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SELF-PROPELLED HYDRAULIC PLATFORM

HA 12 I

0120 2420315010 – E 04.00 Australia

La Péronnière BP9 – 42152 L’HORME – France


( 04 77 29 24 24 7 04 77 31 28 11
E.Mail: haulotte@haulotte.com Web: http://www.haulotte.com
Operating and maintenance – HA12I Pinguely - Haulotte

You have just taken delivery of your Haulotte HA 12 I self-propelled hydraulic platform.

Follow the maintenance and operating instructions carefully and you will obtain complete satisfaction
from your machine.

This instruction manual is designed to help you do this.

It is most important:
• to respect the safety guidelines for the machine itself, its use and its operating environment;
• to use the equipment only within its performance limits;
• to keep the machine in good repair in order to ensure long service.

One service check is provided free of charge: see the warranty booklet provided with the machine.

During and after the warranty period, our After Sales Service is available to provide you with any
services you may require.

You should contact our local agent or our Factory After Sales Service and indicate the exact type of
machine and its serial number.

Refer to this manual and the Parts Catalogue when ordering replacement parts or consumable materials.
In this way, you will receive original parts, your guarantee of interchangeability and perfect operation.

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

You are reminded that our machines comply with the provisions of "Machine Directive" 89/392/EEC of 14 June
1989, amended by the directives 91/368/EEC of 21 June 1991, 93/44/EEC of 14 June 1993 and 93/68/EEC of 22
July 1993.

HYDRAULIC PLATFORM HA 12 I
Ref.: 0120 2420315010 E 04.00

The technical data given in this manual shall in no circumstances be binding upon our company and we reserve the right
to modify or upgrade the machine without necessarily modifying this manual.

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TABLE OF CONTENTS

1 - GENERAL RECOMMENDATIONS - SAFETY 1


1.1 GENERAL WARNING 1
1.2 APPLICATION OF GENERAL REGULATIONS 2
1.3 BASIC RISKS 3
1.4 LIMITS OF USE 3
1.5 VERIFICATIONS 4
1.5.1 Periodic inspections 4
1.5.2 Examination of machine suitability 4
1.5.3 State of conservation 4
1.6 REPAIRS AND ADJUSTMENTS 4
1.7 CHECKS WHEN MACHINE IS BROUGHT BACK INTO SERVICE 4

2 - DESCRIPTION 5
2.1 IDENTIFICATION 5
2.2 MAIN COMPONENTS 6
2.3 WORKING AREA 7
2.5 DIMENSIONS 9

3 - OPERATING PRINCIPLES 10
3.1 HYDRAULIC CIRCUIT (see hydraulic circuit diagram, § 8) 10
3.1.1 Turntable rotation, arm lifting, boom derricking and telescoping and work-
cradle compensation 10
3.1.2 Steering 10
3.1.3 Telescoping, boom derricking and arm lifting cylinders 10
3.1.4 Turntable rotation 10
3.1.5 Work-cradle rotation 10
3.1.6 Work-cradle compensation 10
3.1.7 Brake release on wheel reduction gears during travel 11
3.1.8 Manual emergency and rescue system 11
3.1.9 Functioning of overload system 11
3.2 ELECTRICAL CIRCUIT 11
3.2.1 48/24V current converter (Item 4, photo 5) 11
3.2.2 Electronic variable speed drive (Item 1, photo 15) 11
3.2.3 Contactor plate (Photo 15) 12
3.2.4 Direct electric travel movement 12
3.2.5 Work-cradle load monitoring 12
3.2.6 Tilt monitoring within the 3° limit 12
3.2.7 High travel speed 12

4 - USING THE MACHINE 13


4.1 UNLOADING - LOADING - MOVEMENT 13
4.1.1 Unloading by lifting 13
4.1.2 Unloading using ramps 13
4.1.3 Loading 14
4.1.3 Movement 14
4.2 INSTRUCTION FOR PUTTING MACHINES INTO SERVICE 15
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Operating and maintenance – HA12I Pinguely - Haulotte

4.2.1 Turntable control panel (Photos 1-2) 15


4.2.2 Work cradle control panel (Photos 3-4) 15
4.2.3 Daily operational inspection. 15
4.3 OPERATING INSTRUCTION 17
4.3.1 Ground level operations 17
4.3.2 Operations controlled from the work-cradle 17
4.4 EMERGENCY AND RESCUE OPERATIONS 18
4.4.1 Using hand pump for emergency movements (photo 2) 18
4.4.2 Rescue operations 19
4.5 DISENGAGING THE GEARS (photo 9) 19
4.6 BATTERY CHARGE MONITORING UNIT/HOUR METER 19
4.7 USING THE ON-BOARD BATTERY CHARGER 19
4.7.1 Characteristics 20
4.7.2 Starting of recharging process 20
4.7.3 Equalisation charge: LED 4 20
4.7.4 Compensation charge 20
4.7.5 Charge interruption 20
4.7.6 Fault signalling: red LED 5 21
4.7.7 Precautions for use 21
4.8 BATTERY USE AND MAINTENANCE 21
4.8.1 Commissioning 21
4.8.2 Discharge 21
4.8.3 Recharging 21
4.8.4 Maintenance 22

5 - MAINTENANCE 24
5.1 GENERAL RECOMMENDATIONS 24
5.2 MAINTENANCE SCHEDULE 24
5.3 OPERATIONS 26
5.3.1 Hydraulic oil filter (Photo 11) 27
5.3.2 Drive wheel reduction gears (Photos 12-13) 27
5.3.3 Hydraulic oil storage tank 27
5.3.4 Batteries 27
5.3.5 Slew backlash adjustment (photo 16) 28
5.4 LOAD TESTING. 28
5.4.1 Overload Test 28
5.4.2 Functional Test. 28
5.4.3 Stability Test. 29

6 - OPERATING PROBLEMS 30
6.1 LED DISPLAY ON VARIABLE SPEED DRIVE 31
6.2 TROUBLESHOOTING 32

7 - SAFETY SYSTEMS 34
7.1 LIST AND FUNCTION OF RELAYS, SAFETY CONTACTS AND FUSES 34
7.1.1 Turntable compartment and variable speed drive plate 34
7.1.2 Safety Contacts 34

8 - HYDRAULIC CIRCUIT DIAGRAM 35

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9 - ELECTRICAL CIRCUIT DIAGRAM 37

10 – LABELS 39

11 - PHOTOGRAPHS 44

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1 - GENERAL RECOMMENDATIONS - SAFETY

1.1 GENERAL WARNING

This manual is designed to help familiarize the operator with Haulotte self-propelled hydraulic
platforms so that he can use them efficiently and SAFELY. However, this manual is not intended to
replace the basic training needed by every user of site equipment.

Operators using this equipment must ensure that they have the appropriate qualifications as required in
the country of use. If you are unsure of what is required ask your supervisor.

Before using equipment for the first time, operating and maintenance personnel must have read and
understood all the instructions in this manual. This is essential for the safe and efficient use of the
equipment.

This manual must be available for consultation by all personnel operating the machine. Additional
copies are obtainable from the manufacturer on request.

Make sure that any person operating the machine is suitably qualified to be able to comply with safety
requirements.

Always ensure that the equipment is not accessible to unauthorised persons when it is not in use.

Never use a machine which is faulty or visibly damaged.

Never exceed the maximum permissible load or force specified by the manufacturer.

Never use the machine to carry out work for which it is not designed.

Do not work in conditions which may constitute a safety hazard.

Using the machine in a way which does not comply with operating instructions may expose persons and
property to risks and damage.

Do not modify the characteristics of the machine since this may affect stability and safety.

The user manual must be kept by the user throughout the life time of the machine and handed over in
the event of resale.

Ensure that the various instruction and warning plates fastened to the machine are undamaged and
legible.

ONLY TRAINED OPERATORS MAY USE HAULOTTE MODEL HA 12 I SELF-


PROPELLED HYDRAULIC PLATFORMS.

THERE MUST ALWAYS BE AT LEAST TWO OPERATORS ON HAND SO THAT ONE OF


THEM CAN:
- take emergency action in the event of a problem,
- take over the controls in the event of an accident or fault,
- keep a look out for and avoid other machines and pedestrians in the vicinity of the platform,
- guide the platform driver, if necessary.
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Operators must be more than 18 years of age and must be in possession of a driver's permit issued by
the employer after a medical check-up and practical test.

1.2 APPLICATION OF GENERAL REGULATIONS

Important instructions will be preceded by this standard symbol to draw


the user's attention to these instructions.

Operators must:
- wear protective clothing, footwear and headgear;
- be equipped with a safety harness and any other equipment that might be necessary depending on
working conditions (dangerous areas, for example);

Never use the machine:


- on soft, unstable, ground, in confined spaces or where the gradient is more than 3°
- when exposed to wind (ZERO wind); when used outdoors, use an anemometer to make sure that
wind speed is zero
- near power lines (check on minimum distance to be respected in relation to power line voltage)
- without first putting the protective bar of the work cradle in place and closing the safety gate
- with a cluttered work cradle
- with equipment or objects hanging from the protective rails or the boom
- with items that could increase wind resistance (eg. panels)
- without a fire extinguisher in the work cradle; there is a space in the work cradle reserved for the
extinguisher, which is to be provided by the user

• Never use the guard rail as a means to climb up to or down from the platform; use the steps provided
for this purpose on the machine.
• Never use this machine in explosive environments.
• Always wipe any oil or grease from the machine steps, floor and handrails.
• Never render inoperative the safety limit switches.
• Avoid contact with stationary or moving obstacles.
• Never use ladders or other accessories to increase working height.
• Prevent the machine from being subject to any uncontrolled intervention when not in service.
• Make sure the daily checks are made and make sure the machine operates properly during periods of
use.
• Never:
- move the travel servo-controls from one direction to the opposite direction without first stopping
in the "0" position;
- exceed the maximum load or the maximum number of persons authorised on the platform
(200 kg/incl. 2 operatives); loads should be evenly spread on the working platform and, whenever
possible, placed in the middle of the platform;
- carry out repair on maintenance work in the area of the turret witch requires the booms to be
raised without ensuring that there is no danger of the booms accidentally lowering on to a person
working below them. To avoid this possibility:
• always remove the key from the lower controls when working within the turret area.
• Support the booms with a crane if the hydraulic lift cylinders are being working on.
- climb on the protective rail when the platform is raised; this could result in a serious fall

• HOLD the hand-rail firmly when raising the platform or when travelling.
• Avoid:
- travelling at high speed in narrow or cluttered spaces;
- travelling in reverse gear (limited visibility);
- towing the machine: it was not designed for this; it should be transported on a trailer;
- climbing on the protective hoods.
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Operating and maintenance – HA12I Pinguely - Haulotte

• Allow sufficient braking distance: three meters at high speed, one meter at low speed.

• To stop during travel, gradually move the servo-control to the zero position while keeping the foot on
the pedal.

• During normal use, that is when the machine is operated from the work cradle, the key for the
turntable key-operated control panel selector must be removed and kept by a person on site who is
properly trained in emergency and rescue operations.

NEVER USE THE WORK CRADLE AS A CRANE OR A LIFT

NEVER USE THE MACHINE FOR PULLING OR TOWING PURPOSES


NEVER USE THE BOOM FOR RAMMING OR PUSHING
OR FOR LIFTING THE WHEELS OFF THE GROUND

NEVER DISMANTLE OR MODIFY ANY PART, ACCESSORY OR COMPONENT OF THE


MACHINE WITHOUT OUR PRIOR APPROVAL

FOR ALL REPAIRS, USE ONLY ORIGINAL SPARE PARTS

TO GUARANTEE PROPER OPERATION


DO NOT DESCEND STEEP SLOPES IN HIGH SPEED MODE

IMPORTANT
If the machine is equipped with a 220 V socket outlet, the extension must be connected to a
mains outlet protected by a 30mA residual current circuit-breaker.

1.3 BASIC RISKS


- Sudden movement of the servo-controls can result in jolts and swinging movements.
- Overloading: risk of machine overturning. Be specially careful not to overload the machine at the
top.
- Unstable ground: risk of overturning (see page 17 concerning pressure on ground and load per
wheel). Be careful during winter thaws.
- Gusty wind: risk of overturning.
- Collision with object on ground or at higher level: risk of shock or overturning.
- Contact with power line: risk of electrical shock.
- Work on floors or over drains or culverts, pavements, etc.: risk of overturning.
- Work in explosive atmospheres: risk of explosion.
- Persons in machine operating area (during travel or when operating equipment): risk of injury.
- The operator must always assess the risks from above before using the machine.
- Steep slopes: risk of machine runaway in high speed mode.

1.4 LIMITS OF USE

Never use the machine:


- with a load of more than 200 kg;
- with more than two persons in the work cradle;
- on ground which cannot support the pressure and the load per wheel;
- on slopes or cambers exceeding 3°;
- with lateral force in the work cradle greater than 400 N;
- in wind exceeding 45 km/h;
- in cold stores;
- in explosive atmospheres;

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- at night, unless the machine is equipped with the optional working light;

Do not travel on public roads.

1.5 VERIFICATIONS

Always comply with regulations in force in the country in which the machine is used.
For Australia: Australian standard AS 1418.10-1996 and AS 2550.10-1994.

1.5.1 Periodic inspections

The machine must undergo periodic checks. Details of the checks are covered in the relevant sections of
this manual.

1.5.2 Examination of machine suitability

The employer in the company in which the machine is to be used must ensure that the machine is
suitable for the job in question and that it is used safely and in compliance with the user manual.

1.5.3 State of conservation

Deterioration which might result in dangerous situations must be detected. Such deterioration might
concern safety devices, load limiters, tilt safety devices, cylinder leaks, deformation, welds, loose bolts
or hoses, electrical connections, condition of tyres, excessive mechanical play.

NB: If the machine is hired out, the person responsible for using the hired machine must check
the state of conservation and suitability of the machine. He must check with the hirer that
the general periodic inspections and checks to be made before the machine is used have
been carried out properly.

1.6 REPAIRS AND ADJUSTMENTS

Major repairs and work or adjustments concerning safety systems or components (mechanical,
hydraulic or electrical aspects) must be carried out by Haulotte personnel or personnel working on
behalf of Haulotte. Only original spare parts must be used.

Modifications conducted outside Haulotte's control are not authorised.

The manufacturer cannot in any way be held responsible if original spare parts are not used or if the
work specified above is not carried out by Haulotte-approved personnel.

1.7 CHECKS WHEN MACHINE IS BROUGHT BACK INTO SERVICE

Such checks must be performed after:


- extensive dismantling and reassembly work,
- repairs involving any of the essential components of the machine,
- any accident caused by faulty operation of an essential component.

It is necessary to perform a “state of conservation” examination, a stability (static overload) test and a
functional (dynamic) test See § 5.4. in the maintenance section of this manual. A competent person must
perform these tests.

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2 - DESCRIPTION

The HA 12 I self-propelled telescopic hydraulic platform is used for carrying out high-elevation jobs
within the limits of its performance characteristics (cf. sections 2.3 & 2.4) and complying at all times
with the safety regulations relating to the equipment and to the site where it is being used.

The main operator's station is in the work cradle.

The operator's station in the turntable is for emergency or rescue purposes.

2.1 IDENTIFICATION

Information needed to identify the equipment is engraved on a plate fastened at the back of the chassis,
on the right hand side.

REMEMBER: Always mention the type and serial number when making any inquiries or
when requesting service or replacement parts.

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2.2 MAIN COMPONENTS

1- Steering wheels 13 - Turntable


2- Hydraulic electro-pump 14 - Ground-level control panel
3- Welded chassis 15 - Tilt control unit
4- Bank of batteries 16 - Cylinder for lifting the arms
5- Battery charger 17 - Boom telescoping cylinder
6- Travel electric motors 18 - Telescopic boom (2 parts)
7- Drive wheels: for moving the machine (2 travel 19 - Arm
speeds)
8- Securing and lifting rings 20 - Work cradle compensation reception cylinder
9- Variable speed drive 21 - Work cradle
10 - Slewing control unit 22 - Work cradle control panel
11 - Work cradle compensation transmitter cylinder 23 - Work cradle support with load limiter and
cradle rotation system
12 - Cylinder for lifting the boom 24 - Emergency pump

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2.3 WORKING AREA

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2.4 TECHNICAL DATA
Pay load 200 kg. incl. 2 operatives
Maximum lateral force 40 kg
Working height 12 m
Platform height 10 m
Maximum reach 6.5 m
Turntable rotation 360°
Slope and camber while working (max.) 3°
Work cradle dimensions 1140 x 700 (inside) - Outside: + 60 mm
Maximum gradient during travel 25%
Slow travel speed 1 km/h
Fast travel speed 4.4 km/h
Drive batteries (2) 48 V - 2 boxes
Ground clearance 170 mm
Tyres Solid tyres 700 x 12
Turning circle Chassis (outside): 2.08 m - basket (outside): 2.6 m
Boom angle range - 15.5°+75°
Telescoping (stroke) 2000 mm
Maximum wind speed during use 0 km/h
Maximum pressure on ground with 200 kg in 14 kg/cm2
cradle: concrete
Max. force from one wheel on ground 2800 kg
Time taken for movements with one person in the
work cradle:
- telescoping: extending/retracting: (approx.) 26 / 13 secs
- arm derricking: up/down: (approx.) 21 / 13.5 secs
- boom derricking: up/down: (approx.) 19 / 15 secs
- slewing: (approx.) 90 secs
Engine: manufacturer (standard) LEROY SOMER
- voltage 24 V serial set-up
- power 1.2 kW
- consumption 65 A on flat ground - 230 A max.
Acoustic pressure level in operator's station 72 dB(A)
Degree of vibration on feet < 0.5 m/s2
Degree of vibration on hands < 2.5 m/s2
Hydraulic service pump: cubic capacity 5.5 cm3/rev
Oil tank capacity 20 litres
Hydraulic service pressures*:
- maximum pressure, steering circuit 220 bars
- maximum pressure, slewing circuit 75 bars
- maximum pressure telescoping extended 220 bars
- maximum pressure boom derricking 220 bars
- maximum pressure arm derricking 220 bars
- maximum pressure for brake release 220 bars
Tightening torque of leading wheel nuts 20 kg.m
Tightening torque of drive wheel nuts 14 kg.m
Tightening torque of slewing gear bolts 12 kg.m
Weight 4950 kg
Dimensions see drawing § 2.5
• All pressures, except brake release pressure, can be monitored through a pressure test point (Item 1,
photo 7).
• Two drive wheels with brake reduction gears and electric motors with variable speed drive.
• Lifting, derricking, telescoping, slewing movement: hydraulic electro-pump with variable speed control.
• Steering by solenoid valve block.
• Emergency hand pump from turntable.

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2.5 DIMENSIONS

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3 - OPERATING PRINCIPLES

3.1 HYDRAULIC CIRCUIT (see hydraulic circuit diagram, § 8)

All the movements of the machine, except travelling, are powered by the hydraulic energy from an
electro-pump (1) the operating speed of which is controlled by an electronic variable speed drive.

In the event of breakdown, a hand-operated emergency pump (12) can be used to lower the arms and
boom, retract the boom telescopic elements and slew the turntable.

The pump delivery pipe is fitted with a high-pressure filter (2) to protect the installation from pollution.

3.1.1 Turntable rotation, arm lifting, boom derricking and telescoping and work-cradle
compensation

These movements are carried out through solenoid-valve blocks diverting the hydraulic oil flow from
the pump to the receiving mechanism for the selected movement.

The gradual increase in the speed of the movements is achieved by varying the speed of the electro-
pump and thus the flow rate, controlled by the electronic variable speed drive, according to an electrical
order. Only a single movement is possible at any one time.

3.1.2 Steering

This is controlled by a 4-channel solenoid valve (7). Flow rate of the same electro-pump is either on or
off.

3.1.3 Telescoping, boom derricking and arm lifting cylinders

These cylinders are fitted with flanged watertight balance valves.

CAUTION: These can be adjusted only by specially qualified personnel.

3.1.4 Turntable rotation

Rotation of the turntable is controlled by a crown wheel and "gear and screw" reduction gear assembly,
driven by a hydraulic motor. Service pressure is limited to 75 bars for this movement.

3.1.5 Work-cradle rotation

This is controlled by turning the crank in one direction or the other.

3.1.6 Work-cradle compensation

This operates by oil transfer between two cylinders of identical characteristics.

The receiving compensating cylinder is fitted with a pilot-operated double-flanged check valve (22).
Manual compensation speed is controlled by a throttle valve on the electro-pump specific to this
movement.

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3.1.7 Brake release on wheel reduction gears during travel

Whenever a travel movement command is implemented, the brake release circuit of the reduction gear is
pressurized. The hydraulic pressure is provided by an accumulator with pressure head controlled by a
pressure switch in the range 80 to 220 bars.

When the pressure drops below a minimum threshold level, the travel movement electro-pump is
automatically started-up to recharge the accumulator.

As soon as travel movement ceases, the brake is applied by spring action.

3.1.8 Manual emergency and rescue system

In the event of a power failure preventing:


- either the use of the electro-pump,
- or the operation of various movements,

it is possible to perform these movements from the ground by means of a hand-operated pump. At the
same time as this emergency pump is used, the corresponding solenoid valve block must be actuated in
order to lower the arms, lower the boom, retract the boom telescoping and slew the turntable.

3.1.9 Functioning of overload system

When the charge in the basket exceeds or is equal to 200 kg, the overload buzzer sounds. The overload
system is a mechanical device located between the extremity of the jib and the basket. Take care, when
cleaning around overload system:
- the distance between pressured water cleaning device extremity and overload system must be
more than 60 cm.

3.2 ELECTRICAL CIRCUIT

The electrical energy required for driving the motors and powering the controls is supplied by a set of
two blocks of 48 V - 375 Ah batteries. An on-board charger is available for recharging these batteries in
a single night by connection to an ordinary 16 A domestic socket outlet. (Item 3, photo 8).

The electrical circuit includes two distinct parts:


• power circuit, for operation of the travel motors and electro-pump at 48 V,
• control circuit, with a voltage of 48 V for all items relating to operation of the variable speed
drive, and a voltage of 24 V for powering controls and safety systems.

3.2.1 48/24V current converter (Item 4, photo 5)

To ensure uniform discharging of the batteries, the voltage used for the control circuit is originally 48 V
transformed into 24 V by a current converter.

3.2.2 Electronic variable speed drive (Item 1, photo 15)

This is the key component governing the entire operation of the machine. Its role is to control the speed
of machine movements and travel by adapting the rotation speed of the various electric motors to a
given control order.

The variable speed drive acts as a receiver for the signal sent from the servo-control, but also for
information on the nature of the movement to be made and the status of safety systems.

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All the electric motors are subjected to the variable speed drive control and, consequently, depend on the
built-in operational safety systems on the variable speed drive.

3.2.3 Contactor plate (Photo 15)

The variable speed drive is mounted on a support plate with a series of selection contactors. These are
power relays designed to feed the motors depending on the choice made by the operator.

3.2.4 Direct electric travel movement

Two direct-current motors, connected in series, provide power to the drive wheels via epicycloidal
reduction gears (Item 4, photo 11)

A generator, or tachometer, is installed on one of the motors, feeding return information to the variable
speed drive on the actual instantaneous speed of the motor, in order to control rotation speed. This
device prevents any risk of runaway and trips a counter-current braking system, if necessary (Item 2,
photo 11).

3.2.5 Work-cradle load monitoring

If the load on the work cradle reaches 90% of the maximum authorized load, the buzzer warns the
operator. When this maximum load is exceeded, the control circuit is cut, preventing any cradle
movement.

3.2.6 Tilt monitoring within the 3° limit

The tilt monitoring unit emits an acoustic signal when the maximum permissible tilt angle is reached. If
this situation persists, after a time delay of 1 to 2 seconds, the boom derricking (lifting), arm lifting and
telescoping deployment controls are cut, and no travel movement is possible as long as the machine is
deployed in this manner.

To regain control of travel movement, all raised parts of the platform must be lowered.

N.B.: Once all components of the machine have been lowered, the tilt monitoring unit continues to emit
an acoustic signal as long as the gradient is greater than 3°, informing the operator that it will be
impossible to deploy the work cradle.

3.2.7 High travel speed

The high travel speed is permitted only when the work cradle has been completely lowered. When the
boom is raised or the arms deployed, only low travel speed is possible.

NEVER DESCEND STEEP SLOPES IN HIGH-SPEED TRAVEL MODE

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4 - USING THE MACHINE

4.1 UNLOADING - LOADING - MOVEMENT

IMPORTANT: Before any operation, make sure the machine is in good condition and has not been
damaged during transport. If there is any damage, make the necessary reserves in writing to the
forwarding agent.

A handling error could lead to the machine falling with a


very serious risk of causing personal injury and material damage

Carry out unloading operations on a stable, flat, unencumbered and sufficiently strong surface (see
ground pressure - Section 2.4).

4.1.1 Unloading by lifting

• Use a lifting beam with four slings.


• Precautions
Make sure:
- that the lifting gear is in good working order and is powerful enough for the job,
- that the slings and hooks can withstand the load (refer to nominated rating shown on machine at
the attachment points) and are not abnormally worn or frayed.
- that the lifting rings are clean and in good order,
- that the personnel responsible for unloading the machine is authorized to use the lifting
equipment.
• Unloading
- attach the four slings to the four lifting points,
- lift the machine slowly, making sure that the load is evenly distributed and lower it slowly to the
ground.

Never stay underneath or too close to the machine during


unloading operations

4.1.2 Unloading using ramps

• Precautions:
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- Make sure that the ramps are properly fixed and are strong enough to support the load and that
there is sufficient grip to prevent the machine from sliding while it is being unloaded.

IMPORTANT: The machine has to be started up in order to unload it via ramps. See § 4.3 to avoid
any risk of error. Select low travel speed.

NB: Since the ramp slope is nearly always steeper than the maximum working gradient (3°), the boom
and arms must be lowered in order to authorise travel movement.

In this case, the buzzer will be tripped, but travel is possible.

If the slope is greater than the maximum permissible travel slope (see § 2.4), use a winch for assistance.

NEVER DESCEND THE RAMPS IN HIGH-SPEED TRAVEL MODE

4.1.3 Loading

Take the same precautions as for unloading.

The machine must be secured in accordance with the diagram below. To climb up the ramps onto a
lorry, select high travel speed.

4.1.3 Movement

Always comply with the traffic regulations or instructions applicable to the site.

On rough ground, make a preliminary survey of the area concerned before starting overhead work in the
cradle.

Always keep a safe distance away from unstable shoulders or embankments when moving.
Make sure that no-one is in the immediate vicinty of the machine before starting any machine
movements or travel.
Reminder: It is strictly prohibited to travel on public highways.

Fig. A: Pictograms of the work cradle control panel board


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Operating and maintenance – HA12I Pinguely - Haulotte

4.2 INSTRUCTION FOR PUTTING MACHINES INTO SERVICE

Before performing any operations, get to know the machine by reading this manual and referring to the
instructions on the various plates fastened to the equipment.

4.2.1 Turntable control panel (Photos 1-2)


1- Battery charge indicator 13 - Tilt monitoring unit
2- Arm lifting control 14 - Horn
3- Boom derricking control 15 - Emergency hand pump
4- Boom telescoping control 16 - Manual slewing control
5- Turntable slewing control 17 - Manual derricking control
6- Control station selector 18 - Manual telescoping control
7- Pump control 19 - Manual lifting control
8- Key-operated emergency stop button 20 - Hand pump lever
9- Circuit-breaker (protection of options) 21 - Decompression valve
10 - Circuit-breaker (horn protection) 23 - Supply connector 220 V single - 16 A
11 - Circuit-breaker (tilt protection)
12 - Circuit-breaker (general protection of On option
control circuit) 22 - Flashing light control

4.2.2 Work cradle control panel (Photos 3-4)


1 - Movement selector 6- Indicator showing cradle panel selected
2 - Movement servo-control 7- Overload warning
3 - Emergency stop button 8- Socket 220 V single - 16 A
4 - Low/High speed selector switch 9- "Dead Man" safety pedal
5 - Horn push button

CAUTION
WHEN USING A HIGH-PRESSURE WATER SPRAY TO WASH THE MACHINE,
DO NOT DIRECT THE HOSE TOWARDS THE ELECTRICAL UNITS AND
COMPARTMENTS

4.2.3 Daily operational inspection.

At the beginning of each working shift, the machine must be given a visual inspection covering the
following:
• NO loose and missing parts.
• All bolts and nuts are tight.

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Pinguely - Haulotte Operating and maintenance – HA12I
• Inspect arms, boom, work cradle: No sign of visible damage, no traces of wear or deformation.
• Check for excessive movement between moving parts such as the boom sections, slew bearing
and connections.
• Check guard-rail system and self closing intermediate rail.
• Check personal protective devices such as safety belts.
• Check presence of decals, warnings, controls marking and operating manual.
• Couplings and hoses are tight.
• No oil leaks.
• Check for leak, signs of wear, knocks, scratches, rust or foreign bodies on cylinder rods.
• Pump and hydraulic power pack: check for leaks, loose components.
• Check the hydraulic oil level (Item 1 photo 6) and if necessary, top up through filler cap (Item 2
photo 7) when filling use the products specified in the material chapter.
• Check for leaks on wheel reduction gears.
• Check that reduction gear are not disconnected.
• Check tightness of wheel nuts and wear on tyres.
• No acid leaks from the batteries.
• No electrical wires cut or disconnected.
• Check cleanliness and tightness of batteries (photo 5): loose lugs or corrosion cause a loss of
power.
• Check electrolytic fluid level in batteries (photo 5): the level should be about 10mm above the
battery plates. Add distilled water to make up level if required.
• Check turntable and basket controls.
• The circuit breaker on the turntable control panel must be engaged.
• Check the cable supplying the basket control panel.
• Check that emergency stop the buttons operate properly.
• Check visual and audible alarms.
• Check tilt monitoring unit operates properly (Item 13, photo 1) by inclining the support plate.
The buzzer must sound as soon as inclination exceeds 3°.
• Limit switches of the safety devices are not disabled.
• Check that the turntable rotation lock pin (Item 1, photo 8) has been removed.
• Check working area conditions
- Operating area to have stable ground conditions capable of supporting the machine weight
(see ground pressure §2.4).
- Ensure that the work area at ground level has been cleared of movable obstruction.
- See work area sketches (§2.3) for maximum acceptable gradients.

ANY FAULTS FOUND MUST BE NOTED IN THE MACHINE LOGBOOK AND THE
SUPERVISOR ADVISED PRIOR TO DECIDING IF THE MACHINE IS SUITABLE FOR
USE

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Operating and maintenance – HA12I Pinguely - Haulotte

These machines are not insulated, refer to the “ Danger” sign


attached to the machine to establish safe working distances from
power lines.

4.3 OPERATING INSTRUCTION

IMPORTANT: The machine must not be started up until all the operations described in the
previous chapter have been completed.

To get used to the machine, the operator should carry out the initial movements at ground level with the
machine in the transit position: counterweight at front, boom lowered.

CAUTION: When the counterweight is placed above the steering wheels, the travel
and steering controls are reversed.

Remember: The main control panel is in the work cradle.

In normal conditions, the turntable control panel is an emergency control unit and is used only when
absolutely necessary.

4.3.1 Ground level operations

4.3.1.1 Switching on:


• Close the battery cut-out (Item 2, photo 8).
• Reset the emergency stop button (Item 8, photo 1) by means of the key.
• Set the control panel selector key (Item 6, photo 1) to the "turntable" position. In this position, the
work cradle controls are disabled.

4.3.1.2 Testing the various movements (photo 1)

Remember: Before carrying out any operations, check that there are no obstacles that might hinder the
movements.

• Actuate and hold down the pump control button (Item 7).
• The movements controlled from the turntable panel are of the "On/Off" type (no variable speed).
• Test arm movement in the raising and lowering directions (switch, Item 2).
• Test boom derricking movement in the raising and lowering directions (switch, Item 3).
• Stop lowering the boom when it reaches a horizontal position.
• Test the turntable slewing movement in both directions (switch, Item 5) as well as the boom
telescoping movements (deployment/retraction) (switch, Item 4) before completely lowering the
boom.

4.3.1.3 Changing to work-cradle controls

• Set the key-operated switch (Item 6, photo 1) to the work-cradle position (pictogram on left).

4.3.2 Operations controlled from the work-cradle

• Climb into the work-cradle, making sure that the maximum load is not exceeded. If necessary,
distribute the weight over the entire platform.

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Pinguely - Haulotte Operating and maintenance – HA12I

SELF-PROPELLED HYDRAULIC PLATFORM MODEL HA 12 I: 200 kg, incl. 2


operatives

NB: If the load is almost at maximum, the buzzer (Item 7, phot 3) will be tripped. If the maximum
load is exceeded, the controls will be inoperative. There is no load restriction in relation to reach.

4.3.2.1 Testing the control panel (photos 3/4)

Before carrying out any operations, make sure that the green light (Item 6) is ON to indicate that the
machine is switched on and that the work cradle control panel is selected.

• Ensure that the emergency stop button (Item 3) is unlocked.


• Check that the horn is working properly by pressing the green button (Item 5).

CAUTION
THE "DEAD MAN" PEDAL MUST BE BE PRESSED BEFORE ACTUATING A
CONTROL MOVEMENT.

If a movement does not work despite actuating the control and pressing the foot pedal, press the
emergency stop button and then reset it. Repeat the control taking care to actuate the foot pedal first
(Item 9).

• Adjust the position of the work-cradle if the platform is not horizontal by setting the selector switch
to position 6 (Fig. A, page 16) "Manual compensation", and moving the servo-control (2) from front
to back.
• Test telescoping, arm lifting, boom derricking and slewing movements by setting the selector in
positions 1, 2, 3 and 4 respectively. Each time, actuate the servo-control from front to back.
• Direction movement obtained with the servo-control is indicated by a black arrow and a white arrow.
• Set the selector switch to position 5, corresponding to travel movement, and actuate the servo-control
from right to left to move the steering in that direction. This function is an "On/Off" control so no
gradual movement can be obtained.
• Test travel movement by actuating the servo-control this time from front to back.
Warning: When reversing the unit it is recommended that the top jib be raised to approximately
the horizontal position to provide a better line of vision in the direction of travel for
the operator in the basket.

• Test the two travel speeds by actuating the low speed/high speed selector (Item 4).

Attention: High speed is possible only if the machine is folded down. Even if slightly deployed,
only the low speed is possible.

4.4 EMERGENCY AND RESCUE OPERATIONS

4.4.1 Using hand pump for emergency movements (photo 2)

If the main source of energy fails, the operator can nevertheless carry out all the movements from the
ground.

This is done by means of a hand pump (Item 15) next to the hydraulic control blocks on the turntable.

This pump, combined with a manual control of the solenoid valve blocks, is used to lower the arm and
boom, to retract the boom telescope and to slew the turntable.

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Operating and maintenance – HA12I Pinguely - Haulotte

• Insert the lever (Item 20) in the pump housing.


• Check that the pump decompression valve (Item 21) is in the closed position.
• Move the lever up and down and, at the same time, press the manual control of the solenoid valve
block for the desired movement (Item 16, 17, 18 or 19). The manual control of the solenoid valve
block consists on 8 switches:
- 4 switches near the sign,
- 4 switches behind solenoid valve block.

4.4.2 Rescue operations

If the machine is working normally and the operator in the work cradle becomes ill and is incapable of
bringing the cradle down to ground level, an operator on the ground can bring the cradle down:
• Switch the selector button to "Turntable" position (Item 6).
• Control the required movement by pressing the appropriate button (Item 2, 3, 4 or 5) while
actuating the pump control at the same time (Item 7).

4.5 DISENGAGING THE GEARS (photo 9)

It is possible to disengage the drive wheel reduction gears so that the machine can be towed in the event
of breakdown.
• To disengage screw, using a 24 mm key.

CAUTION: In this configuration, the brake does not work.


To tow the machine, always use a rigid tow-bar and
never exceed 5 km/h

After having moved the machine, follow the above procedure in reverse order (unscrew to reengage) to
obtain the parking brake function again.

4.6 BATTERY CHARGE MONITORING UNIT/HOUR METER

This single unit (Item 1, photo 1) combines the following functions:


1. BATTERY CHARGE CONDITION, by means of a 10-bar display: 2 red, 3 orange and 5 green.
When the battery is properly charged, the green LED on the extreme right is lit.
As the battery discharges, the LEDs light up successively from right to left one after the other.
When the battery is 70% discharged, the first red LED flashes. Battery recharge is recommended.
When the battery is 80% discharged, the two red LEDS flash. The cut-out threshold is reached
and elevation movements are interrupted. Battery recharge is compulsory.
2. HOUR METER: working hours are counted for as long as the electro-pump set is in operation,
shown by a flashing timer sign.
3. RESETTING: This takes place when the battery is properly recharged.

• The monitoring unit is powered by a lithium battery with service life exceeding 15 years.

• A 2A - FU1 fuse (Item 1, photo 10) protects the monitoring unit.

4.7 USING THE ON-BOARD BATTERY CHARGER

Type: FULMEN TONIC 8 48V - 50A (photo 11).

CAUTION: DO NOT USE THE PLATFORM DURING CHARGING


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Pinguely - Haulotte Operating and maintenance – HA12I
4.7.1 Characteristics

– Power supply: 220 V single-phase, 50 Hz


– Current consumption: 14.5 A
– Voltage supplied: 48 V
– Recharge time for 450 Ah battery: 13 hours (80%).
Mains connection: 10/16A socket outlet with 2 conductors + earth

1 - Battery being charged


2 - Battery 80% charged
3 - Battery 100% charged
4 - Equalisation charge
5 - Fault indicator: safety
system
6 - Charge interrupted
7 - Stoppage of a
Stop charging procedure in
progress
8 - Display of charge
current

4.7.2 Starting of recharging process


Charging starts automatically as soon as the charger is connected to the mains supply. The charger runs
a self test of the LEDs for about 8 seconds and then the charging phase starts.
Charging time for a battery 80% discharged: 13 hours.
During the charging period, the LEDs Ref. 8 go out one after the other.

4.7.3 Equalisation charge: LED 4

30 hours after the start of charging, an equalisation charge is started automatically.

4.7.4 Compensation charge

If the battery charger remains connected to the mains, a compensation charge is performed every 8
hours for a period of 8 minutes.

4.7.5 Charge interruption


If the machine has to be moved during the battery charging cycle, the charger must be set to "Pause".
Press the "Stop" button and the LED 6 lights up.

After having moved the machine, press on the "Stop" button again; LED 6 goes out and charging starts
up again.

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Operating and maintenance – HA12I Pinguely - Haulotte

4.7.6 Fault signalling: red LED 5

Fault in electronic system Red LED flashes


Battery voltage too low (1.7 V/e) or too high (2.4 V/e) before Red LED lit
start of charging
Battery voltage does not rise to 2.0 V/e within 60 minutes Red LED lit
Battery voltage does not rise to 2.4 V/e within 13 hours Red LED lit

4.7.7 Precautions for use

• Avoid recharging batteries if the electrolyte temperature is greater than 40°C. Leave them to cool.

• Keep top of batteries dry and clean; a bad connection or corrosion may be the cause of a major loss
of power.

• If new batteries are fitted, recharge them after 3 or 4 hours' use and repeat this operation 3 to 5
times.

• The battery charger was factory adjusted with the cable supplied (Item 3, photo 8). If this cable has
to be replaced, make sure a cable of identical cross-section and length is used.

• Never try to service the charger during the warranty period (1 year) but contact HAULOTTE After
Sales Service if a problem arises.

4.8 BATTERY USE AND MAINTENANCE

The batteries are the energy source of your HA 12 I self-propelled platform. To get the most out of
them without any risk of premature damage, you are advised to respect the following recommendations.

4.8.1 Commissioning
• Check that electrolyte level is OK
• Avoid excessive use of the batteries during the first working cycles. Make sure the batteries are
never run down by more than 70% of the rated capacity (first red indicator bar on monitoring unit
flashes).

• The batteries give their full capacity after ten or so working cycles.

4.8.2 Discharge
• Never discharge the batteries by more than 80% of their capacity in 5 hours (two indicator bars flash
on the charge condition monitoring unit).
• Make use the monitoring unit is working properly.
• Never leave the batteries in a discharged condition.
• In cold weather, do not delay recharging as the electrolyte could freeze.

4.8.3 Recharging
• When should you recharge?
- when the batteries have been discharged between 35 and 80% of their rated capacity,
- after a long period of inactivity of the machine.
• How should you recharge?
- check that the mains voltage is suited to charger unit requirements,
- top up to minimum electrolyte level if one element has an electrolyte level lower than
this minimum,

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Pinguely - Haulotte Operating and maintenance – HA12I
- battery charging should take place in a clean, well-aired place without any naked flame in the
vicinity,
- open the battery compartment covers,
- use the on-board battery charger; it has the right charge rate for the battery capacity.
• During the charging period:
- do not remove or open the battery element plugs,
- make sure that the temperature of the battery elements does not exceed 45°C (take special care in
summer or in an area with high ambient temperature).
• After charging:
- top up the electrolyte levels, if necessary.

4.8.4 Maintenance
• Check the electrolyte levels before charging once a week during normal machine use.
• If necessary, top up levels:
- with distilled or demineralised water,
- after charging.
• Never add acid (if a battery tips over, contact HAULOTTE After Sales Service).
• Never leave discharged batteries idle.
• Avoid overflows.
• Clean the batteries to avoid the formation of salts or current tapping.
- clean the top without removing the plugs,
- dry with compressed air, clean cloths, etc.
- grease the battery lugs.

To obtain a quick diagnosis of the state of health of your batteries, record the density of each element
once a month using an acid hydrometer, in relation to temperature, using the graph below (do not take a
measurement straight after a top-up).

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Operating and maintenance – HA12I Pinguely - Haulotte

CHARGE CONDITION OF A BATTERY AS A FUNCTION


OF DENSITY AND TEMPERATURE
STOP !
RECHARGE
DO NOT RECHARGE RECHARGE NOW

1.30
1.29
- 70
1.28
- 67
1.27
- 62
1.26
- 58
1.25
- 49
1.24
- 42
1.23
-40
1.22
-31
1.21
-27
1.20
-25
1.19
-23
1.18
-20
1.17
-16
1.16
-14 15°C
1.15
-12 30°C
1.14
-11 45°C
1.13
-10
1.12
-8
1.11
1.10

100 % 80 % 60 % 40 % 20 % 0%

ELECTROLYTE FREEZING POINT IN °C


FOR DENSITIES UNCREASED TO 30°C.

NEVER CARRY OUT ANY ELECTRIC ARC WELDING ON THE MACHINE


WITHOUT FIRST HAVING DISCONNECTED THE BATTERIES

NEVER TRY TO USE THE BATTERIES TO START


ANOTHER TYPE OF MACHINE

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Pinguely - Haulotte Operating and maintenance – HA12I

5 - MAINTENANCE

5.1 GENERAL RECOMMENDATIONS

Maintenance operations recommended in this manual are given for normal conditions of use. In difficult
conditions: temperature extremes, high humidity, polluted environments, high altitudes, etc., certain
operations must be carried out more frequently and special precautions should be taken. On this subject,
consult your Haulotte After Sales Service for further details.

Only trained, qualified personnel is authorized to carry out work on the machine and guidelines on the
protection of the environment and operators must be respected.

Regularly check that safety systems work properly:

1) Tilting: buzzer + stop (travel movement cut as well as boom derricking, arm lifting and telescope
deployment).
2) Work cradle overload - load > 250 kg, buzzer + complete stoppage of all movements.
3) Impossible to use high speed while raising boom or arm; if in high speed, check automatic switching
to low speed.

WARNING:
- Maintain signs on the machine in a legible condition.
- Do not use the machine as an earthing point for welding units.
- Do not carry out any welding work without first disconnecting the (+) and (-) battery terminals.
- Do not start up any other vehicle with the batteries connected.
- Do not raise or lower the booms if the lower basket-leveling cylinder has been capped or sealed
for any reason.

5.2 MAINTENANCE SCHEDULE

The schedule shows the frequency of the various maintenance operations, the components concerned
and the products to be used.
• The item number written in the symbol indicates the part of the equipment to be serviced in
relation to the frequency.
• The symbol represents the product to be used.

Lubricants
PRODUCT SPECIFICATION SYMBOL used by ELF TOTAL
HAULOTTE
Differential gear ESSO TRANSELF
SAE 90 TM 80 W/90
case oil EP 80W 90 EP 80 W 90
AFNOR 48 602 BP HYDRELF EQUIVIS
Hydraulic oil
ISO V G 46 SHF ZS 46 DS 46 ZS 46
E.P. lithium CARDREXA
ISO - XM - 2
lubricant DC1
ESSO MULTI MULTID
Lead-free grease Grade 2 or 3
GP Grease MOTIVE 2 EP 2
Replacement or
special operation
EPEXA
Lithium grease ENS / EP 700
2

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Operating and maintenance – HA12I Pinguely - Haulotte

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Pinguely - Haulotte Operating and maintenance – HA12I
5.3 OPERATIONS

FREQUENCY OPERATION REFERENCE


Every day or each • Check:
time the machine is - hydraulic oil level § 4.2.3
used - battery electrolyte level § 4.2.3
- battery charge level using the indicator § 4.6
Every 50 hours • Lubricate:
- wheel swivel pins: 2 x 2 points Dwg Item 3
- turntable slewing lock pin
ATTENTION: after first 50 hours:
• Change hydraulic oil filter (see 250 h frequency) § 5.3.1
• Change oil in drive wheel reduction gears § 5.3.2
(see 1000 h frequency)
• Check tightness of:
- slewing gear bolts (see 250 h frequency)
- slewing gear screws (see 250 h frequency)
- wheel nuts (see 250 h frequency)
- motor-variable speed drive electrical connections
Every 250 hours • Change hydraulic oil filter Dwg Item 5
• Lubricate:
- bearings of steering wheels (remove hub cap) Dwg Item 3
- slewing gear bearing race (slew turntable during Dwg Item 6
operation) 1 point
- friction parts of telescope (spatula) Dwg Item 2
- slewing gear teeth (with brush) Dwg Item 7
- battery terminal lugs § 4.8
• Check oil level in drive wheel reduction gears Dwg Item 2
(§5.3.2)
• Check:
- battery charger connections § 4.7
- tightness of slewing gear bolts (Torque = 120 Dwg Item 12
N.m)
- tightness of leading wheel nuts (T = 200 Nm) Dwg Item 4
- tightness of drive wheel nuts (T = 140 Nm) Dwg Item 13
- tightness of motor and variable speed drive
electrical connections
- tightness of battery terminal lugs § 4.8

Every 1000 hours • Oil change:


- hydraulic oil storage tank capacity (30 l) § 5.3.3 Dwg Item 1
- drive wheel reduction gears (capacity 0.2 l) Dwg Item 2
§5.3.2
Every 2000 hours • Change oil in hydraulic oil storage tank and entire Dwg Item 1
hydraulic circuit (§5.3.3)
• Lubricate rotation reduction gear and change oil Dwg Item 10

Important:
• Use only products recommended in the table in § 5.2 for oil changes, lubrication and greasing.
• Dispose of waste oil in an approved manner to avoid polluting the environment.

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Operating and maintenance – HA12I Pinguely - Haulotte

5.3.1 Hydraulic oil filter (Photo 11)

Filter without a clogging indicator:


- Unscrew collar nut (3) and remove the cartridge.
- Screw on a new cartridge.

5.3.2 Drive wheel reduction gears (Photos 12-13)

Before checking and changing oil, stop the machine and lift it up with a jack or a pulley-block to remove
the wheel.

Check that the machine is properly adjusted, the capacity is adequate and lifting
means are in good order.

• Checking oil level:


- Turn the wheel so that one plug (1) is aligned horizontally with the hub and the other plug (2) is
aligned vertically at highest point (photo 12).
- Unscrew the plug (1) and check that the oil is flush with the hole. If it is not, unscrew the second
cap (2) and add oil until it starts to run out of the first plug hole.

• Changing the oil:


- Turn the wheel so that the plug (1) is vertically aligned with the hub but at the lowest possible
position.
- Unscrew both plugs and let the oil drain out.
- Turn the wheel back to the position for checking the oil level and fill with fresh oil as described
above.

5.3.3 Hydraulic oil storage tank

• Changing the oil:


- The hydraulic circuit is drained means of a drain plug (Item 3, photo 7). Before draining,
unscrew the filler plug.

5.3.4 Batteries

In the event that the battery packs have to be removed from the machine, follow the instructions bellow:
- Stop the machine
- Turn off the battery
- Disconnect the mass
- Disconnect the +
- Put slings extremity into holes at the upper part of the battery.
- Move out the battery and replace the new one by following in reverse order the previous
procedure.

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Pinguely - Haulotte Operating and maintenance – HA12I

5.3.5 Slew backlash adjustment (photo 16)

- Screw both tuning adjustment screws (photo 16, item 1) until having a functionning adjustment
between 0.2 and 0.3 mm.
- Tight screws (photo 16 ,item 2) with a moment of 23 kg.m
- Tight screws (photo 16 ,item 1)

5.4 LOAD TESTING.

The tests below are to be performed after:


- a major strip down operation
- an accident resulting from a critical component failure.

CAUTION:

The .following test must be carried out by a competent person

5.4.1 Overload Test

The structural overload test is 125% of the rated safe working load i.e. test load 250kg See §1.12.3 of
AS 1418.10-1996 for details of the test.

The machine is to show no signs of permanent deformation.

5.4.2 Functional Test.

These tests are to demonstrate that:


• The machine can operate smoothly through all motions whilst carrying the rated safe working load i.e. 200kg.
• All safety devices are working correctly.
• The maximum permitted operating speeds are not exceeded.

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Operating and maintenance – HA12I Pinguely - Haulotte

5.4.3 Stability Test.


The worst case overturning moment applied representing the least favorable loads and forces combined is:
• 2340 m.kg which is represented by a load of 356 kg applied as shown below with the elevating work platform
on a 3.5° side slope.

See § 1.12.2 of AS1418.10-1996 for additional testing details. The elevating work platform must come to
stationary condition without overturning.
WARNING:
In order safeguard the elevating platform against tipping during the stability test, it
is imperative that a restraining device such as an anchor block and chain be used
to restrain the unit during the stability test.
This chain shall not assist in stabilizing the platform prior to it reaching point of tipping should it occur for any
reason i.e. uncontrolled application of test load.

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Pinguely - Haulotte Operating and maintenance – HA12I

6 - OPERATING PROBLEMS

REMEMBER: If the machine is used according to the instructions and is properly maintained,
most trouble can be avoided. However, certain problems could occur and
before any work is carried out the operator should check whether the problem
in question is listed in the table below. The probable cause should then be
traced and the instructions followed.

If it is not listed, the Haulotte agent or the factory After Sales Service should be
contacted.

Before trying to trace the cause of a problem, make sure that:


• the battery cut-out is closed,
• the "mushroom-button" emergency stops on the turntable and work cradle are unlocked,
• the turntable console circuit-breakers are engaged,
• the relays (work cradle control panel, turntable compartment) are correctly engaged in their
supports.

The variable speed drive includes a fault indicator device with a green LED which flashes when a fault
occurs. The flashing frequency of this LED provides a means of establishing a diagnosis in relation to
the number of flashes emitted in a series. Each series is separated by a short extinction period of the
LED. There may be anything from 2 to 11 flashes. However, the LED may remain steadily lit, meaning
that everything in the variable speed drive is working correctly. If the LED remains extinguished, check
that the work cradle is powered up and then call HAULOTTE After Sales Service (cf. arrow on photo
14)

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Operating and maintenance – HA12I Pinguely - Haulotte

6.1 LED DISPLAY ON VARIABLE SPEED DRIVE

GREEN LED PROBABLE CAUSE REMEDY


Off • No voltage • Check:
- battery connection
- battery cut-out
- emergency stop buttons
- circuit-breakers
- variable speed drive fuses
• Faulty LED • Check that everying works
• Variable speed drive faulty • Replace variable speed drive
2 flashes • Fault during start-up procedure: no pedal • Press emergency stop, reset and restart
command received. operation pressing on foot pedal first of
all, then actuate servo-control
3 flashes • Variable speed drive short-circuit • Check power cables
• Find short-circuit
4 flashes • KM2-KM3 pump contactors bonded or • Check power cables
short-circuited • Find short-circuit on contactors and
pump motor
• Check KM2 and KM3 contactors
5 flashes • KM2 - KM3 pump contactors or KM1 • Check contactor contacts
line contactor do not close • Check power cables
• Check connections of control circuit
cables (fine conductors)
6 flashes • Throttle fault, or faulty servo-control • Check servo-control connection
• Check connections of cable harness at
variable speed drive plate inlet.
7 flashes • Battery discharged - Less than 13 volts • Check if battery is charged.
• Check battery terminals
• Check power cables
• Check battery cut-out
8 flashes • Temperature rise safety system (80°C) • Check whether variable speed drive is
hot; if so, leave to cool down
• If fault persists, stop the machine.
10 and 11 flashes • Tachometer fault • Check connection of generator (Item 2,
photo 11)
• Check connections on the variable speed
drive printed circuit board (Item 2,
photo 15)
• Check condition of fuse.

After each check, press the emergency button, reset it and check the LED status on the variable speed drive.
As a general rule: After having checked the LED status on the variable speed drive and having carried out the checks as
indicated above, if the problem persists, contact HAULOTTE's After Sales Service.

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Pinguely - Haulotte Operating and maintenance – HA12I
6.2 TROUBLESHOOTING

PROBLEM PROBABLE CAUSE REMEDY

No travel movement • Turntable key selector in wrong position • Set to work cradle position
• Work cradle overload • Remove the load
• "Dead man" pedal not actuated • Actuate the pedal
• Travel movement selector in wrong position • Set to travel position
• Servo-control operating fault
• Control panel power cable damaged • Replace servo-control
• Camber or slope > 3° • Repair or replace cable
• Variable speed drive fault • Lower arm and boom to reset
• Check LED status.
No travel power • Reduction gear brake not released • Check brake release solenoid
valve
• Low speed (LS) selected • Switch to high speed (HS)
No high speed • Work cradle slightly deployed • Make sure arms and boom are
fully lowered
• Variable speed drive fault • Check fine wire connections
• Control fault • Check LS/HS selector
No low speed • Variable speed drive fault • Check fine wire connections
• Control fault • Check LS/HS selector

No movement in work • Turntable key selector in wrong position • Set to work cradle position
cradle • Work cradle overload • Remove the load
• "Dead man" pedal not actuated • Actuate the pedal
• Travel movement selector in wrong position • Set to travel position
• Servo-control operating fault
• Control panel power cable damaged • Replace servo-control
• Batteries more than 80% discharged, • Repair or replace cable
lifting/lowering movements are cut • Recharge batteries
• Solenoid valve fault on selected movement • Check battery charger
• Camber or slope > 3° - Lifting/lowering • Replace solenoid valve or its coil
movements are cut • Lower arm and boom to reset
• Lifting / slewing / derricking selector in
wrong position • Set switch to desired position
• Variable speed drive fault
• Check LED status
Arms or boom lower • Worn lifting cylinder seals • Replace seals
on their own • Polluted check valve • Replace valve and oil filter

Turntable does not • Rotation locking pin is in place in the chassis • Remove pin.
turn
No steering movement • Movement/Travel selector in wrong position • Set to Travel position
• Steering cylinder not working properly or
rod bent • Repair or replace cylinder
• Control panel power cable damaged
• Insufficient hydraulic oil • Repair or replace cable
• Servo-control operating fault • Top up level
• Variable speed drive fault • Replace servo-control
• Check LED status

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Operating and maintenance – HA12I Pinguely - Haulotte

Arms and boom do • Batteries more than 80% discharged • Change the batteries
not lift up • Faulty charge monitor • Replace the charge monitoring
unit

Electro-pump does • Variable speed drive fault • Check LED status


not work • Battery cut-out open • Close battery cut-outs
• Circuit-breakers open • Engage circuit-breakers
• Starter contactor does not work • Check power cable tightness.
Repair or replace the contactor
• Faulty or discharged batteries • Replace or recharge batteries
• Battery cables do not make contact • Clean and tighten lugs
• No action on "dead man" pedal • Actuate the pedal
• Movement selector in travel position • Select a movement
Insufficient pressure • Hydraulic pump not working properly • Repair or replace pump
or power • Pressure control screw misadjusted • Readjust (1 turn = 100 bars)
• Oil leak on coupling, hose, component • Repair or replace
• Hydraulic block fault • Replace block
• Dirty oil filter. • Replace oil filter cartridge
Noisy hydraulic pump • Insufficient oil in tank • Top up the level
• Broken or loose hose or connector (intake • Repair, tighten or replace.
side)

Hydraulic pump • Blocked breather pipe (filler cap) • Clean breather pipe
cavitation • Oil viscosity too high • Drain the circuit and replace
• Broken or loose hose, coupling or plunger with recommended oil.
tube in tank (intake side) • Repair, tighten or replace

Charge monitoring • Fuse has blown • Replace the fuse


unit does not work • Incorrect or loose electrical wiring • Check connections and tighten
• Monitoring unit operating fault • Replace the monitoring unit
Battery charger does • No voltage at selector. • Check whether current is not cut
not charge batteries at night
• Batteries discharged too much • Recharge batteries with another
charger without a regulator
• Replace or repair charger
• Faulty charger (see § 4.7) • Check the connection
• Incorrect connection of batteries

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Pinguely - Haulotte Operating and maintenance – HA12I

7 - SAFETY SYSTEMS

7.1 LIST AND FUNCTION OF RELAYS, SAFETY CONTACTS AND FUSES


(see circuit diagram)

7.1.1 Turntable compartment and variable speed drive plate


KA 1 Tilt cut-out relay and accumulator capacity indicator Arm lifting
KA 2 Tilt cut-out relay and accumulator capacity indicator Boom derricking, lifting
KA 3 Tilt cut-out relay and accumulator capacity indicator Telescope, extension
KA 4 Forced low speed control Travelling down slope > 3°
KA 5 Tilt cut-out relay Travelling
KA 6 Horn control relay
KA 7 Brake release authorisation relay Variable speed drive fault
KA 8 Steering control relay
KA 9 Steering control relay
KA 10 Electro-pump control relay Steering mode
KA 11 Speed limiting relay Manual compensation
KA 12 Speed limiting relay Turntable slewing
KA 13 Electro-pump control relay Travelling mode
KA 14 Variable speed drive mode selection relay Movements or travelling
KA 15 Brake release control relay
KT 1 Brake release time-delay relay Delay after stopping
KM 1 Line contactor Switching on
KM 2 On/Off pump contactor Steering
KM 3 Pump contactor with variation Movements
KM 4 Travelling contactor Forward/Reverse movement
QF 1 5 A circuit-breaker General protection
QF 2 5 A circuit-breaker Tilt protection
QF 3 5 A circuit-breaker Horn protection
QF 4 10 A circuit-breaker Optional equipment protection
FU 1 7 A fuse Contactor protection
FU 2 30 A fuse Control circuit protection
FU 3 400 A fuse Electric motor protection
FU 4 2 A fuse Accumulator capacity indicator
protection
PV Accu. capacity indicator, charge monitoring unit Battery protection

7.1.2 Safety Contacts


SB 5 "Dead Man" pedal
SQ 1 3° tilt detection unit Cuts travel and lifting movements if slope = 3°
SQ 2 Tilt detector reset If machine is completely lowered
SQ 3 Overload, 1st acoustic warning If 90% of maximum permissible load is reached
SQ 4 Overload, 2nd warning - Cut-out Cuts all movements from work cradle
SQ 5 High speed authorisation If machine is completely lowered
SQ 6 Optional travel cut-out at 8 m

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Operating and maintenance – HA12I Pinguely - Haulotte

8 - HYDRAULIC CIRCUIT DIAGRAM

Item Description
A BRAKE RELEASING
B STEERING
C TURRET ROTATION
D BOOM TELESCOPING
E ARM LIFTING
F BOOM LIFTING
G COMPENSATION
G1 RECEIVER CYLINDER
G2 TRANSMITTER CYLINDER
H TANK
1 Electro-pump for movements
2 High-pressure filter
3 Tank plug
4 Hydraulic oil level gauge
5 Base plate
6 Pressure relief valve
7 Dual solenoid valve
8 Single solenoid valve
9 Hydraulic accumulator
10 Base plate
11 Dual solenoid valve
12 Hand pump
13 Hand pump lever
14 Check valve
15 Check valve
16 Nozzle
17 Emergency control with protection
18 Dual pressure control valve
19 Hydraulic motor
20 Balancing cartridge
21 Cartridge support body
22 Pilot-operated double-flanged check valve
23 Pressure contact with two thresholds
24 Test point for pressure gauge
25 Cap
26 Test point for pressure gauge
27 Pressure contact with two thresholds
28 Hand pump level 30x20x600

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Pinguely - Haulotte Operating and maintenance – HA12I

36
Operating and maintenance – HA12I Pinguely - Haulotte

9 - ELECTRICAL CIRCUIT DIAGRAM

Item Description
GB 1 Battery
GB 2 Battery
U Battery charger
PV Battery charger monitoring unit
QS 1 Battery cut-out
QF 1 5 A circuit-breaker
QF 2 5 A circuit-breaker
QF 3 5 A circuit-breaker
QF 4 10 A circuit-breaker
HA 1 Horn
HA 2 Overload buzzer
HA 3 Travel warning buzzer (optional)
HL 1 "Voltage on" indicator
HL 2 Flashing light (optional)
EL Working flood light (optional)
TV 1 48/24 V current converter
SQ 1 3° tilt monitoring unit
SQ 2 Position switch
SQ 3 Micro-switch
SQ 4 Micro-switch
SQ 5 Position switch
SQ 6 Position switch (optional)
SP 1 Pressure contact - pressure switch
SB 1 Key-operated mushroom switch for turntable emergency
stop
SB 2 Mushroom switch for work cradle emergency stop
SB 3 Green push button for horn control
SB 4 Yellow push button for pump control
SB 5 "Dead man" pedal
SA 1 Turntable/work cradle key-operated selector switch
SA 2 LS - HS selector switch
SA 3 Slewing control switch
SA 4 Arm lifting control switch
SA 5 Boom lifting control switch
SA 6 Telescoping control switch
SA 7 6-position function selection switch
SA 8 Flashing light control switch (optional)
SM 1 Function control combiner
KA 1 Lifting cut-out relay
KA 2 Derricking cut-out relay
KA 3 Telescoping cut-out relay
KA 4 LS or descent cut-out relay
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Pinguely - Haulotte Operating and maintenance – HA12I
KA 5 Travel cut-out relay
KA 6 Horn control relay
KA 7 Brake release authorisation relay
KA 8 Steering control relay
KA 9 Steering control relay
KA 10 Steering pump control relay
KA 11 Manual compensation speed limiting relay
KA 12 Turntable slewing speed limiting relay
KA 13 Steering pump control relay
KA 14 Movement - Travel selection relay
KA 15 Brake release relay
KT 1 Time-delay brake release relay
R1 to Resistors
R13
V1 to Diodes
V30
FU 1 7 A fuse Item 3, photo 15
FU 2 30 A fuse Item 4, photo 15
FU 3 400 A fuse Item 5, photo 15
FU 4 2 A fuse Item 1, photo 10
E Electronic variable speed drive
KM 1 Line contactor
KM 2 Steering contactor
KM 3 Movement / Travel selection contactor
KM 4 Forward / Reverse selection contactor
M1 Travel motor
M2 Travel motor
G Tachometer - Generator Item 2, photo 11
KM 5 Mains voltage on relay

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Operating and maintenance – HA12I Pinguely - Haulotte

10 – LABELS

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Pinguely - Haulotte Operating and maintenance – HA12I

40
Operating and maintenance – HA12I Pinguely - Haulotte

41
Pinguely - Haulotte Operating and maintenance – HA12I

42
Operating and maintenance – HA12I Pinguely - Haulotte

43
Pinguely - Haulotte Operating and maintenance – HA12I

11 - PHOTOGRAPHS

1-2 - Turntable control panel


3-4 - Work cradle control panel
5 - Converter
6 - Oil-level
7 - Hydraulic oil tank
8 - Turntable locking pin - battery cut-out - charger tap
9a / 9b - Disengagement of drive wheel reduction gears
10 - Electrical cabinet
11 - Hydraulic oil filter - Pressure test point - generators
12 - 13 - Drive wheel reduction gears: checking level and draining
14 - Fault indicator LEDs
15 - Variable speed drive plate

44
Operating and maintenance – HA12I Pinguely - Haulotte

Turntable control panel

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Pinguely - Haulotte Operating and maintenance – HA12I
Work cradle control panel

46
Operating and maintenance – HA12I Pinguely - Haulotte

Converter

Oil-level

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Pinguely - Haulotte Operating and maintenance – HA12I
Hydraulic oil tank

Turntable locking pin - battery cut-out - charger tap

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Operating and maintenance – HA12I Pinguely - Haulotte

Disengagement of drive wheel reduction gears

Hydraulic oil filter - Pressure test point - generators

11

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Pinguely - Haulotte Operating and maintenance – HA12I
Electrical cabinet

10

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Operating and maintenance – HA12I Pinguely - Haulotte

Drive wheel reduction gears: checking level and draining

12

13

51
Pinguely - Haulotte Operating and maintenance – HA12I
Fault indicator LEDs

14

Variable speed drive plate

15

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Operating and maintenance – HA12I Pinguely - Haulotte

Slew backlash adjustment:

16
2
2

2
2

53