Pinguely-Haulotte HA20PX Repair Manual Download

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Summary of Contents for HA20PX

Page 1: ...IQUES MATS TRACTEES I S O 9 0 01 PINGUELY HAULOTTE LA PERONNIERE BP 9 42152 L HORME T l 33 0 4 77 29 24 24 Fax SAV 33 0 4 77 31 28 11 email haulotte haulotte com Web www haulotte com REPAIR MANUAL SEL...

Page 2: ......

Page 3: ...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 cat...

Page 4: ...1 Repair manual 2...

Page 5: ...d tipping over 8 1 3 2 Electrical risk 8 1 3 3 Risk of explosion or burning 8 1 3 4 Risks of collision 8 1 4 INSPECTIONS 9 1 4 1 Periodic inspections 9 1 4 2 Examination of machine suitability 9 1 4 3...

Page 6: ...NCTIONS OF THE TURRET CABINET FUSES AND RELAYS 21 3 2 FUNCTION OF THE SAFETY SWITCHES 21 4 WIRING DIAGRAM 23 4 1 WIRING DIAGRAM E 448 FOLIO 01 05 23 4 2 WIRING DIAGRAM E 448 FOLIO 02 05 24 4 3 WIRING...

Page 7: ...36 6 8 ARM LIFTING 36 6 9 BOOM LIFTING 37 6 10 TELESCOPING 37 6 11 TRAVEL 37 6 12 STEERING 37 6 13 DIFFERENTIAL BLOCKING 38 6 14 HORN BUZZER 38 6 15 INDICATORS 38 6 16 OTHER FUNCTIONS OVERLOAD DEAD MA...

Page 8: ...10 1 1 Location 49 10 1 2 Input and output 51 10 2 PVG 32 DANFOSS BLOCK 52 10 2 1 Location 52 10 2 2 Input and output 53 10 3 CETOP 3 AUXOLIARY BLOCK 54 10 3 1 Location 54 10 4 EMERGENCY PUMP UNIT 55...

Page 9: ...12 7 PRESENCE OF LABELS 67 12 7 1 Common yellow label 67 12 7 2 Commom orange label 68 12 7 3 Common red label 69 12 7 4 Other common label 70 12 7 5 Model specific labels 71 12 7 6 Description 72 12...

Page 10: ...Repair Manual vi 15 CORRECTIVE MAINTENANCE PROCEDURES 177...

Page 11: ...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 m...

Page 12: ...out minimum distances according to current In temperatures of less than 15 C in particular in cold rooms consult our service department if work is required in conditions below 15 C In an explosive atm...

Page 13: ...rators must respect the following instructions Do not disable the safety system end of stroke contactors Avoid moving the steering control levers in the opposite direction without stopping in the O po...

Page 14: ...cted 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...

Page 15: ...r can be obtained from trade organisations and in some cases from the OPPBTP or private prevention agencies The designated persons must be experienced in risk prevention Articles R 233 11 or order n 9...

Page 16: ...BEAUFORT SCALE The Beaufort Scale of wind force is accepted internationally and is used when communicating weather conditions It consists of number 0 17 each representing a certain strength or veloci...

Page 17: ...erall height 2 67 m Wheelbase 2 60 m Ground clearance 420 mm max reach 13 50 m Boom range 0 75 Telescoping stroke 4200 mm Turret rotation Continuous Max force on wheel 6194 daN Reducer efficiency 95 3...

Page 18: ...rall width 2 35 m Overall height 2 67 m Wheelbase 2 60 m Ground clearance 420 mm max reach 14 6 m Boom range 0 75 Telescoping stroke 6915 mm Turret rotation Continuous Reducer efficiency 95 30 Max tra...

Page 19: ...40 bar Travel speed proportional LS 1 2 km h HS 4 5 km h max ground pressure with 250 kg hard ground concrete loose ground mud 16 0 daN cm2 4 6 daN cm2 Max force on wheel 6970 daN Starting battery 1 X...

Page 20: ...Manual 14 2 2 OVERALL DIMENSIONS 2 2 1 HA 20PX overall dimensions 2600mm 8ft 6in 1070mm 3ft 6in 3710mm 12ft 2in 870mm 2ft 10in 8925mm 29ft 3in 6754mm 22ft 1in 2380mm 7ft 9in 1950mm 6ft 4in 1800mm 5ft...

Page 21: ...ual 15 2 2 2 HA 26PX overall dimensions 3710mm 12ft 2in 3000mm 9ft 10in 765mm 2f 1800mm 5ft 10in 420mm 1ft 4in 11890mm 39ft 100mm 3in 9570mm 31ft 4in 2670mm 8ft 9in 1990mm 6ft 6in 2345mm 7ft 8in 2600m...

Page 22: ...0 480 M 20 2 5 370 450 520 570 620 680 M 22 2 5 500 620 700 770 840 930 M 24 3 3 630 790 890 990 1070 1180 M 27 3 930 1150 1300 1400 1560 1730 M 30 3 5 1260 1570 1770 1960 2200 2350 Nominal diameter T...

Page 23: ...LG 18 40 7 5 11 2369070380 Hose SP 1707 LG 18 20 7 5 11 2369070390 Hose SP 1756 LG 6 50 18 5 25 81 2369070400 Hose SP 5043 LG 1 010 44 3 59 2369070410 Hose SP 5043 LG 1 170 44 3 59 2369070420 Hose SP...

Page 24: ...ssure limiter 100 bars Telescoping Output pressure 100 bars Input chamber 160 bars Large chamber braking valve 100 bars Boom lifting Lowering pressure 130 bars Valve de freinage grande chambre 210 bar...

Page 25: ...26P Arm lifting From the basket 50s 4s 60s 4s Arm lowering From the basket 50s 4s 60s 4s Boom lifting From the basket 30s 3s 40s 3s Boom lowering From the basket 30s 3s Rotation left From the basket 5...

Page 26: ...Repair Manual 20...

Page 27: ...ontrol circuit fuse FU9 20 A Accessories circuit fuse FU10 3 A Circuit fuse FU11 250 A Engine circuit fuse SB1 Mushroom headed emergency stop button turret SB2 Mushroom headed emergency stop button pl...

Page 28: ...Repair Manual 22...

Page 29: ...d ric DENEZE 08 04 1999 30 04 1999 5 NBRE TOTAL DE FOLIOS TEL 04 77 29 24 24 HA20P HA26P SCHEMAS c 21 03 2001 Ajout Shunt HA20P HA26P LDF b a 08 01 2001 21 04 2000 Voyant Nacelle BP Pompe Shunt sur 1...

Page 30: ...29 24 24 HA20P HA26P SCHEMAS c 21 03 2001 Ajout Shunt HA20P HA26P LDF b a 08 01 2001 30 10 2001 Voyant Nacelle BP Pompe Shunt sur 15 4 et 15 8 LDF LDF T O N SA1 U1 F8 F7 F5 F6 20A 5A 20A 3A 3A 30A ES...

Page 31: ...4 6 4 9 30 9 30 8 4 14 4 15 30 11 30 10 29 10 29 9 29 8 29 7 4 12 3 2 29 12 17 10 18 19 35 34 15 8 15 7 15 3 15 6 8 9 8 6 8 12 8 11 U1 Accelerator Differential Lock Gantry Rotation Compensation Gantry...

Page 32: ...3 3 42 2 43 2 44 2 45 2 37 2 36 2 46 2 47 2 40 2 27 4 27 3 27 2 27 1 27 7 31 21 15 9 15 4 20 52 2 52 3 14 4 1 4 2 4 3 4 4 3A U1 Tilt Detector Arm Boom 8M Cut Off 8M Cut Off Oil Temperature Oil Pressur...

Page 33: ...08 01 2001 21 04 2000 Voyant Nacelle BP Pompe Shunt sur 15 4 et 15 8 LDF LDF Y X Y Y SM31 SM2 SM4 B A U1 29 1 30 7 30 15 29 4 30 12 30 14 30 13 29 15 29 2 29 3 29 5 29 6 28 9 28 4 28 6 28 3 28 2 28 1...

Page 34: ...4 Boom raising slewing control SM2 05 6 Arm lifting controller SM4 05 10 Travel direction controller SQ1 04 4 Tilt detector SQ2 04 5 Pendular position switch SQ4 04 7 Arm boom position switch SQ5 04...

Page 35: ...1 03 10 FORWARD direction control solenoid valve YV22 03 11 REVERSE direction control solenoid valve KM4 01 3 M4 electropump contactor SQ7 04 8 Engine cut out position switch SQ8 04 9 Engine cut out p...

Page 36: ...Repair Manual 30...

Page 37: ...8 5A 242 Permanent FU9 20A Accessories FU10 3A Load Sensing valve 5 3 INPUT 5 3 1 Control inputs SB3 Turntable start 117A SB4 Platform start 117B SB5 Buzzer 901 SA2 Accelerator 605 SA3 Differential bl...

Page 38: ...7 SA17b electric 918 SA18 Turntable electrical thermical SA18a thermic 919 SA18b electric 920 SM31 Steering and lifting Consign X Rotation 512 Consign Y Lifting 403 Up from 2 5 to 4 5v Down from 2 5 t...

Page 39: ...ssure 112 0v if pressure 0 5b B4 Oil tank temperature 904 0v if temperature 130 C D Alternator 109 12v If the alternator work W Anti starter 108 12v When the engine is on 5 4 OUTPUT 5 4 1 Relay KP1 Mo...

Page 40: ...6 to 6V in the other YV3 Lifting 403A YV4 Telescoping 506A YV5 Rotation 512A YV6 Travel 612A YV7 Travel 612A 5 4 4 Buzzer and light indicators HA1 Horn 260 261 HA2 Overload 1st threshold buzzer 213 H...

Page 41: ...en KA2 1 6 2 STOP MOTEUR if KA2 1 or No motor fault for more than 6 seconds then KP1 1 No motor fault D 1 and B2 1 and B3 1 6 3 ACCELERATOR if HM4 1 or HM31 1 or HM2 1 or SA9a 1 or SA9b 1 and SQ6 1 or...

Page 42: ...5 1 Platform Left if HM31 1 and SM31ab 0 puis SM31ab 1 and SQ6 1 and then YV1 1 and YV5 1 Right if HM31 1 and SM31ab 0 puis SM31ab 1 and SQ6 1 and then YV1 1 and YV5 1 6 8 ARM LIFTING Turntable Up if...

Page 43: ...ntable position then YV14b 1 and YV2a 1 and YV1 1 6 11 TRAVEL if unfolded machine then micro speed 1 if machine folded then micro speed 0 if SA11a 0 and SA11b 1 and MicroSpeed 0 then LowSpeed 1 YV1 1...

Page 44: ...if SA3 1 and SA11a 0 and MicroSpeed 0 then YV9 1 and YV13 1 6 14 HORN BUZZER if SB5 1 then HA1 1 if SQ1 0 and machine unfolded then the buzzer sounds continuously if B4 0 then the buzzer sounds with...

Page 45: ...he turntable the latter is slowed down 6 16 2 Dead man During the movement dead man pedals can be released for 0 5 seconds If the dead man is actuated for x seconds joystick neutral the movement can n...

Page 46: ...135 Repair manual 40...

Page 47: ...Repair manual 135 41 7 SAFETY LOCATION...

Page 48: ...135 Repair manual 42...

Page 49: ...ine option 38 14 Buzzer RELAYS 39 47 SQ13 12 KA2 Start 40 22 Boom lifting PVG 13 KP1 Motor stop 41 23 Telescoping or arm lifting PVG 14 KA32 Electric power thermal power switch 42 24 Rotation PVG 15 K...

Page 50: ...5 Repair manual 44 8 1 2 Positions of screws connectors and relays 1 2 3 4 5 28 29 6 7 8 30 14 9 48 57 56 55 54 53 52 51 46 45 50 49 44 43 42 41 40 15 31 12 13 38 32 33 16 34 35 17 10 36 18 11 37 39 4...

Page 51: ...Repair manual 135 45 8 1 3 Positions of fuses 19 22 26 27 23 25 24 21 20...

Page 52: ...135 Repair manual 46 8 1 4 Positions of diagnosis help LEDs YV20 YV2A YV11 YV10 YV2B YV12 YV8 YV23 YV14B YV14A YV9 YV18B YV18A YV15B YV15A YV21B YV21A YV13A YV22B YV22A YV1 YV16B YV16A YV19B YV19A...

Page 53: ...Repair manual 47 9 HYDRAULIC DIAGRAMS 9 1 HYDRAULIC DIAGRAM FOR HA20 26PX AND HA61 80JRT MODELS B1539 0 B15390 b...

Page 54: ...5 bar 7 Pressure filter clogging indicator 8 PVG32 12V S5086 distribution block 10 4x4 12V S5095 travel block 11 Double displacement hydraulic motor 12 Hydraulic motor 13 Cartridge balancing valve r...

Page 55: ...1 TRAVEL BLOCK 10 1 1 Location Ref Description 2 YV12 high speed solenoid valve 3 AF1 flow divider 4 YV13 differential lock solenoid valve 5 AF2 flow divider 6 YV9 7 YV10 High speed solenoid valve sup...

Page 56: ...escription 8 AD1 Equilibrating valve of front motor only using in low speed 9 AD2 Equilibrating valve of front motors only using in low speed 10 AD3 Equilibrating valve of rear motor only using in low...

Page 57: ...engines feeding outlet DR Engines drain retourn P1 Pressure input coming from proportional Danfoss valve outlet A from YV7 passage n 2 from slewing collector B1 Pressure input coming from proportiona...

Page 58: ...arm lift from boom B output A input 4 YV11 Proportional valve for rotation command 5 YV14 Proportional valve for driving command output A towards input 1 towards slewing ring output B towards input 4...

Page 59: ...k output A towards outlet 1 from slewing ring and input B1 from driving block output B towards outlet 4 from slewing ring going in A1 from driving block YV5 A B Supply output for slewing turntable eng...

Page 60: ...supply B output A input 3 YV10 Proportional valve for arm lifting supply B output A input 4 YV11 Proportional valve for rotation command 5 YV14 Proportional valve for driving command output A towards...

Page 61: ...Repair manual 135 55 10 4 EMERGENCY PUMP UNIT 10 4 1 Location Ref Description 1 Emergency pump pressure regulator 2 Emergency electric pump 1 2...

Page 62: ...scop supply output way to telescop output 2 Telescop supply output way to telescop input 3 Telescope input entry pressure regulator set at 200 Bars 2900 PSI 4 Telescope outlet pressure regulator set a...

Page 63: ...A Rear left steering 3 YV22 B Front left steering 4 YV21 B Rear right steering 1 2 3 4 P Input of block feeding T Output return to tank 4 2 Output unbreaking supply when steering is stopped when no dr...

Page 64: ...135 Repair manual 58...

Page 65: ...LE ROTATION YV1 YV5 A or B 11 3 ARM LIFTING YV1 YV4 B up A down 11 4 BOOM LIFTING YV1 YV 3 B up A down 11 5 TELESCOPING YV1 YV 2A YV 14 A out B in 11 6 OTHER MOVEMENT YV1 YV2B Jib YV 18 A up B down or...

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Page 67: ...e stopping of all movements except basket rotation 1 High speed impossible or intermediate speed for 4x4 model if boom raised arm raised telescope extended Do not use the machine as a weldingearth Do...

Page 68: ...to use original parts and to respect the initial setting and tightening torque values see corresponding paragraph 12 2 3 Locating the breakdown Certain checks require the elevating platform to be swi...

Page 69: ...ELECTRIC POWER SUPPLY Instructions Cutting off the electric power supply Press the turntable emergency stop ref 1 Photo 2 page 63 Photo 2 Restoring the electric power supply Reset the emergency stop r...

Page 70: ...ICA TION SYMBOL Lubricants used by PINGUELY HAULOTTE ELF TOTAL Engine oil SAE 15W40 SHELL RIMULAX Gearbox oil SAE 90 SHELL SPIRAXA EP80W90 TRANSELF TM 80 W 90 Hydraulic oil AFNOR 48602 ISO VG 46 SHELL...

Page 71: ...Repair manual 65 50 500 1 000 2 000 10 50 250 500 10 50 250 500 1 000 2 000 31 22 9 26 3 22 9 19 29 7 17 23 25 18 25 18 2 13 14 15 x 21 10 27 28 30 12 10 5 16 6 18 4 18 11 9 25 1 8 20 24 9 25 HOURS...

Page 72: ...e hinge pin 4 points boom bottom shaft 1 point Clean gasoil pre filter 8 9 10 11 12 13 14 15 31 16 After the first 50 hours Change the hydraulic filter s cartridge see 250 hour interval Drain the driv...

Page 73: ...ators 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...

Page 74: ...Repair manual 68 12 7 2 Commom orange label 6...

Page 75: ...D 7814 518 Composant sp cifique cette machine NE PAS INTERCHANGER Component specific to this machine DO NOT INTERCHANGE Komponenten nur f r diese maschine geeignet BITTE AUF EINE ANDERE MASCHINE NIGHT...

Page 76: ...Repair manual 70 12 7 4 Other common label 7814 393 7814 394 GPL 7814 306 a 13 15 17 14 16 24 18 75 77...

Page 77: ...Repair manual 71 12 7 5 Model specific labels 12 7 5 1 HA20PX 12 7 5 2 HA26PX 19 7814 647 3 19 76...

Page 78: ...ing 12 30 7814 5070 1 Travel direction danger 13 30 7814 3520 1 Hydraulic oil label 14 30 7814 3590 1 Oil level 15 3 07814 3930 a 1 Green arrow 16 30 7814 3940 a 1 Red arrow 17 30 7814 3060 1 Chassis...

Page 79: ...abel positioning 76 04 16 29 17 07 14 13 5 77 09 26 08 80 10 28 11 26 10 04 25 79 78 18 19 20 22 12 24 23 02 05 03 11 01 75 19 21 08 22 20 06 15 27 09 Machine standard Sp cifique Hollande Sp cifique A...

Page 80: ...document holder provided on the platform An illegible manual may lead to incorrect or dangerous use of the machine Operating instructions Check presence of manuals Check that all the manuals are legib...

Page 81: ...NTIVE MAINTENANCE SHEET lList of maintenance preventive sheets Sheet no Description P005 Checking filling the hydraulic oil tank P006 Changing the hydraulic filter cartridge P007 Checking changing the...

Page 82: ...135 Repair manual 76...

Page 83: ...ph Switch off electric power see corresponding paragraph 2 Checking filling the hydraulic oil tank NB This operation must be carried out when the oil is cold i e before star ting the machine Check tha...

Page 84: ......

Page 85: ...ot 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 hydra...

Page 86: ...PREVENTIVE MAINTENANCE SHEET...

Page 87: ...by the manufacturer 3 Changing the oil In the 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 pollutio...

Page 88: ...PREVENTIVE MAINTENANCE SHEET...

Page 89: ...Ds in the turntable box Check the state of the LEDs see corresponding paragraph The LEDs inside the turntable box indicate the state of the electrovalves LED off electrovalve present and not controlle...

Page 90: ...ation but does start from the platform station Switch SB3 defective Wiring harness defective Fiche DP020 No motor acceleration regar dless of the movement con trolled from the platform Electronic modu...

Page 91: ...onnector hose or component Clogged oil filter Change the filter Adjust speed Repair or replace Replace oil filter cartridge No travel telescope out boom and arm lifting buz zer sounding Slope or tilt...

Page 92: ...ve Printed circuit defective Flow limiter defective Jib switch SA7 or SA6 defective Fiche DP028 No telescoping movement out and or in from the plat form or turntable control station Electrovalve YV14...

Page 93: ...selec tor Electrovalve YV8 YV10 or YV12 defective Coil of electrovalve YV8 YV10 or YV12 de fective Wiring harness defective Printed circuit defective Speed selector SA11 defective Electronic module U...

Page 94: ...ive Fiche DP037 No steering movement right and or left on the rear axle Electrovalve YV21 or YV2 defective Coil defective Electronic module U1 defective Wiring harness defective Printed circuit defect...

Page 95: ...unlocked Check the position of the platform and turntable emergency stop buttons NO YES Check the state of battery charge Check the state of the generator and replace if necessary A Folio 1 3 Battery...

Page 96: ...the turntable control panel and check the state of fuses FU1 FU4 and FU8 NO YES 12V OK END Replace the defective fuse Check the 12V on line 242 of the turntable control panel YES Folio 2 3 NO END Acti...

Page 97: ...turntable control box NO YES Replace the relay KA2 See Fiche C062 Folio 3 3 YES 12V OK Check wiring between switch SB3 or SB4 and the turntable control box The fault persists NO END Check continuity o...

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Page 99: ...diesel tank NO YES END Fill the diesel tank Check the diesel supply circuit See motor manufacturer manual Circuit OK NO YES Check the state of the motor safety systems motor oil pressure motor oil tem...

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Page 101: ...ing OK NO Repair wiring Place the key switch in the platform position Open the platform control panel Press the pedal and tilt the rotation manipulator as far as possible Check for 0 5V or 4 5V voltag...

Page 102: ...e the rotation switch SA15 from the turntable panel and check for 3V or 9V voltage depending on the movement direction at the terminals of electrovalve YV5 B A NO YES Voltage OK Maintain the control a...

Page 103: ...EL Folio 3 3 B Activate the arm lifting movement in the emergency mode Put the emergency lever on the manual control of the rotation distributor YV4 Activate the lever to the right and left while pres...

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Page 105: ...ity and connector of switch SB4 Connection OK YES Activate switch SB4 and check continuity between the two terminals of the switch Open the turntable control panel and check the state of fuse FU6 Fuse...

Page 106: ...2 2 Repair wiring or replace the wiring harness between the platform control panel and the turntable control panel END B YES 12V OK Replace the U1 module See Fiche C058 or C107 END NO YES The fault pe...

Page 107: ...en the turntable control panel Activate switch SB3 and check continuity between the two terminals of the switch Continuity OK YES Repair wiring of switch SB3 connection or replacement of electric wire...

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Page 109: ...e platform acceleration travel lifting turntable rotation telescope The motor accelerates Place the key switch in the turntable position and activate the accelerator switch SA2 on the turntable contro...

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Page 111: ...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 printe...

Page 112: ...sition and activate the accelerator switch SA2 from the turntable control panel Check for 12V voltage at the terminals of connector YA2 Repair or replace the electric wiring harness between the accele...

Page 113: ...rol distributor YV3 Activate the lever up then down while pressing the emergency control of the safety valve YV1 or activate the emergency power unit END Movement OK NO YES See Fiche P005 or P008 See...

Page 114: ...ifting manipulator SM31 Check that the LED associated with electrovalve YV1 is on Maintain activation of the controls and check connector YV1 for 12V voltage 1A to 1 6A current END C C NO YES 12V OK R...

Page 115: ...NO Pressure 25 to 32 bars E Adjust the load sensing pressure B See Sheet C073 or C111 NO Pressure OK YES YES Check the coupling between the hydraulic pump and the thermal motor See Fiche C042 or C091...

Page 116: ...of the PVG input module Clean the protective filter screen NO The fault persists YES Replace the PVG input module See Fiche C076 or C094 NO The fault persists YES Adjust or replace the pump regulatio...

Page 117: ...table position Check for 12V voltage between points 0 and 240 of the turntable panel printed circuit Replace the U1 module See Fiche C058 or C107 END NO YES The fault persists Replace the printed circ...

Page 118: ......

Page 119: ...place the fuse 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 END 12V OK NO YES Hold down the pedal an...

Page 120: ...OM THE PLATFORM CONTROL PANEL A Open the turntable control panel Check for 12V voltage on terminal 211 12V OK NO YES Replace the wiring harness between the turntable control panel and the platform con...

Page 121: ...O YES Top up with oil See Fiche P005 or P008 END Check that the oil used is the recommended oil problem of oil viscosity being too high Oil conform NO YES Change the hydraulic oil END Check that the h...

Page 122: ...C PUMP Folio 2 2 A Valves open NO YES Check the state of the suction pipes clogging etc Open the suction valves END Pipes OK NO YES Replace the hydraulic pump suction pipes END Incorrect operation of...

Page 123: ...the pedal and activate the basket rotation switch on the platform control panel NO YES A Stop movement and release the pedal Open the turntable control panel and check that the LED associated with ele...

Page 124: ...lace the PVG YV2 control head END Open the turntable control panel Press the pedal and activate the compensation switch Check for 12V voltage on terminal 305 415 for H14 16 HB40 44J of the printed cir...

Page 125: ...n the turntable control panel Press the pedal and activate the compensation switch Check for 12V voltage on terminals 401A up or 402A down of the printed circuit Replace coil YV15A up or YV15B down EN...

Page 126: ...END Repair wiring END Open the platform control panel and check the wiring of the compensation switch SA5 NO YES Wiring OK Check the electric continuity of the switch contacts when closed NO YES Cont...

Page 127: ...OMPENSATION MOVEMENT UP AND OR DOWN E Replace the double flow limiter See Fiche C083 NO YES The fault persists Replace the electrovalve YV15 See Fiche C067 END END Folio 5 5 Replace the balancing valv...

Page 128: ......

Page 129: ...the pedal and activate the compensation switch on the platform control panel NO YES A Stop the movement and release the pedal Open the turntable control panel and check that the LED associated with t...

Page 130: ...eplace the PVG YV2 control head END Open the turntable control panel Press the pedal and activate the platform rotation switch Check for 12V voltage on terminal 305 415 for H14 16 HB40 44J of the prin...

Page 131: ...NO YES 12V OK Open the turntable control panel Press the pedal and activate the platform rotation switch Check for 12V voltage on terminals 310A left or 311A right of the printed circuit Replace coil...

Page 132: ...he C043 END Repair wiring END Open the platform control panel and check wiring of the jib switch SA4 NO YES Wiring OK Check the electric continuity of the switch contacts when closed NO YES Continuity...

Page 133: ...BREAKDOWN DETECTION FLOW CHART Sheet DP027 NO PLATFORM ROTATION MOVEMENT RIGHT AND OR LEFT E Replace the electrovalve YV19 See Fiche C067 END Folio 5 5...

Page 134: ......

Page 135: ...he platform position Press the pedal and activate the basket rotation switch on the platform control panel NO YES A Stop the movement and release the pedal Open the turntable control panel and check t...

Page 136: ...Replace the PVG YV2 control head END Open the turntable control panel Press the pedal and activate the jib switch Check for 12V voltage on terminal 305 of the printed circuit NO YES 12V OK Replace the...

Page 137: ...l positions D E NO YES 12V OK Open the turntable control panel Press the pedal and activate the jib switch Check for 12V voltage at terminals 407A down or 408A up of the printed circuit Replace coil Y...

Page 138: ...able and check the wiring of jib switch SA7 or SA6 NO YES Wiring OK Check the electric continuity of the switch contacts when closed NO YES Continuity OK Repair the connection or replace the electric...

Page 139: ...RT Sheet DP028 NO JIB MOVEMENT UP AND OR DOWN FROM THE PLATFORM OR TURNTABLE CONTROL PANEL E Replace the double flow limiter See Fiche C083 NO YES Thefault persists Replace the electrovalve YV18 See F...

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Page 141: ...wiring Place the key switch in the platform position Open the platform control panel Tilt the lifting manipulator SM2 as far as possible Check for 0 5V or 4 5V voltage depending on the movement direc...

Page 142: ...vate the lifting switch SA14 of the turntable control panel and check for 3V or 9V voltage depending on the movement direction on the electrovalve connector YV4 B A NO YES Voltage OK Maintain the cont...

Page 143: ...EL Folio 3 3 B Activate the rotation movement in the emergency mode Put the emergency lever into place on the manual rotation distributor control YV5 Activate the lever right left while pressing the e...

Page 144: ......

Page 145: ...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 wheel...

Page 146: ...he travel manipulator SM4 and check the setpoint at output Y of the manipulator SM4 Setpoints Forward 2 5 to 4 5V Reverse 2 5 to 0 5V SM4ab 12V NO YES Check for setpoints at inputs 29 2 29 3 and 29 4...

Page 147: ...ectrovalve YV6 and YV7 Setpoint Output 26 3 and 25 3 Forward 6 to 9V Reverse 6 to 3V END Replace the U1 electronic module See Fiche C058 or C107 The fault persists NO YES END Replace the printed circu...

Page 148: ...4 4 C NO YES END The fault persists END Replace the printed circuit See Fiche C063 Replace the U1 module See Fiche C058 or C107 Replace defective wiring har nesses no 612 606 and 611A Setpoints 29 2 e...

Page 149: ...able control panel and check that the LEDs associated with electovalves YV9 and YV13 are off All the LEDs are off NO YES Place switch SA3 in the differential blocked position Press the pedal and make...

Page 150: ...question YV9 and YV13 Open the turntable control panel Press the pedal and make a forward travel movement Check for 12V voltage at the terminals of the printed circuit associated with the electrovalve...

Page 151: ...setpoint at the output of switch SA3 807 C NO YES END Replace switch SA3 See Fiche C044 Open the turntable control panel Maintain the pedal and switch SA3 activated Check for 12V voltage on terminal...

Page 152: ......

Page 153: ...vel movement Activate the FRONT steering switch SA12 Check that the LED associated with electrovalve YV22A left or YV22B right is on LED on NO YES C B Place the key switch in the platform position Put...

Page 154: ...K Replace the PVG YV2 control head END Open the turntable control panel Press the pedal and make a travel movement Activate the FRONT steering switch SA12 and check for 12V voltage on terminal 305 of...

Page 155: ...s Open the turntable control panel Press the pedal and make a travel movement activate the FRONT steering switch SA12 and check for 12V voltage on terminals 304 left and 306 right of the printed circu...

Page 156: ...che C043 END Repair wiring END Open the platform control panel and check the wiring of the FRONT steering switch SA12 NO YES Wiring OK Check the electric continuity of the switch contacts when closed...

Page 157: ...avel movement Activate the REAR steering switch SM4 Check that the LED associated with electrovalve YV21A left or YV21B right is on LED on NO YES C B Place the key switch in the platform position Put...

Page 158: ...K Replace the PVG YV2 control head END Open the turntable control panel Press the pedal and make a travel movement Activate the REAR steering switch SM4 and check for 12V voltage on terminal 305 of th...

Page 159: ...Open the turntable control panel Press the pedal and make a travel movement activate the REAR steering switch SM4 and check for 12V voltage on terminals 307 left and 308 right of the printed circuit...

Page 160: ...iche C043 END Repair wiring END Open the platform control panel and check the wiring of the REAR steering switch SM4 NO YES Wiring OK Check the electric continuity of the switch contacts when closed N...

Page 161: ...s activated Diesel OK Check the level of diesel in the tank NO YES END Fill the diesel tank Open the turntable control panel and check the state of fuse FU1 Fuse OK NO YES Check the diesel supply circ...

Page 162: ...OK A NO B YES E Check the continuity of wiring harnesses no 115A and 115B Setpoint SQ7 0V and SQ8 0V NO E YES C Check the setpoint at the outputs of detectors SQ7 and SQ8 Continuity of harnesses 115A...

Page 163: ...wiring harness between relay KP1 turntable box terminal 115 and the solenoid of the motor stop YA1 Continuity OK NO Replace the motor stop solenoid YA1 END Replace the defective wiring harness END B...

Page 164: ...BREAKDOWN DETECTION FLOW CHART Folio 4 4 Sheet DP066 THE MOTOR DOES NOT START THE STARTER IS ACTIVATED...

Page 165: ...in the platform position Press the pedal and activate the basket rotation switch on the platform control panel NO YES A Stop the movement and release the pedal Open the turntable control panel and ch...

Page 166: ...o 115A 218A and 218B Setpoint SQ7 12V SQ10 0V SQ11 0V NO F YES A Check the setpoint at the output of detectors SQ7 SQ10 and SQ11 Harness continuity OK YES NO Replace the defective wiring harness es EN...

Page 167: ...ector NO YES 12V OK Replace the PVG YV2 control head END Open the turntable control panel Press the pedal and activate the telescope switch and check for 12V voltage at terminal 415 of the printed cir...

Page 168: ...original positions D E NO YES 12V OK Open the turntable control panel Press the pedal and activate the telescope switch and check for 12V voltage at terminals 414A in or 417A out of the printed circui...

Page 169: ...panel and check the wiring of the telescope switch SA9 or SA8 NO YES Wiring OK Check the electric continuity of the switch contacts when closed NO YES Continuity OK Repair the connection or replace th...

Page 170: ...RT Sheet DP067 NO TELESCOPING MOVEMENT OUT AND OR IN FROM THE PLATFORM OR TURNTABLE CONTROL PANEL E Replace the pressure limiter See Fiche C081 NO YES The fault persists Replace electrovalve YV14 See...

Page 171: ...he key switch in the platform position Open the platform control panel Tilt the boom lifting manipulator SM31 as far as possible Check for 0 5V or 4 5V voltage depending on movement direction on termi...

Page 172: ...sses no 115A 115B and 218B Setpoint SQ7 0V SQ8 12V SQ11 0V NO C YES A Check the setpoint at the output of detectors SQ7 SQ8 and SQ11 Harness continuity OK YES NO Replace the defective harness es END C...

Page 173: ...ment OK NO YES Activate the lifting switch SA13 of the turntable control panel and check for 3V or 9V voltage depending on movement direction on the connector of electrovalve YV3 B C NO YES Voltage OK...

Page 174: ...vate the rotation movement in the emergency mode Put the emergency lever into place or activate the emergency unit on the manual control of the rota tion distributor YV5 Activate the lever right left...

Page 175: ...with electovalves YV8 YV10 and YV12 are off All LEDs are off NO YES Place the key switch in the platform position Place the speed selector in the high speed position Press the pedal and make a forwar...

Page 176: ...t the terminals of the connector of the electrovalve concerned YV10 and YV12 Open the turntable control panel Press the pedal and make a forward travel movement Check for 12V on the terminals of the p...

Page 177: ...r 12V voltage at the terminals of the electrovalve YV10 connector Open the turntable control panel Press the pedal and make a forward travel movement Check for 12V voltage on terminal 814A of the prin...

Page 178: ...ntrol panel Check for 12V at terminal 805 12V OK YES F Replace harness 805 NO YES END Replace the U1 module The fault persists YES NO END Place the speed selector SA11 on high speed Check the setpoint...

Page 179: ...on END Check the setpoint at the output of detectors SQ9 SQ4 SQ2 Setpoint 12 V NO YES Check the continuity of harnesses no 204 232 206 Harness no 204 232 206 continuity OK Replace the defective harnes...

Page 180: ......

Page 181: ...ins available on the machine regardless of the speed selected Check that the machine is folded SQ2 1 SQ9 1 and SQ4 1 NO YES END Fold the machine Check the setpoint at the output of detectors SQ2 SQ9 a...

Page 182: ...ETECTION FLOW CHART Sheet DP071 ONLY TRAVEL MICRO SPEED REMAINS AVAILABLE ON THE MACHINE REGARDLESS OF THE SPEED SELECTED The fault persists NO YES END A Replace the printed circuit See Fiche C063 END...

Page 183: ...g the u1 electronic module SHEET C059 Changing a coil SHEET C062 Changing a relay SHEET C063 Changing the printed circuit SHEET C064 Changing the fail safe pedal SHEET C067 Changing an electrovalve SH...

Page 184: ...g the slew ring SHEET C108 Changing a control unit of the distribution block SHEET C109 Changing the emergency electropump unit SHEET C114 Changing the emergency hydraulic circuit pressure limiter SHE...

Page 185: ...corresponding paragraph Close the shut off valve if any if not empty the hydraulic tank 2 Removing a hose Disconnect the hose from the equipment to which it is connected NB Unscrew the hose slowly to...

Page 186: ......

Page 187: ...raph Switch off electric power see corresponding paragraph 5 Removing a wheel Unblock without completely unscrewing the fixing screws 1 of the wheel to be removed Raise the machine using a jack or hoi...

Page 188: ......

Page 189: ...en the upper chassis cover Mark and disconnect the two hoses 2 of the steering cylinder 1 NB Unscrew the hoses slowly to release residual hydraulic pressure Put caps on the hoses Put the cylinder in s...

Page 190: ......

Page 191: ...lt sensor Remove the tilt sensor 2 by unscrewing the fixing bolts 1 3 Installing the tilt sensor Put a new tilt sensor into place and fix using the fixing bolts 1 Reconnect the electric connections ac...

Page 192: ......

Page 193: ...ections 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...

Page 194: ......

Page 195: ...raph 2 Removing the buzzer Mark and disconnect the buzzer s electric connections 1 Remove the buzzer by unscrewing the fixing bolts 2 3 Installing the buzzer Put the buzzer back into place and fix wit...

Page 196: ......

Page 197: ...nnections 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 pane...

Page 198: ......

Page 199: ...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...

Page 200: ......

Page 201: ...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...

Page 202: ......

Page 203: ...nals 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 f...

Page 204: ......

Page 205: ...h Switch off electric power see corresponding paragraph 2 Removing a gas spring Open the cover 1 concerned Put the cover in slings Remove the fixing nuts and washers 2 at both ends of the gas spring 3...

Page 206: ......

Page 207: ...the flow limiters 1 by unscrewing the unions 5 and adapters 6 Remove the hydraulic motor by unscrewing its fixing screws 3 3 Installing the hydraulic motor Replace the flow limiters if necessary Put a...

Page 208: ......

Page 209: ...etain 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 plat...

Page 210: ...k into place and fix using its fixing bolts equipped with new toothed washers Reconnect the then terminals of the starter battery Put the machine back into the operational configuration Adjust the wei...

Page 211: ...CORRECTIVE MAINTENANCE SHEET CHANGING THE BASKET Sheet C053 X 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 Figure 3 Folio 3 3...

Page 212: ......

Page 213: ...s 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 Put new rolling elements on the bearing track Bloc...

Page 214: ......

Page 215: ...the hydraulic filter hoses 1 NB Unscrew the hoses slowly to release residual hydraulic pressure Fit caps to the hoses Unscrew the fixing screws 2 and remove the hydraulic filter Remove the two connect...

Page 216: ...CORRECTIVE MAINTENANCE SHEET...

Page 217: ...odule previously programmed by the manu facturer Install the fixing flange Close the electric box Reconnect the then terminals of the starter battery Put the machine back into the operational configur...

Page 218: ......

Page 219: ...ponding paragraph 2 Removing a coil Disconnect the electric connector 2 from the coil concerned Unscrew the nut 3 and remove the coil 1 3 Installing a coil Put a new coil into place 1 and fix with the...

Page 220: ......

Page 221: ...y 2 Removing a relay Open the turntable electric box Mark and disconnect the electric connections 1 of the relay 2 Remove the relay by removing the fixing bolt 3 3 Installing a relay Put a new relay i...

Page 222: ......

Page 223: ...lts 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 Put a new printed circuit into plac...

Page 224: ......

Page 225: ...ling 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 Put a new ped...

Page 226: ......

Page 227: ...e 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 i...

Page 228: ......

Page 229: ...move the unit s 4 unions 2 Remove the unit 1 by unscrewing the 2 fixing bolts 4 3 Installing a double balancing valve Put a new unit into place and fix with the two bolts equipped with new too thed wa...

Page 230: ......

Page 231: ...ut the jib cylinder 1 and vertical elements 2 and 3 into slings Remove the four bolts and pin stop rings 5 fixing the platform assembly 4 Remove the two M canindus pins blocking the pins 5 Remove the...

Page 232: ...two articula tion pins Block the pins with new M canindus pins Install the four pin stop rings and fix using their fixing bolts Pass the hydraulic hoses and electric cables along the jib according to...

Page 233: ...g 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...

Page 234: ......

Page 235: ...intenance configuration see corresponding paragraph Switch off electric power see corresponding paragraph 2 Removing a balancing valve Remove the balancing valve 1 by unscrewing it 3 Installing a bala...

Page 236: ......

Page 237: ...ixing screws 2 then take out the electrovalve 3 balan ging valve 4 double flow limiter 1 assembly Remove the double flow limiter 1 3 Installing the double flow limiter Replace the seals and put into p...

Page 238: ......

Page 239: ...corresponding paragraph Switch off electric power see corresponding paragraph 2 Removing a non return valve Remove the non return valve 1 by unscrewing it 3 Installing a non return valve Screw a new n...

Page 240: ......

Page 241: ...1 4 Installing a pivot Put the steering pivot into place Replace pins lubricators and support washers if necessary Put back the support washers and pivot pins and block using new M ca nindus pins Put...

Page 242: ...CORRECTIVE MAINTENANCE SHEET Folio 2 2 CHANGING A STEERING PIVOT ON A NON DRIVE WHEEL Sheet C085 2 3 5 4 6 7 A A 8 9 1 13 12 11 10 14 16 15...

Page 243: ...rews 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 pin...

Page 244: ...CORRECTIVE MAINTENANCE SHEET Folio 2 2 DISMANTLING AND RE ASSEMBLING THE STEERING SYSTEM Sheet C086 A A A 1 2 3 10 11 6 4 5 8 9 12 B B B B A 14 13...

Page 245: ...nd disconnect the two hoses 2 of the steering cylinder 1 NB Unscrew the hoses slowly to release residual hydraulic pressure Put caps on the hoses Put the cylinder in slings Remove the Nylstop nuts 4 t...

Page 246: ......

Page 247: ...7 Discard the O rings 13 Installing the hydraulic pump Equip the unions with new O rings Screw the hydraulic unions on the pump Check that the circlips and spacer and in good condition and in positio...

Page 248: ...CORRECTIVE MAINTENANCE SHEET Folio 2 2 CHANGING THE HYDRAULIC PUMP Sheet C091 7 6 3 3 1 2 4 5...

Page 249: ...lic block 1 Mark and disconnect the block s hoses 4 NB Unscrew the hoses slowly to release residual hydraulic pressure Put caps on the hoses Place a wedge under the hydraulic block if necessary Remove...

Page 250: ......

Page 251: ...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...

Page 252: ......

Page 253: ...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 con...

Page 254: ......

Page 255: ...ts 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...

Page 256: ......

Page 257: ...emoving the hydraulic motor Mark and disconnect the two hoses 1 of the hydraulic motor 3 NB Unscrew the hoses slowly to release residual hydraulic pressure Put caps on the hoses Place a wedge under th...

Page 258: ......

Page 259: ...aths Mark and disconnect the hydraulic caps and hoses 1 of the swing joint 3 on the turntable and below the chassis NB Unscrew hoses slowly to release residual hydraulic pressure Put caps on the hoses...

Page 260: ...CORRECTIVE MAINTENANCE SHEET Folio 2 2 CHANGING THE SWING JOINT ASSEMBLY Sheet C100 7 4 Figure 1 3 2 3 1...

Page 261: ...5 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 3 Installing the gearing Change the rings pads and keys if necessary Put in...

Page 262: ...CORRECTIVE MAINTENANCE SHEET Folio 2 2 CHANGING THE BASKET ROTATION GEARING Sheet C104 14 12 11 13 17 16 21 20 7 10 8 15 5 4 19 18 9 2 3 6 1 A A...

Page 263: ...4 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...

Page 264: ...cturer Make several turntable rotation steering and travel movements using all possible travel speeds to purge the hydraulic circuit Check that the electric controls work properly Check the level of t...

Page 265: ...CORRECTIVE MAINTENANCE SHEET Folio 3 3 CHANGING THE SLEW RING Sheet C106 12 13 11...

Page 266: ......

Page 267: ...ark and disconnect the electric connections 2 of the coil 1 Remove the coil by removing the fixing screws 4 Discard the O rings 3 3 Installing the coil Replace the O rings Put back the coil and fix us...

Page 268: ......

Page 269: ...e 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...

Page 270: ......

Page 271: ...ly to release residual hydraulic pressure Put a cap on the hose Remove the pressure limiter 2 by unscrewing the adapter 3 Retain the pressure limiter s union and adapter 17 Installing the emergency ci...

Page 272: ......

Page 273: ...pin stop rings from the cylinder pin 4 on the cylinder body side Remove the pin 4 Remove the pin stop clevis from the cylinder pin 5 on the rod side Remove the pin 5 Remove the jib cylinder 1 3 Instal...

Page 274: ...CORRECTIVE MAINTENANCE SHEET Folio 2 2 CHANGING THE JIB CYLINDER Sheet C115 2 4 3 5 1...

Page 275: ...s 3 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 poss...

Page 276: ...CORRECTIVE MAINTENANCE SHEET Folio 2 2 CHANGING THE TURNTABLE ROTATION REDUCING GEAR Sheet C117 4 2 5 3 1...

Page 277: ...over 1 Put the cover in slings Remove the gas springs see corresponding sheet Remove the screws 3 fixing the cover 1 to the two hinges 2 Remove the cover 3 Installing a cover Put a new cover into plac...

Page 278: ......

Page 279: ...moving the thermal motor Put the motor in slings according to the instructions in the motor manufac turer s manual Remove the motor s 4 fixing screws 10 and remove the motor 6 Installing the thermal m...

Page 280: ...s Reconnect the then terminals of the starter battery Put the machine back in the operational configuration If the motor installed is new follow the first commissioning instructions see motor manufact...

Page 281: ...the vehicle lift Switch off electric power see corresponding paragraph 2 Removing the small counterweight HA26 HA80 Remove the fixing screws 2 on the small counterweight Remove the small counterweigh...

Page 282: ...CORRECTIVE MAINTENANCE SHEET CHANGING THE COUNTERWEIGHTS Sheet C134...

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Pinguely-Haulotte HA20PX, Repair Manual

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