OPERATING AND ce MAINTENANCE MANUAL SELF-PROPELLED PLATFORM HA 16P - HA 16PX - HA 16PN - HA 16PE HA 18P - HA 18PX 0120 2420313860 - E 02.00 Pinguely - Haulotte La Péronniére - BP 9 - 42152 L'HORME - FRANCE © 0477 29 24 24 - Fax 0477 3128 11 EMail : Haulotte @ haulotte.com - Http : \Wwww.haulotte.comOperating and maintenance manual - HA16P HA18P Pinguely - Haulotte @ You have just taken delivery of your PINGUELY-HAULOTTE self-propelled platform, Your platform will give you full satisfaction if you carefully follow the operating and maintenance instructions provided, This manual is designed to help you. {tis very important to: + Respect the safety instructions relative to the machine itself, its use and environment, + Use the machine within its performance scope, + Maintain the machine properly, to ensure long service life.. During, and after expiry of, the warranty period, our After-Sales Department is at your disposal to provide any service you may need. In this case, contact our local Agent or our Factory After-Sales Department, and specify the exact type of machine and its serial number. Whenever you order consumables or spare parts, use this manual and the «Spare Parts» catalogue to ensure you receive original parts, which are your sole guarantee of interchangeabilty and optimal operation. IMPORTANT: This manual is supplied with the machine, and is enclosed with the delivery note. You are reminded that our machines comply with the provisions of «Machinery Directive» 89/392/CEE of 14 June 1989, modified by directives 91/368/CEE of 21 June 1991, 93/44/CEE of 14 June 1993, 93/68/CEE (98/37/CE) of 22 July 1993 and 89/336 CEE of 3 May 1989 PLATFORM HA 16P / HA 18P E 02-00 Ref. 0120 2420313860 We cannot be held liable for the technical data contained in this manual, and we reserve the right to improve or modify our machines without updating this manual.Pinguely - Haulotte # Operating and maintenance manual - HA16P HA18P- CONTENTS 1. GENERAL RECOMMENDATIONS - SAFETY. 1.1 GENERAL WARNING. 12 GENERAL SAFETY INSTRUCTIONS. 13 RESIDUAL RISKS....... E 14 OPERATING SCOPE 15 INSPECTIONS.. 151 Periodic inspections. 152° Ezaninin af machine sbiiy 153 State of conservation. 1.6 REPAIRS AND ADJUSTMENTS... 1,7 INSPECTION ON RE-OPERATION 2. PRESENTATION 2.4 IDENTIFICATION, 2.2 MAIN COMPONET 6 23 WORK SPACE .. 7 ae 23.1 HA IOP Work space... 7 23.2 HA ISP Work space. 8 24 ‘TECHNICAL CHARACTERISTICS 9 24.1 ‘Technical characteristics HA 16P - HA 16PE.. 9 24.2 Technical characteristics HA 18P. 10 24.3 Options HA 16PE. sn nnn u 2.5 OVERALL DIMENSIONS .....snn —— snnne HY 25.1 Overall dimensions HA 16P. u 28 Overall dimensions HA 16PE 2 29 Overall dimensions HA I8P. 3 26 LABELS sno 4 2.6.1 Comun labels. 4 2.6.2 Labels specific to models 16 2.6.3 Labels specific 0 options... 16 3. PRINCIPLE OF OPERATION... 3.1 HYDRAULIC CIRCUIT 7 3.1 Travel, slewing, arm lifting and boom raising movements 7 3.2 Telescoping, pendular, bucket rotation, compensation and steering movements. 7 S1g Telescoping, Boom rang, arm iting and pendula exlinders 7 BUA Gantry rOtAti OM wernnnn : 7 Plasform levelling .n.0.0 snnnennannnennnnenns ID Travel (Moving the machine) oe peeeareeas 7 Manual emergency assistance system .. 18 Emergency assistance and rescue .. 18 ELECTRICAL CIRCUIT. Plasform load control. Tilt control. High travel speed.Operating and maintenance manual - HA16P HA18P Pinguely - Haulotte # 4. OPERATION et 19 4.1 OPERATING SAFETY DEVICES..... 1D 41.1 Travel (operation from the ground). 19 41.2 Travel {operation from the platform) : 7 19 42 UNLOADING - LOADING - TRAVEL - PRECAUTIONS. 20 421 Unloading by lifting... sen 20 422 Unloading with ramps nn nn 20 423 : : 21 424 : Se eee 21 42.5 Filling the fuel tank — : 21 43°" OPERATIONS BEFORE FIRST USE .. 22 43.1 Ground control panel... 22 43.2 Platform control panel 2 43.3 Pre-operation inspection... 23 44 OPERATION. 25 44.1 Operation from the ground . 25 442 Operation from the platform nu. 25 45. RESCUE AND FAULT-OVERRIDE OPERATIONS. 26 45.1 Fault-override with the hand pump 26 45.2 Rescue eee 26 46 BRAKE DISENGAGEMENT...... seni DT 47 BATTERY CHARGE TESTER / HOUR-METER : eee 2 4.8 USING THE ON-BOARD CHARGER ...-.r ee 2 481 Characteristics. 7 27 48.2 Starting to charge .. 28 49° USE AND MAINTENANCE OF BATTERIE: 29 49.1 Firstuse 29 49.2 Discharge .. 29 493 Charging 29 494 Maintenance 29 5. MAINTENANCE, 1 5.1 GENERAL RECOMMENDATIONS 31 5.2 MAINTENANCE CHART. 31 53 OPERATIONS... 33 53.1 Summary table 33 53.2 Procedure 34 533° List of consumables 34 6. TROUBLESHOOTING 35 7. SECURITY SYSTEM... 37 7.1 FUNCTIONS OF RELAYS AND FUSES IN TURRET CABINET sonnnninninnnnnnn 37 72 FUNCTION OF SAFETY CONTACTS .... eeaeoeet 37 8. ELECTRIC WIRING DIAGRAM. ——- 81 DIAGRAME 436 38 82 NOMENCLATURE 4 9. HYDRAULIC DIAGRAM nn 9.1 92 93 DIAGRAM HA 16 aa DIAGRAM HA 16PE, 4B DIAGRAM HA 16PX - HA 18PX 50Pinguely - Haulotte @ Operating and maintenance manual - HA16P HA18POperating and maintenance manual - HA16P HA18P. Pinguely - Haulotte @ 1. GENERAL RECOMMENDATIONS - SAFETY 1.1 GENERAL WARNING The present manual is designed to familiarise the operator with HAULOTTE self-propelled platforms in order to use them efficiently and in total safely. However, it cannot replace the basic training required by any user of work place equipment ‘The site manager is bound to inform the operators of the instructions contained in the manual. ‘The site manager is responsible for applying the «user regulations» in force in the country of platform use. Before using the machine, it is essential to understand all these instructions in order to ensure safe and efficient operation. This manual must be kept available for all operators. The manufacturer will provide extra copies on request. In addition, read and understand the instructions on the plates affixed to the machine, and keep them visible. Ensure that any persons to whom you entrust the machine are fit to meet the safely requirements that its use imposes. Prevent any uncontrolled work being done on the machine when itis not in use. Never use the machine if it is malfunctioning or not in visibly good condition (cracks, hydraulic oil leaks, severed wires, etc.) Never apply to the machine a load or force greater than its maximum service load. Do not overload, Never use the machine to perform an operation for which it was not intended. Avoid any working method that may jeopardise safety. Any use not compliant with the instructions may cause risk and damage to persons and property. Do not modify the machine or its characteristics; this may reduce machine stability and safety. This manual must be kept by the user throughout the machine's service life, including in the case of loan, lease and resale. Ensure that all plates relative to safety and hazards are complete and legible. ONLY TRAINED OPERATORS CAN USE THE HAULOTTE SELF-PROPELLED PLATFORM HA 16 P/HA 18P. ‘THERE MUST ALWAYS BE AT LEAST TWO PERSONNEL PRESENT, SO THAT ONE CAN: Take fast action if necessary. ‘Take over the controls in case of accident or malfunction. = Monitor and prevent movement of vehicles and people near the platform. ~ Guide the platform operator if required. ‘These persons shall be aged over 18, and hold an operating permit issued by their employers after undergoing a ‘medical check and a practical test that prove they are fit to operate the machine.Pinguely - Haulotte # Operating and maintenance manual - HA16P HA18P 1.2 GENERAL SAFETY INSTRUCTIONS A\ To attract the reader's attention, the instructions are signalled by this standardised sign + Operators must: ~ Wear personal protective equipment suited to working conditions and to the local regulations in force, particularly works in hazardous areas. + Never use the machine: = on ground that is soft, unstable, congested or has a slope greater than 5°. ~ with exposure to wind greater than 45 km/h (HA16PE - HA18P) and 60 krvh (HA16P). If used outside, make sure, using an anemometer, that the wind speed is not greater than 45 kmvh (for HAT6PE - HA18P) and 60 km/h (for HA1EP). ~ near power lines (check minimum safe approach distances according to voltage carried) ~ without putting in place the platform safety bar or closing the safety gate - with a congested platform with equipment or objects hanging from the guardrails or boom - with items liable to increase the wind load (e.g. panels) ~ without a fire extinguisher in the platform: a holder is provided, but the extinguisher must be supplied by the user Never use the guardrails to climb into or out ofthe platform; use the steps provided. Never use the machine in an explosive atmosphere. Remove any traces of oil or grease on the platform steps, floor or guardrails. Never disable the limit switches of the safely devices. Do not increase the platform operating height by means of ladders or other accessories. Prevent any uncontrolled work being done on the machine when itis not in use. Do the daily checks and monitor the machine's good working order during use. Never: = move the control handles from one direction to the other without stopping in the «O» position ~ exceed the maximum load or the number of occupants allowed in the platform (230 kg, including 2 people). Spread the load and if possible place in the centre of the platform carry out maintenance on the machine with the platform raised, without first installing the required safety provisions (overhead crane, crane) = climb on the guardrails when the platform is up: you risk a serious fall. Grip: - the guardrail firmly when lifting the platform or driving, Avoid! = contact with stationary if moving obstructions. - driving the machine at high speed in narrow or congested areas ~ reversing (poor visibility) ~ towing the machine, it was not designed for this purpose. It must be transporied on a trailer - climbing on the covers Allow sufficient stopping distance: 3 metres at high speed, 1 metre at low speed. To stop when travelling, gradually move the handle to «O» position, keeping your foot down on the pedal. In normal service (i.e. operating from the platform), the platform/turntable control select key must be removed and kept at ground level by a person who is present and trained in rescue/fault-override manoeuvres. NEVER USE THE PLATFORM AS A CRANE, HOIST OR LIFT NEVER USE THE MACHINE TO PULL OR TOW, A NEVER USE THE BOOM AS A RAM OR THRUSTER OR TO LIFT THE WHEELS NEVER DISMANTLE OR MODIFY ANY MACHINE SECTION, ACCESSORY OR COMPONENT WITHOUT OUR PRIOR CONSENTOperating and maintenance manual - HA16P HA18P Pinguely - Haulotte # 4.2 GENERAL SAFETY INSTRUCTIONS (contd.) For all repairs use only original spare parts, which guarantee correct operation Do not drive down steep slopes at high speed IMPORTANT if the machine has a 220 V power outlet, max. amp rating 16 A, the extension cable must be connected to a mains outlet protected by a 30 mA differential breaker. 1.3 RESIDUAL RISKS ~ Sudden operation of control handles: risk of jerky and swaying movements. = Overload: risk of tip-over (be careful not to overioad from above). = Unstable terrain: risk of tip-over (refer to page 11: ground pressure and wheel load). Be careful of thawing ground in winter. - With great wind : risk of tip-over. ~ Collision with a ground or aerial obstruction: risk of impact shock or tip-over. = Collision with a live power line: risk of electrocution. ~ Work on platforms, wharves, pavements, etc.: risk of tip-over. ~ Work in explosive atmosphere: risk of explosion. Persons in machine operating area (during machine travel or manoeuvres): risk of crushing Before use, the operator must assess work area for existing overhead risks. - Hot engine parts: risk of burns. IMPORTANT THE DIRECTION OF TRAVEL CAN BE REVERSED AFTER A 180° TURRET ROTATION TAKE ACCOUNT OF THE COLOUR OF THE ARROWS (GREEN = FORWARD, RED = REVERSE) ON THE CHASSIS COMPARED WITH THE DIRECTION OF TRAVEL 8 1.4 OPERATING SCOPE Do not use the machine: a load greater than allowed load, S ~ with more than two occupants in platform, ~ on terrain that cannot withstand pressure and load per wheel, + on a side slope or grade greater than 5° (9%), + with a side load in the platform greater than 40 DaN, ~ if wind speed exceeds maximum speed, - in cold rooms, + in explosive atmospheres, - in poorly-ventitated areas, since the exhaust fumes are toxic, ~ during storms (tisk of lightning), ~ in the dark, unless the optional floodlight is fitted, = In the presence of intense electromagnetic fields (radar, communication transmitters, high currents) Driving on public roads is prohibited. 1.5 INSPECTIONS Comply with the national regulations in force in the couniry of machine use. For FRANCE: Order of 9 June 1993 + circular DRT 93 of 22 September 1993 which specifies:Pinguely - Haulotte @ Operating and maintenance manual - HA16P HAt8P 1.5.1 Periodic inspections The machine must undergo a periodic inspection every 6 months in order to detect any defect liable to ‘cause an accident. ‘These inspections are performed by a body or personnel specially designated by the site manager and under his responsibility (whether or not the personnel belong to his company) Articles R 233-5 and R 233-11 of the French Labour Code The results of these inspections are recorded in a safety register opened by the site manager and kept at the constant disposal of the labour inspector and of the site safety committee (if one exists) and the list of specially designated personnel (Article R 233-5 of the French Labour Code).NOTE: This register can be obtained from trade organisations, and in some cases from the OPPBTP or private prevention agencies. ‘The designated persons must be experience in risk prevention (Articles R 233-11 or order n* 93-41). No personnel member is allowed to perform any check whatsoever during machine operation (Article R 233-11 of the French Labour Code), 1.5.2 Examination of machine suitability ‘The manager of the site where the machine is operated must ensured the machine is suitable, ie. capable of performing the work in complete safety, and in compliance with the operating manual, Furthermore, the French order of 9 June 1993 addresses problems relative to leasing, to examination ofthe state of conservation, to checking upon operation after repairs, and to test conditions (static test coefficient 1.25: dynamic test coefficient 1.1). Every user must consult this order's requirements and comply with them. 1.5.3. State of conservation Detect any deterioration liable to cause hazardous situations (concerning safety devices, load restrictors, tilt sensor, cylinder leaks, deformation, welds, bolt tightness, hoses, electrical connections, tyre state, excessive mechanical gaps), NOTE: If the machine is rented/leased, the user responsible for the machine must examine its state of conservation and suitability. He must obtain assurance from the lessor than general periodic inspections and re-operation inspections have been performed. 4.6 REPAIRS AND ADJUSTMENTS These cover major repairs, and work on or adjustments to safety systems or devices (of a mechanical, hydraulic or electrical nature). These must be performed by personnel from or working for PINGUELY-HAULOTTE who will use only original parts. ‘Any modification not controlled by PINGUELY-HAULOTTE is unauthorised, ‘The manufacturer cannot be held responsible if non-original parts are used or if the work specified above is not performed by PINGUELY-HAULOTTE-approved personnel,Operating and maintenance manual - HA16P HA18P. Pinguely - Haulotte @ 2. - PRESENTATION Self-propelled gantries, models HA16P and HA18P, are designed for all height work within the limit of their characteristics (see § 2.3.,2.4.) and in compliance with all safety instructions specific to the machine and work areas. ‘The main control panel is in the platform. ‘The ground control panel is for rescue or fault-override operation. 2.1 IDENTIFICATION A plate affixed to the rear side of the chassis shows alll (engraved) indications allowing machine identification. : - 7 Y Pinguely-HoulolteZZ ¢ REMINDER: For all requests con- cerning information, maintenance Sou puewT ed or spare parts, specify machine Tee type and serial number. semua w* == ora weir] 3) YEAR OF MANUFACTURE NOMINAL PORER Maxi LOAD NUMBER OF PERSONS + LOAD LATERAL FORCE MAX. WINDSPEED wax SLOPE OPERATION Max. degres|Pinguely - Haulotte @ Operating and maintenance manual - HA16P HA18P 2.2 MAIN COMPONENTS Welded chassis, Drive and steered wheels Steered wheels, Fly Jib Platform support with load limiter Platform Platform control panel Input compensation cylinder Two-piece boom 10. Top arm 44. Turret 12. Covers. 13. Boom support PEN OVA OD= 44. Slewing ring 18. Hydraulic travel motors + reducing gear 16. Right compartment (diesel tank and hydraulic reservoir, control console) 17. Bottom arm 18. Top tie rod 19. Left compartment (engine + pump + starting battery) 20. Link piece 21. Bottom tie rod 22. Securing and lifting lugs 2, Bottom counterweight 24, Top counterweight,Operating and maintenance manual - HA16P HA18P Pinguely - Haulotte # 2.3 WORK AREA 2.3.1 HA16P Work areaPinguely - Haulotte @ Operating and maintenance manual - HA16P HA18P 2.3 WORK AREA (Contd.) 232 HA18P Work areaOperating and maintenance manual - HA16P HA18P Pinguely - Haulotte @ 2.4 TECHNICAL CHARACTERISTICS, 2.4.1 HA 16P - HA 16PE Technical characteristics. DESIGNATIONS. HATGP, HA 16 PX HA 16 PE fax. allowable Toa jg Tncluding 2 occupar Max. manual side force FOKg 40 kg a0kg Max. wind speed 60 kmh 60 kmih 45 kmh Floor height 74.10 m. 74.40 m 74.10 m- Working height 76.10m 16.10m 76.10m Length, overall 6.80m. 6.80 m: 6.65m Width, overall 225m 2.25 m 783m Height, overall 2.25 m 225m. 2.20 m Wheel base 2.00 m 2.00 m 2.00:m Ground clearance 350 mm, 350 mm, 265 mm, Max. reach 3.40: m 9.40. m 9.40 m: Boom range OF +75 O75" OF TS Boom extend travel 2285 mm 2285 mm 2285 min “Turntable rotation Continuous Continuous Continuous Reducing gear (efficiency = 95%) 224 224 19.4 ‘Gradeability 25% 50% 25% Tyre dimensions 335780 - RIB 335780 - RIS 245760 - RIGS ‘Outer turning radius 35m a5m 35m sensor limit 5 (« 3%) 3 (« 8%) 5 (<9) Hydraulic oll tank, capacity 100 Titres 700 Tires, 700 Titres: Fuel tank, capacity 65 litres 65 litres 66 litres Total weight 6800 kg 7100 kg 7050 kg ‘Number of drive wheels 2 4 2 ‘Number of steer wheels 4 4 4 Differential lock Yes Yes Yes Hydraulic brakes Yes: Yes: Yes Free-wheel enable Yes ‘Yes Yes: Tightening torque, wheel nuts 32m.dan 32m.daN az m.dan Tightening torque of the slew ring nuts 27 m.daN 27 m.daN 27 m.daN Vibration, foot level <05 mist <0.5 mis* <0.5 mis* Vibration, hand level <25 mis? <25 mist <2.5mis* ‘Sound level at control panel DEUTZ diesel engine FAL TOT F = Power 38 CH / 28 kW at 2400 trmin - Power, idling 20.4 CH/ 45 kW at 1250 trimin = Consumption 230 g/kWh. = Consumption, idling 230 g/kWh_ 5 cmairev hydraulic pump 85 Umin maxi LOADSENSING. Fiydraulic pressure = ~ General 240 bars - Travel 240 bars - Steering 240 bars - Rotation 100 bars - Equipment 240 bars Travel speed (PROPORTIONAL) PV:15 mh MV :3 Km/h GV:6 kmh Max. ground pressure with 250 Kg - Loose ground in gantry (concrete) 11 daNicm2 - (hard-packed surface) 3,5 daN/cm2 Max. load on one wheel 4050 daN ‘Start battery 7X12 V-95 Ah ‘Supply voltage T2VPinguely - Haulotte @ Operating and maintenance manual - HA16P HA1P 2.4 TECHNICAL CHARACTERISTICS (Contd.) 2.4.2 HA 18P Technical characteristics. [ DEsicnation HA18P HA 18 PX mi kg including 2 occupants Max. manual side force akg a0 kg Max. wind speed 5 kif a5 kmihy Floor height. 764m 164m ‘Working height 174m 74m Length, overall 750m 750m ‘Width, overall 225m 2.25 m- Height, overall 225m 2.25 m. ‘Wheel base 2.00'm 2.00:m- ‘Ground clearance: 360 mm, 360 mm Max. reach 77.00 m, 77.00. m ‘Boom range 0 +75" 0+ 75 Boom extend travel 2375 mm 2375 mm Tumtable rotation Continuous Continuous Reducing gear (efficiency = 95%) 26. 26 Gradeability 25% 30% ‘Tyre dimensions 335/80 - RIB 35580- RIB Outer turning radius 35m 35m. Tilt sensor limit B (« 9%) 3 (« 9%) Hydraulic oil tank, capacity “100 Titres 700 Titres Fuel tank, capacity 65 tres 66 litres Total weight 7750 kg 8050 kg Number of drive wheels 2 2 Number of steer wheels 4 4 Differential lock Yes Yes Hydraulic brakes Yes: Yes Free-wheel enable Yes Yes Tightening torque, wheel nuts m.daN 32m.daN Tightening torque of the slew ring nuts 27 mdaN 27 m.daN Vibration, foot level <0.5 mis <0.5 mis* Vibration, hand level <25 mis <25 mis ‘Sound level at control panel Moteur diesel DEUTZ = Power 38 CH / 28 KW at 2400 tr/min - Power, idling 20.4 CH / 15 kW at 1250 tr/min - Consumption 230 glkWh. = Consumption, idling 230 glkWh FSU 1011 F “45 cma/rev hydraulic pump LOADSENSING 85 Vmin maxi Hydraulic pressure = = General 240 bars - Travel 240 bars, - Steering 240 bars = Rotation 100 bars Equipment 240 bars Travel speed (PROPORTIONAL) Max. ground pressure (with 250 kg in gantry) ~ Loose ground (concrete) 12 daNicm* - hard-packed surface 4 daN/om* Max. load on one wheel 4050 daN ‘Start battery TXi2V-95 Ah ‘Supply voltage T2V 10Operating and maintenance manual - HA16P HA18P. Pinguely - Haulotte @ 2.4.3 OPTIONS HA 16PE Drive battery ‘375 Ah - 48V. Battery charge tester Yes ‘Charger 48 V-50A Motor pump set SKW—48V_ 8,1 kW-48V 2.5 OVERALL DIMENSIONS. 2.5.1 Overall dimensions HA 16P. 2250 1"Pinguely - Haulotte # Operating and maintenance manual - HA16P HA18P 2.5 OVERALL DIMENSIONS (Contd.) 2.5.2 Overall dimensions HA 16PE. 2230 2000 260 |200 palalo0 1830 1500Operating and maintenance manual - HA16P HA18P Pinguely - Haulotte # 2.5 OVERALL DIMENSIONS (Contd.) 2.5.3 Overall dimensions HA 18P. 7500 6000 2250 2400 BPinguely - Haulotte @ Operating and maintenance manual - HA16P HA1aP 2.6 Labels. 26.1 Common labels. FORE USING THIS WAGHINEOperating and maintenance manual - HA16P HA18P- Pinguely - Haulotte #Pinguely - Haulotte @ Operating and maintenance manual - HA16P HA18P 2.6.2 Labels specific to models. HA16P HAJ6PE - HA16PN 2.6.3 Labels specific to options Bi-energy option.Operating and maintenance manual - HA16P HA18P Pinguely - Haulotte @ 3. PRINCIPLE OF OPERATION 3.4 HYDRAULIC CIRCUIT All the machine's movements are performed by the hydraulic energy supplied by an open-circuit self-regulating piston pump, equipped with a «LOAD SENSING» compensator. 3.1.1. Travel, slewing, arm lifting and boom raising movements Carried out in pressure-compensated proportional distribution for travel and boom raising. The pump's fiow rate, through the «LOAD SENSING» line, adapts automatically to suit the demand. In neutral, there is no pump flow. 3.1.2 Telescoping, pendular, bucket rotation, compensation and steering movements Are controlled by 4-way solenoid valves. On/off flow. A spool in the proportional position valve supplies the flow necessary for these movements. 3.1.3. Telescoping, boom raising, arm lifting and pendular cylinders ‘Are equipped with leaktight and flanged balancing valve WARNING Adjustment must only be performed by specialist personnel 3.1.4 Gantry rotation Uses a hydraulic motor. The rotation speed is adjustable by the chokes 3.1.5 Gantry compensation Works by oil transfer between 2 cylinders with similar characteristics. The compensation input cylinder is equipped with a flanged double piloted valve. 3.1.6 Travel (moving the machine) x2 diesel and 4 x 2 half-eneray version: Two hydraulic motors drive the rear axle (bucket side) via epicyclic reducers. Two travel speeds (high, low) are controlled by a switch. High travel speed : The 2 motors are supplied in series. They receive the flow from the pump (or the electropump unit in electric mode for half-energy machines) which goes into one motor and then into the other. ‘Low travel speed : The 2 hydraulic motors are supplied in parallel. Each receives hal of the pump’s flow. =4x4 diesel version: Four hydraulic motors drive the wheels via epicyclic reducers. Three speeds (high, medium, low) are controlled by a switch High travel speed : The rear axle's 2 hydraulic motors are supplied in series. They receive the flow from the Pump which goes into one motor and then into the other. The front axle’s are freewheeling, ‘Medium travel spead: The rear axle's 2 hydraulic motors are supplied in parallel. They each receive haif the Pump's flow. The front axle's are freewheeling, Low travel speed : Each axle receives haif of the flow supplied by the pump. On each axle the motors are supplied in parallel. They each receive a quarter of the pump’s flow. On each axle there is provided a hydraulic differential lock. The pressure supply of these motors eliminates the action of the brake. As soon as the movement stops, the brake puts itself back in position under the action of springs. 7guely - Haulotte @ Operating and maintenance manual - HA16P HA18P 3.1.7 Manual emergency assistance system If the diesel engine is working, and in case of breakdown not allowing the use of arm lifting, boom raising, turret slewing, pendular, bucket rotation, compensation of turret and gantry consoles, it is possible to perform these movements using the mechanical levers, and pushing the manual control of the solenoid valve situated at the top on the general distribution block. 3.1.8 Emergency assistance and rescue OPERATIONS TO BE CARRIED OUT BY A TRAINED, QUALIFIED OPERATOR AND AN ASSISTANT - Emergency assistance: If an operating problem does not allow the user in the gantry to come down to the ground, a qualified operator and an assistant on the ground can do it using the hand pump and the mechanical controls of the general distribution block. ‘where the operator in the gantry is no longer in a position to control the movements although the machine is working normally. Here too, a qualified operator on the ground can use the turret console with the main diesel Power supply to bring the operator in the gantry down. 3.2 ELECTRICAL CIRCUIT The electrical power used for the controls and starting the engine is supplied by a 12 V battery. The electrical power to run the bi-fuel motor pumps is supplied by a 48 V - 375 Ah drive battery pack. These batteries can be recharged overnight using the on-board charger, plugged in a 16 A domestic socket. Main safety devices - details - Automatic engine cut-ou ~ Battery charge too low - oil temperature too high ~ oil pressure too low 3.2.1 Platform load control: If the platform load reaches 90% of the maximum allowable load, the alarm sounds to alert the operator. ‘When the maximum load is reached, the control circuit cuts out, disabling all movements. To reset, the load must be reduced. 3.2.2 Tiltcontrot ‘The tlt sensor emits a sound when the maximum allowable tilt is reached. If this state continues, after a time delay of 1 to 2 seconds the controls for the boom-iift and arm-lift with boom extended functions cut out; in addition, the travel function is disabled so long as the platform is raised. To re-enable the travel function, the entire platform assembly must be stowed, NOTE: when the platform is stowed, the tit sensor emits a sound as long as the slope exceeds 5°; this tells the operator the platform cannot be lifted. 3.23 High travel speed: High travel speed is allowed only when the platform is fully stowed. When the boom or arm is up, only low speed is allowed. Hour-meter This shows engine running time, In the bi-energy version, a meter shows the motor pumps’ running time. Charging the drive batteries In the bi-uel version, if the drive batteries reach 80% discharge, the only enabled movements are platform stowage and travel, in order to reach a recharging point. 8Operating and maintenance manual - HA16P HA16P. Pinguely - Haulotte # 4, OPERATION 4.1 OPERATING SAFETY DEVICES In order to prevent machine operation beyond its performance scope, safety de the personnel and machine. 5 are filted to protect These immobilise the machine or disable movements. In this event, poor understanding of machine characteristics and operation may cause the operator to diagnose a fault, whereas the safety devices are in fact working properly. Itis therefore essential to fully understand all the instructions in the following sections. DO NOT PERFORM MANOEUVRES BEFORE UNDERSTANDING THE INSTRUCTIONS IN SECTION 4.3. 4.1.1 Movement (controlled from the « gantry « post) To move the machine, it is necessary to put the « dead man’s « safety device into service by keeping the controller's button depressed. Releasing the pedal stops travel. Travel is possible on slopes not greater than 5° (about 9%). WARNING: + at high speed (4x4 model), the boom liftlower, telescoping and rotation functions are disabled. + high-speed travel is possible only if the telescope is in and the boom is horizontal, 4.1.2 Rescue or fault-override procedure WARNING Ifit proves necessary to perform a rescue or fault-override procedure, because the safety devices are disabled only a competent operator is allowed to do so. 19Pinguely - Haulotte @# Operating and maintenance manual - HATGP HA1EP 4.2 UNLOADING - LOADING - TRAVEL - PRECAUTIONS. IMPORTANT: Prior to any manoeuvres, check that the machine is in good condition and was not damaged in transit. If damage is observed, make the necessary reservations in writing to the carrier. A false manoeuvre can cause the machine to fall, and cause very serious physical or material accidents. Perform unloading manceuvres on terrain that is stable, sufficiently resistant (see ground pressure, § 2.4.), flat and uncongested 4.2.1 Unloading by lifting + Use a four-sling hoist. + Precautions: Ensure that ~ the lifting gear is in good working order and of sufficient capacity. ~ the sling gear can withstand the load and is not abnormally worn ~ the sling lugs are clean and in good condition. the personnel performing the manoeuvres are authorised to use lifting gear. * Unloading: = secure the four slings to the four sling lugs. + lift slowly, making sure that the load is well spread, then slowly put down the machine. WARNING. Never stand under or too near the machine during manoeuvres. Precautions: ensure that the ramps can withstand the load, that grip is sufficient to prevent skidding during manoeuvres, and that they are properly secured, IMPORTANT: Because this method requires starting the machine engine, refer to § 4.4 to prevent any risk of false manceuvres. Select low travel speed NOTE: Because the ramp is almost always greater than the maximum allowable slope (5°), the boom and arm must be down to enable travel. In this case, the alarm will sound but travel is possible. If the slope is greater than the maximum gradeable slope (see § 2.4), use a pulling hoist in addition. 20Operating and maintenance manual - HAT6P HA18P Pinguely - Haulotte 42.3 Loading Precautions are identical to those for unloading, ‘The machine must be secured as per the drawing below. To go up a lorry’s ramps, select low speed 424 Travel + Carefully respect the regulations or instructions relative to work place driving + On uneven terrain, assess the work area before starting aerial work. + Always drive a safe distance from unstable drop-offs or embankments. + Before performing a platform movement or driving, ensure there is no one in the vicinity of the machine. Reminder: driving on public roads in prohibited. 4.2.5 Filling the fuel tank + Before filing, ensure that the fuel is as specified, and that it has been propery stored to avoid being polluted. + Do not take fuel from a drum that has not settied, and never use the dregs. + Due to the fire risk when filing, take the following precautions: ~ do not smoke stop the engine if running stand upwind to avoid being splashed by fuel Place the pump spout on the tank plug hole rim before pouring, to prevent the risk of sparks due to static electricity close the tank plug securely, and remove any traces of fuel from the tank 24Pinguely - Haulotte @# Operating and maintenance manual - HA16P HA18P 3 OPERATIONS BEFORE FIRS Reminder : Before use, familiarise yourself with the machine using this manual, the engine manual and the instructions ‘on the machine plates. 4.3.1 Ground control panel: (photos 1-2) ee 1. Engine preheat light 411. Option 2. Low engine oil pressure indicator light 12. Hour-meter 3. Engine overheat indicator light 13, Engine acceleration 4. Battery charge indicator 14. Engine start button 5. Filter clogging indicator 15. Platform/tumtable control select switch 6. Boom up/down control 16. Emergency stop button 7. Gantry compensation control 17. Beacon control 8. Arm up/down control 18. Power outlet 220 V single phase - 16 A 9. Turntable rotate control 19. Tilt sensor 10. Option WARNIN oint jet A 22Operating and maintenance manual - HA16P HA18P Pinguely - Haulotte # 4.3.2 Platform contro! panel |: (photo 3) boom lifting and slewing con- troller. arm liting controler. steering and travel controller power light starting switch, hom switch. low, medium, high speed selector switch. steering switch. diferential lock switch Pendular switch, gantry rotation switch telescope switch 3. compensation switch Emergency stop button Outlet, 220 V single phase - 16 NB: Controllers are equipped with adead man secutity device 4.3.3. Pre-operation inspection + Ensure that the machine is on flat, stable ground able to withstand the weight of the machine (see § 2-4 - ground pressure) NOTE: see «work area» drawing (§ 2.3) for maximum allowable tit values. + Ensure that no obstructions can impede the following movernents: ~ travel (driving the machine) = tumtable rotation - boom lifliower and extend/retract: see «work area» drawing + Visually inspect the entire machine: paint flecks or battery acid leaks must attract your attention. + Check that there are no loose bolts, nuts, couplings or hoses; no cil leaks; no severed or disconnected electrical wires. + Check the boom, arm and platform: there must be no signs of wear or deformation. + Check there are no leaks, signs of wear, dents, scratches, rust or foreign bodies on the cylinder rods. + Check that the reducing gears are not leaking. + The hydraulic pump and motor must be free of leaks, and have no loose parts. + Check the reducing gears are not disconnected. + Check that wheel nuts are tight and tyres not excessively wom. + Check that battery lugs are clean and tight: looseness or corrosion can cause loss of power. + Check the electrolyte level in the batteries: this must be about 10 mm above the plates: top up if necessary with distilled water. battery manu Av Respect th n + Check that the platform control panel supply cable is in good condition. + Check that the emergency stop buttons are working propery. WARNING These machines are not isolated, and must not be operated near power lines. 23Pinguely - Haulotte # Operating and maintenance manual - HA16P HA18P + Check cleanliness of air filter: refer to engine manual, + Check levels: ~ of engine oil: refer to gauge (item1, photo 4) and top up if necessary (see engine manual). of hydraulic oll (3 lights under plug, item 1 photo 5) and top up if necessary (see § 5.3.2.3) = Diesel level : the min. and max. levels are visible, when the cover is closed, thanks to 2 slots. Fill up if necessary (plug item 2 photo 5). ingredi + Check the clogging indicator (item 2, photo 4) of the hydraulic oil fiter. If the red light is visible, replace the filter cartridge (see § 5.3.2.1), + Check the tit sensor is working property (item 19, photo 2), by pushing down on one side of the bearing plate. In excess of 5°, it should emit a sound. _ ee = a - — + Tumtable lock pin: = ensure that the turntable rotation lock pin (item 1, photo 6) is removed. 24Operating and maintenance manual - HA16P HA18P Pinguely - Haulotte # 44 OPERATION MPORTANT: Operation must only begin when all the operations described in the previous section have been thoroughly performed. To familiarise yourself with the machine, carry out the first manoeuvres from the ground, leaving the machine in transit configuration: counterweight at the front, boom down. WARNING: AV when the counterweight is placed over the steer wheels, the travel and steer controls react in the reverse direction. Reminder: the main control panel is in the platform, During normal operation, the ground control panel is used for rescue and fault-override, and only if absolutely necessary. 4.4.1 Operation from the ground From this control panel, the machine can only be used with engine drive. Starting the engine: (photo 1) + Make sure the stop button (item 16) is pulled out. + Move the ground/platform control select switch (item 15) to the «ground» position (Yellow rectangle). In this position, the platform controls are disabled + The indicator lights for engine oil pressure (item 1) and battery charging (item 3) are on. The air fiter clogging indicator light (item 4) is off. + Start the engine (item 14). Once the engine has started, the lights (items 1 and 3) go out.. NOTE: If the engine does not start, cut the contact by pressing the emergency stop button and repeat the operation. + Let the engine warm up, and use the time to check that the hour-meter (item 12), engine and pump and working propery. Function tests (photo 1) Reminder: before effecting any movements, ensure that no obstructions can impede manoeuvres. + Operating the movement functions automatically speeds up the engine. + Test the arm functions, up then down (switch, item 8). + Test the boom functions, up then down (switch, item.6 ) + Stop the boom when horizontal + Then, test the turntable rotate function in both directions (switch, item 9) and the telescope extendiretract function (switch, item 5), then fully lower the boom. + Move the select switch (item 15, photo 1) to the platform position (Green rectangle). * Check that the tit sensor is working properly (item 19, photo 2) Operation from the platform (photo 3) 19 the maximum load allowance: if necessary, spread the load all over MAXIMUM LOAD: 250 ki NOTE: If the maximum load is approached, the buzzer should sound; if the load is exceeded, all the machine functions will cut out and the load must be reduced. There is no load restriction in relation to reach, Fault-override with the hand pump (photo 7-8) + Prior to any manoeuvure, ensure that the green indicator light (item 4) is on, signalling that the machine is energised and that the groundiplatform select switch is set to platform control. + Ensure that the emergency stop button (item 14) is unlocked. * Check the hom is working properly. WARNING: high speed is possible only when the machine is stowed. Even if it is slightly raised, only low speed is possible. 25Pinguely - Haulotte @ Operating and maintenance manual - HA16P HA18P You may now start work. Testing the functions To carry out a movement, itis necessary to choose the corresponding controller or selector switch, Press the « dead man’s» contact and operate the desired controller. The titing angle and speed of the controllers will give the progressiveness of the movement. If the floor Is not horizontal, correct the position of the gantry with the corresponding selector switch. Test the telescoping, pendular and bucket rotation movements with the associated selector switch Test the front axle’s steering movement using the selector switch located on the travel controller's handle, and test the rear axle’s using the selector switch located on the gantry’s console. Test the 2 (in 4x2x4 version) or 3 (in 4x4x4 version) travel speeds by operating the low or high speed selector switch (in 4x2x4 version) or the low or medium or high speed selector switch (in version 4x4x4), The direction of the movements is indicated by blue arrows, 4.5 RESCUE AND FAULT-OVERRIDE OPERATIONS 4.5.1 Fault-override with the hand pump (photo 7-8) If the main power supply works badly, you can perform movements from the ground, using the hand pump (item 1), which is located next to the spool valves on the turntable. When combined with manual control of the solenoid spool valves, this pump lets you lower the arm, lower and retract the boom, and rotate the turntable. + Insert the lever (item 2) in the pump housing + Check that the pump decompression valve (item 3) is closed. * Move the lever down, while continuing to press down on the manual control of the spool valve corresponding to the required function, as shown on the plate (item 4), 4.5.2 Rescue (photo 9) If the machine is in normal operation and the operator, in the platform, cannot lower the platform to the ground, ‘an operator at ground level can do so: Move the selection key (item 15) to the « turret « position. Operate the desired movements using the controls corresponding to normal working, 26Operating and maintenance manual - HA16P HA18P Pinguely - Haulotte @ 4.6 BRAKE DISENGAGEMENT (photo 9). Itis possible to uncouple the reducers of the 2 wheels in 4x2x4 and 4 wheels in 4x4x4 so as to be able to tow the machine, in the event of a breakdown. To tow, use a rigid tow bar in order to avoid any risk of accident + Remove the citclip (1), + Turn the centre plug (2) over and put it in place Refit the circlip (1), CAUTION When the centre plug is removed, oil flows out of the reducer. + to correctly reposition the centre plug on each wheel + to top up according to the instructions in chapter 53.2. WARNING. In this configuration the machine brakes are no longer engaged. To tow the machine, itis essential to use a rigid rod and not to exceed 5 km/h, 4.7 BATTERY CHARGE TESTER Battery charge The charge of the batteries can be seen on the hour recorder (located on the turrets console) by a 10-bar display (2 red, 3 yellow and 5 green), = When the battery is correctly charged, the green diode on the far right lights up. - When the battery discharges, the diodes light up from right to left, one after the other. - When the battery is 70% discharged, the first red light flashes. It is advisable to recharge the batteries, = When the battery is 80% discharged, both red diodes flash. The cut-out threshold has been reached, and the lift functions are interrupted. Battery recharging is now compulsory. Hour-meter: ‘The hours are recorded as soon as the electropump units are operating, Reset This happens when the battery is properly recharged. 4.8 USING THE ON-BOARD CHARGER A\ WARNING : DO NOT USE THE MACHINE WHILE CHARGING. 481 Characteristics. ‘The drive batteries must be charged with the charger provided. DO NOT OVERCHARGE. - Type of charger: ZIVAN NG3 48V = Power supply: 230 Volts +/- 10% single phase - 50 Hertz = max. input current: 20 Amperes. - Supply voltage: 48 Volts - Charging time: - Mains connection: standard socket aguely - Haulotte @ Operating and maintenance manual - HAT6P HA18P 48.2 STARTING CHARGING Starting is automatic on connection to the mains. The charger is equipped with an LED located on the side of the chassis. + The green LED indicates that the battery is 100% charged. + The yellow LED indicates that the battery is 80% charged. + The red LED indicates that the charger is in the initial phase of charging. If there is a fault, the LED indicator flashes in different colours according to the type of alarm (see table). State of the flashing LED ‘TYPE OF ALARM DESCRIPTION (ACTION) RED Battery presence Battery not connected or not to standard (check the connection or the rated voltage) YELLOW Thermocouple ‘Thermocouple disconnected during charging or ‘outside the malfunction (check its connection and ‘measure the temperature of the battery). GREEN Time-delay Phase 1 or 2 has a duration greater than the ‘maximum allowed. (Check the capacity of the battery). RED - YELLOW Battery current Loss of control of output current (Fault on the control logic). RED - GREEN Battery voltage Loss of control of output voltage déconnectée ou défaut sur la logique de controle). RED - YELLOW - GREEN Thermal (Overheating of the semi-conductors (check the operation of the fan) ‘When there is an alarm, the charger ceases to supply current. 28Operating and maintenance manual - HA16P HA18P Pinguely - Haulotte # 4.9 USE AND MAINTENANCE OF BATTERIES The batteries provide the power for your platform. Follow the advice below to best utilise their capacity without risk of premature deterioration. 494 Firstuse + Check that the electrolyte level is correct. + Treat the batteries carefully during the first cycles. Be sure not to discharge by more than 70% of rated capacity (first red LED on tester flashes). + The batteries run to their full capacity after about ten cycles. Do not add electrolyte before these have elapsed 492 Discharge + Never discharge the batteries by over 80% of their capacity in 5 hours (two red diodes flash on tester). + Check the tester is working properly. + Never leave the batteries discharged. + In cold weather, do not postpone recharging as the electrolyte may freeze. 49.3 Charging + You should rechargt = when the batteries are discharged by 35-80% of their rated capacity - after a long period without use. + Recharge as follows: = Check that the mains supply corresponds to charger consumption A ~ if cell is below the minimum electrolyte level, top up to this level. = charge in a clean, well-ventilated room away from flame. = open the box lids = use the machine's on-board charger. Its charging rate is adapted to the batteries’ capacity. + During charging = do not remove or open the cell plugs ~ be sure that the temperature of the cells does not exceed 45°C (be careful in summer or in a room of high ambient temperature). “After charging ~ top up the electrolyte levels if necessary. 4.9.4 Maintenance + In normal conditions, cheok the electrolyte levels weekly before charging, + Ifnecessary, top up - with distilled or demineralised water + after charging + Never add acid (in case of acid spillage, contact PINGUELY-HAULOTTE After-Sales Dp!). + Never leave discharged batteries without running. + Avoid spillage + Clean the batteries to prevent salt formation or current bypass: ~ clean the top without removing the plugs + dry with compressed air and clean cloths... = grease the lugs. + Battery maintenance operations must be performed safely (wear gloves and goggles). To quickly assess the condition of your batteries, measure monthly the density of each cell using a hydrometer, as a function of temperature, using the graphs below (do not measure immediately after filling). 29Pinguely - Haulotte @ Operating and maintenance manual - HA16P HA18P CHARGE STATE OF A BATTERY ‘AS A FUNCTION OF DENSITY AND TEMPERATURE DO NOT RECHARGE RECHARGE 100 % 80% 60% 40 % 20 % 0% Do not electric arc weld on the machine without first disconnecting the batteries to start another machine 30Operating and maintenance manual - HA16P HA18P Pinguely - Haulotte # 5. MAINTENANCE 5.1 GENERAL RECOMMENDATIONS ‘The maintenance operations described in this manual are for normal operating conditions. In harsh conditions, {extreme temperature, high humidity, polluting atmosphere, high altitude, etc.) some operations must be performed more frequently and special precautions must be taken: (On this subject, consult the engine manufacturer or your local PINGUELY-HAULOTTE agent. Only authorised, competent personnel are allowed to maintain the machine. They must comply with safety instructions relative to protection of personnel and the environment. For engine maintenance, refer to the manufacturer's manual Periodically check the good working order of the safety devices : 4°) Tilt: buzzer + stop (cut-out of: travel, boom lifvlower and extend/retract, arm lifvower).. 2°) Platform overload - load > 200 ka, buzzer + full disable of all movement functions. 3°) High speed not possible (or medium speed for 4x4 mode) if boom up or extended, or arm up. WARNING = do not use the machine as an earth for welding - do not disconnect the (+) and (-) lugs of the batteries - do not start other vehicles with the batteries. 5.2 MAINTENANCE CHART ‘The chart on the next page specifies the frequencies, locations and the products to be used. + The mark in the symbol indicates the maintainance point according to frequency. + The symbol represents the product to use (or the operation to perform) [Lubricants used by] INGREDIENT | SPECIFICATION | SYMBOL. PINGUELY ELF TOTAL HAULOTTE Engine oil SAE 20 W oO Esso PERFORMANCE| RUBIA HD x30 XC 30 $30 Casing oil SAE 90 Esso TRANSELF [TM 80 Wi90) EP 80 W 90 EP 80 W 90 Hydraulic oi AFNOR 48602 BP HyoreLF | Equivis ISO VG 46 SHF ZS 46 DS 46 78 46 Extreme- 1SO-XM-2 pressure lithium grease Lead-free Grade 2 ou 3 O Esso MULTIMOTIVE 2} MULTIS grease GP GREASE EP2 Special —— OQ operation Grease Ceplattyn KG FUCHS © 10 HMF Lithium grease oy Enerprease BP SS Ls-EP2 EtPinguely - Haulotte # Operating and maintenance manual - HA16P HA18P MAINTENANCE CHART HOURS 32Operating and maintenance manual - HA16P HA18P Pinguely - Haulotte @ 5.3 OPERATIONS 5.3.1 Summary table FREQUENCY OPERATIONS ITEM + Check levels = engine oil 1 = hydraulic oll 2 Daily or before - diesel 3 each use - electric batteries 4 = battery charge level, refer to indicator (bi-fuel) 8 + Check cleanliness: = diesel pre-fiter, replace if water or impurities present 5 - engine air iter 6 = machine (in particular, check leaktightness of couplings and hoses), also check state of tyres, cables and all equipment and accessories. * Check hydraulic oil fit for clogging; an indicator shows if clogged; 7 iflight is on, replace the filter cartridge. Engine: see manufacturers manual 2B + Grease: - wheel pivot spindles: 2 x 2 points 10 = turntable rotation lock pin 1 * Check diesel pre-fter: replace if water or impurities present 16 + Check level of drive-wheel reducing gears (see § 5.3.2.2) 9 WARNING: after first 50 hours: Every 50h + Change the hydraulic fiter cartridge (see 250 h frequency) 7 + Drain the drive-wheel reducing gears (see 500 h frequency) 18 = 2 points for 4x2 model - 4 points for 4x4 model + Check tightness: = of rotation ring gear bolts (torque: 25 daNm) 19 = of whee! nuts (torque: 25 daNm) 2 Engine: see manufacturer's manual 24 Every 250h | + Change the hydraulic fier cartridge 23 + Grease: = the 4x2 steer-wheel bearings (remove cap) 4 = rotation ring gear ball race (rotate during the operation): 2 points 15 = the rubbing parts of the boom extension assembly (use a spatula) 20 - the rotation ring gear teeth (use a brush) 13 = the battery lugs (see § 4.8) + Check: ~ the battery charger connection (bi-fuel) (see § 4.7) - that battery lugs are tight (see § 4.8) Every 500h —_| Engine: see manufacturer's manual * Drain the wheel reducing gears 25 + Refill: capacity is 2 x 0.7 | in 4x2 version - 4 x 0.7 | in 4x4 version + Ring gear bolts: check tightness, tighten in necessary 28 Every 1000h Engine: see manufacturer’s manual or yearly * Drain hydraulic tank a Engine: see manufacturer's manual 3t Every 2000h —_| + Drain hydraulic tank and entire circuit 28 + Drain and clean diesel tank 29 + Grease rotation reducing gear: 1 point 30 Every 3000 hours | + Check: or every 4 years - state of boom extension friction pads ~_ state of electrical cables and hydraulic hoses, etc. 33guely - Haulotte @ Operating and maintenance manual - HA16P HA18P_ 5.3.2 Procedure IMPORTANT + For filing and greasing, use only the lubricants specified in the chart in § 5.2. + Retrieve drained oil in order not to pollute the environment 5.3.2.1 Hydraulic oll filter: (photo 10) This fter has a clogging indicator. ~ change the cartridge (2) if the clogging light appears in the indicator (1) NOTE: the clogging check must be done when the circuit is hot: if done cold, the light may come on due to oll viscosity ~ unscrew base nut (3) and remove cartridge ~ screw the new cartridge back on. ‘Checking and draining require the wheel to be dismounted: to do this, immobilise the machine and lift using a jack or hoist. re that the machine is A secured, and thatthe ling gear isn good condition and of ample capac + Level check: tum the wheel so that one plug (1) is on a horizontal line and one plug (2) is on a vertical line. - unscrew plug (1) and check the level, which must be up to the plug hole; top up if necessary. - Screw the plug back on. + Draining: ~ In the same position, unscrew both plugs and let the oil pour out - Fill as shown above ~ Screw the plugs back on 5.3.3 List of consumables - Hydraulic filter cartridge -air filter media - diesel pre-filter - diesel filter - engine oil filter 34Operating and maintenance manual - HA16P HA18P Pinguely - Haulotte # . TROUBLESHOOTING REMINDER: you can prevent most incidents by respecting the machine operating and maintenance instructions. However, an incident may occur. Before attempting a repair, it is essential to check in the chart in § 6.1 to see if itis listed. Ifits, just follow the instructions, Otherwise, contact the PINGUELY-HAULOTTE agent or the factory After-Sales Department. Before diagnosing a malfunction, check that = the fuel tank is not empty ~ the batteries are properly charged - the emergency stop buttons on the ground and platform control panels are unlocked ~ the relays (platform control panel - turntable box) are correctly pushed into their base. INCIDENTS. LIKELY CAUSES: SOLUTIONS Engine does not start or stop + Fuel tank empty + Electric batteries discharged + Fuse on PCB (in electrics box) defective «Emergency stop button pressed down, “Engine safety device activated: oil pressure, overheat, alternator charge, air filter clogged + Charging light bulb burnt out + Air filer clogging light on + Engine safety relay defective + Battery cables and lugs poorly connected + Filltank + Recharge batteries + Replace defective fuses + Reset + See manufacturer's manual or call Afier-Sales Department * Change bulb + Change cartridge + Replace relay + Unscrew lugs and clean + Dead man safety device not actuated + Handle operating fault Batteries more than 80% discharged: - arm-iit function disabled (bi-fuel) + Solenoid spool valve fault on selected + Lack of hydraulic oil + Tilt > 5°: arm-iift function disabled Lack of pressure | + Air fier clogged + Change the filter or power at + Engine speed too low + Adjust speed (call ASD) pump + Oil leak from coupling, hose, part + Repair and replace (call ASD) + Clogged oil fiter + Replace oil fiter cartridge: No functions —_| +Platform/ground control select switch in | + Move switch to platform position ‘working from wrong position platform + Surcharge dans la nacelle + Reduce the load “Actuate Dead man device and lift handle ring + Replace handle (consult ASD) + Recharge the batteries + Check battery tester + Replace solenoid valve or spoo! + Fill up + Lower arm and boom to reset No high speed + Platform slightly up + Fully stow arm and boom No steer function + Lack of hydraulic oil + Dead man safety device not actuated + Top up + Lift handle ring 35Pinguely - Haulotte # Operating and maintenance manual - HA16P HA18P 6 TROUBLESHOOTING (contd.) INCIDENTS LIKELY CAUSES: SOLUTIONS No travel, boom | + Titt> 5° extend, arm or boom lift, + buzzer, To reset, first retract telescope then lowe boom making a noise ‘sounding Turntable not + Lock pin is engaged in chassis + Remove pin rotating Hydraulic pump | Lack of oil in tank + Top up Cavitation in + Oil viscosity too high hydraulic pump * Drain circuit and replace by specified oi ‘ot gripping (One drive wheel + Insufficient load on one wheel + Press the lock button Proportional + Handles poorly adjusted movements too fast + Have handles reset by ASD technician Travel is sudden | + Ramp generator poorly adjusted + Have RG reset by ASD technician Buzzer sounding | Tit> 5° + Platform load near cut-out threshold + Hydraulic oll temperature too high + Reset by retracting and lowering boom + Reduce load * Leave to cool not lift + Charge tester faulty ‘Arm and boom will |+ Battery over 80% discharged * Change the batteries + Replace the tester Motor pump not | Battery cut-out open working + Fuses faulty + Batteries faulty or discharged + Baltery cables not making contact + Close cut-out + Replace fuses + Replace or recharge batteries * Clean and tighten lugs + Charger faulty (see § 4.7) + Batteries faulty Charge tester not _| + Fuse faulty + Replace fuse working + Electrical cabling incorrect or loose * Check connections and tighten Charger not * No power supply * Check that current is not cut charging + Batteries too discharged + Recharge batteries with another, + Incorrectly connected to batteries unregulated charger + Replace or repair charger * Check connection + Replace batteries. NOTE : in the turret unit, LEDs indicate the state of each output so as to check whether the turret is indeed enabled. 36Operating and maintenance manual - HA16P HA18P. Pinguely - Haulotte @ 7. SECURITY SYSTEM 2. (see electrical diagram) FUNCTIONS OF RELAYS AND FUSES in turret cabinet KAZ Starting of heat engine FU3-80 A | Accelerator circuit fuse KP1 ‘Stopping of heat engine FU4-30A — | General circuit fuse KT2 Acceleration of movements FUS-3A | Fuse - circuit for control of (@lectro-motor) movement from turret kG. Mains supply FU6-3.A | Fuse - circuit for control of ‘movement from gantry KA32 Battery-converter switching FU7-20 | Fuse - solenoid valve supply circuit KA37_ Converter's supply FU8-5 A Fuse - circuit for control from gantryiturret KMt Control of motor-driven pump unit N°4 FU9-20A | Fuse - accessories circuit (half-energy) Kua Control of motor-driven pump unit N°2 | FU10-3A | Fuse - circuit FU1-10 A | Engine stop circuit fuse FU11-250 A | Fuse - electropump n° circuit FU23A_ | Computer fuse FU12-125 A _| Fuse - electropump n° 2 circuit 7.2 FUNCTION OF SAFETY CONTACTS (see electrical diagram) asi Battery cut-out a6 | Overload 2nd alarm - cut-out Cuts all the movements in gantry sB1 Mushroom-headed emergency stop SQ3__| Tilt reset, if machine folded button (turret) (boom) SB2 Mushroom-headed emergency stop 81 Air filer contact. Cutting-out of button (gantry) engine if air filter clogged sat Tilt unit, prohibits by a cut, the arm 82 Engine temperature contact. liting, boom raising, telescoping, Cutting-out of engine if pendular raising and travel movements temperature too high S04 Titt reset, if machine folded (arm) B3 pressure contact. Cutting-out of engine if pressure insufficient SOS Overload ‘st audible alarm, Threshold B4 Hydraulic oil temperature contact of 90% of maximum charge reached Audible alarm if temperature too high 7Pinguely - Haulotte # Operating and maintenance manual - HA16P HA18P 8. ELECTRIC WIRING DIAGRAM 8.1 E436 DIAGRAM - Page 01/06 { q a : eli W ©) + im ae , 2 + Ee 4 B i4 5 i u | es ty iF 3) . 2 : H ty} i 4 | . ameem ceceaaes i Hl | ; , e 1 z 0 pt : Uy z | to r| i [| —_ _—— +—____—— — uy SS OF 38cy oe 4 | q | | ae HATE? HATEP EAB 90/z0 e6e¢q ‘GBLVH dgIVH - lenuew soueuajureW pue Buperedo @ enonen - AjonBugPinguely - Haulotte # Operating and maintenance manual - HA16P HA18P Page 03/06Operating and maintenance manual - HA16P HA18P Pinguely - Haulotte # Page 04106 oa Ge] § i Ee] SoS > Ge] HATSP FATSP EAS 1 awPinguely - Haulotte Page 05106 Operating and m iaintenance manual - HA16P HA18P- Ls y A 3 i 3 [} $s U I oo =} = ite (| ce fen U Th ser Bots H a (| P aPinguely - Haulotte # Operating and maintenance manual - HA16P HA18P. Page 06106 30 = I ae sean saa wes SCV dBtWH dOHWH ae tic : I : seer - Bese eeeg. | ca @ © a : \teo mn 4 tag o¢2 |Z M+ i t i 7 ‘ae a \ Lo \ Lin ie i luee > o S 4 Ley ee cea wept Om gee we : ——— oe ieee re eee ae = 43Pinguely - Haulotte # Operating and maintenance manual - HA16P HA18P 8.2 NOMENCLATURE REP Page-Col DESIGNATION BGt o1-1 Battery SBt 2-7 Mushroom-headed button S82 2-7. Mushroom-headed button S83 03-17 “Turret starting switch S84 03-18 Gantry starting switch S85 03-19 ‘Warning switch SAI 02-10 Post selection switch SAZ 03-2 ‘Accelerator switch ‘SAS 03-3 Differential lock switch, ‘SAA 03-5 Bucket rotation switch ‘SAS. 03-6 Gantry compensation switch ‘SAG 03-8 Turret pendular switch ‘SAT 03-9 Gantry pendular switch ‘SAB. 03-17 Turret telescoping switch SAS 03-12 ‘Gantry telescoping switch ‘SAT 03-14 Lowimediumihigh speed switch: SAI 03-15 Forward direction switch ‘SATS 05-17 “Turret raising switch ‘SAI4 05-15 Turret lifting switch SAIS 05-14 Turret slewing switch HLT O1-12 Battery charging light LZ 04-17 ‘Ar fier ight HLS 04-16 Oil temperature fight LG 04-16 Oil pressure light HLT 02-18 Power light Swat 05-4 Boom raising/siewing control ‘SM2 05-6 “Arm lifting controller SMa 05-10 Travel/direction controller Si 04-4 Tilt detector SQZ 04-5 Pendular position switch 'SQ3 04-6 Boom position switch 'SO4 04-7 ‘Arm position switch ‘SOS 04-2 Threshold 1 weighing position switch 'SO6 4-1 Threshold 2 weighing position switch KMG 02-70 ‘General relay KP1 04-18 Engine stop relay KT2 04-19 ‘Accelerator relay KAZ 04-20 ‘Starter relay FUT o1- 18 Engine stop circuit fuse FU3 01-15 ‘Accelerator circuit fuse FUS 02-3 ‘General citcuit fuse FUS 02-9 “Turret Movements conirol circuit fuse Fue 02-11 ‘Gantry Movements control circuit fuse FUT 02-12 ‘Solenoid valves supply circuit fuse Fus 02-14 Turret/gantry common circuit fuse “4Operating and maintenance manual - HAT6P HA18P Pinguely - Haulotte REP Page-Col DESIGNATION Fug 2-15, ‘Accessories circuit fuse FUIO 04-12 ‘YV1 circuit fuse FUIS 02-17 ‘Computer supply circuit fuse Yi 04-12 Load Sensing solenoid valve (EV) _ Y2 05-16 ‘On/off control selection EV. wv3 05-14 ‘Boom raising control EV. Ya 05-11 ‘Arm lifting control EV. Ys 05-3 ‘Slewing control EV. Wwe 05-7 “4x2 travel control EV. Yva 03-18 “4x2 and 4x4 high speed selection EV. Yva 04-6 “4x2 differential lock control EV. Wid 04-2 “Telescoping control EV. Wis 03-6 ‘Compensation control EV, Wi6 03-13 4x2 FRONT/REAR axle steering control EV. Wir, 03-14 4x2 steered axie selection EV. Wis, 03-4 Pendular control EV. Wis 03-7 Bucket rotation control EV. Pr 01-79 Hour recorder HAT 04-14 Warning HAZ 04-3 Weighing buzzer HAS 04-14 Tilt waming ‘4x4 OPTION Wr 5-5 Travel control EV. Wid 03-17 Travel speeds combination EV. Wit 03-16 Travel speeds combination EV. wie 03-18 Travel speeds combination EV. wis 04-4 Differential tock control EV. 7 03-10 FORWARD direction control EV. w22 03-11 REVERSE direction control EV. HALF-ENERGY OPTION. SATT 06-76 Gantry energy selection switch SAIB 06-18 Turret energy selection switch KA32 06-10 Battery switching relay KA37 06-15 Converter supply coupling relay KM 06-5 Mi electropump contactor KM2 06-7 M2 electropump contactor FUTT 06-5 Pump M1 circuit fuse FUI2 06-7 Pump M2 circuit fuse wi 06-5 Mit electropump M2 06-7 M2 electropump P2 06-9 Battery tester U2 06-9 Voltage converter US. 06-1 Battery charger GB2 06-3 Battery asi 06-3 ‘Switch 55 04-7 Pressure controler Yv23 04-7 ‘Steering overpressure evacuation EV. BEACON OPTION Hs 2-15 Beacon SAT6 02-15, ‘Switch ‘ m CUT-OUT OPTION Saiz ‘& m cut -out_position switch Sars 04-14 ‘ m cut-out position switchPinguely - Haulotte @ Operating and maintenance manual - HA16P HA18P 9. HYDRAULIC DIAGRAM 9.1 HA 16P DIAGRAM, reference B15159C LE=3) WVETYVE VE) 46Operating and maintenance manual - HA16P HA18P Pinguely - Haulotte # 815159C diagram nomenclature High speed Low speed Hydraulic rotating joint ‘Bucket rotation Compensation jacks Pendular arm lifting cylinders. Telescoping cylinders Jib raising jack ‘Arm lifting jack Turret slewing Front axle steering cylinder Rear axle steering cylinder. Reservoir Front axle. Filling plug Oillevel Piston pump. Hand pump. Hand pump lever ‘One-way valve. ‘One-way valve Pressure filter Distribution block ‘Transmission block including: = Balancing valve - Flow divider = Solenoid valve = Solenoid valve ~ Circuit selector, Hydraulic motor Hydraulic motor Balancing valve One-way valve. BREREISISISIS IS |Slolo|joloafcohol! feojojoim|njolz|lelal-fs} [ZI Base 20 Solenoid valve 22 Body 23 Pressure limiter 24 Dual flow-limiting valve 25 Hydraulic motor 26 Circuit selector 27 Flow-limiting valve 28 ‘One-way valve 29 Balancing vaive a7Pinguely - Haulotte @ Operating and maintenance manual - HA6P HA18P 9.2 HA 16PE DIAGRAM, reference B15160b Ya]YV6]¥vB} 48Operating and maintenance manual - HA16P HA18P B15160b diagram nomenciature Pinguely - Haulotte # High speed Medium speed Low speed Hydraulic rotating joint Bucket rotation Compensation jacks. Pendular arm lifting cylinders Telescoping cylinders Jib raising jack Arm lifting jack ‘Turret slewing Front axle steering cylinder Rear axle steering cylinder Reservoir Front axle Filling plug Oillevel Pump Hand pump. Hand pump lever One-way valve One-way valve Pressure filter Distribution block Transmission block including: - Balancing valve = Flow divider Seis laleleNlolo|ajoi=| folojolmajolzi-tefajr jz} (2IE|e - Solenoid valve 10d) = Solenoid valve 102. ~ Circuit selector 4 Hydraulic motor, 12 Hydraulic motor 14, Balancing valve 17 ‘One-way valve 18 Base 19 Pressure limiter 20 Solenoid valve 21 ‘Solenoid valve 22 Body 23 Pressure limiter 24 Dual flow-limiting vaive 25 Hydraulic motor 26 Circuit selector 27 Electropump unit 28 Electropump unit 29 Circuit selector 30, Base plate 31 Solenoid valve 32 Pressure limiter, 33 Flow-limifing valve 34 One-way valve 35 Balancing valve 49Pinguely - Haulotte # Operating and maintenance manual - HA16P HA18P 9.3 HA 16PX-HA 18PX DIAGRAM, reference B15164¢ a we Lr oT eTOperating and maintenance manual - HA16P HA18P. Pinguely - Haulotte @ B15161¢ diagram nomenclature GV High speed Mv. Medium speed PV, Low speed M Hydraulic rotating joint L Bucket rotation K ‘Compensation jacks J Pendular arm lifting cylinders 1 ‘Telescoping cylinders H Jib raising jack G Arm lifting jack F Turret slewing E Front axle steering cylinder D Rear axle steering cylinder Cc Reservoir B Front axle A Rear axle 41 Filling plug 2 Oillevel 3. Pump. 4 Hand pump. 5. Hand pump lever 6 ‘One-way valve 7 One-way valve. 8 Pressure filter 9 Distribution block 10 Transmission block Including: 40a ~ Balancing valve 40b - Flow divider 10c Solenoid valve 100 Solenoid valve 10e - Circuit selector 4 Hydraulic motor 12 ‘Hydraulic motor 14 Balancing valve. 17 ‘One-way valve 18 Base 20 ‘Solenoid valve 21 Steering block including: 21a - Solenoid valve 21b - Circuit selector 2ic = One-way valve 22 Bod) 23 Pressure limiter 24 Dual flow-limiting valve 25. Hydraulic motor 26 “Transmission block including: 26a = Solenoid valve, 26> = Balancing valve 26c = Flow divider 26d = Solenoid valve. 260 = Solenoid valve 27 Flow-limiting valve: 28 One-way valve 29 Balancing valve 51