key switch in the turntable position and activate the accelerator switch SA2 from the turntable control panel Voltage NO Check for 1
117. moving a flow separator Remove the flow separator 1 by unscrewing it 3 Installing a flow separator Screw a new flow separator whose characteristics correspond to the machine in question into the hydraulic block Tighten to the recommended torque Flow separator ref FDC1 10 47 to 54 Nm 34 to 39 8 Ib ft Flow separator ref FDC1 16 108 to 122 Nm 79 6 to 89 9 Ib ft Put the machine back into the operational configuration Make several movements using the replaced flow separator to purge the circuit Check that the corresponding movement is made correctly Sheet C082 A Caution Ensure that the oil is not too hot A Caution Use a container to collect oil to prevent pollution of the environment A Caution Balancing valves are safety elements They are calibrated in the plant and must not be re adjusted Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET CHANGING A BALANCING VALVE Folio 1 1 FOR THE COMPENSATION FUNCTION 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 page 32 Switch off electric power see 6 4 page 32 2 Removing a balancing valve Remove the balancing valve 1 by unscrewing it 3 Installing a balancing valve Screw a new balancing valve whose characteristics correspond to the machine in question into the hydraulic block Tighten to a torque of 45 to 50 Nm 33 to 36 7 Ib ft Putthe machine back into the
118. n marked during dismantling and fix using bolts 3 Adjust and test the contact see paragraphs below If necessary put back the protective plate 4 and its fixing screws 5 4 Adjusting and testing 502 SQ3 and 509 see chapter on positioning the safety elements Putthe machine back in the operational configuration Figure 1 Make the movement corresponding to the replaced contact see table and check that it works Adjust the position of the contact if necessary and tighten its fixing bolts CONTACT MOVEMENT CHECK Tilt the tilt The tilt buzzer sounds if the jib is above 5 sensor the horizontal position Ee SR The tilt buzzer does not sound if the jib is below the horizontal position and the machine is completely folded Tilt reset if Tilt the tilt The tilt buzzer sounds if the boom is lif machine fol sensor ted ded boom The tilt buzzer does not sound if the SQ3 machine is completely folded Tilt the tilt The tilt sensor sounds if the telescope Telescope out sensor is out SQ9 The tilt sensor does not sound if the machine is completely folded Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C110 Folio 2 2 CHANGING A LIMIT CONTACT 5 Adjusting and testing SQ7 see chapter on positioning the safety ele ments Inthe telescope in position check that there is 2 mm between the contact lever and the telescope tube as shown in figure 2
119. n of the environment Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Folio 1 3 CHANGING THE SLEW RING 1 Preliminary operations Move the turntable to the locking position Put the machine in the maintenance configuration see S 6 3 Switch off electric power see S 6 4 2 Removing the slew ring NB Open the chassis box 1 mark and disconnect all electric connectors 2 Free the electric wiring harness 3 of the swing joint 4 after marking its path Mark and disconnect the hoses of the swing joint 4 under the chassis travel motor oil supply and return Unscrew the hoses slowly to release residual hydraulic pressure Put caps on the hoses Remove the swing joint s rotation stop screw 5 Put the turntable in slings and unlock the turntable rotation blocking pin Remove the 24 screws 6 and washers fixing the slew ring to the lower part 7 of the machine Remove the turntable carefully avoiding damage to the swing joint 4 Wedge the ring 8 mark its position in relation to the turntable Remove the 24 screws 9 bolts 10 and washers fixing the slew ring 8 to the turntable Free the turntable 3 Installing the slew ring Put the slew ring 8 into place on suitable supports in the position marked during dismantling Position the turntable on the ring Fix the ring with the 24 screws 9 bolts 10 and washers without pre stressing Tighten in a star pattern see figure 2
120. n the platform control panel and check the wiring of NO the compensation switch SA5 YES NO Replace the U1 module SeeFiche Repair wiring C107 YES END Check the electric continuity of the switch contacts when closed NO The fault persists END Replace the See Fiche NO printed circuit C063 YES Replace the See Fiche END compensation switch C043 SA5 Repair the connection or replace the wiring END harness between the compensation switch SA5 and the printed circuit of the turntable control panel Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP050 Folio 5 5 NO COMPENSATION MOVEMENT UP AND OR DOWN Replace the double flow See Fiche limiter C083 The fault persists Replace the balancing See Fiche valve C082 The fault persists YES Replace electrovalve See Fiche YV19 C067 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP051 Folio 1 2 THE COMPENSATION MOVEMENT IS MADE WHEN PLATFORM ROTATION IS ACTIVATED When platform rotation is activated the compensation movement is made Do not press the pedal Open the turntable control panel and check that the LED associated with electrovalve YV24 is off YES Press the pedal and activate the compensation switch Check that the LED associated with
121. nd washers Adjust wheel alignment if necessary slacken the counter nut 8 screw or unscrew the clevis 9 to adjust the length of the steering bar tighten the counter nut 8 Put back the steering clevis pin and fix using the screw equipped with a new grower washer It is essential to put the component in slings before dismantling re assembling it NB When re installing the pins take the measures necessary to avoid damanging the pins rings and bores 5 Installing the bearings if applicable e Lubricate the bearings and pivot pin NB Only use lubricants recommended by the manufacturer Install a new seal 15 Install the bearings 16 on the hub 14 Install the hub 14 on the pivot 1 Install the nut 13 Block the nut 13 until the wheel turns with difficulty and turn back one quarter turn nstall the brake washer 12 and counter nut 11 Block the counter nut 11 then raise the wings of the brake washer Putback the cap 10 6 Additional operations Putback the wheel see corresponding sheet Putthe machine back in the operational configuration Make several travel movements to check correct operation Lubricate the pins with the lubricators Pinguely Haulotte Z Lu I o O z lt 2 lt lt gt O m c c O CHANGING A STEERING PIVOT ON A Folio 2 2 Sheet C085 NON DRIVE WHEEL
122. ndicated 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 Bii 1 1 3 Safety Ensure that any person entrusted with the machine is take the safety measures implied by its use Avoid any working mode that may affect safety Any use that does not comply with the recommendations may generate risks and damage to people and equipment After intervention maintenance personnel must check that the operator manual is present This must be kept by the user throughout the machine s service life even if it is loaned rented or sold Ensure that all the plates or labels related to safety and danger are complete and legible A Caution To attract the reader s attention instructions are indicated by this standardised sign Pinguely Haulotte Z Operating and maintenance instructions 1 2 GENERAL SAFETY INSTRUCTIONS A Caution Only trained operators can use Haulotte self propelled platforms 1 2 1 Operators Operators must be aged over 18 and hold an operating permit issued by their employer
123. ness END Replace the motor stop solenoid END YA1 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP016 Folio 1 3 THE MOTOR DOES NOT START THE STARTER IS NOT ACTIVATED The motor does not start the starter is not activated Check the position of the platform and turntable emergency stop buttons Position Unlock the emergency stop button unlocked Check the state of battery charge Battery charge OK NO r Check the state of the generator Charge the batteries and replace if necessary Replace the batteries See Sheet C046 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP016 THE MOTOR DOES NOT START THE STARTER IS NOT ACTIVATED Open the turntable control panel and check the state of fuses FU1 FU4 and FU8 NO YES Replace the defective fuse Check the 12V on line 242 of the turntable control panel M YES Repair key switch SA1 wiring or replace the switch Activate switch SB3 turntable or SB4 platform and check continuity between the 2 switch terminals NO m z U Replace the defective See Fiche switch C044 ES Ce END Folio 2 3 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP016 Folio 3 3 THE MOTOR DOES NOT START THE STARTER IS
124. ng gear FICHE P008 Checking filling the hydraulic oil tank FICHE P009 Changing the hydraulic filter cartridge 49 Pinguely Haulotte 2 Repair manual 50 Pinguely Haulotte Z PREVENTIVE MAINTENANCE SHEET Sheet P007 Folio 1 1 CHECKING CHANGING THE OIL OF A WHEEL REDUCING GEAR 1 Preliminary operations A Caution Putthe machine in the maintenance configuration see S 6 3 page 32 Use a container to collect oil Switch off electric power see S 6 4 page 32 to prevent pollution of the environment 2 Checking the level Turn the wheel so that one cap 1 is on a horizontal line and the other 2 is on a vertical line Unscrew the cap 1 and check the level that should be up to the hole Top up if necessary A Caution Screw the cap back into place Make sure that the machine is properly stabilised and NB Only use the oil recommended by the manufacturer that the lifting means are in good condition and of sufficient capacity 3 Changing the oil Inthe same position unscrew the 2 caps and let the oil flow out Re fill as described above Screw the caps back into place NB Collect old oil to prevent pollution of the environment 4 Additional operations Putthe machine back into the operational configuration HA16 18PX HA46 51JRT HA20 26 PX HA61 80JRT H14T X H16TP X HB40 44J Pinguely Haulotte Z PREVENTIVE MAINTENANCE SHEET Pinguely
125. ng the adapter onto the rigid pipe of the emergency motor Reconnect the hydraulic hose Put the machine back in the operational configuration Do not start the thermal motor and trip the emergency electropump unit Make several movements to purge the hydraulic circuit Adjust the pressure limiter if necessary see adjusting a pressure limiter sheet Putthe machine back in the operational configuration Check the level in the hydraulic oil tank Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C114 CHANGING THE EMERGENCY HYDRAULIC CIRCUIT Folio 2 2 PRESSURE LIMITER Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C115 Folio 1 2 CHANGING THE JIB CYLINDER 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 AN Caution Switch off electric power see S 6 4 Ensure that the olf Is not to Anchor the basket on the ground hot 2 Removing the jib cylinder Put the cylinder 1 and jib vertical elements 2 and 3 in slings Mark and disconnect the jib cylinder s two hydraulic hoses AN Caution NB Use a container to collect oil to prevent pollution of the Unscrew the hoses slowly to release residual hydraulic pressure Put caps on the hoses environment Remove the two bolts and pin stop rings from the cylinder pin 4 on the cylinder body side Remove the pin 4 Remove the pin stop clevis from th
126. ng the collars replacements will be required Remove the spiral protective sheaths and take the cable and hoses 11 from the turntable Markthe 4 small hoses 12 and disconnect them from the connection Pinguely Haulotte 4 Sheet C119 CORRECTIVE MAINTENANCE SHEET Folio 2 13 DISMANTLING RE ASSEMBLING THE BOOM NB plate under the boom Free the slings 13 after noting the length of the free threaded part Take the cable and hoses from the side chutes of the large drum and allow to hang freely from the flap Remove the telescope cylinder pin Free the chain fixture on the large drum and pass the chain through the flap figure below Put the intermediary element 14 head element 15 assembly into slings Remove completely using lift s the intermediary element 14 head ele ment 15 assembly of the large drum 16 completely using lift s Stop the movement before the cable chain 17 unwinds completely Figure 2 Be careful of the sling support pad Figure 2 Then finish taking out the chain and the rest of the cables and hoses from the large drum 3 Separating the head element 15 and the intermediary element 14 Figure 3 Dismantle the chain guide at the back of the intermediary element 14 Remove the cylinder support half pins 19 Take out the cylinder 20 from the head element 15 and intermediary element 14 assembly Free the slings 21 of the back pulleys by taking
127. ng the fixing screws and washers 3 Installing the hydraulic block Putthe hydraulic block into place and fix using screws equipped with new toothed washers Reconnect the hydraulic hoses according to the marks made during dis mantling Reconnect the electric connections of the hydraulic block according to the marks made during dismantling Put the machine back in the operational configuration Make several movements using the replaced hydraulic block to purge the hydraulic circuit Check the level of the hydraulic oil tank On off movement Travel Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C092 CHANGING THE HYDRAULIC BLOCK Folio 2 2 TRAVEL ON OFF MOVEMENT STEERING Sheet C093 Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Folio 1 2 CHANGING THE DISTRIBUTION HYDRAULIC BLOCK Caution Ensure that the oil is not too hot AN Caution Use a container to collect oil to prevent pollution of the environment 1 Preliminary operations Put the machine in the maintenance configuration see S 6 3 Switch off electric power see 6 4 2 Removing the distribution hydraulic block NB Mark and disconnect the electric connections 1 of the hydraulic block 3 Mark and disconnect the block s hoses 2 Unscrew the hoses slowly to release residual hydraulic pressure Put caps on the hoses Put the hydraulic block in slings Remo
128. nsion Attach the cables and hoses in the turntable with sliding nylon collars Connect the 42 wire cable in the turntable control box and install the mains plug Install the parachute cable half pulley Close the flaps with the appropriate plates 7 Install the upper and side guide pads 5 as described for the dismantling operation 10 page 8 Take care to pass slings above the pads Reconnect the parachute cable by passing through the 40 washers To obtain the safety elastic system arrange the washers in opposi tion Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C119 Folio 12 13 DISMANTLING RE ASSEMBLING THE BOOM 12 Finishing Putback contactors SQ3 SQ7 SQ8 SQ9 SQ10 and SQ11 see corres ponding sheet Put back the jib if applicable see corresponding sheet Put back the platform see corresponding sheet Fill the compensation hydraulic circuit by moving the platform with the manual control Putthe machine back in the operational configuration 13 Adjustments and checks before operation Make 2 or 3 full telescoping movements using the turntable controls Set max telescope out pressure at 100 bars if the telescope cylinder has been replaced If necessary re adjust the guide pads bring into contact then slacken the Screws by one quarter turn for the side pads and one half turn for the top pads If necessary re adjust the slings see S 14 page 12 M
129. nt Steering Rear axle 1 Left If SM4c 1 then YV16a 1 and YV2b 1 and YV1 1 2 Right If SM4d 1 then YV16b 1 and YV2b 1 and YV1 1 Differential blocking If SA3 1 and SA11a 0 and MicroSpeed 0 then YV9 1 and YV13 1 Buzzer and horn If SB5 1 then HA1 1 If SQ1 0 and machine extended then the buzzer sounds continuously If B4 0 then the buzzer sounds at frequency F1 If option_Travel_buzzer 1 and HM4 1 then the buzzer sounds at fre quency F2 Light indicators If B1 0 then HL2 1 If B3 0 then HL4 1 Other functions Overload Fail safe Tilt Fail safe During movements the fail safes can be released for 0 55 If the fail safe is maintained for x seconds manipulator in neutral the movement cannot be made Travel x 6s Movements x 4s Tilt When the machine is extended and tilted the buzzer sounds conti nuously Pinguely Haulotte Z 4 WIRING DIAGRAMS DIAGRAM E 455 FOLIO 01 05 Repair manual 4 1 21 666L v0 0 HZANAG 9ugpgu4 SINS CHES her 10 SVIN3HOS i an eres LEE S _ 6661 0 80 fblNOT4 IG Jua ne7 e SE EE dLSTH EZH LIZH a as ILLOTAVH A13N9NId 6 20 EEI e e e e e e 81 90 ee 1 sor 1 1 M lt 8 i 4 1 0 1
130. nuts from the two screws 3 Unscrew the two screws 3 by a few turns without removing them Remove the four fixing screws 4 from the turntable rotation reducing gear 1 Put in slings then remove the turntable rotaton reducing gear 1 Remove and retain the adjustment screws 2 with their counter nuts Installing the turntable rotation reducing gear Put back the adjustment screws 2 and 3 with their counter nuts on the new reducing gear without blocking them so that the heads are as flush as possible Position the new reducing gear on the turntable Put back the reducing gear s four fixing screws 4 without blocking them Adjust the position of the reducing gear using the adjustment screws 2 and 3 Turn the reducing gear to position the ring teeth marked with a colour opposite the reducing gear pinion this coloured mark corresponds to the most excentric point of the ring Adjust the gap between the teeth to 300um with a set of flakes When the gap is set block the counter nuts of adjustment screws 2 and 3 Block the reducing gear s four fixing screws 4 to a torque of 196 N m Additional operations Put back the turntable rotation hydraulic motor 5 see corresponding sheet Remove the wedges from the boom Put the machine back in the operational configuration Make several turntable rotation movements to purge the hydraulic circuit and check reducing gear operation Check the level of the hyd
131. o 510 570 to 630 690 to 760 22 1 5 550 to 680 780 to 870 920 to 1000 M 24 1 5 690 to 860 970to 1070 1160 to 1290 M 27 2 1000 to 1300 1400 to 1560 1690 to 1880 M 30 2 1400 to 1700 1960 to 2180 2350 to 2610 2 3 3 Tightening torque values for wheels Tightening torque in N M Steering wheel nut Drive wheel nut Repair manual Pinguely Haulotte Z 2 3 4 Tightening torque values for hydraulic hoses Description Torque to apply Nm Spanner to use turning equal elbow JIC37 90 10 turning equal elbow JIC37 90 12 turning equal elbow JIC37 90 18 turning equal elbow JIC37 90 25 nut F JIC37 25 nut FJIC37 12 nut FJIC37 18 hose SP 1663 Igth 0 830 hose SP 1663 Igth 1 100 hose SP 1663 Igth 2 100 hose SP 1707 Igth 2 150 hose SP 1756 Igth 8 400 hose SP 5025 Igth 1 680 hose SP 5113 Igth 1 700 hose SP 5113 Igth 1 800 hose SP 5113 Igth 2 170 hose SP 5113 Igth 2 230 hose SP 5238 Igth 1 900 hose SP 5261 Igth 1 320 hose SP 5261 Igth 1 800 hose SP 5273 Igth 0 900 hose SP 5273 Igth 1 460 hose SP 5293 Igth 0 950 hose SP 791 Igth 1 170 hose SP 791 Igth 0 510 hose SP 791 Igth 0 690 hose SP 791 Igth 0 720 hose SP 791 Igth 1 020 hose SP 791 Igth 1 730 equal turning T MFM JIC37 6 inverted turning T MMF JIC37 10 inverted turning T MMF JIC37 12 inverted turning T MMF JIC37 18 inverted turning T MMF JIC37 25 union MJIC 37 10 M1 2 BSPP union MJIC 37 10 M1 4 BSPP union MJIC 37 12 M1 2
132. o movement available from turntable or platform panel 58 Insufficient hydraulic oil Fuse FU7 or FU4 or FU10 defective Wiring harness defective Electrovalve YV1 defective Incorrect Load sensing pressure setting Motor pump coupling defective Hydraulic pump defective Pressure limiter defective Distribution block input module defective Pump regulation unit incorrectly set or de fective Hydraulic pump defective Electronic module U1 defective Relay KMG defective Printed circuit defective Key switch SA1 defective Sheet DP023 Repair manual Pinguely Haulotte Z ANOMALY PROBABLE CAUSE SOLUTION No movement available from the platform control panel Fuse FU1 defective Platform control panel defective Fail safe pedal defective Wiring harness defective Sheet DP024 Noisy hydraulic pump Oil non conform Obstruction of the tank air vent Suction valves closed Defective pipes Hydraulic pump defective Insufficient oil level Cavitation Sheet DP025 Insufficient pressure or power at the pump Clogged air filter Motor speed too low Oil leak on connector hose or component Clogged diesel filter Change the filter See manufacturer s manual Repair or replace Replace diesel filter cartridge No travel telescope out boom and arm lifting buzzer sounding Slope or tilt 25 First retract the telescope and lower the boom to rese
133. o not fall into the chute Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C119 Folio 11 13 DISMANTLING RE ASSEMBLING THE BOOM NB NB oe Free sling Figure 15 Bring the head element intermediary element assembly into alignment with the large drum Insert the cables hoses and chain in the large drum bringing them out through the flap Curve the chain 17 inside the large drum 16 Insert the head element intermediary element assembly in the large drum until the cylinder clevis 2 comes opposite the pin bearing on the large drum Assemble the telescope cylinder on the drum with the crossing pin if necessary adjusting alignment with excentric rings and install the lateral blocking flanges Insert cables and hoses in the chutes 34 inside the large drum the 4 hoses in one and the cables in the other then pull up all slack inside the large drum from the back Fix the out slings on the large drum lifting beam and screw the nuts to the value of the free threads noted during dismantling if the slings have not been replaced otherwise see sling adjustment on the next page Connect the 4 small hoses 12 on the connection plate Connect the hoses of the telescoping cylinder to the cylinder and cover the parts of the cables and hoses outside the turntable or exposed to fric tion with a spiral sheath Fix the lower sling support pad and adjust sling te
134. oil to prevent pollution of the environment Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Folio 1 1 CHANGING AN ELECTROVALVE 1 Preliminary operations Put the machine in the maintenance configuration see S 6 3 page 32 Switch off electric power see 6 4 page 32 2 Removing an electrovalve Mark and disconnect the electric connections 1 of the coils Mark the installation position of the electrovalve on the block Unscrew the four fixing screws 3 of the electrovalve 2 and remove 3 Installing an electrovalve Put a new electrovalve equipped with its seals into place and fix using the 4 screws in the position of the electrovalve on the block Tighten to the recommended torque see 2 3 page 10 Reconnect the electrovalve s electric connections according to the marks made during dismantling Put the machine back into the operational configuration Make several movement cycles using the replaced electrovalve to purge the hydraulic circuit Check the level of the hydraulic oil tank Sheet C079 AN Caution Ensure that the oil is not too hot A Caution Use a container to collect oil to prevent pollution of the environment Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Folio 1 1 CHANGING A FLOW SEPARATOR 1 Preliminary operations Put the machine in the maintenance configuration see S 6 3 page 32 Switch off electric power see 6 4 page 32 2 Re
135. oing pipes Remove the fixing collar 4 on the exhaust Remove the extension tube at exhaust exit 5 Remove the motor backflow duct 6 Removing the coupling Remove the hydraulic pump 7 see corresponding sheet Remove the screws 8 fixing the motor flap flange 9 and remove the flange Remove the fixing screws 10 from the coupling plate 11 and remove the plate Removing the thermal motor Putthe motor in slings according to the instructions in the motor manufac turer s manual Remove the motor s 4 fixing screws and nuts 12 and remove the motor Installing the thermal motor e Check the condition of the 4 silent blocks and replace if necessary Putthe thermal motor into place and fix with the 4 fixing screws and new nylstop nuts Installing the coupling Putthe coupling plate 11 into place and fix with the fixing screws pre viously coated with normal blue loctite 243 Tighten to a torque of 25 N m 18 43 Ib ft Putthe motor flap flange into place and fix with the screws equipped with new grower washers Tighten to a torque of 49 N m 36 14 Ib ft Putback the hydraulic pump see corresponding sheet Connections Putinto place the extension tube at exhaust exit 5 and fix using the fixing collar 4 Putback the motor backflow duct 6 Reconnect the fuel incoming and outgoing pipes 3 Onthe motor reconnect the electric connections 2 then fix the trunking using pl
136. ore complete insertion in the intermediary element When changing the hoses copy all the marks on the old hoses onto the new ones before installation Caution most pins use a screw blocking system either in the middle of the pin length or by an Hc screw between the two materials So metimes it is necessary to grind the anti rotation welding points which are only used during assembly and will not need to be redone Before any sling movement protect the threaded parts with the nut screwed to the end Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C119 Folio 6 13 DISMANTLING RE ASSEMBLING THE BOOM Spurs to be removed o on the first link HE Figure 7 7 Installing the receiver compensation cylinder Bring the receiver compensation cylinder to the end of the head element 1 to reconnect the two hydraulic hoses of the cylinder according to the marks made during dismantling Put back the cylinder pin 4 on the body side of the cylinder and block with the pin blocking clevis 3 Put back the top cap 2 8 Assembling the boom elements Put the pin into place 26 Prepare the slings on the head element see Figure 8 NB Hold the sling 29 in the position shown to prevent the top strand from passing under the bottom strand The top strand passes above the pad 27 Leave the parachute cable 28 free Figure 8 Head element in the intermediary Figure 9 Put the isol
137. ose the shut off valve if any otherwise empty the hydraulic oil tank Caution Close the shut off valve if 2 Removing the hydraulic pump any otherwise empty the Mark and disconnect the pump hoses 1 hydraulic oil tank NB Unscrew the hoses slowly to release residual hydraulic pressure Caution a Use a container to collect oil to prevent pollution of the Fut capsan the hoses Remove the hydraulic unions 4 screwed on the pump Remove the screws and washers 2 fixing the pump to the motor flange 3 then remove the pump 5 Remove the split spined hub 6 by unscrewing its tightening screw 7 Discard the O rings 3 Installing the hydraulic pump 1 Equip the unions with new O rings It is essential to put the Screw the hydraulic unions on the pump component in slings before Check that the circlips and spacer and in good condition and in position gaiei ci inside the split spined hub it Lubricate then fit the split spined hub onto a new pump until the pump shaft comes up agains the spacer Tighten to a torque of 83 N m 61 21 Ib ft Coat the hub s tightening screws with normal blue loctite 243 Install the pump on the flange and fix using fixing screws previously coated with normal blue loctite 243 and equipped with new grower washers Tighten to a torque of 86 N m 63 43 Ib ft Reconnect the hydraulic hoses according to the marks made during dismant ling
138. out the retaining Hc screws and removing the lower plate 22 then take the free strands from the outlet passages Partially 20 cm take the head element out of the intermediary element from the front After marking the positions remove all guide pads 23 on the interme diary element side top and bottom Take out the retaining Hc screws and remove the front pulleys 24 Take out the slings 25 from the front Finish taking out the head element 15 assisting passage of the chain cables and hoses Replace any defective parts If necessary remove the receiver compensation cylinder Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C119 Folio 3 13 DISMANTLING RE ASSEMBLING THE BOOM Figure 3 4 Removing the receiver compensation cylinder Figure 4 Figure 5 Put the receiver compensation cylinder in slings 1 Remove the top cap 2 Remove clevis 3 blocking the pin on the cylinder body side Remove the cylinder pin 4 then take out the receiver compensation cylinder Mark and disconnect the 2 hydraulic hoses of the receiver compensation cylinder 1 and remove the cylinder Putcaps on the hoses S Y QIZIZIOTTIZZO Figure 5 Pinguely Haulotte 4 Sheet C119 CORRECTIVE MAINTENANCE SHEET Folio 4 13 DISMANTLING RE ASSEMBLING THE BOOM 5 Removing the large drum Figure 6 Put the large drum 16 emitting comp
139. ove the machine from the basket to check all movement controls emer gency stop and motor control e Check the level of the hydraulic circuit 14 Adjusting sling tension Pull the out slings taut at the back of the large drum until the head ele ment out movement is started the smallest possible movement have an observer stationed near the platform the threaded rod sticks out of the first nut by about 54 mm Pullthe in slings taut at the front of the large drum until the head element in movement is started compensating for the previous the threaded rod stickes out of the first nut by about 58 mm Fully extend the telescope horizontally Pullthe parachute cable taut without reaching the limit contact a gap of approx 10 mm remains Check that the safety system is tripped by pulling the middle of the cable sharply downwards motor cuts out after a time delay e Make 2 full telescoping movements Repeatthe safety system trip operation and adjust if necessary Check sling tension taking care that the telescope and intermediary ele ment come out at the same time if not adjust sling tension Adjust contactors SQ3 SQ7 SQ8 SQ9 SQ10 and SQ11 see corres ponding sheet 15 Adjusting the parachute cable and its contactor Extend the telescope fully and retract by 10 cm Pull the cable sufficiently taut that it does not touch the drum Extend the telescope fully again and adjust the length of the scr
140. pair manual 2 2 DIMENSIONS 2 2 1 H21T X dimensions 800 1800 Haulotte 340 Repair manual Pinguely Haulotte Z 2 2 2 H23TP X dimensions 3100 10241 ze 2504 LS 05 x 2550506 LX lt gt ES OPTS 555066 555505250 255052506050 QO ENS i d d 2920 255 b b SI Kx ks Q 2 340 2084 2478 11 Pinguely Haulotte 4 Repair manual 2 2 3 H23T X dimensions O Co N _ 11052 800 o CH 00 N C ne E I I TL 1 4 but _ 2084 2478 12 Repair manual Pinguely Haulotte Z 2 2 4 H25TP X dimensions H25TP 1
141. point SQ7 0V SQ8 12V SQ11 0V YES Check the continuity of harnesses 115A 115B and 218B NO Replace the defective harness es Y YES Check the setting of the limit See Fiche detectors SQ7 SQ8 and C410 SQ11 Adjust or replace the limit detectors SQ7 SQ8 or See Fiche e YES Replace the U1 module See Fiche END C107 END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP054 NO BOOM LIFTING MOVEMENT Folio 3 5 UP AND OR DOWN FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Activate the boom lifting movement in manual Put the emergency lever into place on the manual control of the boom lifting distributor YV3 Activate the lever up down while pressing the emergency control of the safety valve YV1 or activate the emergency unit Movement OK Place the key switch in the turntable position Activate the turntable control panel rotation switch SA15 Rotation movement OK See Fiche DP023 YES Activate the lifting switch SA13 on the turntable control panel and check for 3V or 9V voltage depending on the movement direction at the terminals of the PVG YV3 control head Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Folio 4 5 Sheet DP054 NO BOOM LIFTING MOVEMENT UP AND OR DOWN FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Maintain t
142. raulic oil tank Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C117 CHANGING THE TURNTABLE ROTATION REDUCING GEAR Folio 2 2 Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C118 CHANGING A CIRCUIT SELECTOR Folio 1 2 OF THE TRAVEL HYDRAULIC BLOCK 1 Preliminary operations AN Caution Put the machine in the maintenance configuration see 6 3 Ensure that the oll Is notta Switch off electric power see S 6 4 hot ia 2 Removing a circuit selector Remove the circuit selector 1 by unscrewing it 3 Installing a circuit selector Caution Screw a new circuit selector whose characteristics correspond to the Use a container to collect oil machine in question in the hydraulic block to prevent pollution of the Put the machine back in the operational configuration environment Make several movements using the replaced circuit selector to purge the circuit Check that the corresponding movement is made correctly Check the level in the hydraulic oil tank Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C118 CHANGING A CIRCUIT SELECTOR Folio 2 2 OF THE TRAVEL HYDRAULIC BLOCK Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C119 Folio 1 13 DISMANTLING RE ASSEMBLING THE BOOM 1 Preliminary operations A Caution Put the machine in the maintenance configuration see 6 3 Ensure that the oil is not too Switch off electric po
143. ring of switch SB3 NO connection or replacement of electric wires Replace the U1 module See Fiche C058 or C107 NO The fault persists Replace the printed circuit See Fiche C063 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP021 MOTOR ACCELERATION FOR ANY MOVEMENT CONTROLLED Folio 1 1 FROM THE PLATFORM ACCELERATION TRAVEL LIFTING TURNTABLE ROTATION TELESCOPE No motor acceleration regardless of the movement controlled from the platform acceleration travel lifting turntable rotation telescope Place the key switch in the turntable position and activate the accelerator switch SA2 on the turntable control panel The motor See Fiche accelerates DP022 Check electric continuity of the wiring harness between the turntable control panel and the platform control panel NO YES Replace U1 See Fiche module C058 or C107 END Y Replace the wiring harness Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP022 NO MOTOR ACCELERATION ON ACTIVATING THE Folio 1 2 ACCELERATOR SWITCH SA2 FROM THE TURNTABLE CONTROL PANEL No motor acceleration on activating the accelerator switch SA2 from the turntable control panel Place the key switch in the platform position Press the pedal and make a telescoping movement from the platform Check that the
144. rminals of the battery Putthe machine back into its operational configuration Make several movements controlled from the basket to test manipulator operation Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C046 Folio 1 1 CHANGING THE STARTER BATTERY 1 Preliminary operations A Caution Put the machine in the maintenance configuration see 6 3 page 32 Wear protective goggles and Switch off electric power see 6 4 page 32 gloves for any operation on the batteries 2 Removing the starter battery Disconnect the then terminals 1 of the battery 3 Remove the fixing screws from the battery fixing tab and remove the fixing tab 2 Remove the battery 3 Installing the starter battery Put a new battery into place Put back the fixing tab and secure with the fixing screw equipped with a new toothed washer Re connect the then terminals of the battery and lubricate them to improve contact Put the machine back into its operational configuration Start the machine to check that the battery works properly Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C047 Folio 1 1 CHANGING A COVER GAS SPRING 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 page 32 Caution Switch off electric power see 6 4 page 32 Do not use the machine 2 Removing a gas spring maintenance Op
145. rom the caps on the pivot pin and remove the two caps 5 Take out the M canindus pin from each pivot pin 6 then remove the pivot pin and support washer 7 Remove the steering pivot 1 Installing a reducing gear or a motor Put the steering pivot into place Replace the pins lubricators and support washers if necessary Put back the support washers and pivot pins and block using new M ca nindus pins Put back the pivot pin caps and fix using fixing screws and washers Adjust the wheel alignment if necessary slacken the counter nut 8 tighten or slacken the clevis 9 to adjust the length of the steering bar tighten the counter nut 8 Put back the steering clevis pin and fix using the screw equipped with a new grower washer When installing pins take measures necessary to avoid deteriora ting the pins rings and bores 4 Additional operations Put back the motor and reducing gear see correpsonding sheet Put back the wheel see corresponding sheet Put the machine back into the operational configuration Make several travel movements to purge the hydraulic circuit Check the oil level of the wheel reducing gear see corresponding sheet Check the hydraulic oil tank level Lubricate the pins with the lubricators Pinguely Haulotte Z I o O z lt 2 lt lt gt O c c O Folio 2 2 Sheet 6 CHANGING A STEERING PIVOT
146. s associated with electrovalves YV8 YV10 and YV12 are on Allthe LEDs are NO Allthe LEDs are off Pinguely Haulotte 4 BREAKDOWN DETECTION FLOW CHART Sheet DP034 Folio 2 4 MACHINE TRAVEL SPEED DOES NOT CORRESPOND TO THE SELECTOR SPEED Place the key switch in the platform position Place the speed selector in the High speed position Press the pedal and make a forward travel movement Check for 12V voltage at the terminals of the connector of the electrovalve in question YV8 YV10 and YV12 Open the turntable control panel YES Press the pedal and make a forward travel movement Replace the electrovalve coil Check for 12V voltage on the terminals of the printed circuit associated with the electrovalve in question 813 for YV8 END 814A for YV10 814B for YV12 See Fiche C059 YES Replace the U1 module 22 107 Replace the wiring harness between the turntable control panel and the electrovalve in question YV8 YV10 and YV12 The fault persists END Replace the printed circuit See Fiche C063 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP034 Folio 3 4 MACHINE TRAVEL SPEED DOES NOT CORRESPOND TO THE SELECTOR SPEED Press the pedal and make a forward travel movement Check for 12V voltage at the terminals of the connector of electrovalve YV10
147. sts END Replace the See Fiche NO printed circuit C063 YES Replace the jib switch See Fiche END SA7 or SA6 C043 or Fiche C044 Repair the connection or replace the END electric wiring harness between the jib switch SA7 or SA6 on the printed circuit of the turntable control panel Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP028 NO JIB MOVEMENT UP AND OR DOWN Folio 5 5 FROM THE PLATFORM OR TURNTABLE CONTROL PANEL Replace the double flow See Fiche limiter C083 The fault persists Replace the electrovalve See Fiche YV18 C067 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP032 Folio 1 4 NO MACHINE TRAVEL MOVEMENT No machine travel movement Place the key switch in the platform position Press the pedal and make an arm lifting movement Movement NO See Fiche DP023 OK e YES Put the machine on wedges so that the wheels are not touching the ground From the platform control panel select low speed Press the pedal and make a travel movement in the FOR direction Put the emergency lever on the manual control of the travel distributor YV6 and tilt the lever in the FOR operation direction The wheels turn Y Maintain action on the platform panel controls Putthe emergency lever into place on the manual travel distributor YV7 and tilt the lever
148. sure they are underneath Bring the Hc screws forward and install the lower plate to keep the slings in the grooves Figure 14 Check that the back pulleys turn freely Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Sheet C119 Folio 10 13 DISMANTLING RE ASSEMBLING THE BOOM Figure 14 Assemble the front pulleys from inside the element Finish inserting the head element to its mechanical stop Pull the out slings taut to place them in the front pulley groove then put in the Hc screws to keep them in place Install the side 3 on each side top and bottom guide pads Adjust the pads by balancing the lateral gap between the elements with the pad adjustment screws Push all the pads against the head element without forcing then slacken each pressure screw by one half turn and block the counter nuts do the same for the top pads slackening each screw by one half turn nsert the telescoping cylinder in the head element Install the cylinder half pins and block them in position with Hc screws between the two materials using threaded holes if necessary Re install the chain guide at the back of the intermediary element Complete the chain to replace missing links 11 Assembling the intermediary element head element assembly in the large drum Putthe sling support at the end of the two in slings Figure 15 NB Curve the chain before inserting the elements Ensure that the hoses d
149. t Buzzer sounding Slope or tilt gt 5 Platform load close to cut off Hydraulic oil temperature too high Reset by retracting the teles cope and lowering the boom Remove load Leave to cool The electropump does not work Battery breaker open Fuses broken Defective or discharged batteries Electropump unit defective The battery wires do not make contact Close the battery breaker Replace the fuses Replace or recharge the batteries Repair or replace the unit Clean and tighten the terminals 59 Pinguely Haulotte 2 No platform up and or down compensation movement 8 1 2 Lifting system PROBABLE CAUSE Electrovalve YV19 or YV2 defective Coil defective Electronic module U1 defective Wiring harness defective Printed circuit defective Compensation switch SA5 defective Lifting manipulator defective Repair manual SOLUTION Sheet DP050 The compensation movement is made in response to a platform rotation control Electrovalve YV24 defective Coil defective Electronic module U1 defective Wiring harness defective Printed circuit defective Sheet DP051 No jib movement up and or down from the platform or turntable control panel Electrovalve YV18 or YV2 defective Coil defective Electronic module U1 defective Wiring harness defective Printed circuit defective Jib switch SA7 or SA6 defective Sheet DP028
150. t Computers may not be the movement is made in micro speed interchanged They have a Lower the jib serial number corresponding Lift the boom to a given machine Non e Make a travel movement with the selector on high speed and check that respect of this rule may result the movement is made in micro speed in dangerous malfunction Lower the boom Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C107 Folio 2 2 CHANGING THE U1 ELECTRONIC MODULE Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C108 CHANGING A CONTROL UNIT Folio 1 1 OF THE DISTRIBUTION BLOCK A Caution 1 Preliminary operations Ensure that the oil is not too e Put the machine in the maintenance configuration see 6 3 hot Switch off electric power see S 6 4 2 Removing the coil Mark and disconnect the electric connections 2 of the coil 1 A Caution Remove the coil by removing the fixing screws 4 Use a container to collect oil Discard the O rings 3 to prevent pollution of the environment 3 Installing the coil Replace the O rings Put back the coil and fix using fixing screws Tighten the screws to a tor que between 7 5 and 8 5 N m 5 53 and 6 26 Ib ft e Reconnect the coil s electric connections e Check that there is sufficient oil in the hydraulic circuit tank Putthe machine back in the operational configuration Test the movement corresponding to the replaced coil Make several
151. t DP024 Folio 1 2 NO MOVEMENT AVAILABLE FROM THE PLATFORM CONTROL PANEL No movement available from the platform control panel Open the turntable control panel Check the state of fuse FU6 NO Replace the fuse YES Place the key switch in the platform position Open the platform control panel Press the pedal and check for 12V voltage on terminal 2110 or 211A NO Hold down the pedal and check for 12V voltage on terminal 211 of the platform YES control panel Internal wiring of the platform control panel is defective Repair cabling or replace the NO platform control panel a YES END See Fiche C064 Replace the pedal Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART GU NO MOVEMENT AVAILABLE 22 FROM THE PLATFORM CONTROL PANEL Open the turntable control panel Check for 12V voltage on terminal 211 NO YES Check wiring of wire 211 inside the platform control panel Replace the wiring harness between the turntable control panel and the platform control panel Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP025 Folio 1 2 NOISY HYDRAULIC PUMP The hydraulic pump makes a noise Check the oil level in the circuit Oil level Top up with oil See Fiche
152. than angle defined in S 3 3 17 Pinguely Haulotte 4 3 3 18 Repair manual POSITIONS OF ELECTRIC CONTACTS 26 25 24 23 22 21 20 19 18 17 16 14 13 12 11 10 TI JE y SQ11 1 0 1 508 0 SQ3 SQ 1 0 SQ10 Non 9 w 28 NU TE 34 13 14 15 16 17 18 Zone a no break Zone b movements slowed Zone c telescope out disabled Zone d boom lowering disabled Zone e telescope out cut Zone f motor cut Repair manual Pinguely Haulotte Z 3 4 OPERATING EQUATIONS Start If SB3 1 or SB4 1 and U3 0 and D 0 and YV1 not supplied then KA2 1 If SB3 1 or SB4 1 then module frequency 1 1 then module frequency 2 1 two signals are sent at a one second interval to 698 then 699 in return the frequency module sends 12V to 485 if the motor is running Motor stop If KA2 1 or no motor fault for more than 6 seconds and SQ14 1 then KP1 1 No motor fault gt D 1 and B3 1 Accelerator If HM4 1 or HM31 1 or HM2 1 or SA2 1 then KT2 1 The accelerator is time delayed for 0 5 seconds Compensation If SA5a 1 and SM31ab 0 and SM2ab 0 then YV15a 1 and YV2b 1 and YV1 1 Down If SA5b 1 and SM1ab 0 and SM2ab 0 then YV15b 1 and YV2b 1 and YV1 1 Rotation Right If SA4a 1 then YV24 1 and YV19b 1 and YV2b 1 and YV1 1 Left If SA4b 1 then YV24 1 and YV19a 1 and YV2b 1 and YV1 1 Jib Up If SA6b 1 or SA7b 1 then YV18b 1 and Y
153. ting platform to intervention personnel only 6 2 1 Specific tools Personnel should therefore be familiar with the use of the specific tools used measurement device torque tightening device lifting apparatus etc and respect the operating limits specified in the documentation that is supplied with the tools Incorrect use of a tool incorrect adjustment after a reading error may lead to premature deterioration of the elevating platform or more seriously an accident for which PINGUELY HAULOTTE cannot be held responsible 6 2 2 Replacing an element Before replacing an element the machine must be put in the maintenance configuration see Chapitre 6 3 page 38 and the electric power supply cut off see Chapitre 6 4 page 38 All distributing valves are with open centre breaking the electric circuit therefore decreases pressure in the hydraulic circuits up to the non return valves flanged on the cylinders An element can be replaced safely if the procedures described in the maintenance sheets are respected unscrew hydraulic connectors slowly to release residual pressure 37 Pinguely Haulotte 4 6 3 MAINTENANCE SYSTEM Photo 1 Repair manual To preserve the integrity of the safety systems and the technical characteristics of the elevating platform it is essential to use original parts and to respect the initial setting and tightening torque values see Chapitre 2 page 7 6 2 3 Locating the breakdown
154. tor Reconnect the hydraulic hoses according to the marks made during dis mantling see table of tightening torque values Put the machine back into the operational configuration Make several platform rotation movements to purge the hydraulic circuit and adjust rotation speed using the flow limiter adjustment buttons see 2 3 6 page 13 Table of adjustment times Check the level of the hydraulic oil tank Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C053 Folio 1 3 CHANGING THE BASKET 1 Preliminary operations A Caution Putthe machine in the maintenance configuration see S 6 3 page 32 It is essential to put the Switch off electric power see 6 4 page 32 componentin slings before Disconnect the lt gt then lt gt terminals of the starter battery dismantling re assembling it 2 Removing the platform Disconnect the platform control panel electric wiring harness Remove the control panel fixing screws 17 Remove the control panel and its silent blocks 18 Remove the platform s electric plug 19 if any by unscrewing its fixing bolts Putthe platform in slings Remove the pre stressing stop by unscrewing the screw 1 and nut 2 Upper part Remove the Nylstop nut 3 and its washer 4 on the platform side Remove the stop pad 5 on the platform side Remove the weighing articulation pin 6 Lower part Remove the lower pivot pin 7 by
155. trol panel elescoping movement OK Open the platform or turntable control panel and check the wiring of the telescoping manipulator SM2 or telescoping switch SA8 NO Repair wiring YES Platform panel END telescoping fault Turntable panel Y telescoping fault Place the key switch in the turntable position Open the turntable control panel Activate the telescoping switch SA8 and check for 12V on terminals 412 or 411 of the printed circuit Place the key switch in the platform position Open the platform control panel Tilt the telescoping manipulator SM2 as far as possible Check for 0 5V or 4 5V voltage depending on movement direction on terminal 506 of the printed circuit Replace the telescoping manipula See Fiche tor SM2 or telescoping switch SA8 C045 Fiche C044 Repair the connection or replace the wiring harness END between the telescoping manipulator SM2 or telescoping switch SA8 to the printed circuit of the turntable control panel END Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP053 NO TELESCOPING MOVEMENT Folio 2 5 IN AND OR OUT FROM THE PLATFORM OR TURNTABLE CONTROL PANEL H Check the setpoint at the outputs of limit detectors SQ7 SQ10 and SQ11 Setpoint SQ10 0V SQ7 12V SQ11 0V Y YES Check the continuit y of wiring harn
156. tures 1 Retract the telescope and put the jib in the low position Switch off electric power see S 6 4 Wedge the boom place a firm support to take its weight while the cylin AN der is removed 1 Ensure that the oil is not too hot Use a container to collect oil fe prevent paupe GF He 2 Removing the boom lifting cylinder environment Put the boom lifting cylinder in slings Mark and disconnect the boom lifting cylinder s two hydraulic hoses NB Unscrew the hoses slowly to release residual hydraulic pressure Caution It is essential to put the Put caps the hoses component in slings before Remove the pin stop screw 3 on the rod side of the cylinder and remove dismantling re assembling it the pin 3 the cylinder body side release the counter nuts of the pressure screws 4 then remove the pressure screws 4 Remove the pin 2 Remove the boom lifting cylinder 1 3 Installing the boom lifting cylinder NB Before re installing check the condition of all the articulation pin rings and replace if necessary Lubricate all bores before re installing the pins Only use lubricants recommended by the manufacturer Position the cylinder on the machine Put back the pin on the body side 2 Putback the pressure screws 4 to block the pin 2 Make sure they are correctly positioned in the pin counter bores 2 e Block the pressure screw counter nuts 4
157. uest if necessary Repair manual Pinguely Haulotte Z 6 7 1 Yellow labels s t 7814 354a al SO S 7814 353 7814 360 d 7814 357 6 7 2 Orange labels H RECOMMENDATIONS FOR USE ISTRUZIONI PER L USO GEBRUKSAANWNZINGE BEFORE USING THIS MACHINE PER UTILIZZARE QUESTA MACCHINA LOPERATORE VOOR HET GEBRUK VAN DIT TOESTEL OPERATOR MUST DEVE OSSERVARE Le SEGUENTI ISTRUZIONI DE OPERATOR CONSIGNE D UTILISATION eh gone van aan tern POUR UTILISER CET APPAREIL L OPERATEUR DOIT 1 Lire et comprendre les informations contenues dans le manuel de conduite et les inscriptions appos es sur la machine se familiariser avec les commandes TZ eter dale a 2 Etre form et entra n pour la conduite de celui ci sous la responsabilit SS ni e tatn ES de son employeur en 3 Assurer correctement l entretien suivant le catalogue constructeur TR TT MSTRUCTIES VOOR MET 4 Ne pas utiliser l appareil en cas de disfonctionnement Sei ocra ae hr m Lore eee 5 Ne pas laver sous pression les composants lectriques ee de 6 d monter la stabilit serait modifi e TIENI UR EPA 7 Ne pas modifier l appareil sans accord du constructeur Pe racine o wegen EE E tetako 8 Ne pas utiliser la machine comme masse de soudure Se USED AE SEE 9 Ne pas souder sur la machine
158. upling NO OK Y Replace the hydraulic See Fiche Replace the See Fiche pump C042 or C091 coupling C042 or C091 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Sheet DP023 i Folio 4 5 NO MOVEMENT AVAILABLE FROM TURNTABLE OR PLATFORM CONTROL PANELS Replace the pressure limiter of the PVG input module Clean the protective filter screen The fault NO persists YES END Replace the PVG input See Fiche module C076 or C094 The fault NO persists YES END Adjust or replace the pump See Fiche regulation valve pressure C073 or C111 limiter 240 bars The fault NO persists YES END Replace the hydraulic See Fiche pump C042 or C091 Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART NO MOVEMENT AVAILABLE FOO FROM TURNTABLE OR PLATFORM CONTROL PANELS Place the key switch in the turntable position Check for 12V voltage between points 0 and 240 of the turntable panel printed circuit NO YES Replace relay KMG See Fiche Replace the U1 module See Fiche C062 C058 or C107 The fault NO The fault NO persists persists YES END YES END Repair the wiring of the key See Fiche Replace the printed circuit See Fiche switch SA1 or C044 C063 replace the switch Pinguely Haulotte Z BREAKDOWN DETECTION FLOW CHART Shee
159. urn Repair manual Pinguely Haulotte Z 3 SAFETY SYSTEM 3 1 FUNCTION OF RELAYS AND FUSES IN TURNTABLE BOX see wiring diagram Ref Description KA2 Thermal motor start KP1 Thermal motor stop KT2 Motor speed acceleration electromotor KMG Main supply KMA Electropump contactor FU01 10 A Motor stop circuit fuse FUO3 80 A Accelerator circuit fuse FU04 30 A Main circuit fuse FU05 3 A Turntable movement control circuit fuse FU06 3 A Platform movement control circuit fuse FUO7 20 A Electrovalve supply circuit fuse FU08 5 A Turntable platform control circuit fuse FU09 20 A Accessory circuit fuse FU10 3A Circuit fuse FU11 250 A Emergency pump fuse 3 2 FUNCTION OF SAFETY CONTACTS see wiring diagram Ref Description B1 Air filter contact Motor cut off if air filter clogged B3 Oil pressure contact Motor cut off if pressure insufficient B4 Hydraulic oil temperature contact Audible alert if temperature too high SB1 Palm button emergency stop turntable SB2 Palm button emergency stop platform 501 sensor 502 Jib jib detection if gt 0 SQ3 Detection if boom lowered SQ7 Reach limitation motor cut off if SQ10 defective 508 Reach limitation motor cut off if 5011 defective 509 Boom out detection SQ10 Reach limitation disables telescope out movement SQ11 Range limitation disables movement if boom angle less
160. ve the fixing screws and washers 4 from the hydraulic block Take out the block from the top of the turntable Dismantle the hydraulic block to change one of its elements if necessary see corresponding sheet 3 Installing the distribution hydraulic block If the distribution block installed is new fit the new block with the unions retained from the old one but replace the O rings Tighten to the recom mended torque see concerned chapter Put the hydraulic block into place and fix with screws equipped with new grower washers Reconnect the hydraulic hoses according to the marks made during dis mantling Tighten to the recommended torque see chapter concerned Reconnect the hydraulic block s electric connections according to the marks made during dismantling Put the machine back in the operational configuration Check that there is sufficient oil in the hydraulic tank Make several lifting travel steering and turntable rotation movements to purge the hydraulic circuit and test block operation Check the level of the hydraulic oil tank Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C093 Folio 2 2 CHANGING THE DISTRIBUTION HYDRAULIC BLOCK Sheet C094 A Caution Ensure that the oil is not too hot AN Caution Use a container to collect oil to prevent pollution of the environment Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Folio 1 1 INTRINSIC DISMANTLING RE ASSEMBLY OF THE
161. washers 18 and 19 e Put into place the disk 16 and pad 17 then the articulation pin assem bly 15 Put into place the plate 14 elastic washers 13 bushing 12 then a new nylstop nut 11 Put into place the Nylatron washer 10 platform link part 9 end cap 8 and Stauff collar Fix the assembly with the screw 4 equipped with a new toothed washer 5 Put back the endless screw 2 and the adjusting washers 3 if necessary Put back the motor fixing flange 1 Put back the basket rotation hydraulic motor see corresponding sheet Put back the basket see corresponding sheet Lubricate the gearing NB Only use lubricants recommended by the manufacturer Putthe machine back in the operational configuration Pinguely Haulotte 4 CORRECTIVE MAINTENANCE SHEET Folio 2 2 Sheet C104 O 2 2 lt ui O z O lt X 0 lt o I O 2 O Z lt O T Ka Omg AIDA EN RS al OSEN N NTZA Hee D BN x n ISS SSS N 1 N E 222222222222022 ANN Eiz EI H Aie RM L li SAIS NIDI Z22222 Sheet C106 A Caution Ensure that the oil is not too hot Caution Ensure that the lifting equipment is in good condition and of sufficient capacity AN Caution Use a container to collect oil to prevent pollutio
162. wer see 6 4 hot Remove the platform see correponding sheet Remove the jib see corresponding sheet Remove contactors SQ3 SQ7 SQ8 SQ9 SQ10 and 5011 see corres ponding sheet ion 2 Remove the head element and the intermediary element IE Ensure that the lifting equipment is in good condition and of sufficient capacity Figure 1 With the boom lowered marked the positoin of each side and top guide pad 5 Figure 1 then remove all pads by removing their fixing screws and washers Free the parachute cable 6 after noting the length of the free threaded part NB Retain the 40 cable washers Remove all flap closing plates 7 on the large drum LD by removing their fixing screws and washers Remove the fixing screws 8 from the lower sling support pad Remove the parachute half pulley 9 e Mark the path and connections of the wires and hoses passing in the boom Disconnect all the wires of the 42 wire cable in the turntable control box 10 and remove the mains plug Bind the wires together with adhesive tape cut the wires if the cable needs replacing Consult the panel s wiring diagram and make sure the necessary tools are at hand to pull out the connectors he boom to the horizontal position using the emergency unit Free the cables and hoses fastened in the turntable by cutti
163. wer see 8 6 4 Ensure that the oil is not too hot 2 Removing the steering cylinder Open the upper cover of the chassis mM Mark and disconnect the two hoses 2 of the steering cylinder 1 A Caution Use a container to collect oil to prevent pollution of the NB Unscrew the hoses slowly to release residual hydraulic pressure environment Put caps the hoses Put the cylinder in slings Caution Remove the Nylstop nuts 4 then remove the two fastening pins 3 from the It is essential to put the steering cylinder component in slings before Remove the steering cylinder dismantling re assembling it 3 Installing the steering cylinder Puta new steering cylinder into place Put back the fastening pins and fix using new Nylstop nuts and washers Reconnect the hydraulic hoses according to the marks made during dismant ling Check that there is sufficient oil in the hydraulic tank Putthe machine back into the operaitonal configuration Make several steering movements to purge the hydraulic circuit Checkthe level of the hydraulic oil tank Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C087 Folio 2 2 CHANGING THE STEERING CYLINDER Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C091 Folio 1 2 CHANGING THE HYDRAULIC PUMP A Caution hot Putthe machine in the maintenance configuration see S 6 3 Switch off electric power see S 6 4 Cl
164. 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 A Caution Ifthe machine has 220 V 16 max plug the extension must be connected to a mains socket protected by a 30 mA differential circuit breaker Operating and maintenance instructions 1 3 1 Risks of jerky movements and tipping over Risks of jerky movement and tipping over are high in the following situations Sudden action on the controls Overloading of the platform Uneven ground Be careful during thaw periods in winter Gusts of wind Contact with an obstacle on the ground or at a height Working on platforms pavements etc Allow sufficient stopping distances 3 meters at high speed 1 meter at low speed Allow sufficient stopping distances 3 metres at high speed and 1 metre at low speed Do not alter or neutralise any components connected in any way to the machine 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
165. ws the area maintained based on the frequency The symbol represents the consumable to use or the operation to be carried out Consumable Specification Symbol SAEZ ES ELF TOTAL Pinguely Haulotte Motor oil SAE 15W40 SHELL RIMULA X SHELL Tranself Gearbox oil SAE 90 SPIRAXA EP 80 W 90 EP 80 W 90 TM 80 W 90 ETOR rea AFNOR 48602 SHELL HYDRELF EQUIVIS ere ISO VG 46 lt TELLUS T 46 DS 46 75 46 Biodegradable hydrau SHELL lic oil option gt Naturelle HF E46 e Sp ESSO Lithium grease KP 2K GA 2 2 ESSO po Multis Leadfree grease Grade 2 or 3 GP GREASE Multimotive 2 EP 2 Exchange or specific operation 39 Pinguely Haulotte 4 Repair manual HOURS 4 25 40 SSI 7 3 25 OX daaa 50 250 500 Repair manual Pinguely Haulotte Z 6 6 OPERATIONS 6 6 1 Summary table Frequency Ref Operation Test the horn the tilt detector and safety systems Check the levels 1 motor oil 2 hydraulic oil see fiche 008 3 diesel 4 electric batteries SEARA Check the cleanliness each use 1 j y 5 diesel prefilter replace if water or impurities are found 6 motor air filter machine in particular check the tightness of the connectors and hoses Use this opportunity to check t
166. y Check the level of the hydraulic oil tank KH Figure 1 3 21 Figure 2 Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C106 Folio 3 3 CHANGING THE SLEW RING T Hd 5 Pinguely Haulotte Z CORRECTIVE MAINTENANCE SHEET Sheet C107 Folio 1 2 CHANGING THE U1 ELECTRONIC MODULE 1 Preliminary operations Putthe machine in the maintenance configuration see S 6 3 Switch off electric power see 6 4 Disconnect the then terminals of the starter battery to isolate the electric circuit 2 Removing the U1 electronic module Openthe electric box in the turntable Remove the fixing flange 2 of the U1 electronic module Remove the U1 electronic module 3 Installing the U1 electronic module Putinto place a new U1 electronic module previously programmed by the manufacturer Put back the fixing flange Close the electric box Reconnectthe lt gt then lt gt terminals of the starter battery Putthe machine back in the operational configuration Check full operation of the U1 electronic module using the checklist for the relevant machine 4 Testing the U1 electronic module Make all movements from the bottom control panel for two seconds Make all movements from the top control panel for two seconds Lift the jib gt 0 A Caution Make a travel movement with the selector on high speed and check tha

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