haulotte ha15dx operating instructions maintenance.pdf

7/25/2019 Haulotte HA15DX Operating Instructions Maintenance.pdf

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La Pronnire BP9 42152 LHORME France(04 77 29 24 24 704 77 31 28 11

E.Mail: [email protected] Web: http://www.haulotte.com

OPERATING AND MAINTENANCE

INSTRUCTIONS

SELF-PROPELLED ACCESS PLATFORMS

HA15D - HA15DX

Code:01202420314310

Issue:02-00


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Pinguely - Haulotte Operation and maintenance HA15D / HA15DX

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You have just taken delivery of your PINGUELY-HAULOTTE self-propelled access platform.

It will give you complete satisfaction if you follow the operating and maintenance instructions exactly.

The purpose of this instruction manual is to help you in this.

We stress the importance:

of complying with the safety instructions relating to the machine itself, its use and its environment,

of using it within the limits of its performances,

of proper maintenance upon which its service life depends.

During and beyond the warranty period, our After-Sales Department is at your disposal for any service you might

need.

Contact in this case our Local Agent or our Factory After-Sales Department, specifying the exact type of machineand its serial number.

When ordering consumables or spares, use this manual together with the Spares catalogue so as to receiveoriginal parts, the only guarantee of interchangeability and perfect operation.

IMPORTANT :

This instruction manual is supplied with the machine and is included on the delivery note.

You are remin ded that our m achines comp ly with th e provisio ns of the Machines Directive 89/392/EEC of

Jun e 14th1989 as amended b y th e directives 91/368/EEC of J une 21

st1991, 93/44/CEE of June 14th 1993,

93/68/CEE of Jul y 22nd1993 and 89/336/EEC of May 3

rd1989.

ACCESS PLATFORM HA15D / HA15DX

Ref. : 01202420314310

Issue E 02-00

The technical data contained in this manual cannot involve our responsibility and we reserve the right to proceedwith improvements or modifications without amending this manual.


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Operation and maintenance HA15D / HA15DX Pinguely - Haulotte

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CONTENTS

1. GENERAL RECOMMENDATIONS SAFETY 5

1.1 GENERAL WARNING .............................................................................................................................51.2 GENERAL SAFETY INSTRUCTIONS.....................................................................................................6

1.3 RESIDUAL RISKS ...................................................................................................................................71.4 OPERATING LIMITS ...............................................................................................................................71.5 VERIFICATIONS .....................................................................................................................................8

1.5.1 Routine verifications...........................................................................................................................81.5.2 Examination of suitability of a machine..............................................................................................81.5.3 State of conservation .........................................................................................................................8

1.6 REPAIRS AND ADJUSTMENTS.............................................................................................................81.7 VERIFICATIONS AT THE TIME OF PUTTING BACK INTO SERVICE..................................................8

2. PRESENTATION 9

2.1 IDENTIFICATION ....................................................................................................................................92.2 MAIN COMPONENTS ...........................................................................................................................102.3 WORK SPACE.......................................................................................................................................11

2.4 TECHNICAL CHARACTERISTICS........................................................................................................122.5 OVERALL DIMENSIONS.......................................................................................................................13

3. OPERATING PRINCIPLE. 14

3.1 HYDRAULIC CIRCUIT...........................................................................................................................143.1.1 Travel, turret rotation, arm lifting, boom raising, boom telescoping, platform compensation

movements .......................................................................................................................................143.1.2 Direction movement. ........................................................................................................................143.1.3 Telescoping, boom raising, arm lifting cylinders. .............................................................................143.1.4 Turret rotation ..................................................................................................................................143.1.5 Platform compensation ....................................................................................................................143.1.6 Brake release of the wheel reducers when travelling ......................................................................143.1.7 Travel ...............................................................................................................................................15

3.1.8 Manual emergency and back-up system .........................................................................................153.2 ELECTRICAL CIRCUIT. ........................................................................................................................16

3.2.1 Automatic engine stop. ....................................................................................................................163.2.2 Platform load monitor.......................................................................................................................163.2.3 5 angle monitor...............................................................................................................................163.2.4 High travel speed. ............................................................................................................................163.2.5 Hour counter: ...................................................................................................................................16

4. USING THE MACHINE 17

4.1 OPERATING SAFETY DEVICES ..........................................................................................................174.1.1 Movement (control from the platform post)....................................................................................174.1.2 Emergency or recovery procedure ..................................................................................................17

4.2 OFFLOADING LOADING MOVEMENT PRECAUTIONS. ...........................................................18

4.2.1 Offloading by lifting ..........................................................................................................................184.2.2 Offloading with ramps ......................................................................................................................184.2.3 Loading ............................................................................................................................................194.2.4 Travel ...............................................................................................................................................194.2.5 Filling the fuel tank ...........................................................................................................................19

4.3 OPERATIONS BEFORE FIRST PUTTING INTO SERVICE.................................................................204.3.1 Turret control post: (photos 1 - 2) ..................................................................................................204.3.2 Platform control post: (photo 3) .....................................................................................................214.3.3 Checks before using the machine....................................................................................................21

4.4 PUTTING INTO SERVICE.....................................................................................................................234.4.1 Operations from the ground.............................................................................................................234.4.2 Operations from the platform: (photo 3)...........................................................................................23

4.5 EMERGENCY AND BACK-UP OPERATIONS......................................................................................254.5.1 Emergency assistance with the hand pump: (photo 8) ....................................................................254.5.2 Back-up : (photo 1) ..........................................................................................................................25

4.6 UNCOUPLING.......................................................................................................................................25


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5. MAINTENANCE. 26

GENERAL RECOMMENDATIONS.....................................................................................................................265.2 MAINTENANCE SCHEDULE. ...............................................................................................................265.3 OPERATIONS .......................................................................................................................................28

5.3.1 Summary table.................................................................................................................................285.3.2 Procedure ........................................................................................................................................295.3.3 List of consumables .........................................................................................................................30

6. OPERATING FAULTS. 31

6.1 FAULT LOCATION TABLE....................................................................................................................31

7. SAFETY SYSTEM 33

7.1 FUNCTIONS OF THE TURRET CABINET FUSES AND RELAYS (SEE ELECTRICAL DIAGRAM) ............337.2 FUNCTIONS OF THE LIMIT SWITCH AND SAFETY SWITCHES ......................................................34

8. HYDRAULIC DIAGRAM 35

9. ELECTRICAL DIAGRAM 37

9.1 SHEET 1. .................................................................................................................................................379.2 SHEET 2. .................................................................................................................................................389.3 SHEET 3. .................................................................................................................................................39

9.4 SHEET 4. .................................................................................................................................................409.5 SHEET 5. .................................................................................................................................................419.6 SHEET 6. .................................................................................................................................................429.7 NOMENCLATURE 1. ..................................................................................................................................439.8 NOMENCLATURE 2 ...................................................................................................................................449.9 NOMENCLATURE.3 ...................................................................................................................................459.10 NOMENCLATURE.4 ...................................................................................................................................46

LABELS 47

10.1 PICTURES.............................................................................................................................................4710.2 TABLE OF DESIGNATIONS. ................................................................................................................50


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1 . GEN ERAL RECOM MENDAT ION S SAFET Y

1.1 GENERAL WARNING

The purpose of this manual is to help the operator to get to know HAULOTTE self-propelled access platforms so asto use them efficiently and SAFELY. It cannot, however, replace the basic training necessary for any user of siteplant.

The head of establishment has an obligation to ensure that operators know the instructions in the instructionmanual.

The head of establishment is responsible for the implementation of the user regulations in force in the country ofuse.

Before using the machine, it is essential for safe use of the platform and its efficiency to familiarise yourself with allthese instructions.

This instruction manual must be kept available to any operator. Additional copies can be supplied by themanufacturer on request.

Similarly, familiarise yourself with the instructions on the plates fixed on the machine and keep them legible.

Ensure that any person to whom you entrust the machine is capable of assuming the safety requirements of its use.

Protect your machine from any unsupervised intervention when it is not in use.

Never use a machine which is defective or which is not apparently in good condition (cracks, hydraulic leaks, cutwires, etc.).

Never apply to the machine a load or force greater than the maximum operating load. Do not overload.

Never use the machine for an operation for which it is not designed.

Avoid any working mode liable to jeopardise safety.

Any use not compliant with the instructions could lead to risks and injury to people and damage to property.

Do not modify the machines characteristics or carry out modifications; they could reduce the machines safety andstability level.

The operating manual must be kept by the user throughout the machines life including in the event of loan, hiring-out or re-sale.

Make sure that all the plates relating to safety and danger are complete and legible.

Only tra ined operators can use

HAULOTTE HA15D self-propelled access platfo rms .

THERE MUST BE AT LEAST TWO OPERATORS SO THAT ONE OF THEM CAN:

Intervene quickly if necessary.

Take the controls in the event of an accident or breakdown.

Monitor and prevent machines and pedestrians going round the platform.

Guide the platforms operator if required.These people must be over 18 and must hold an operating permit issued by the employer after he has checkedtheir medical fitness and after they have passed a practical platform driving/operating test.


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1.2 GENERAL SAFETY INSTRUCTIONS.

To att ract at tent ion, the instruct ions w i l l be preceded by this standard mark.

Operators must:

Wear individual protective equipment suited to the working conditions and local regulations in force,

particularly when working in a dangerous area. Never use the machine:

on soft, unstable, cluttered ground with a tilt greater than 5

with exposure to a wind greater than 45 kph. If used outside, make sure, using an anemometer, that the windspeed is not greater than 45 kph.

near power lines (find out the minimum distances depending on the voltage)

without fitting the platforms protective bar or without closing the safety gate

with a cluttered platform

with equipment or objects suspended from the guard rails or boom

with elements which could increase the wind load (e.g.: panels)

Never use the guard rails as a means of access for getting onto and off the platform; use the steps provided forthis purpose on the machine.

Never use this machine in an explosive atmosphere. Wipe any traces of oil or grease off the steps, floor and hand rails.

Never neutralise the limit switches on the safety devices.

Avoid hitting fixed or moving obstacles.

Never increase the working height by using ladders or other accessories.

Protect the machine from any unsupervised intervention when it is not in service.

Carry out the daily checks and monitor proper operation during periods of use.

Never :

operate the control levers for one direction in the opposite direction without stopping in the 0 position

exceed the maximum load or the number of people authorised on the platform (230 kg including 2 people).Distribute the loads and place them if possible in the centre of the platform.

carry out machine maintenance operations when it is raised without having put in place the necessary safety

devices (travelling crane, crane). climb onto the guard rails when the platform is in the raised position: risk of a serious fall.

Hold:

the guard rails firmly when the platform is being raised or driven.

Avoid :

hitting fixed or moving obstacles.

driving the platform at high speed in areas which are narrow or not cleared.

travelling in reverse (lack of visibility).

towing the platform. It was not designed for that. It must be transported on a trailer.

climbing onto the covers.

Allow a sufficient stopping distance: 3 metres at high speed and 1 metre at low speed.

In order to stop when travelling, gradually move the operating lever to the zero position, keeping your foot on the

pedal. In normal use, that is operation from platform, the turret or platform post selection key must be removed and kept

on the ground by a person present and trained in emergency/back-up operations.

Never use the platform as a crane, goods lif t o r li f t .

Never use the plat form to pul l or to w.

Never use the boom as a ram or pus her, or to l i f t the wheels

Never remove or m odify any part , accessory or

com ponent of the machine w ithout our p r ior agreement.

For any repair, use on ly origin al spares,

the guarantee of proper operation.


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IMPORTANT

I f the machin e has a 220 V pow er point, MAXIMUM 16 A

i t is essent ial for the extension lead to be connected to a mains out let protected by a 30 mA

quic k-tr ip circuit-breaker.

1.3 RESIDUAL RISKS

Sudden operation of the control levers: risk of jolting and rocking. Overload: risk of overturning (beware of overloads at the top).

Ground weakness: risk of overturning (see page 11 Ground pressure and load perwheel). Beware of thawing in winter.

Gusting wind: risk of overturning (use in wind not greater than 45 kph).

Hitting an obstacle on the ground or high up: risk of impact or overturning.

Hitting a power line: electrical risk.

Working on quays, bays, pavements, etc.: risk of overturning.

Working in an explosive atmosphere: risk of explosion.

People in the area in which the machine is being used (when the equipment istravelling or being operated): risk of crushing.

Evaluation by the operator, before using the machine, of the risks above him.

Hot engine parts: risk of burns.

CAUTION :

The dir ectio n o f trav el can b e inv erted after a 180tur ret

rotat ion. Take accoun t of the colo ur of the arrows on the ch assis

in relat ion to the direction of travel (green=forw ard, red=backw ards)

1.4 OPERATING LIMITS

Do not use the machine:

with a load greater than 230 kg,

with more than two people in the platform,

on ground not suitable for the pressure and load per wheel, on a slope or tilt greater than 5, ( 9%)

with a platform lateral force greater than 400 N,

in a wind greater than 45 kph,

in cold stores,

in an explosive atmosphere,

in an area not properly ventilated, since the exhaust gases are toxic.

during storms (risk of lightning),

at night if it is not equipped with the optional light.

when there are very strong electromagnetic fields (radar, mobiles and highcurrents).

Do not travel on public highways.


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1.5 VERIFICATIONS

Comply with the national regulations in force in the country of use. For FRANCE: Order of June 9th1993 + circular

DRT 93-22 September 1993 specifying:

1.5.1 Routine verifications

The machine must be the subject of routine inspections every 6 months so that any defect liable to cause anaccident is detected.

These inspections must be carried out by an organisation or personnel specially designated by the head ofestablishment and under the latters responsibility (companys personnel or not) Articles R 233-5 and R 233-11 ofthe Code du Travail.

The result of these inspections must be entered in a safety register opened by the head of establishment and keptconstantly available to the works inspector and safety committee of the establishment, if there is one, as well as alist of the specially designated personnel (Article R 233-5 of the Code du Travail).

NOTE : Such registers can be obtained from the trade organisations and some of them can be obtained from theOPPBTP or private prevention organisations.

The people designated must be experienced in the field of risk prevention (Articles R 233-11 of Decree n 93-41).

It is forbidden to allow any worker to proceed, during the operation of the machine, with any verification whatsoever(Article R 233-11 of the Code du Travail).

1.5.2 Examination of suitability of a machine

The head of the establishment in which this equipment is put into service must make sure of the suitability of themachine, that is, that it is appropriate for the works to be carried out safely and that it is used in accordance with theinstruction manual.

In addition, in the above-mentioned French order of June 9th 1993, problems associated with hiring, the

examination of the state of conservation, verification at the time of putting back into service after repair, as well ascoefficient 1.25 static test and coefficient 1.1 dynamic test conditions are mentioned. Each person responsibleusing the machine must acquaint himself and follow the requirements of this decree.

1.5.3 State of conservation

Detect any damage liable to be the cause of dangerous situations (safety devices, load limiters, tilt monitor, leaksfrom cylinders, deformation, condition of welds, tightness of bolts, hoses, electrical connections, condition of tyres,

excessive mechanical play.NOTE : In the case of hiring, the person responsible using the hired machine has the responsibility of examiningthe state of conservation and for examining suitability. He must check with the hirer that the routine generalverifications and verifications before putting into service have indeed been carried out.

1.6 REPAIRS AND ADJUSTMENTS

Major repairs, maintenance work or adjustments on the safety elements or systems (concerns mechanics,hydraulics and electricity).

These must be carried out by PINGUELY-HAULOTTE personnel or personnel working on behalf of PINGUELY-HAULOTTE who must use original parts only. Any modification outside PINGUELY-HAULOTTEs control is notauthorised.

The manufacturer is not liable if original parts are not used or if the work specified above is not carried out byPINGUELY-HAULOTTE approved personnel.

1.7 VERIFICATIONS AT THE TIME OF PUTTING BACK INTO SERVICE

To be carried out after:

major removal/refitting,

a repair involving the machines essential parts,

any accident caused by the failure of an essential part.

It is necessary to proceed with an examination of suitability, an examination of the state of conservation, a statictest, a dynamic test (see coefficients, chapter 1.5.2).


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2 . PRESENTAT ION

The HA 15 D self-propelled access platform is designed for any high work within the limit of its characteristics (seechapters 2.3 and 2.4) and complying with all the safety instructions particular to the machine and to the locationswhere it is used.

The main operating post is in the platform. The turret operating post is an emergency or back-up post.

2.1 IDENTIFICATION

A plate, fixed on the back right of the chassis, bears all the indications (engraved) enabling the machine to beidentified.

REMINDER: Whenever requestinginformation, intervention or spares,specify the type and serial n.


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2.2 MAIN COMPONENTS

1 - Drive wheels2 - Rolling chassis.

3 - Hydraulic travel motors and reducers4 - Steered wheels5 - Platform compensation input cylinder6 - Platform

7 - Platform control panel8 - Platform support with load limiter9 - Link piece

10 - Arms lifting cylinder

11 - Bottom arm

12 - Top arm13 - Boom raising cylinder

14 - Slewing ring15 - 2-piece boom16 - Boom support17 - Heat engine and hydraulic pump

18 - Lifting and fixing lugs19 - Turret20 - Ground control panel21 - Boom telescoping cylinder

22 - Direction/steering


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2.3 WORK SPACE


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2.4 TECHNICAL CHARACTERISTICS.

DESIGNATIONS HA15D HA 15DX

Charge 230 kg including 2 people

Maximum lateral manual force 400 N

Max. wind speed 45 kph

Floor height 13.20 m

Working height 15.20 m

Overall length 5.52 m

Overall width 2.05 m

Overall height 2.40 m

Wheelbase 1.90 m

Ground clearance 370 mm

Max. reach 7.50 m

Boom range -20 / +71

Telescoping (stroke) 2550 mm

Turret rotation 360

Max. force on wheel 3000 daN

Max. ground pressure:

- On soft ground- On hard ground

4 kg/cm14 kg/cm

Max. travel slope 25% 40%

Tyre sizes 10.5 x 18

Outside turning radius 4.5 m

Tilt Monitor 5 ( 9%)

Hydraulic reservoir 150 litres

Diesel tank 65 litres

Total weight 5450 kg 5600 kg

Number of drive wheels 2 4

Number of steered wheels 2

Differential lock YESHydraulic brakes YES

Freewheeling YES

Wheel nut tightening torque 320 m.N

Vibration level at feet < 0.5 m/s

Vibration level at hands < 2.5 m/s

Operating post sound level 78 dB(A)

Hatz Silent-pack 2L41C diesel engine- Power output

- Idling

32.6 HP / 24 kW at 2400 rpm.

1250 rpm.

22.8 + 8 cm3/rev hydraulic pump

- Travel and movements

- Steering

52 l/min.

18 l/min.Hydraulic pressure- General- Travel- Steering- Slewing

- Equipment

210 bar210 bar100 bar75 bar

210 bar

Travel speed(proportional)

LS : 0.8 kphHS : 4.6 kph

LS : 0.8 kph

IS : 2.3 kphHS : 4.6 kph

Starting battery 12 V - 95 Ah

Supply voltage 12 V


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2.5 OVERALL DIMENSIONS


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3 . OPERAT IN G PR INC IPLE .

3.1 HYDRAULIC CIRCUIT.

See hydraulic diagrams:

HA15D B 15361

HA15DX B 15362

All the machines movements are provided by hydraulic power.

This is supplied by a gear pump driven by a heat engine.

In the event of a breakdown, a manual back-up pump permits lowering of the arms and boom, retraction of thetelescope, compensation and slewing of the turret.

A high pressure filter mounted on the pumps delivery protects the installation from pollution.

3.1.1 Travel, turret rotation, arm lifting, boom raising, boom telescoping, platform compensation

movements

These are controlled by shuttle valves via a proportional control valve which gives progressiveness of movement.A single movement at a time is possible.

3.1.2 Direction movement.

This is controlled by a solenoid-operated shuttle valve supplied by the small pump body.

3.1.3 Telescoping, boom raising, arm lifting cylinders.

These are equipped with balancing valves, leakproof and flanged on their bodies.

IMPORTANT :

Adjustm ent can only b e carr ied out by sp ecial ist personnel .

Disturbing the set t ings may cause the machines safety devices not to w ork, and co nsequent ly

r isks o f ser ious accidents.

3.1.4 Turret rotation

This is provided by a ring and reducer assembly, driven by a hydraulic motor.

3.1.5 Platform compensation

This works by oil transfer between 2 cylinders with similar characteristics.

The compensation input cylinder is equipped with a flanged double piloted valve.

The manual compensation speed is controlled by a limitation of the operating speed of the electropump specific tothis movement.

3.1.6 Brake release of the wheel reducers when travelling

Whenever a travel movement is actuated, the brake release circuit for the reducers mounted on the fixed axle ispressurised.

As soon as the movement stops, or if there is a lack of pressure, the brake is applied again.


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3.1.7 Travel

3.1.7.1 4 x 2 version.

Two hydraulic motors drive the wheels on the fixed axle via epicyclic reducers.

Two speeds (high, low) are controlled by a switch.

High speed 4 x 2: The 2 motors are supplied in series, they receive the pumps flow which goes into one

motor and then the other. Low speed 4 x 2: The 2 motors are supplied in parallel, each receives half of the pumps flow.

3.1.7.2 4 x 4 version.

Four hydraulic motors drive the wheels via epicyclic reducers.Three speeds (high, intermediate, low) are controlled by a switch.

High speed - 4 x 4 : The fixed axles 2 motors are supplied in series, the steered axle is in freewheel.

Intermediate speed - 4 x 4 : The fixed axles 2 motors are supplied in parallel, the steered axle is in freewheel.

Low speed - 4 x 4 : Each axle receives half of the flow supplied by the pump. On each axle the motors aresupplied in parallel.

One hydraulic differential lock per axle is useable in low and intermediate speed.3.1.8 Manual emergency and back-up system

In the event of a breakdown preventing:

use of the pump,

operation of the movements,

it is possible to carry out these movements from the ground, by means of a hand pump. At the same time as theuse of the back-up pump, it is necessary to operate manually the corresponding solenoid valve in order to carry outthe arms down, boom down, telescope retraction and turret slewing and platform compensation movements.


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3.2 ELECTRICAL CIRCUIT.

The electrical energy used for the controls and for starting the heat engine is supplied by a 12 V battery. Details ofthe main safety devices:

3.2.1 Automatic engine stop.

In the event of:

oil pressure too low

clogging of the air filter braking of the fan or alternator belt

3.2.2 Platform load monitor.

If the platform load reaches 90% of the maximum permitted load, the buzzer alerts the operator.

When this maximum load is reached, the control circuit is cut, preventing all movements. It is necessary to shedsome load in order to reset the unit.

3.2.3 5 angle monitor.

The tilt monitor box gives an audible signal when the maximum permissible angle is reached.

If this situation persists, after a time delay of 1 to 2 seconds, the controls of the boom raising (up), arm raising (up)and telescoping (extension) movements are cut, as well as travel so long as the machine is deployed.

In order to use travel again, it is necessary to fold all of the elevation elements.

NOTE: With the machine folded, the tilt monitor box gives an audible signal so long as the slope is greater than 5,indicating to the operator that it will be impossible to deploy the platform.

3.2.4 High travel speed.

The high and intermediate travel speeds (4 x 4 model) are permitted only when the platform is completely folded.

When the boom is raised or telescoped or the arms deployed, only low speed is possible.

3.2.5 Hour counter:

An hour counter indicates how long the heat engine has been operating.


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4 . US I NG THE MA CH INE

4.1 OPERATING SAFETY DEVICES

For the purpose of not enabling the machine to be used beyond its possibilities, safety devices are provided toprotect the personnel and the machine.

They immobilise the machine or neutralise the movements.

In this case poor knowledge of the characteristics and operation of the machine can lead one to believe that thereis a breakdown when in fact it is the safety devices which are working properly.

It is therefore essential to assimilate all the instructions in the following chapters.

IMPORTANT

Do not carry out any operat ions before having assimi lated the instruc t ions in chapter 4.4.

4.1.1 Movement (control from the platform post)

To move the machine, it is necessary to enable the dead mans safety device by keeping the movement controlmanipulators ring raised (see chapter 4.3.2).

Travel is possible up to a maximum slope of 5 (about 9%).

In order to permit movement of the machine for access to the work place, unloading or loading with slopes greaterthan 5 and 40% maximum, it is necessary to ensure that:

the arms and boom are lowered,

the telescope is completely retracted.

Otherwise the machine is immobilised.

REMINDER: The high and intermediate travel speeds (4x4 model) are only permitted if the arms are folded, theboom is down and the telescope is retracted.

4.1.2 Emergency or recovery procedure

CAUTIONIn the event of the need to proceed with an emergenc y or recov ery operation, the safety devices

being neutral ised, only a com petent o perator can carry out these operat ions.


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4.2 OFFLOADING LOADING MOVEMENT PRECAUTIONS.

IMPORTANT : Before any operation, check the condition of the machine, so as to make sure that it has not beendamaged during transport. Otherwise, make the necessary reserves with the carrier in writing.

IMPORTANT

An inc orrect operation can c ause the machine to fal l and cause very ser ious b odi ly in jury and

material damage.

Carry out the offloading operations on a stable, sufficiently resistant (see chapter 2.4 Ground pressure), flat anduncluttered surface.

4.2.1 Offloading by lifting

Use a lifting beam with 4 slings.

Precautions :Make sure that:

the lifting accessories are in good condition and have sufficient capacity.

the slinging accessories can support the load and do not have abnormal wear.

the slinging lugs are clean and in good condition.

the personnel performing the operations is authorised to use lifting equipment. Offloading :

hook the 4 slings on the 4 slinging lugs.

lift slowly, making sure that the load is evenly distributed, and set the machine down slowly.

IMPORTANT

Never stand un der or too c lose to the m achine dur ing op erat ions.

4.2.2 Offloading with ramps

Precautions :

make sure that the ramps can support the load and that adherence is sufficient to avoid any risk of slippingduring the operation and that they are correctly fixed.

IMPORTANT : Since this method requires the machine to be switched on, refer to chapter 4.4 to avoid any risk of

incorrect operation. Select low travel speed.

REMINDER: Since the slope of the ramp is practically always greater than the maximum working slope (5), it isnecessary to have the boom and the arms lowered and the telescope retracted to authorise travel. In this case, thetilt monitor box gives an audible signal but travel is possible.


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If the slope is greater than the maximum travel slope (40%): use a hoist in addition to traction.

4.2.3 Loading

The precautions are identical to the offloading precautions.Chocks must be provided in accordance with the sketch below.

In order to go up a lorrys ramps, select high speed.

4.2.4 Travel

Comply carefully with the traffic instructions or regulations where the machine is travelling.

On uneven ground, do a prior reconnaissance of the route before beginning high work.

Always keep a sufficient distance away from unstable edges or tilts.

Make sure that there is no one in the immediate vicinity of the machine before carrying out a movement ortravelling.

REMINDER: It is forbidden to travel on the public highway.

4.2.5 Filling the fuel tank

Make sure, before any filling operation, that the fuel is the one recommended and that it is stored cleanly so asnot to be polluted.

Do not pump from a drum if the latter is not decanted and never use the bottom.

Because of fire risks during tank filling, take the following precautions :

do not smoke, switch off the heat engine if it is on,

stand downwind so as not to be sprayed with fuel,

with the pumps pouring spout, touch the outside of the filling hole before beginning to fill up, so as to avoidthe risk of sparks due to static electricity,

replace the tank filler cap properly and clean off any fuel which has run outside the tank.


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4.3 OPERATIONS BEFORE FIRST PUTTING INTO SERVICE

REMINDER: Before any operation, familiarise yourself with the machine by referring to this manual, the enginesmanual, and the instructions on the various plates.

4.3.1 Turret control post: (photos 1 - 2)

1 2 3 4

11 12

8

10

7

65

9

13

1

14

15

2

1 - Engine oil pressure warning light2 - Engine temperature warning light3 - Battery charge indicator

4 - Filter clogging indicator5 - Boom telescoping control6 - Boom raising control7 - Arm lifting control

8 - Turret slewing control

9 - Revolving light control10 - Engine starting switch11 - Turret/platform control post selection

12 - Key emergency stop switch13 - Hour counter14 - 220 V single-phase 16 A power point15 - Tilt monitor box

IMPORTANT

When using a pressure washer, do not aim the jet direct ly at the electr ical equipment cabinets

and bo xes.


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4.3.2 Platform control post: (photo 3)

1

2 3 4

5

8

7

6

3

1 - Movement selector2 - Speed selector3 - Mains on warning light

4 - Engine starting switch5 - Differential lock control6 - Movement control manipulator7 - Emergency stop switch8 - Horn

4.3.3 Checks before using the machine

Make sure that the machine is on flat and stable ground which can support the weight of the machine(see chapter 2-4 Ground pressure).

Make sure that no obstacle can interfere with the following movements:

travel (machine travel)

turret slewing arm lifting

boom raising and telescoping (see chapter 2.3 WORK SPACE).

Visually inspect all of the machine: chipped paint or battery acid leaks must attract your attention.

Check that there are no bolts, nuts, connectors and hoses undone, no oil leaks, no electric conductors cut ordisconnected.

Check the arms, boom and platform: no visible damage, no signs of wear or deformation.

Check that there are no leaks and no signs of wear, impacts, scratches, rust or foreign matter on the rods of thecylinders.

Check that there are no leaks on the wheel reducers.

Hydraulic control block and pump: no leaks, components tight.

Check that the reducers are not disconnected.

Check the tightness of the wheel nuts and the tyre wear.

Check the cleanness and tightness of the battery terminals: loose terminals or corrosion cause loss of power.

Check the battery electrolyte level: the level must be about 10 mm above the plates; top up if necessary withdistilled water.

IMPORTANT

Comply with the battery manufacturer s safety instruct ions .

Check the condition of the main control panels supply cable.

Check the operation of the emergency stops.

CAUTION

These machines are not isolated and mus t not b e put into s ervice near power l ines.

Check the cleanness of the air filter: see engine manual.

Check the following levels:


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engine oil: dipstick (item 1 photo 4); if necessary top up (see engine manual).

fuel: sight glass, translucent tank (items 1 and 2 photo 5)

hydraulic oil (item 1 photo 6), if necessary top up by filling through the cap (see chapter 5.3.2).

WHEN TOPPING UP, USE THE PRODUCTS RECOMMENDED IN THE INGREDIENTS CHAPTER

Check the hydraulic oil filters clogging indicator (item 1 photo 10). If the red mark is visible, replace the filtercartridge (see chapter 5.3.2.1).

Check the operation of the tilt monitoring box (item 15 photo 1) by inclining the support plate. Beyond an angle of5 it must give an audible signal.

Turret rotation locking rod:

make sure that the turret rotation locking rod (item 1 photo 7) is removed.

1

2

4

1

2

5

1

6

1

7


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4.4 PUTTING INTO SERVICE

IMPORTANT : Putting into service must begin only when all the operations in the previous chapter have beenscrupulously carried out.

To familiarise yourself with the machine, it is necessary to do the first operations on the ground, leaving themachine in the transport position: counterweight forward, boom and arms lowered.

CAUTION :When the coun terweight is placed above the steered w heels, the travel and direct ion c ontrols

react in the oppo si te direct ion.

REMINDER: The main operating post is in the platform.

In normal use the turret operating post is an emergency or back-up post and must be used only if absolutelynecessary.

4.4.1 Operations from the ground

Close the battery breaker (item 2 photo 4).

4.4.1.1 Starting the engine: (photo 1) Make sure that the emergency stop button (item 12) is pulled out.

Put the control post selection key switch (item 11) in the ground control position (right pictogram). In this positionthe platform panels controls are overridden.

The battery charge (item 3) and engine oil pressure (item 1) warning lights are on. The air filter clogging light(item 4) is off.

Press the starting button (item 10); when the engine has started, the on lights (items 1 and 3) go off.

NOTE : If the engine does not start, switch off the ignition by pressing the emergency stop button and start theoperation again.

Check the operation of the pump and engine hour counter (item 13).

4.4.1.2 Testing the movements: (photo 1)

REMINDER: Make sure before any movement that no obstacle can interfere with the operations.

The actuation of movements automatically causes the engine to speed up.

Test the arms lifting movement in the up and then down direction (switch, item 7).

Test the boom raising movement in the up and then down direction (switch, item 6). Stop the boom downmovement when it is in the horizontal position.

Then test the turret slewing movements in both directions (switch, item 8) and the booms extension and thenretraction telescoping (switch, item 5), then lower the boom again completely.

4.4.1.3 Switching to platform control

Put the control posts key selector switch (item 11 photo 1) in the platform position (left pictogram).

Check the operation of the tilt monitoring box (item 15 photo 2).

To facilitate access to the platform basket, it is recommended that the lowered boom be telescoped.

4.4.2 Operations from the platform: (photo 3)

Get into the basket, complying with the maximum load instructions, and if necessary distributing the load over thewhole platform.

MAXIMUM LOAD: 230 kg includ ing 2 peop le.

NOTE : If you are approaching the maximum load, the buzzer must give an audible signal. If this load is exceeded,all the machines movements are cut off. It is then necessary to shed the load. There is no load restriction with thereach.


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4.4.2.1 Testing the control post

Make sure before any operation that the green light (item 3) is on. This indicates that the machine is on andthat the control posts selector switch is in the platform position.

Make sure that the emergency stop button (item 7) is unlocked.

Check the operation of the horn.

4.4.2.2 Testing the movements

To carry out a movement, it is necessary first of all to select it (item 1) and then to activate the dead mans safety

device by keeping the movement control manipulators ring (item 6) raised and then to operate this manipulator inthe required direction. The direction of movements obtained with the manipulator is indicated by a red arrow and agreen arrow.

The speed and angle of the manipulator will give progressiveness of the movement.

If the floor is not horizontal, correct the position of the platform by putting the selector switch in the manualcompensation position. Lift the ring and operate the manipulator forwards or backwards.

Test the telescoping, arms lifting, boom raising and slewing movements by putting the selector switch in turn inthe corresponding positions.In each selector switch position, raise the ring and operate the manipulator forwards or backwards.

Put the selector switch in the position corresponding to travel. Lift the ring and operate the manipulator from rightto left in order to obtain the direction movement. This function reacts all or nothing without progressiveness.

Test travel by keeping the ring lifted and by operating this time the manipulator forwards or backwards.

CAUTION :

The directio n o f travel c an be the o ther w ay ro und after a 180turret ro tation.

Take account of the colour o f the arrows on the chassis in relat ion to the direct ion of travel

(green=forwards, red=backwards ).

Test the travel speeds by operating the selector switch (item 2)

CAUTION : The high and intermediate travel speeds (4 x 4 model) are possible only if the machine is totally folded.Even slightly deployed, only the low speed is permitted.

The work can begin.


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4.5 EMERGENCY AND BACK-UP OPERATIONS.

4.5.1 Emergency assistance with the hand pump: (photo 8)

1

2

3

4

8

There is a way of carrying out movements, from theground, when the main energy source is not operatingproperly. This is a hand pump (item 1) situated next tothe hydraulic control valves on the turret.

This pump makes it possible, in combination with amanual control for the solenoid valves, to lower thearms, lower the boom, retract the telescope and slewthe turret.

Insert the lever (item 2) in the pumps housing.

Check that the pumps decompression valve (item 3)

is in the closed position. Operate the lever from top to bottom, keeping the

manual control of the solenoid valve of the requiredmovement indicated on the plate (item 4) depressed.

4.5.2 Back-up : (photo 1)

If the machine is in normal operation and the operator, on the platform, is unable to lower the platform to the ground,

an operator on the ground can do it:

Put the selection key (item 11) in the turret position. Actuate the required movements using the correspondingcontrols.

4.6 UNCOUPLING.

1

2

9

It is possible to uncouple the drive wheel reducers soas to be able to tow the machine in the event of a

breakdown.

Remove the circlip (item 1).

Turn over the centre plug (item 2) and put it backin.

Re-fit the circlip (item 1).

CAUTION :In this conf igurat ion, the machine is no longer braked. To tow the machine, i t is essent ia l to use

a r ig id bar and not to exceed 5 kph.


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5 . MA I NTENAN CE.

5.1 GENERAL RECOMMENDATIONS.

The maintenance operations indicated in this manual are given for normal conditions of use.

In difficult conditions: extreme temperatures, high humidity, polluting atmosphere, high altitude, etc., some

operations must be carried out more frequently and special precautions must be taken. Refer to the engine manualand your local PINGUELY-HAULOTTE agent.

Only qualified and competent personnel can carry out any work on the machine and they must comply with thesafety instructions relating to the protection of personnel and environmental protection.

For the engine part, refer to the instru ction s in the engine manufac turers manual.

At regular intervals, check the operation of the safety devices:

Tilt monitor (tilt > 5): buzzer + stopping of the following movements: travel, arm lifting, boom raising andtelescope extension.

Platform overload (load > 230 kg): buzzer + complete stopping of all movements

Travelling at high and intermediate speeds (4x4 model) impossible if arms lifted, boom raised or telescope

extended.

CAUTION :

do not use the machine as a welding earth.

do not weld without disconnecting the batterys (+) and (-) terminals.

do not start other vehicles with the battery connected.

5.2 MAINTENANCE SCHEDULE.

The schedule on the next page indicates the intervals, the maintenance points (parts) and the ingredients to beused.

The mark in the symbol indicates the maintenance point depending on the interval.

The symbol represents the ingredient to be used (or the operation to be carried out).

INGREDIENT SPECIFICATION SYMBOLE

Lubricants

used by

PINGUELY

HAULOTTE

ELF TOTAL

Engine oil SAE 20 WESSO

HD X 30PERFORMANCE

XC 30RUBIAS 30

Gearbox oil SAE 90ESSO

EP 80 W 90TRANSELFEP 80 W 90

TM 80W/90

Hydraulic oilAFNOR 48602

ISO VG 46BPSHF ZS 46 HYDRELFDS 46 EQUIVISZS 46

Lithium extremepressure grease

ISO - XM 2

Lead-freegrease

Grade 2 or 3ESSO

GP GREASEMULTIMOTIVE 2

MULTISEP 2

Replacement orspecial

operation

Lithium grease ENS / EP 700 Mobilux EP2


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MAINTENANCE SCHEDULE


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5.3 OPERATIONS

5.3.1 Summary table

INTERVALS OPERATIONS ITEMS

Each day or before

each putting into

service

Check the following levels:

engine oil

hydraulic oil

diesel battery

Check the cleanness of the following:

diesel pre-filter; replace it if water or impurities present

engine air filter

machine (check in particular the watertightness of the connectorsand hoses), take this opportunity to check the condition of the tyres,cables and all accessories and equipment.

Check the clogging of the hydraulic oil filter:

an indicator indicates clogging; change the cartridge when the markappears.

1

2

34

5

6

7

Every 50 hours

Engine: see engine manufacturers manual

Grease : the wheel pivot pins: 2 x 2 points

the turret slewing locking rod

Check the diesel pre-filter; replace it if water or impurities present

Check the level of the drive wheel reducers (see chapter 5.3.2.3)

2 points for 4x2 model 4 points for 4x4 modelCAUTION : After the first 50 hours:

Change the hydraulic filters cartridge (see 250 hour interval)

Drain the drive wheel reducers (see 500 hour interval)

2 points for 4x2 model 4 points for 4x4 model

Check the tightness:

of the ring screws (see 500 hour interval)

of the wheel nuts (see 250 hour interval h)

8

9

10

11

12

13

14

15

16

Every 250 hours h


Change the hydraulic filters cartridge

Grease :

the bearings of the steered wheels on the 4x2 model (remove thecap)

the slewing rings bearing race (slew during the operation) : 2 points

the slewing rings teeth (brush)

the telescopes friction parts (spatula)

Check the tightness and cleanness of the battery terminals

Check the tightness of the wheel nuts (torque = 32 mN)

17

18

19

20

21

22

23

24

Every 500 hours


Drain the drive wheel reducers and fill up again capacity : 2 x 0.7 l for 4x2 model - 4 x 0.7 l for 4x4 model

Check the tightness of the slewing ring screws (torque = 135 mN)

25

26

27

Every 1000 hours orevery year


Drain the hydraulic oil reservoir

2829

Every 2000 hours


Drain :

the hydraulic oil complete circuit and reservoir

the diesel tank and clean it

Grease the slewing reducer: 1 point

30

31

32

33

Every 3000 hours or

every 4 years

Check :

the condition of the telescopings friction pads

the condition of the electric cables and hydraulic hoses, etc.

Reminder :All these intervals must be reduced if working in difficult conditions (refer to the After-Sales Departmentif necessary).


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5.3.2 Procedure

IMPORTANT :

For filling and greasing operations, use only the lubricants recommended in the table if chapter 5.2

Collect the drained oils so as not to pollute the environment.

5.3.2.1 Hydraulic oil filter: (photo 10)

1

2

3

10

Filter with a clogging indicator.

Change the cartridge (item 2) when the cloggingmark appears in the indicator (item 1).

NOTE : Clogging must be checked when the oil ishot. When the oil is cold the mark can appear

because of the viscosity of the oil.

undo the base nut (item 3) and remove thecartridge

fit a new cartridge.

CAUTION :

Before remov al , make sure that the oi l circui t is no longer pressur ised and that the oi l is no

long er at too hig h a temp erature.

5.3.2.2 Diesel filter: (photo 11)

11

1

2

Replacing the diesel filter:

undo the base nut (1) and remove the cartridge (2)

fit a new cartridge.


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5.3.2.3 Drive wheel reducers: (photo 12)

To check the oil level and to do an oil change it is necessary to remove the wheel. To do this, immobilise themachine and raise it using a jack or a hoist.

12

2

3

1

Checking the oil level:

rotate the wheel so as to put 1 plug on ahorizontal line (item 1) and 1 plug on a verticalline in the raised position (item 2).

undo the plug (item 1) and check the levelwhich must be flush with the hole, if necessarytop up.

to do this, undo the plug (item 2) and fill untiloil runs out through the other hole (item 1).

tighten the plug or plugs.

Doing an oil change :

rotate the wheel so as to put 1 plug on ahorizontal line (item 1) and 1 plug on a verticalline in the lowered position (item 3).

undo the 2 plugs and let the oil run out.

put the wheel in the position indicated underChecking the oil level and fill up as indicatedabove.

tighten the plugs.

CAUTION :

Make sure that the machine is correct ly ch ocked, and that the l i f t ing equipment h as suf f ic ient

capaci ty and is in go od cond i t ion.

5.3.2.4 Batteries : (item 1 photo 13).

13

1

Check the cleanness and tightness of the batterysterminals regularly: loose terminals or corrosioncause loss of power.

Check the battery electrolyte level: the level mustbe about 10 mm above the plates; top up if

necessary with distilled water.

5.3.3 List of consumables

hydraulic filter cartridge

air filter element

diesel pre-filter

diesel filter engine oil filter


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6 . OPERAT ING FAULTS .

REMINDER: Complying with the machines operating and maintenance instructions will prevent the majority offaults.

However, some may occur and, before doing any work, it is essential to look in the following table (see chapter 6.1)to see if they are listed in it. Then follow the instructions.

Otherwise, it will be necessary to contact the PINGUELY-HAULOTTE agent or the factorys After-SalesDepartment.

Before diagnosing a fault, it is necessary to check that:

the fuel tank is not empty

the battery breaker is closed

the battery is correctly charged

the turrets and platforms mushroom-headed emergency stop switches are unlocked

the turret cabinets relays are correctly pushed into their holder.

6.1 FAULT LOCATION TABLE

FAULT PROBABLE CAUSES REMEDIES

Engine does notstart or stops

Battery breaker open

Diesel tank empty

Battery discharged

Fuse on printed circuit board (in electricalequipment cabinet) defective

Mushroom-headed switch depressed

Engine in safety mode: oil pressure,overheating, alternator charge, air filterclogging

Charge light bulb burnt out

Air filter clogging light on Engine safety relay defective

Bad battery cable and terminal contacts

Close the battery breaker

Fill the tank

Recharge the battery

Replace the defective fuses

Reset

See engine manufacturers manual or call inAfter-Sales Department

Change the bulb

Change the cartridge Replace the relay

Undo the terminals and clean them

Lack of pressureor power on the

pump

Air filter clogged

Engine speed too low

Oil leak on connector, hose, component

Oil filter dirty

Change the filter

Adjust the speed (see After-SalesDepartment)

Repair or replace (see After-SalesDepartment)

Replace oil filter cartridge

No movementon platform

Turret key selector switch in the wrongposition

Overload on the platform Dead mans safety device not actuated

Manipulator malfunction

Defect on the solenoid valve for themovement chosen

Lack of hydraulic oil

Tilt or slope > 5: up lifting cut-off

Put it in the platform position

Shed load Lift the manipulators ring

Replace the manipulator (see After-SalesDepartment)

Replace the solenoid valve or its coil

Check hydraulic oil level

Lower arms and boom to reset

No high speed Platform slightly deployed Lower the arms and the boom completely

No directionmovement

Lack of hydraulic oil

Dead mans safety device not actuated

Check hydraulic oil level

Raise the manipulators ring


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FAULT PROBABLE CAUSES REMEDIES

No travel, telescopeextension, arms

and boom raising,

and buzzersounding

Slope or tilt > 5 Retract first of all the telescope, lower the

arms and the boom to reset travel and

return to level ground

The turret does notrotate

The rotation locking rod is inserted in

the chassis

Pull out the rod

Hydraulic pumpnoisy

Lack of oil in the reservoir Top up

Cavitation of thehydraulic pump

Oil viscosity too high Drain the circuit and replace with therecommended oil

No adherence on adrive wheel

Insufficient load on a wheel Adjust the differential lock control

Proportionalmovements too

quick

Manipulators out of adjustment Have the manipulators adjusted by After-Sales Department technician

Suddenness oftravel movement

Ramp generator out of adjustment Have it adjusted again by After-SalesDepartment technician

Buzzer sounding

Slope or tilt > 5

Load on the platform close to cut-off

Hydraulic oil temperature too high

Return to level ground

Shed load

Allow to cool


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7. SAFETY SYSTEM

7.1 FUNCTIONS OF THE TURRET CABINET FUSES AND RELAYS (see electrical

diagram)

LIST FUNCTION

KA 1

KA 2

KA 3

KA 4

KA 5

KA 6

KA 7

KA 8

KA 9

KA 11

KA 12

KA 13

KA 15

KA 17

KA 18

KA 19

KA 20

KA 21

KA 38

KA 39

KL 1

KL 2

FU1 - 3A

FU2 - 80A

FU3 - 3A

FU4 - 3OA

FU5 - 3OA

FU6 - 1OA

FU7 - 2OA

FU8 - 1OA

Prohibits the actuation of boom up if the machines tilt is greater than 5 %

Prohibits the actuation of arms up if the machines tilt is greater than 5 %

Prohibits the actuation of telescope extension if the machines tilt is greater than 5 %

Prohibits the starting of the heat engine when it is running

Prohibits the actuation of all the movements if the machines tilt is greater than 5 %

Permits the starting of the heat engine

Permits the manual actuation of the horn HA 1

Triggers the horn HA 1 according to the temperature

Prohibits the actuation of travel if the machines tilt is greater than 5 %

Permits the actuation of forward travel

Permits the cutting of tilt

Permits the actuation of reverse travel

Prohibits change of speed when travelling

Permits the acceleration of the movements

Permits the actuation of intermediate and high speeds

Permits the actuation of high speed

(Option)

(Option)

Permits the actuation of the right/left direction solenoid valve

Permits the actuation of the right/left direction solenoid valve

Permits the actuation of low and intermediate speeds

Permits the actuation of high speed

Signalling circuit protection fuse

Pre-heating circuit protection fuse

Weighing and tilt circuit protection fuse

Movements actuation circuit protection fuse

Accelerator and travel circuit protection fuse

Horn circuit protection fuse

light and rotating light circuit protection fuse

travel pump selection circuit protection fuse


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7.2 FUNCTIONS OF THE LIMIT SWITCH AND SAFETY SWITCHES

LIST FUNCTION

QS 1

SB 1

SB 2

SQ 1

SQ 2

SQ 3

SQ 4

SQ 5

B1

B2

B3

B5

Battery cut-off

Lockable mushroom-headed emergency switch (turret)

Mushroom-headed emergency switch (platform)

Tilt unit, prohibits by a cut-off, the arms up, boom up, telescoping extension and travelmovements

Resetting of tilt, if machine folded (arms)

1stthreshold weighing safety device: buzzer.

2nd

threshold weighing safety device:- Cutting of all movements from the platform- Movement from turret very slow

Resetting of tilt, if machine folded (boom)

Air filter switch: light on if air filter clogged

Engine temperature switch: cutting of engine if temperature too high

Engine oil pressure switch: cutting of engine if pressure insufficient

Hydraulic oil temperature switch: audible warning if temperature too high


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8 . HY DRAUL IC D I AGRAM


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1 102 litre hydraulic reservoir unit

2 Fixed displacement 22.8 + 8 cm3/rev double pump

3 Pressure filter

4 Distribution block 4x4 12V S511

5 Travel block 4x4 12V S5096

6 80cm3/rev hydraulic motor

7 Hand pump kit comprising /

7a - 20 cm3 hand pump7b - Hand pump lever

8 BSPP non-return valve

9 CETOP3 5 section base

10 Closed centre 12V 4/3 solenoid valve

11 12V 4/3 AB towards T solenoid valve

12 Back-up control

13 3:1 ratio cartridge balancing valve

14 Body NG6 2 housings T11

15 Hydraulic motor according to S5033 comprising :15a - Hydraulic motor 50 cm3/rev shaft dia. = 2515b - Double pressure limiter

16 Flanged single body

17 Flanged double body

18 Flanged piloted double non-return valve

19 CETOP5 1 section base

20 Open transitory NG10 12V 4/2 solenoid valve

21 3/4 BSPP non-return valve

22 Solenoid valve in line 3/2 12V + block 3/8 BSPP

23 Flow limiter in line BSPP

A Steered axle

B Drive axle

C Turret slewing

D Boom raising

E Arms liftingF Telescoping

G Compensation

H Direction

I Reservoir

J Heat engine


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9 . ELECTR ICAL D I AGRAM

9.1 Sheet 1.


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9.2 Sheet 2.


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9.3 Sheet 3.


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9.4 Sheet 4.


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9.5 Sheet 5.


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9.6 Sheet 6.

9.7


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Nomenclature 1.

Item Qty Sheet-Col DesignationsA2 1 02/21 VALVE MODULE

B1 1 01/14 AIR FILTER CLOGGING SWITCH

B2 1 01/15 WATER TEMPERATURE SWITCH

B3 1 01/17 OIL PRESSURE SWITCH

B4 1 01/24 OIL TEMPERATURE SWITCH



F1 1 01/17 FUSE 3A Signalling circuit

F2 1 01/29 FUSE 80A Pre-heating circuit

F3 1 02/07 FUSE 3A Tilt and weighing circuit

F4 1 02/15 FUSE 30A Movement actuation circuit

F5 1 04/03 FUSE 30A Accelerator and travel circuit

F6 1 06/03 FUSE 10A Horn circuit

F7 1 06/07 FUSE 20A Light and rotating light circuit

F8 1 04/17 FUSE 10A Pump selection circuitF9 1 06/15 FUSE 250A Motor-driven pump 1 circuit

F10 1 06/17 FUSE 250A Motor-driven pump 2 circuit

F11 1 06/37 FUSE 3A

G1 1 01/01 12V BATTERY

G2 1 01/07 ALTERNATOR

G3 1 06/09 24V BATTERY

H1 1 01/12 BATTERY CHARGE RED WARNING LIGHT

H2 1 01/14 AIR FILTER CLOGGING RED WARNING LIGHT

H3 1 01/15 WATER TEMPERATURE RED WARNING LIGHT

H4 1 01/17 OIL PRESSURE RED WARNING LIGHT

H7 1 02/17 MAINS ON GREEN LIGHT

H8 1 06/07 ROTATING LIGHT (option)

H9 1 06/09 LIGHT (option)

HA1 1 06/03 HORN

HA2 1 02/11 WEIGHING BUZZER

HA3 1 02/09 TILT MONITOR BUZZER

HA4 1 04/07 TRAVEL BUZZER

KA1 1 02/03 UP LIFTING SOLENOID VALVE CUTTING RELAY

KA2 1 02/05 UP RAISING RELAY

KA3 1 02/07 EXTENSION TELESCOPING RELAYKA4 1 01/29 ANTI-STARTING RELAY

KA5 1 02/12 TRAVEL CUTTING RELAY

KA6 1 01/33 STARTER CONTROL RELAY

KA7 1 06/01 HORN RELAY

KA8 1 06/05 OIL TEMPERATURE RELAY

KA9 1 02/07 TRAVEL CUTTING RELAY


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9.8 Nomenclature 2

Item Qty Sheet-Col DesignationsKA11 1 04/02 FORWARD CONTROL RELAY

KA12 1 02/01 TILT MONITOR RELAY

KA13 1 04/05 TIME-DELAY MODULE RELAY

KA15 1 04/13 SPEED CHANGE NEUTRALISATION RELAY

KA17 1 04/11 THERMAL ACCELERATOR CONTROL RELAY

KA18 1 04/21 LOW SPEED/INTERMEDIATE SPEED TWO-STEP RELAY

KA18 1 04/23 HIGH SPEED/INTERMEDIATE SPEED TWO-STEP RELAY

KA20 1 01/30 OPTION RELAY

KA21 1 01/30 OPTION RELAY

KA22 1 06/21 BATTERIES DISCHARGED MONITOR RELAY

KA23 1 06/24 ENGINE MONITOR LIGHTS SUPPLY CUTTING RELAY

KA24 1 06/26 STOP ACCELERATOR PRE-HEATING STARTING CUTTING RELAY

KA25 1 06/29 MOTOR-DRIVEN PUMP UNIT 1 STARTING RELAY

KA26 1 06/30 MOTOR-DRIVEN PUMP UNIT 2 STARTING RELAY

KA27 1 05/07 ELEC. MODE 70b STARTING CONTROL RELAY

KA29 1 06/23 BI MODE 12V MAINS SUPPLY SELECTION RELAYKA30 1 06/37 CONVERTER SUPPLY RELAY

KA31 1 05/07 PUMP SELECTION RELAY

KA38 1 05/25 RIGHT/LEFT DIRECTION CONTROL RELAY

KA39 1 05/27 RIGHT/LEFT DIRECTION CONTROL RELAY

KA40 1 06/31 DIRECTION SUPPRESSION RELAY

KAB 1 01/13 BATTERY BREAKER OVERSIGHT RELAY

KL1 1 04/31 INTERMEDIATE SPEED TWO-STEP RELAY

KL2 1 04/35 HIGH SPEED TWO-STEP RELAY

KM1 1 04/15 RELAY FOR STARTING OF M1 IN BI-ENERGYKM2 1 05/29 RELAY FOR STARTING OF M2 IN BI-ENERGY

KP 1 01/19 ENGINE SAFETY MODULE

M1 1 06/13 MOTOR-DRIVEN PUMP UNIT 1

M2 1 06/16 MOTOR-DRIVEN PUMP UNIT 2

M3 1 01/04 STARTER MOTOR

P1 1 01/21 12V HOUR COUNTER

P2 1 06/19 12V BATTERY CONTROLLER

QS1 1 01/01 BATTERY BREAKER

SA1 1 02/13 -- POST SELECTION KNURLED LOCKABLE KNOB-- AUXILIARY CONTACT "a"-- AUXILIARY CONTACT "b"

SA2 1 04/21 4x4 VERSION LOW SPEED/INTERMEDIATE SPEED/HIGH SPEEDKNURLED KNOB


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9.9 Nomenclature.3

Item Qty Sheet-Col DesignationsSA2 1 04/13 4x2 VERSION LOW SPEED/HIGH SPEED

KNURLED KNOB

SA3 1 03/25 MOVEMENT SELECTION KNOB (slewing)

SA4 1 03/12 MOVEMENT SELECTION KNOB (raising)

SA5 1 03/18 MOVEMENT SELECTION KNOB (lifting)

SA6 1 03/04 MOVEMENT SELECTION KNOB (telescoping)

SA7 1 03/03 6-POSITION SELECTOR SWITCH comprising:- Operating head- Bipolar contact block- Rubber seal

SA8 1 06/07 ROTATING LIGHT OPTION KNOB

SB1 1 01/12 LOCKABLE MUSHROOM-HEADED EMERGENCY STOP (turret)AUXILIARY CONTACT b

SB2 1 02/17 MUSHROOM-HEADED EMERGENCY STOP (platform)AUXILIARY CONTACT b

SB3 1 01/31 TURRET STARTING PUSHBUTTONSB4 1 01/33 PLATFORM STARTING PUSHBUTTON

SB5 1 04/25 DIFFERENTIAL LOCK KNOB

SB6 1 06/01 PLATFORM HORN PUSHBUTTON

SQ1 1 02/01 TILT SAFETY DEVICE

SQ2 1 02/05-04/23 ARM DETACHED LIMIT SWITCH

SQ3 1 02/11 1ST

THRESHOLD WEIGHING LIMIT SWITCH

SQ4 1 02/12 2ND

THRESHOLD WEIGHING LIMIT SWITCH

SQ5 1 02/05-04/23 BOOM DETACHED LIMIT SWITCH

SM1 1 02/25 1-AXIS MANIPULATOR WITH BUTTON Left Right

V2 1 01/13 DIODE ON PRINTED CIRCUIT BOARD




V15 1 03/03 PROTECTION DIODE
















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Page 46

9.10 Nomenclature.4

Item Qty Sheet-Col DesignationsV35 1 04/29 PROTECTION DIODE















V50 1 05/35 PROTECTION DIODEV51 1 06/19 DIODE ON PRINTED CIRCUIT BOARD




YA1 1 01/23 ENGINE STOP SOLENOID VALVE

YA2 1 01/37 ACCELERATION ELECTROMAGNET

YV1 1 02/25 PROPORTIONAL FLOW LIMITER SOLENOID VALVE

YV2a 1 05/01 TRAVEL SOLENOID VALVE

YV2b 1 05/04 TRAVEL SOLENOID VALVE

YV5a 1 05/31 DIRECTION SOLENOID VALVEYV5b 1 05/33 DIRECTION SOLENOID VALVE

YV10 1 04/26 SOLENOID VALVE

YV11 1 05/12 HIGH SPEED SOLENOID VALVE

YV12 1 06/33 TRAVEL PRESSURE LIMITATION SOLENOID VALVE

YV13 1 05/15 INTERMEDIATE SPEED SOLENOID VALVE (4X4 option)


YV15 1 04/29 DIFFERENTIAL LOCK SOLENOID VALVE


YV17 1 05/35 DIRECTION FLOW SELECTION SOLENOID VALVE

YV23a 1 03/32 COMPENSATION SOLENOID VALVE

YV23b 1 03/35 COMPENSATION SOLENOID VALVE

YV24a 1 03/24 SLEWING SOLENOID VALVEYV24b 1 03/27 SLEWING SOLENOID VALVE

YV25a 1 03/11 RAISING SOLENOID VALVE (down)

YV25b 1 03/13 RAISING SOLENOID VALVE (up)

YV26a 1 03/18 LIFTING SOLENOID VALVE (down)

YV26b 1 03/21 LIFTING SOLENOID VALVE (up)

YV27a 1 03/03 TELESCOPING SOLENOID VALVE (retraction)

YV27b 1 03/06 TELESCOPING SOLENOID VALVE (extension)

YV28 1 05/09 SOLENOID VALVE (direction suppression

YV29 1 04/17 PUMP SELECTION SOLENOID VALVE

YV30 1 04/19 PUMP SELECTION SOLENOID VALVE

V71 1 05/07 DIODE

V72 1 05/09 DIODE

V75 1 02/13 DIODE + DIODE HOLDER UNIT


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1 0 . LABELS

10.1 PICTURES.

13

12

20


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22

10

11

14

19

921


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18 15

3

4

16 7 1 5

6 8 17 2


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10.2 TABLE OF DESIGNATIONS.

Code Designat ion

1 02103078143640 Do not put your foot on the cover

2 02103078143630 Risk of crushing (body)

02103078143420 Operating instruc tions (French)

02103078143430 Operat ing instruct ions (Spanish)

02103078143440 Operat ing instruct ions (German)

3 02103078143450 Operat ing instruct ions (Engl ish)

02103078143460 Operating instru ction s (Ital ian)

02103078143470 Operat ing instruct ions (Dutch)

4 02103078143490 This machine is not iso lated. Risk of electrocut ion.

5 02103078143620 Risk of cru shing (hands and f ing ers)

6 02103078143550 Do not park in the area in which the machine is working .

7 02103078143540 The plug m ust b e conn ected to () 220 V.

8 02103078143600 Do not use as a welding earth. Do no t wash

9 02103078143680 Read the operating and maintenance manual

10 02103078143520 Hydraul ic oi l

11 02103078143590 Hydraulic o il (high level and low level)

12 02103078137430 Red arrow (backw ards)

13 02103078137440 Green arrow (forw ards)

14 02103078143820 Use of the hand pum p

15 02103078143730 a Floor heigh t + load capacity (small form at)

16 02103078143530 Remove the rod before turret rotat ion

17 02103078143570 Greasing of the rotat ion r ing

18 02103078145070 DANGER dir ectio n of tr avel

19 02103078143190 Turret unit label

20 02103078143200 Platform unit label

21 02103078142000 ON

22 02103078142010 OFF

haulotte ha15dx operating instructions maintenance.pdf

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