C€ OPERATION AND MAINTENANCE MANUAL | SELF-PROPELLED TELESCOPIC ACCESS PLATFORMS H 21T- TX H 23 T - TX oi ae scams GPINGUELY - hauloticH REGISTERED OFFICE AND FACTORY: La Péronniére - B.P. 9 - 42150 L'HORME (FRANCE) Telephone (33) 4 77 22 82 80 - Fax After Sales Service: (33) 4 77 31 28 11 - Telex 330 169 FCE OPERATION AND MAINTENANCE MANUAL SELF-PROPELLED TELESCOPIC ACCESS PLATFORMS H 21T- TX H 23 T - TX @PINGUELY - hauloticH REGISTERED OFFICE AND FACTORY: La Péronniére -B.P. 9 - 42150 LHORME (FRANCE) Telephone (33) 4 77 22 82 80 - Fax After Sales Service: (33) 477 31 28 11- Telex 330 169 FYou have just taken delivery of your PINGUELY HAULOTTE self-propelled telescopic platform. This machine will give you entire satisfaction if you carefully follow the instructions for operation and mainte- nance. The purpose of this manual is to assist you. We must stress the importance of: * complying with the security instructions concerning the machine itself and its environment, * Using the machine within the limits ofits capacities, * correct maintenance which will determine its perennialty During and beyond the guarantee period, our After Sales Department will be at your disposal to provide the service which you may require. In this case, contact our local Agent or our Factory After Sales Department, giving full details of the exact type of the machine and its serial number. For any orders for consumables or spare parts, use this documentation or the “Spare Parts* catalogue in order ‘to obtain original spare parts, the sole guarantee of interchangeability and perfect operation. The list of warnings and security instructions is not exhaustive. This is why it is the responsiblity of the company head and the operator to comply with the rules of hygiene, security and operation in force in the country in Which the equipment is operated. May we remind you that our machines comply with the provisions of the “Directive Machines” 89/392/CEE dated 14th June 1989 as amended by the directives 91/368/VCEE dated 21st June 1991, 93/44/CEE dated Ath June 1993, 93/68/CEE dated 22nd July 1993 and 89/366 CEE dated 3rd May 1989 This manual is supplied with the machine and is mentioned on the delivery voucher, TELESCOPIC PLATFORMS H21T&TX H23T&TX £05-97 Reference N° The technical data given in this manual cannot engage our responsibility and we reserve the right to carry out Jimprovements or modifications without modifying this manual. Without our authorization, partial or total reproduction of this manual is absolutely forbidden. 1TABLE OF CONTENTS GENERAL RECOMMENDATIONS - SECURITY. 4 1.1. GENERAL WARNING. 4 1.2. GENERAL SECURITY INSTRUCTIONS. 5 1.3. POSSIBLE RISKS J 1.4, LIMITS OF USE. 6 1.5. CHECKS 7 1.5.1. Periodical checks : wD 1.5.2, Examination of the suitability of a machine 7 1.5.3. State of conservation a 1.6. REPAIRS AND ADJUSTMENTS. - 7 1.7. INSPECTIONS BEFORE BEING PUT BACK INTO SERVICE. 8 PRESENTATION sn 9 2.1, IDENTIFICATION eer sn ee) 2.2, MAIN COMPONENTS a sessmmnsonnansinecinnnennsnnsed 2.3, ZONE OF OPERATION sn sessions 2.3.1. Machines models H 21 T &H 21 Tx. seo nance 2.3.2. Machines models H 23 T & H 23 TX. sooner d TECHNICAL CHARACTERISTICS oo 13 DIMENSIONS....... a 14 2.5.1. Machines models H 21 T &H 21 TX.. 14 2.5.2. Machines models H 23 T & H 23 TX 14 OPERATING PRINCIPLE. 5 3.1, HYDRAULIC CIRCUIT. oS . Travelling, jb-raising, telescoping and slewing movements : AS . Steering, compensation and platform rotation movements. Cylinders for telescoping and raising movernents.... Platform rotation Platform compensation Travelling (displacing the machine) ‘Manual repair system Repairs and rescue 3.2, ELECTRIC CIRCUIT, OPERATION 18 4.1. OPERATIONAL SECURITY SYSTEMS 18 4.1.1, Displacement (control from turret post) 18 4.1.2, Displacement (control from platform post) 18 4.1.3. Platform overload 18 4.1.4. Procedure for repairs or rescue 18 4.2. UNLOADING- LOADING- DISPLACEMENT : sl 4.2.1, Unloading by hoisting - 19 4.2.2. Unloading with ramps 19 42.3, Loading 19 4.2.4, Displacement 204.3. OPERATIONS BEFORE EACH COMMISSIONING. 4.3.1. “Turret” control post. 4.3.2. “Platform” control post 4.3.3. Checks before use, 4.4, BEFORE EACH USE 4.4.1. Operations from the ground 4.4.2. Operations from the platform 4.5. CONNECTING THE ELECTRICAL SYSTEMS. 4.6. TRAVELLING UNDER DIFFICULT CONDITIONS. 4.7. UNCOUPLING THE TRAVELLING SYSTEM IN CASE OF BREAKDOWN. 4.8, MANUAL CONTROL OF DISTRIBUTORS 4.9. USING THE AXILIARY UNIT IN CASE OF BREAKDOWN, 4.10. RESCUE CHECK 5 MAINTENANCE. 5.1. GENERAL RECOMMENDATIONS. 5.2, MAINTENANCE PLAN 5.3. OPERATIONS. 5.3.1. Recapitulation. 5.3.2. Method of operation 5.3.3. List of consumables. 6 OPERATIONAL INCIDENTS 7 SECURITY SYSTEM.. sn 7.1. FUNCTION OF RELAYS AND FUSES... 7.2. FUNCTION OF SECURITY CONTACTS. 8 HYDRAULIC DIAGRAM. 8.1. DIAGRAM H 21 T- H 23T.... 8.2. DIAGRAM H 21 TX - H 23 TX. 9 ELECTRIC WIRING DIAGRAM 10 LABELS. 11 PHOTOS. 20 20 2 au 22 23 24 2s 25 25 2s dS 26 27 27 27 29 29 30 3 32 35 35 36 sn 3B 38 a a2 431. GENERAL RECOMMENDATIONS - SECURITY 4.1. GENERAL WARNING The purpose of the present manual is to help the operator to get to know the PINGUELY HAULOTTE telescopic platforms and to use them efficiently and in complete SECURITY. It cannot however replace the basic training required for everyone who uses equipment on the site The head of the establishment has the obligation to inform the operators of the prescriptions in the instruction manual. The head of the establishment is responsible for the application of the “user regulations” in force in the ‘country in which itis used. Before using the appliance, itis essential for the security of the equipment in use and its ef iency to get to know all these prescriptions. This instruction manual must be kept available for all operators, Extra copies may be provided on demand from the manufacturer. Get to know the instructions figuring on the labels/plates fixed on the machine and keep them clean and legible. Make sure that any person to whom you entrust the appliance is apt to assume the security requirements involved in its use. Keep your equipment safe from any uncontrolled repairs when it is not in use. Do not use any appliance which is defective or which is not in good apparent condition (cracks, hydraulic leaks, wires cut, nuts or screws unscrewed). "Never subject the appliance to any load or effort which is greater than the maximum operating load. No overloading. Never use the appliance for any operations for which it was not designed. Avoid any mode of work which may be likely to adversely affect security. Any use which is not in compliance with the prescriptions may lead to risks and injury/damage to persons or property Do not modify the characteristics of the machine or carry out any modifications, as these may reduce the degree of stability or security The operation manual must be kept by the user throughout the whole of the machine's life, including when it is resold, Check that all the plates relating to security and danger are complete and legible. ONLY TRAINED OPERATORS SHOULD OPERATE THE PINGUELY HAULOTTE TELESCOPIC PLATFORM. THEY MUST AT LEAST BE TWO OPERATORS, SO THAT ONE OF THEM CAN: * Intervene rapidly in case of need. ‘+ Take over the controls in case of an accident or breakdown, 44.2. + Survey and prevent the movements of machines and pedestrians around the platform. * Guide the platform operator if necessary These personnel must be at least 18 years old, holders of a driving permit issued by the employer after checking their medical aptitude and a practical test in operating the platform GENERAL SECURITY INSTRUCTIONS In order to draw attention, the instructions are preceded by this standardised logo The operators must always: ~ wear overalls, and protective helmets and footwear, ~ be equipped with a safety hamess and any other equipment if necessary depending on the working conditions (e.g., danger zone). Never use the machine: = on ground which is soft, unstable, or cluttered with a slope or camber greater than 5° (about 9%), = with a wind speed higher than 60 kph, — near to electric power lines. (obtain information on the minimum distances as a function of the voltage), = without positioning the safety bar, or closing the safety gate, ~ with the platform cluttered up with equipment, with equipment or objects hanging from the handrails or the jib, = with elements which could increase the force of the wind (panels, for example), ~ without an extinguisher on the platform; a bracket is provided to take the extinguisher, but this must be supplied by the customer, ~ never use the handrails as a means of climbing up to or down from the platform: use the steps provided for this on the machine, ~ in explosive zones, ~ wipe al traces of cil and grease from the steps, floor, handrails, ~ avoid contact with static oF mobile obstacles. Do not increase the working height by the use of ladders or other accessories. Protect the machine against uncontrolled repairs when not in use. Carry out the daily checks and check for correct operation during use. Never: ~ pass the control levers from one direction to the other without pausing in the middle, in position *0 ~ exceed the maximum load on the platform or the number of persons authorised on the latter (see § 2.4) — forget to distribute the loads, and if possible place them in the centre of the platform, ~ carty out maintenance operations on the machine when its in the raised position without having positioned the security systems required (overhead crane, crane) and with the motor switched off, ~ dimb on the handrails when the platform is raised: risk of serious accident by falling Hold firmly onto the handrail when the platform is being raised or moved. Avoid: = contacts with stationary or mobile obstacles, driving the platform at high speeds in narrow or dluttered zones, driving in reverse (lack of visibility) towing the platform, Itis not designed for this. t should be transported on a trailer, —dlimbing onto the bonnet, Allow sufficient distance for stopping, 3 metres at high speed and 1 metre at low speed To stop when in traveling phase, gradually bring the control lever to the zero position, while keeping your foot on the pedal.Do not use the platform as a crane, lift or elevator. Do not use the platform for towing, Never use the jib as a battering ram or for pushing, or for raising the wheels. Never dismantle or modify any part, accessory or component, without our prior authorisation. For any repairs, use only original spare parts, a guarantee of correct operation. For machines equipped with a 220 V socket: maximum amperage 16 A. Connection obligatory to a socket equipped with a 30 mA differential circuit-breaker. teggas 1.3. POSSIBLE RISKS ‘Brutal action on the control levers: risk of jerking or swinging. * Overloads risk of overtuming (beware of overloads when platform raised). * Ground problems: risk of overturning (see § 2.4., ground pressure and load per wheel) (beware of frost melting in winter) * Gusts of wind: risk of overturning + Impact against an obstacle, on the ground or at a height: risk of impact or overturning. * Touching a line under electric tension: risk of electrocution. * Operation on quays, kerbs, etc. risk of overturning * Operation in explosive atmosphere: risk of explosion. * Persons in the zone of operation of the machine (when travelling or manoeuvring the equipment): risk of crushing. ‘+ The operator must assess the risks above and below him before any operations. ‘* Hot parts on the motor: risk of burns. 1.4. LIMITS OF USE Do not use the machine: ‘= With a total load of more than 250 kg. ‘= With more than 2 persons on the platform. ‘+ On ground which will not withstand the pressure and load per wheel * On a slope or incline greater than 5° (about 9%). * With a lateral stress on the platform of more than 40 daN. ‘With a wind speed greater than 60 knv/h. * Inside cold stores. *1n an explosive atmosphere + In an incorrectly ventilated zone (toxic exhaust gases). * During a storm (tisk of lightning). * At night, without the working spottight option. ‘In the presence of intense magnetic fields (radar, cellular telephones and high currents). Do not travel on public roads (Optional: lights and direction indicator) CHECKS Comply with the local regulations in force in the country in which the machine is being used. In France: Decree dated 9 June 1993 + Circular DRT 93-22 September 1993 specifyingical spections The machine must be subject to periodical inspections every 6 months, in order to detect any faults which may cause accidents These inspections must be carried out by an organization or a person specially appointed by the head of the establishment and under his responsibilty (whether personnel of the company or nol) Articles R 233-5 and R 233-11 of the French Works Code, The results of these inspections must be entered in a security register drawn up by the head of the establishment and kept constantly at the disposal of the works inspector and the company security committee, if there is one, as well as a list of the personnel specially appointed. (Article R 233-5 of the Works Code) NB. This register may be obtained from professional organizations, and for some of them from the ‘OPP8TP or private safety prevention organizations. The personnel appointed must have experience in the field of prevention of risks. (Articles R 233- 11 of Decree N° 93-41). Its strictly forbidden to allow any workman to proceed, while the machine is operating, with any inspection whatsoever. (Article R 233-11 of the Works Code), ‘On the next page you wil find an example of the security register in which the operator must enter the results of the inspections 1.5.2. Examination of the suitability of a machine The head of the establishment in which this equipment is put into service must ensure the suitability of the appliance, that means that itis suited to the work to be carried out in complete safety and that itis used in compliance with the operation manual In addition, in this French decree dated 9th June 1993, there are mentioned the problems linked with the rental, the state of conservation, and the checks when putting the machine back into service after repairs as well as the conditions of static tests with coefficient 1,25 and dynamic tests with coefficient 1.1. Each operating manager must get to know and comply with the requirements of this decree. 1.5.3. State of Conservation Detect any deterioration likely to cause any dangerous situation (safety systems, load limiters, slope controllers, leaks from cylinders, deformation, condition of welds, tightness of bolts, hoses, electrical connections, condition of tyres, excessive mechanical play). N.B.: In case of rental, the user manager of the appliance rented is responsible for examining the state of conservation and the suitability examination. He must make sure by checking with the rental firm that the periodical general inspections and the inspections before commissioning have in fact been correctly carried out. REPAIRS AND ADJUSTMENTS Important repairs, interventions or adjustments on the security systems or components (relating to mechanics, hydraulics and electricity) must be carried out by PINGUELY HAULOTTE personnel or personnel working on its account, and they must exclusively use original spare parts, No modifications without inspection by PINGUELY HAULOTTE are authorised, The manufacturer will not be responsible if original spare parts are not used or if the works specified above are not carried out by PINGUELY HAULOTTE-approved personnel.INSPECTIONS BEFORE BEING PUT BACK INTO SERVICE Tobe carried out after: important dismantling/re-assembly operations, ‘repairs involving essential components of the machine, * any accident caused by the failure of an essential component. Itis necessary to carry out a suitability examination, an examination of the state of conservation, a static proof test, a dynamic proof test (see coefficients § 1.5.2.)2. PRESENTATION The self-propelled platform is designed for working at height within the limits of its characteristics (see § 2.3. and 2.4,), on condition that the security instructions relative to the equipment and the place of operation are respected, The main operating post is on the platform. The turret control post is an auxiliary or emergency control post. 2.1, IDENTIFICATION A plate, fixed on the rear right side of the chassis, is engraved with all the indications to enable the machine to be identified haulotte# C€ ° 1 mapTineRe 73000 cxAMBERY For any requests for information, interventions or spare parts, please quote the type of the machine and the serial number. seriatne NomicaPower(w) [J ° 2.2, MAIN COMPONENTS (Gee diagrams on next page) 1+ Chassis 2- Tower 3+ Three-section jib 4- Platform 5 = Motor and hydraulic pump 6 - Gas oil fuel tank 7- Oil tank 8 - Turret control panel 9 Main distributor PVG 10- Standby unit 11-- Slewing gearbox 12.- Platform control panel: proportional control by lever of the travelling, slewing, jib-raising movements differential contiol, telescoping, steering, compensation, high speed, platform rotation movements,13- Jiberaising cylinder 14 Telescoping cylinder 15 - Compensation transmitting cylinder 16 - Compensation receiving cylinder 17 - Platform rotation motor 18 - Steering oylinder 19 - Front driving-steering wheels 9 Gears without brakes 20 - Rear driving-steering wheels (optional: 4WD = version X) 9 Gears with brakes 21 - Weighing + platform brake 102.3. ZONE OF OPERATION 2.3.1. Machines models H 21T & H21 1X2.3.2, Machines models H 23 T & H 23 TX2.4, TECHNICAL CHARACTERISTICS CHARACTERISTICS H21T-H217K H237-H23 7K Maximum load +360 ka, Incl. 2 persons [360 kg, incl. 2 persons Maximum lateral force 40 kg 40kg Operating height 20.40 m 23.00 Height of platform floor 48.60.m 21.20m Maximum radius 16.70m 19.20m Turret rotation 360° 360° Platform rotation 180° 180° ‘Maximum slope and tit during operation 5° (about 9%) 5° (about 9%) Dimensions ofthe platform 2.00x0.80m 2.00x0.80 m Maximum slope when traveling 25% 25% Travelling low speed 15 kph 15 kph Medium traveling speed (models TPX) 25 kph 25kph High traveling speed 45 kph 45 kph Starting batteries (2) 12V-70.An 12V-70.An Ground clearance 340 mm 340 mm Tyres 15R22.5XF 15R22.5XF External turing radius 615m 615m Jib oxcilation 90" 90° Telescoping course 9.525 mm 9525 mm ‘Maximum wind speed in service 60 kph 60 kph ‘Maximum pressure on ground with 230 kg on platform * concrete 20 bar 20 bar + soft soil (packed earth): Tar 7 bar Maximum effort on one wheel 8000 dan 8000 dan Movement times with 1 person in the platforn: + mov. telescopic: ouv in about 28/19 sec. about 28/19 sec. * ib rasing: up/ down about 42/45 sec. about 42/45 sec slewing about 1 rpm ‘about 1 rpm Engine make (standard) HATZ type 3 40 HATZ type 3 1.40 + Maxi speed 3000 rpm 3000 rpm + Power rating 56 HP/ 39 kW 56 HP /39 kW * Consumption about 240 g/kWrh about 240 ghkWhn Gas cil tank capacity 150 litres 4150 litres Variable fiow hydraulic pump «Load Sensing» 85 ltresmin| 85 ltresmin Oil reservoir capacity 150litres 450 litres Service hydraulic pressure 20 bar 220 bar Tightening torque for wheel nuts 32 mdaN 32 mdaN Tightening torque for screws on slewing crown 27 mda 27 mda Weight 413 100 kg 13.650 kg Dimensions See §2.5.1 see § 2.5.2 ‘Acoustic pressure level in driving post engine 3L 40: 68 do (A) engine 3 40: 68 db (A) with engine under load engine 3M 40: 75 db (A) | engine 3M 40: 75 db (A) Vioration level at feet | <25mst <25 ms Vibration level at hands <05 mit < 05 ms * Load limiter on platform + Hydraulic differential blocking * Ring for slinging and towing * Free-wheeling * Proportional hydraulics on all movements OPTIONS * Operating spotlight * Rotating lamp * Catalytic exhaust * Power socket 220 V - 16 A + Electropump auxiliary unit ‘Mechanical blocking on slewing + Blocking pin on slewing * Cooler + Wide wheels 18x 19.5 F + Engine not sound-proofed 132.5, DIMENSIONS 2.5.1, Machines models H 21 T & H 21 TX © Lea S| | naottes g @ CL) 2490 = S e671 8 os 2.5.2. Machines models H 23 T & H 23 TX het 2018 \ 2490 Tet 11247 43. OPERATING PRINCIPLE 3.4, HYDRAULIC CIRCUIT (Gee hydraulic diagrams and nomenclatures in chapter 8) All the machine's movements are carried out by hydraulic power provided by an open-circuit, self- regulating piston pump, equipped with a compensator and a "Load Sensing" control. Itis driven by a diesel engine. In case of breakdown, an auxiliary electro-pump unit comprising 2 DC motor (powered by electric batteries) and a low flow rate gear pump, makes it possible to overcome the failure of the diesel engine. A high-pressure filter mounted on the pump discharge side protects the installation. 3.1.1. Travelling, jib-raising, telescoping and slewing movements These movements are carried out by proportional distribution, with pressure compensation, The displacement of the slide depends on the angle of the lever. The pump flow rate, via the "Load Sensing” tube, automatically adapts itself to the demand. In neutral position, there is zero pump flow. 3.1.2. Steering, compensation and platform rotation movements ‘These movements are controlled by 4-way electrovalves. All or nothing flow rate. ‘A proportional distributor slide provides the flow required for these movements. 3.1.3. Cylinders for telescoping and raising movements ‘These are equipped with balancing valves and are sealed and flanged WARNING: Adjustments can only be done by specialist personnel. 3.1.4, Platform rotation A hydraulic motor powers this; the rotation speed is adjusted by choke valves. 3.1.5. Platform compensation Operates by oil transfer between 2 cylinders with similar characteristics. The receiver compensation cylinder is equipped with a flanged non-return block, ‘The compensation speed is regulated by a choke valve. 3.1.6. Travelling (machine displacement) Version 2WD: The travelling is powered by 2 hydraulic motors in the wheels. Two speeds (High and low) are controlled by a switch Version 4wo: The travelling is powered by 4 three-speed hydraulic motors in the wheels. Three speeds (High, medium and low) are controlled by a switch (On low speed: Version 2WD: The two motors are powered in parallel; they receive a flow equal to half the discharge of the ump due to a flow divider system Version awo: The 4 motors are of large cubic capacity. Each axle receives an independent flow equal to half the pump discharge, due to 2 proportional drawers controlled by the same lever. On each axle the ‘motors are powered in parallelOn medium speed: Version 4WD only: The two motors on the fixed drive axle are powered in parallel with the maximum flow from the pump. N.B.: the steering axle is on "flow" On high speed: Version 2W0: The two motors are powered in series: they receive the flow from the pump which passes into one motor then the other. Version 4WD: The 2 motors on the fixed drive axle are powered in series with the maximum pump flow. The pressure supply to these motors suppresses the brake action. ‘As soon as the movement stops, the brake returns to its position by spring action ‘An electro-hydraulic differential lock is also provided for. 3.1.7. Manual emergency system In case of breakdown preventing the use of the jib-raising, telescoping and slewing system for the turret (from the platform panel or the turret panel) itis possible to act directly on the DANFOSS distributors by a mechanical lever. This removable lever is located at the side of the tower distributors (for its use, see § 4.7.) 3.1.8, Repairs and rescue ‘These operations must be done by trained, competent personnel. Repairs: If an operational problem prevents the operator in the platform from descending to the ground, a ‘competent operator on the groiund can do this using a motor pump unit working on batteries and control it from the turret control panel (see § 4.8.) Rescue: This is the case where the operator in the platform is no longer in a position to control the movements even though the machine is operating normally. Here again a competent operator on the ground can use the turret control panel with the main diesel power source to bring the ‘operator down again to the ground (see § 4.9.) 3.2, ELECTRIC CIRCUIT The electric power used for the controls and starting the enigine is supplied by 2 electric batteries. They also ensure the operation of the safety systems on: * Starting the engine: Prevents the risk of the starter operating when the engine is already running, * Stopping the engine, in case of: = Insufficient oil pressure. ~ Engine cylinder head temperature too high. ~ Rupture of the alternator belt = Air filter dogged. + Control over the platform load If the load gets near to the nominal load level, the audible alarm alerts the operator. At the maximum load level, the platform electro-distributor selection control is cut off. The platform load must be reduced 16+ Tilt greater than 5° The tilt detector box gives out an audible alarm when the maximum admissible tt is attained. Ifthe tit is not immediately reduced, after a set time period, the controls are cut off to the jib-raising movement (lifting and lowering), the telecoping extension and travelling movement. To reset, you must retract the telescope system and lower the jib. The machine can then travel to correct the tit situation. N.8.: The alarm will keep sounding as lang as the tilt is greater than 5°. * High and medium travelling speeds: The high and medium speeds (AWD) are only possible when the jib is lowered and the telescope retracted. When the jib is raised and the telescope extended, only low speed is possible. + Travelling In case of an operating fault on the electric travelling lever or the propor hydraulic travelling block: = travelling is impossible, = the red warning light ights up on the coil head (see chapter 6). The "dead-man" security system on travelling is a pedal system. Press this before activating the lever. Remove your foot from the pedal once the travelling operation is completed. Its not possible to change speed during travelling During travelling, the movements of slewing, jib-raising and telescoping are neutralised and it is also impossible to carry out platform compensation movements simultaneously. ‘TELESCOPING: This is impossible at high speed. + Hydraulic oil temperature If this oil temperature is too high, the audible alarm will sound. You must allow it to cool down. 7OPERATION 1. OPERATIONAL SECURITY SYSTEMS In order to prevent any risk of accidents if an attempt is made to operate the machine beyond its Possibilities, security systems are provided to protect the personnel and the machine. These immobilise the machine or neutralise the movements, In this case, a lack of knowledge or the characteristics or operation of the machine may lead to the belief that a breakdown has occurred, whereas it is the security systems which have operated correctly. It is therefore essential to assimilate all the instructions in the following chapters. 4.1.1, Displacement (control from the turret post) {In order to permit the displacement of the machine to its operating position, unloading or loading with slopes less than 40%, you must ensure that: =the jb is lowered, ~ the telescopic arm is fully retracted. Ifnot, the machine will be immobilised. 4.1.2, Displacement (control from the platform panel) To displace the machine it is necessary to activate the “dead-man” system by pressing the pedal down, Releasing the pedal will stop the displacement. Travelling is possible up to a maximum slope of 5° (about 9%). WARNING * at high and medium speeds (model 4WD), itis impossible to carry out jib-raising, telescoping and slewing movements * high speed travelling is only possible with the telescoping arm retracted and the jib lowered to a horizontal position. 4.1.3. Overloading on the platform {f the maximum load is attained, the alarm sounds and all movements are neutralised. The load must be reduced 4.1.4. Procedure for repairs or lifesaving WARNING | A Where itis necessary to carry out a repair or rescue manoeuvre with the security systems neutralised, only a competent operator can carry out these manoeuvres4.2. UNLOADING - LOADING - DISPLACEMENT IMPORTANT ! Before carrying out any manipulation, check that the machine is in good condition, to make sure that it has not been damaged during transport. In case of problems, make the necessary reservations in writing to the shipper. —____ ‘A false manoeuvre may result in the machine falling, ‘and cause serious injuries or material damage Carry out unloading on a stable surface, sufficiently resistant (see ground pressure - chapter 2.4.) flat and free from obstructions. 424. 4.2.2. 4.2.3. Unloading by hoisting ‘Access to the lifting rings requires pivoting the turret to place the jib perpendicular to the axis of the chassis. * Use a lifting beam with 4 adjustable slings * Precautions: Check that: = the lifting accessories are in good condition and are of sufficient capacity, ~ the sling accessories can withstand the load and are not abnormally worn, ~ the lifting rings are clean and in good condition, ~The personnel carrying out the operations are authorised to use the lifting equipment. * Unloading: Fix the 4 slings to the 4 lifting rings. ~ Raise the machine slightly and adjust the length and position of the slings to correctly distribute the load. Lift the machine slowly and set it down slowly. A ‘Never place yourself underneath or dose to the machine during the manoeuvres. Unloading with ramps Precautions Check that the ramps can withstand the load and that the adherence is sufficient to prevent any risk of slipping during the manoeuvre, and that they are correctly fied. IMPORTANT ! This method requires starting up the engine. Refer to § 4.3. to avoid any risk of false manoeuvres. N.B.: As the slope of the ramps is almost always greater than the maximum working slope (5°), itis necessary to have the jib and arms lowered to authorise the travelling movement. In this case the alarm sounds but the travelling movement is possible. If the slope is greater than the maximum travelling slope (see § 2.4), use a winch to increase the traction Loading The precautions are the same as for unloading. The chocking up should be as shown in the diagram below.424, jisplacement * Strictly respect the regulations or instructions for travelling in the displacement zone, * On uneven ground, carry out a prior reconnaissance of the path before starting working at height and refer to the instructions in § 4.5. “travelling under difficult conditions”. + Always travel maintaining enough distance from unstable edges and slopes. * Check that no-one is in the immediate vicinity before carrying out any movement or displacement. Reminder: its forbidden to travel on a public highway. 4.3. OPERATIONS BEFORE EACH COMMISSIONING Before any operation, get to know the machine by reading this manual, that of the engine, and the instructions on the various labels/plates. 4.3.1. Control panel on the “turret* (photo 1) 1 Red indicator lamp (engine oil pressure) 2 - Red indicator lamp (charge batteries) 3 - Red indicator lamp (engine air filter clogged) 4 Handle for opening box (2) 5 = Hour-counter 6 - Key switch for selecting control post: turret/platform 7 - Rotating light switch (optional) 9 Auxiliary unit control 10 Engine acceleration button 11 Engine-starting push-button 12+ Emergency stop button with key 13- Battery cut-out 14- Slope and tit box with audible alarm 204.3.2. Control panel on the platform (photos 2 and 3) 1 *Slewing” lever 2 "Telescopic movement” lever 3 “Jib-raising” lever 4- “Travelling with steering” lever 5 - “Platform rotation" control 6 = *Compensation" control 8 - Green indicator lamp for switching on the platform panel 9- ‘Low, medium and high speed” control 10 “Differential lock" control 11 = Push-button for starting engine 12 Horn button 13 - Emergency stop button (mushroom button) 14+ Socket 220 V. 15 - *Dead-man’s* pedal for travelling WARNING ‘When washing machines with high pressure hoses, do not spray water directly onto electric boxes and panels, 4.3.3. Checks before use ‘+ Check that the machine is placed on flat, stable ground which can withstand the weight of the machine (see § 2.4. “pressure on ground”). N.B.: See diagram “OPERATING ZONE SPACE" (§ 2.3.) for the maximum admissible slopes. * Check that no obstacle can obstruct the movements of: © travelling (displacement of the machine), 9 slewing the turret, 9 telescoping and jib-raising movements (see diagram “OPERATING SPACE"), * Visually inspect the whole machine: damage, paintwork or acid leaks should draw your attention ‘+ Check that there are no slackened bolts, nuts, connections or hoses, no oil leaks, no electric wires cut or deformed, * Check the jib and the platform: no damage visible, no trace of wear or deformation. * Check that there are no leaks, traces of wear, impacts, scratches, rust or foreign matter on the oflinder stems. * Check that there are no leaks on the wheel reducers. + Pump and hydraulic power unit: no leaks, components correctly tightened. * Check that the reducers are not uncoupled, * Check the tightness on the wheel nuts and the degree of wear on the tyres. * Check that the battery terminals are clean and tight (slackening or corrosion can cause a loss of power) *+ Check the electrolyte level in the batteries: the level should be about 10 mm above the plates; top up if necessary with distilled water. Respect the security instructions of the battery manufacturer (marked on the batteries) a* Check the correct condition of the feed cable to the main control panel. + Check that the emergency stops work correctly. * Check that there isa fire extinguisher on the working platform and that itis in working condition. WARNING ! These machines are not insulated and must not be used near to electric power lines * Check that the engine air filter is clean (see manufacturer's instructions). * Check the indicator for dogging on the hydraulic oil filter (5, photo 10 - arrow). If the red indicator is visible, replace the filter cartridge (see chapter 5). Check that the feed valve (1, photo 5) to the hydraulic pump is open. Check the levels: ~ of the engine oil: gauge (1, photo 4); top up if necessary, = of the hydraulic oil level (1, photo 6); if necessary top up by filing the plug (2) + Gas-oil evel: — check the level (3, photo 6) using the gauge, ~ use only fuel which is dean and which complies with the qualities required by the motor constructor, especially for use in low temperatures, ~do not extract fuel from a barrel if it has not been decanted and never use the dregs, ~Top up in the evening to avoid condensation forming during the night due to a drop in ambient temperature. SECURITY: When filling, do not forget to: = stop the engine, ~ place yourself upwind to avoid splashes, = correctly close the plug after filling, ~ clean off any fuel which has spilled outside the tank, —no smoking, For topping up, use only the products recommended in the chapter "PRODUCTS" Cleanliness of the gas-oil prefilter: Check that the prefilter (2, photo 4) does not contain any water or impurities, not replace it. Gas-oil tap: Check that the tap located under the tank (1, photo 9) is open. # Turret locking pin: Check that the pin for preventing the turret rotating (photo 8) has been removed. 4.4, BEFORE EACH USE IMPORTANT | The machine must not be put into service before all the operations in the above chapter have been strictly carried out. To get to know the machine, itis necessary to carry out the first manoeuvres on the ground, leaving the machine in the transport position: counterweight to the front, jib lowered, ‘WARNING ‘When the counterweight is placed above the steering wheels, the travelling and steering controls work in the opposite way 2Reminder: the main driving post isin the platform. Under normal use the “turret” control post is an emergency or breakdown post and should only be used in case of absolute necessity 4.4.1. Operations from the ground position 4.4.1.1, Starting the engine (photo 1) * Close the battery cut-out (13). * Check that the stop button (12) is pulled out. * Set the key switch (6) for selecting the control position on the position “control from ground "(pictograms). In this position the platform panel controls are neutralised. ‘+ The pressure indicator lamps for the engine oil (1) and battery charge (2) are on. The lamp (3) for air filter clogging remains off. + Press the start button (11), and as soon as the engine has started, tum the engine accelerator ‘switch (10) to the "maxi" position: the lamps (1) and(2) go out. N.B. if the engine does not start, cut the contact by pressing the emergency stop button and repeat the operation. + Allow the engine to warm up for a few minutes and use this time to check: the correct, ‘operation of the hour-meter (5), the rotating light (7) (optional), the engine and the pump. 4.4.1.2. Tests on movements (for breakdown operations only) Before any movement, check that no obstacle can affect the manoeuvres. * Place the emergency lever (5, photo 10) on the distributor corresponding to the movernent desired. ‘+ Maintain the switch turned (9, photo 1) during all the tests * Test the telescoping movements (1, photo 10 bis), jib-raising (2, photo 10 bis) and finally slewing (3, photo 10 bis) by using each emergency lever. N.B.: Stop raising the jib when itis in the horizontal position, then lower it again + Once the tests have been completed, set the engine to tick-over speed. * Stop the engine by pressing the button (12, photo 1), Once the engine has stopped, unlock the button by turning the key. 4.4.1.3. Test on the tilt detector * Check the operation of the audible alarm by pulling it towards you (14, photo 1). When the tit exceeds 5°, the alarm should sound. 4.4.1.4, Test on the standby power unit IMPORTANT ! For the unit to be able to work, it is essential that the batteries be correctly charged (see chapter 5). The standby unit can only be used if the engine is stopped and the button (12, photo 1) unlocked. ‘+ Maintain the switch turned (9, photo 1) and test the movements of telescoping, jib-raising and slewing and proceed as indicated in § 4.4.1.2. 4.4.1.5. Transfer to “platform* control (photo 1) + Set the key switch (6) to the position “platform control” (pictogram above the switch). ‘* Check that the control (10) for the engine speed is in the “mini position. The key for the switch (6) must be removed and kept by the competent person on the ground who is capable of carrying out rescue or repair work. 234.4.2. Operations from the platform Mount into the platform, respecting the instructions for maximum load, and distributing, if necessary, the load over the whole platform. MAXIMUM LOAD : 230 kg, including 2 persons N.B.: if the maximum load is attained, the alarm should sound, and all the machine movements, are cut off. You must remove the load. There is not load restriction with the radius. Test on the control panel (photo 2) ‘+ Before carrying out any manoeuvres, check that the green lamp (8) ison. ‘* Check that the red emergency button (13) is unlocked, ‘Start the engine by pressing the start button (11): the hour-meter and the rotating lamp (if there is one) on the turret control panel are in service. + Check the operation of the horn by pressing the button (12). * Press the pedal (15, photo 3) to obtain the hydraulic power require for travelling, * Correct the position of the platform if the floor is not horizontal: use the compensation switch © for the platform. WARNING AN ‘Asudden manoeuvre from the platform when itis on a slope can unbalance the operator '* Check the platform "rotation" movement with the switch (5). ‘= Check the control of all the steering wheels with the lever (4). ‘= Check the movements “slewing” - telescoping -jib-raising" with the levers (1, 2 and 3). a causes the engine to accelerate To unlock the movement of the levers (1, 2 and 3) lift the ring on the handle. To learn to manouuvre correctly, press gently on the levers and do not pass through neutral position without a pause, GRADUAL ACTION ON THE LEVERS = PROGRESSIVE MOVEMENTS * Check that rapid releasing of the lever causes the movement to stop. * Test the “travelling” movement with lever (4), by pressing at the same time on the pedal (15, photo 3) to accelerate the engine and carry out the movement. + When travelling, the automatic brake should maintain the machine braked as soon as the displacement stops WARNING ! At high travelling speed (hare) and low speed (snail), in version 4WD: ~ no possibility of telescoping, jb-raising and slewing movements, ~ possibility of high speed if the telescope is retracted and the jb lowered to horizontal + Check that the audible alarm works by overloading the platform. Once all the tests are completed, and the handling of all the controls assimuilated, work can begin. 2445. 46. 47, 4.8, 4.9. CONNECTING THE ELECTRICAL SYSTEMS The socket 220 V - 16 A (14, photo 2) is provided to supply power to small tools and lighting equipment. Its supplied by connection to the mains supply 220 V single-phase, with a cable and plug (6, photo 10) Reminder: provide protection by a differential circuit-breaker switch 30 mA (standard C 15100) which is obligatory for supply circuits. NEVER USE EQUIPMENT WITH A POWER CONSUMPTION GREATER THAN 16 A. WARNING Respect the security instructions relating to the use of electric equipment ‘TRAVELLING UNDER DIFFICULT CONDITIONS ‘Adherence on the 4 wheels: do not use the differential: control with the switch (10, photo 2). ‘Adherence on only 1, 2 or3 wheels: set to low speed and use the differential. WARNING ! On steep slopes remain on low speed UNCOUPLING THE TRAVELLING SYSTEM IN CASE OF BREAKDOWN It is possible to uncouple the reducers in the drive wheels to be able to tow the machine, in case of breakdown, For towing, use a rigid towbar to prevent any risk of accident. Unscrew the central screw (1, photo 12) with a 40 mm spanner up to the stop. WARNING A In this situation the machine is not braked. ‘When towing the machine uncoupled, maximum speed 5 kph MANUAL CONTROL OF DISTRIBUTORS Ifthe diesel engine is running and in case of breakdown, or rescue, preventing the use of the telescoping, {ib-raising, turet slewing, from the turret and platform panel, itis possible to carry out these movements: see §.4.4.1 DANGER Never attempt to carry out travelling from the distributor controls USING THE AUXILIARY UNIT This is done from the turret control panel. Where the main power source breaks down, use the axiliary power unit, * Turn the key switch (6, photo 1) to the turret position. * The thermal engine must be stopped. * Check that the emergency button (12, photo 1) is unlocked. * Activate the switch (9, photo 1) and keep it in position to make the auxliary unit give power. Retract the telescope arm, lower the jib and slew the turret by activating the corresponding lever or switch (photo 11), 254.10, RESCUE CHECK This is done from the turret control panel with the thermal engine running. * Turn the key switch (6, photo 1) to the turret postion * Activate and hold the switch (9, photo 1) and use the emergency lever on the distributor corresponding with the movernent necessary for the rescue operation (photo 11). WARNING. A Under these conditions, the security systems for limiting (radius, load) are neutralised 265. MAINTENANCE 5.1, GENERAL RECOMMENDATIONS The maintenance operations indicated in this manual are given for normal operational conditions. Under difficult conditions: extreme temperatures, high humidity, polluted atmosphere, high altitude etc., certain ‘operations must be done more frequently and special precautions taken: for this, consult the instructions from the engine constructor and the local PINGUELY HAULOTTE agent. Only authorised, competent personnel can intervene on the machine and they must respect the security instructions relating to the protection of Personnel and the Environment. For the engine itself, please refer to the Constructor's instructions Check periodically the correct operation of the security systems: 1°) Tilt: audible alarm + stoppage (travelling cut off as well a jib-raising and telescope extension). 2°) Platform overload (load > 230 kg): audible alarm + stoppage of all movements. 3°) Impossible to engage high speed (or medium speed for 4WD models) if jib raised, telescope extended. WARNING ‘never use the machine as “earth” for welding operations, * do not weld without disconnecting the (+) and (-) terminals on the batteries, + do not jump-start other vehicles with the batteries connected. 5.2, MAINTENANCE PLAN ‘On the following page there are the frequencies and points of maintenance (components) and the products to be used ‘The mark inscribed in the symbol indicates the maintenance point as a function of the frequency. «The symbol represents the product to be used. Tubes wed by proouct | —spcciricanion SYMBOL puiguety ELF TOTAL HAULOTTE ‘SAE 20W sso PERFORMANCE | RUBIA. Engine oil Oo} (Cy HOXs0 x02 $20 Centbon ol ‘SAE 90 an eso | TRANSELF | Tweows0 ePe0ws0 | EP s0ws0 eutcon | APHOR ao e02 oP WvORELF | Eau ele ISO VG 46 SHF ZS 46 os 46 78.46 treme | 6O-KM2 lchium grease teadstree | Grado ord oO eso | motores | muLTiS arease __| ce cnease Ep2 ‘Exchange or | special operation ‘EN “" ~ Lithium grease eae ma So? | 25.2, MAINTENANCE PLAN (continued) 000-2 285.3. OPERATIONS 5.3.1. Recapitulation table FREQUENCY OPERATIONS Rof. Ne ‘Check levels: * engine oil 1 * hydraulic oi 2 + gasoil 3 «+ battery electrolyte 4 Daily, Check cleanliness: or before | * of gas-oll prefiter (replace if it contains water or impurities) 5 ak * engine air filter 6 commissioning | * of the machine (check in particular the watertightness of the connections and hoses), and check the condition of the tyres, cables and all accessories and equipment Check the hydraulic ol filter for clogging (see § 5.3.2) 7 + an optical indicator indicates clogging; change the cartridge ifthe visual indicator appears Engine: see the constructor's manual 8 Check the levels in the reducers in the drive wheels (see § 5.3.2.) 9 = 2 points for model 2WD ~4 points for model WO Check the cleanliness of the gas-il prefiter(replace if water or impurities) 16 Grease: ee * wheel pivot spindles: (8 greasing points) 10 eye * steering hub, central pivot, and articulation spindle (10 points) n sours * slewing crown (2 points) 12 ‘+ slewing crown: teeth (with brush) 13 * articulation spindle on liaison part (4 points) 15 « jib base spindle (1 point) 3 WARNING After the first 50 hours’ operation: * change the hydraulic ol filter (see § 5.3.2.) a + change the oil in the wheel reducers (see § 5.3.2.) 18 * crown screw: check the tightness and tighten if necessary 19 (torque: 27 datvm) then every 500 hours Engine: see the constructor's manual 20 Grease: * the jb components: friction part (with a spatula); take opportunity to a check the wear on the slides (see § 5.3.2) pane * telescopic arm cable 2 0 ours | checks ‘* wheel nuts; check tighteness (torque: 32 dati) 2 Change: + hydrautic of filter 23 295.3.1. Recapitulation table (continued) FREQUENCY OPERATIONS REFN? Engine: see the constructor’s manual 24 Drai Every | * wheel reducers: top up 25 500 (capacity: 4x 1.4 litres) hours | Chee: * Crown screw: check tightness and retighten if necessary 6 Drain: Every _| + hhydraulic oil tank and complete circuit (ee § 5.3.2.) and top up a7 1000hours | (capacity 150 litres) orevery year | checks * ‘tension of cables on telescopic arm (see § 5.3.2.) O Every —_| * hydraulic ol tank and complete circuit 28 2000 | * drain and clean the gas-oil tank (see § 5.3.2.) 29 hours | Grease: * the rotation gearbox (1 point) 30 Check: Every 3000 | + the concition of the security cable hours or | « the condition of the cables (ib input, output) years | + the condition of the friction shoes on the telescoping jib * the condition of the electric cables, and hydraulic hoses, etc Periodically | Check: * the degree of wear on the articulation spindles Warning 1 All these frequencies must be reduced in case of operation under difficult conditions (consult the After-Sales Service if necessary). 5.3.2. Method of operation IMPORTANT I: * For topping up and lubrication, only use the products recommended in the table in § 5.2 * Recuperate the oil drained to avoid pollution for the environment, Hydraulic oi ilter (photo 10) filter with clogging indicator: © change the cartridge (5) if clogging is indicated (arrow), © unscrew the base nut (6) and withdraw the filter, © screw in a new cartridge 305.3.3. Reducers in the drive wheels (photo 12) * Check the level: Turn the wheel to place one of the plugs (2) in the horizontal position. © Unscrew the plug (2) and check the level, which should be at the height of the hole; top up if necessary through the hole 6 Screws the plug in again. * Oil draining: Turn the wheel so that one plug (2) is on a horizontal line, and another (3) on a vertical line. 0 Unscrew the two plugs (2 and 3) and let the oil drain into a recuperation tank 0 Top up as indicated above. 0 Screw the two plugs back in again. Hydraulic * Oil chan ‘A drain plug (3) located under the tank allows the hydraulic cirit to be drained and after having unscrewed the filler plug, tank (photo 9) Gas-oil tank (photo 9) * Draining: One plug (2) allows the whole circuit to be drained if the outlet tap (1) is open; if not, only the tank is drained. * Cleaning: In order to eliminate all sediment. Jib sliding shoes (photo 11) ‘* Checking the adjustment: The shoes (1) should rub against the jib without effort. To obtain correct adjustment: '* unscrew the locking-nut on the screw (2)and adjust the screw; * once the adjustment has been done, relock the locking nut and grease the jib. Security cable (photo 11) * Visual inspection of the condition of the cable (3) N.B.: This cable is for stopping the engine, via a limit switch, if the cable is under tension following an anomaly on the telescoping cables. Telescopic arm cables (photo 11 bis) * Lubrication: Two inspection hatches (see arrow) allow an internal check. Telescope the jib to gain access to the two hatches. * Check on tension: When the command for the telescopic arm extension is given, the two sections of the telescope should come out simultaneously. If not the tension of the cables is incorrect. Contact the PINGUELY HAULOTTE after sales service for the correct tension. List of consumable products * Hydraulic filter * Air fiter * Gas-oil prefiter * Gas-oilfiter + Engine oil filter 3”6. TROUBLESHOOTING Respecting the instructions for use and maintenance on the machine will prevent most incidents, However, certain incidents may occur and before taking any action itis essential to check that they are not listed in the table below. If so, its sufficient to follow the instructions. If they are not listed, please contact the PINGUELY HAULOTTE agent or the after-sales department at the factory. Before diagnosing a breakdown, it is necessary to check that. + the gas-oil tank is full, * the battery circuit-breaker is dosed, + the batteries are correctly charged, * the emergency stop buttons on the turret and platform are unlocked, * the relays (control panel on the platform, box on the turret) are correctly pressed into their bases. INCIDENTS PROBABLE CAUSES REMEDIES * Battery circuit breaker open * Close the circuit breaker * Gasoil tank tap closed + Open the tap + Gasoil tank empty * Fill the tank + Electric batteries discharged + Charge the batteries ‘+ Fuses on the printed circuit (in * Replace the defective fuses the electric box) defective Engine fails | * Emergency stop button pressed down —_| « Reset tostart, | « Engine on “security (cil pressure, + Refer to constructor's manual or call or stops overheated, alternator charge, in the after sales service air filter dogged) * Charge indicator bulb bumnt out * Change the bulb * Ar ter dogging warning lamp © Change the filter it up * Engine security relay defective + Change the relay ‘+ Bad contact battery cables and terminals _| + Unscrew terminals and clean them. * Engine air filter dogged * Change the filter + Pump damaged * Check condition of pump * Engine speed too low + Regulate the speed (see § 2.4.) Lack of pressure or power | * Oilleaks * Eliminate the leaks inthe pump | + “Load Sensing" pressure too low + Adjust the pressure: 18 to 20 bar | ess than 16 bar) ‘+ Hydraulic pressure insufficient in the + Regulate the pressures: There are circuit and in the movements | pressure points for fitting a pressure | gauge | 32INCIDENTS, | PROBABLE CAUSES. REMEDIES No movements at the platform + Turret key selector in the wrong position * Lack of hydraulic oil * Overload on the platform + "Dead man" pedal not activated + Turretplatform selection electrovalve defective * Defective supply to the Danfoss coils (ren lamps on coil off) ‘+ Switch to “platform” position + Check the hydraulic il level |+ Remove the excess load | + activate the pedal + Change the electrovave or its cil * Check the electric circuit No travelling telescoping out, | + Slope or tit < 5° * First retract the telescope, then lower the jib-raisings alarm jib to reset functioning + Platform in high position * First retract the telescope, then lower the oigh speed jib to reset * Electrovalve or switch not operating * Change the switch, the electrovalve or its coil No adherence on 1 drive wheel ** Load insufficient on one wheel '* Activate the switch to neutralise the differential effect Propor. movem'ts ‘00 rapid * Levers deregulated * Have the levers regulated by the After- sales technician Travelling move- ment too brutal ‘+ Ramp generator deregulated + Have it regulated by the After-sales technician * Slope or tlt > 5° ‘Reset by retracting the telescope and lowering the jib ‘Audible alarm sounds * Platform load near to the cut-off * Unload the excess weight * Temp. hydraulic ol too high * Allow to cool * Control switch defective * Change the switch No movements allor nothing: | * Control electrovalve not working + Change the electrovalve or its coil (steering, _ | » Steering cylinder not working correctly compensation and platform rotation) '* Repair or replace the cylinder Hydraulic pump noisy * Lack of oil in the tank ‘+ Hose or connection broken or slack (on admission side) }* Top up + Repair, retighten or replace Overheating on the hydraulic Greuit * Viscosity of oil too high * Intensive travelling * Drain and change the oil * Have a cooler installed 33INCIDENTS PROBABLE CAUSES REMEDIES (Open the tap + Tank tap closed Cavitation in the hydraulic pump | * Breather (filer plug) obstructed (wacuum inthe | « viscosity of the oil too high | « Drain the circuit and replace with pump due to lack recommended oil Clean the breather 2101) | Hose, connection or intake tube broken | « Repair rtighten or replace** or slackened (admission side) : * WARNING 1 * Cavitation bubbles + Bubblese pressur serious problem (oilpneumatic system) * Bubbles + pressure + heat =......inadmissible situation. NL It takes about 4 hours for oil emulsified by cavitation to return to normal condition 347. SECURITY SYSTEM 7.1. FUNCTIONS OF RELAYS AND FUSES - BOX ON TURRET (SEE ELECTRIC DIAGRAM) RELAYS | Function KA1 | Prevents the thermal engine from starting when itis already running KA2 | Prevents the command for starting the standby pump motor when the thermal engine is already| running KA3 | Activates the alarm HAI in accordance with the oil temperature KA4 | Stops the jib-raising command if the telescopic arm is extended and if the machine is on a slope greater than 5° KAS | Stops the telescoping command if the slope is greater than 5° and ifthe jib-raising cylinder is extended KA6 | Stops the travelling command if the slope is greater than 5° and if the telescope or jib oylinder. KA7 | Allows starting the thermal engine from the turret KA8 | Allows the command for timing for the weighing security 95% KA9 | Stops the turret slewing command if the machine is on overload KA10 | Allows the manual command for the horn HAT KA11 | Authorises the command for the security electrovalve KA12 | Stops the travelling command if the telescope or jb-raising control is activated KA13 | Allows the acceleration of the movements done from the platform KA14 | Allows the command for timing if one of the movements is carried out and if the machine is on overload KA15 | Prevents changing speed during travelling KA 16 Allows the activation of the steering electrovalve KA17 Allows the activation of the steering electrovalve KA18 | Allows the activation of the low or high speed KA21 | Inversion 4WD, allows the command for the low, medium or high speed KL1 | Bistable for high speed command, electrovalve YV 11 command KL2 | Bistable for medium or high speed command, electrovalve YV 14, YV 16 & YV 17 command KM | Allows start up of standby pump engine KP Allows start up of thermal engine from cold FU1-2A | Signals circuit protection fuse FU2-5A | Horn circuit protection fuse FU3-2A | Slope circuit protection fuse FU4~2A | Slope circuit protection fuse FUS-5SA | Acceleration circuit protection fuse FU6-2A | Weighing circuit protection fuse FU7-3A | Electro security circuit protection fuse FU8-5A | Differential command circuit protection fuse Fu9-3A | Fuse FU10-3A | Platform rotation circuit protection fuse FU11-3A | Platform rotation circuit protection fuse FU12-3A | Compensation circuit protection fuse FU13-3A | Compensation circuit protection fuse FU14-3A | Steering circuit protection fuse FU15-3A | Steering circuit protection fuse 35FU16-3A FUIT-24 FU 18-24 FU19- 2A Fu20- 2A FU22-3A FU23-SA FU24-SA FU28-SA FU29-5A FU30-3A Standby pump circuit protection fuse Raising crcuit protection fuse Telescoping movement circuit protection fuse Slewing circuit protection fuse Travelling circuit protection fuse High speed electrovalve circuit protection fuse Rotating lamp circuit protection fuse (optional) Oil cooling circuit protection fuse (optional) Low speed, medium speed, high speed circuit protection fuse (as per version) Spotlight circuit protection fuse (optional) YW 13 circuit protection fuse (optional) 7.2. FUNCTION OF SECURITY CONTACTS (see electrical diagram) Relays Function Qs Battery circuit-breaker $81 | Turret emergency stop button (mushroom button with key) $82 | Turret emergency stop button (mushroom button) S86 | “Dead man* type pedal. Travelling command cut off if pedal released sm Engine temperature contact. Stops engine if temperature too high ST2 | Engine temperature contact. Stops engine if oil temperature too high sP Oil pressure contact - Stops engine if pressure too low eo) Air filter contact - Stops engine if filter is clogged $Q1 | Tilt control box - stops by cutting off the movements of jib-raising, telescoping and travelling SQ2 | After telescope arm retraction, authorises jb-raising 523 | After retraction of jb-raising cylinder, authorises machine travelling (and telescoping movement if the slope is less than 5° 5Q4 | Jib cable rupture security system - stops the engine SQ5 | Weighing security system - Causes alarm HA 2 to sound $Q6 | Weighing security system (105% of useful load). Cuts off turret slewing movement $Q3 | Option for travelling cut-off at 8 metres 368. HYDRAULIC DIAGRAM 8.1. DIAGRAM H 21 T- H 23 T (Drawing N°: B 14.850) Ref.N°} Qty Part N° Designation 1 1 | 242020394 filler plug UC AB 1163 10 2 | 1 | 242030255 Strainer UC SE 13.23 3 | 1 | 242140156 | Oiflevel UCL 31111 4 | 1 | 242180427 | Valve KHNVNG 171/2-2.2-33 5 1 | 242620804 Pump SAUER OVP - 1/038 -RS-Z-RQN 6 | 1 | 242070183 Electro-pump unit 1500 W - 24 V CC 7 | 2 | 243120323 Hydraulic motor OMSS 100 a | 1 | 242020853 Travelling block St. SP. 2464, including we | 4 Distributor CETOP-S WETODAS380240 a | 2 | Bolance valve CBEH-LCN a | 1 Divider FSEH-KAM, ad 1 Distributor CETOP-3 WEOEDA11A0240 9 | 1 | 242220139 Double overpressure valve for OMR VAQ6/E1 to | 1 | 243120309 Motor OMR 100 Ref. 151 0212 u" 1 | 242020179 Balance block Ref. 8306 29U 802 12 | 1 | 243120330 Hydraulic motor Ref. OMM 32 3 1 | 242660218 Double flanged non-return valve Ref. 554-575, 14 | 3 | 242120195 Flow limiter DVOB-1-1/0-P Code 705-012 15 | 1 | 242020180 | Orifice balance block 15/21, including 15a | 2 Fiter CBEA-LAN adjustable to 200 bar 1b | 1 Valve RPEC-JAN adjustable to 100 bar 16 | 1 | 242160178 Base plate OGMS3-3-E-10R 17 | 2 | 248050653 Electrovalve DG4V3 6C MU H760 19 | 1 | 242660176 | Controted non-return valve DGMPC-3-ABK-BAK-40 20 | 1 | 242220129 | Double balance valve OVC DEF C3 22 | 1 | 244050660 | — Electrovaive DGAV-3-2-CMUH 760 23 | 1 | 242020323 Distribution block 5 movements PVG 32 24 | 1 | 242701035 | 6" Filter Ref. VHF 9800C12KMFBPYE77 25 | 1 | 242660190 | Non-return valve RA04040000 Spring 0.5 b 26 | 1 | 242660202 Non-return valve 9C 600 $10 3/8G 0.35 b 27 | 1 | 248080687 Electrovalve DG4V3-24-MU H760 28 | 1 | 244160533 | Base plate NG6 1815 504 903 29 | 1 | 244160415 | *Minimess" pressure gauge 1/4 30 | 1 | 242190323 | 6-way selector vs 150 3 1 | 244050652 Electrovalve ED 06/32.01.24v with block 32 | 2 | 242190148 Selector VFC NC 14 ALU 388.2. DIAGRAM H 21 TX -H23 TX (Drawing N°: B 14 863) Ref.ne| Qty Part N° Designation 1 1 | 242020394 Filler plug UC AB 1163 10 2 1 | 242030255 StrainerUC SE 13.23 3 1 | 242140156 il level UCFL 311.11 4 | 1 | 242180427 Valve KH NVNG 1°1/2-2.2-33 5 | 1 | 242620804 Pump SAUER OVP - 1/038 -RS-Z-RQN 6 | 1 | 242070183 Electropump unit 1500 W - 24 V CC 7 | 1 | 242020321 Block as per specification $5000, including 7 | 2 | 244050689 Electrovalve Bosch NG6 0810 031 266 7a | 1 | 244080683 Electrovalve Bosch NG10 810 001 816 ve | 1 | 244050681 Electrovalve with cartridge 24v FLUTEC 2SV5. wm | 4 | 242080170 Flow divider BEMA MTOP 08 050 M 7g | 2 | 242700702 Balance valve SUM CBCH LCN a | 1 | 242020853 Travelling block St SP.2464, including sa | 1 Distributor CETOP 5 WE10DA9380240 so | 2 Balance valve CBEHAACN se | 4 Dividor FSEH-XAN ad 1 Distributor CETOP 3 WEOEDATTAO240 9 1 | 242220139 Double overpressure valve for OMR VAQ6/E1 to | 1 | 243120309 Motor OMR 100 Ref. 151 0212 " 1 | 242020179 Balance block Ref. 8306 29U 802 2 1 | 243120330 Hydraulic motor Ref. OMM 32 B 1 | 242660218 Double flanged non-return valve Ref. 554-575 14} 3 | 242120195 Flow limiter DVO8-1-1/0-P Code 705-012 15 1 | 242020180 Balance valve, orifice 15/21, including ioe Fiter CBEA-LAN adjustable to 200 bar 150 | 4 Valve RPEC-JAN adjustable to 100 bar 16 1 | 242160178 Base plate DGMS3-3-E-10R 17 | 2 | 244050653 Electrovalve DG4V3 6C MU H760 19 | 4 | 242660176 Controled non-return valve DGMPC-3-ABK-BAK-40 20 | 1 | 242220129 Double balance valve OVC DE-F C3 2 1 | 244050660 Electrovalve DGAV-3-2-CMUH 760 23 | 1 | 242020326 Distribution block 6 moverents PVG 32 2a | 1 | 242701035 Filter 6° Ref. DHF 9800C 12KNFBPYE77 25 | 1 | 242660190 Non-return valve RA04040000 Spring 0.5 b 26 | 1 | 242660202 Non-return valve 9C 600 S10 3/86 0.35 b 27 | 1 | 248050687 Electrovalve DG4V3-24-MU H760 28 | 1 | 244160533 Base plate NGG 1 815 504 903 29 | 1 | 244160415 “Minimess* pressure gauge 1/4 3 4 | 243120323 Hydraulic motor OMSS 100 32} 1 | 242190323 6-way Selector VS 150 33 | 1 | 244050652 Electrovalve ED 06/32.01.24v with block 3a | 2 | 242190148 Selector VFC NC 14 ALU 409. ELECTRIC WIRING DIAGRAM See drawings £ 338, sheets 13-23-38 a10. LABELS WARNING THIS MACHINE IS NOT INSULATED ; AND MUST NOT BE OPERATED NEAR TO ELECTRIC LINE! Sneed | RISK OF ELECTROCUTION | | THIS MACHINE IS NOT INSULATED DO NOT GO NEAR TO ELECTRIC LINES TO USE THIS MACHINE CPANGER) THE OPERATOR MUST: + BE TRAINED FOR OPERATING IT UNDER THE RESPONSABILITY WIND SPEED HIGHER THAN 60 KPH OF HIS EMPLOYER + KNOW AND APPLY THE OPERATION PROHIBITED RECOMMENDATIONS CONTAINED IN THE OPERATING MANUAL = | DO NOT PARK | | INSIDE THE MACHINE'S | OPERATING ZONE 4210. LABELS | machine Type Serial N° Wei ° Year of construction DO NOT USE Nominal Power (kW) HIGH-PRESSURE WASHING 5 haulotte# C€ IMPORTANT ‘THE PLUG MUST BE CONNECTED TO aaa Pus must BE cONNECTEd PROTECTED BY A 30mA DIFFERENTIAL CIRCUIT-BREAKER ON THE ELECTRIC BOXES WARNING | BEFORE SLEWING HYDRAULIC OIL ' REMOVE THE PIN WARNING -DO NOT USE THE MACHINE AS AN "EARTH" FOR WELDING OPERATIONS -DO NOT WELD ON THE MACHINE WITHOUT DISCONNECTING THE POSITIVE AND NEGATIVE BATTERY TERMINALS (REFER TO THE OPERATING AND MAINTENANCE MANUAL) -DO NOT JUMP-START OTHER VEHICLES WITH THE BATTERIES CONNECTED LOAD MUST BE UNIFORMLY DISTRIBUTED10. LABELS MAXIMUM FLOOR HEIGHT: 19.6 m MAXIMUM OPERATING LOAD: 360 kg including 3 persons MAXIMUM SLOPE OR TILT: 5° MAXIMUM WIND SPEED: 60 kph LATERAL FORCE: 40 kg (20 kg per person) - READ AND UDNERSTAND THE INFORMATION IN THE OPERATING - CHECK THE LEVELS ON THE HYDRAULIC OIL AND BATTERY FLUID 2- CHECK FOR SIGNS OF FAULTS (HYDRAULIC LEAK, BOLTS LOOSE, 2+ SET THE KEY TO THE TURRET POSITION AND TEST ALL THE OPERATING INSTRUCTIONS MANUAL AND THE LABELS ON THE MACHINE GET TO KNOW THE CONTROLS CARRY OUT MAINTENANCE CORRECTLY AS PER THE CONSTRUCTOR'S CATALOGUE DO NOT USE THE MACHINE IF IT DOES NOT OPERATE CORRECTLY MAXIMUM WIND SPEED: 60 kph DO NOT DISMANTLE ANYTHING, THE STABILITY WILL BE AFFECTED DO NOT CARRY OUT ANY MODIFICATIONS WITHOUT THE CONSTRUCTOR'S PERMISSION DAILY INSPECTIONS ELECTRIC CONNECTIONS) CHECK THE CORRECT OPERATION OF THE TILT DETECTOR BY MAKING ‘THE AUDIBLE ALARM SOUND INSTRUCTIONS BEFORE USE REMOVE THE SLEWING BLOCKING PIN MOVEMENTS SET THE KEY TO THE PLATFORM POSITION WHEN ON THE PLATFORM, WEAR A SAFETY HELMET AND A SAFETY HARNESS 4410, LABELS MAXIMUM FLOOR HEIGHT: 21.2 m MAXIMUM OPERATING LOAD: 230 kg including 2 persons MAXIMUM SLOPE OR TILT: 5° MAXIMUM WIND SPEED: 60 kph LATERAL FORCE: 40 kg (20 kg per person) Lf A Ae 7 | 9 HH —— a “dh? Io > ‘oe + ’ t © Cc q » ie 220 VOLT, Onan 9 4x4 4x2 4x2 am & 4510. LABELS USING THE AUXILIARY UNIT (engine stopped) Press simultaneously on the 4 switch and the switch whose symbol corresponds with the selected movement WARNING ! DO NOT USE THE PLATFORM WHERE THE SLOPE OR TILT ARE GREATER THAN 5° TRAVELLING CONFIGURATION WHEN TRAVELLING, THE JIB MUST BE RETRACTED AND LOCATED ON THE STEERING WHEELS' SIDE WITH SUFFICIENT ‘CLEARANCE BETWEEN THE GROUND AND THE BOTTOM OF THE PLATFORM TRAVELLING WITH THE JIB EXTENDED MAY RESULT IN ITS BEING SERIOUSLY DAMAGED INSPECTION OF CABLES PERIODICAL INSPECTION OF THE CABLES MUST BE CARRIED OUT TO DETECT ANY ANOMALIES IT IS DANGEROUS TO OPERATE WITH A DAMAGED CABLE ANY DAMAGED CABLES MUST BE REPLACED DO NOT USE THE JIB TO RAISE THE WHEELS10. LABELS i+ a @ STARTING UP + Turn the key in the contact, then activate the starter button within 10 seconds +f the engine does not start, cut the contact and repeat the operation 4zon7 DO NOT CLIMB ONTO THE BONNET11, PHOTOS 8 9 10-10 bis 11-11 bis 2 Turret control panel Platform control panel Engine- Oil evel gauge - Gas-oil prefiter Hydraulic pump supply valve Hydraulic tank - Fuel tank Batteries Turret locking pin Drain plugs for gas-oil and hydraulic ol Emergency lever manoeuvres Jib sliding shoes - Security cable - Telescopic arm cables Drive wheel reducers: Uncoupling- Level- Drainage 48H 21/23 T - TXH 21/23 T- TXH 23/25 TP - TPXH 23/25 TP - TPXH 23/25 TP - TPXH 23/25 TP - TPX 10 - 10 bisH 23/25 TP - TPX 11-11 bis C—O —rr”t~—™t — r—~—sS Bed Be ed St ‘H 23/25 TP - TPX 12mergency afore. Pepe Reda patteries SRO ede ler | Lester ee (ae Tile security system Axil ni Star [starter | | fri RES. way a femperature| Horn {Reset | Bin | (95 conal)’ a limi Fer Emergency syste stop. Selector control Paro ren) ‘Securi Florn ‘control 2 feaicaesr differential control version 4x2 = YAS veriion 4x) = 7V AS +YVAB a Camel tyra ae 3 PlatPorm, ont Salat M alirm ccelerat or control = ia (turret) he Turret bie Fupor= | Hour | Slar fer control THOF% "Securify SEE, [unter | (rurret ) [ew!-our i “| elecrovalve T | | | Sri a z FUT 28 x 7° 2 | x > ae =f nr} EV ‘ _ zo pres ard 48: Tmt = e Ta q Tm" ye 4a KAS KAG *| TH rev! = 2 | + ale ret fs m1 na \ 2 DIAGRAM OF CIRCUITS NOMENCLATURE OF ELECTRICAL EQUIPMENT LIST OF DOCUMENTS IN TECHNICAL DOSSIER TFou0 No173 £338 — £339 ~ £340 E341 _ £342 PENDULAR SUPPLEMENT ~ |E343-@ | SUPPLEMENT 4D E344 Cities i [E345 SUPPLEMENT 21/0 E346 + yilRston 2410 - [yve Tress) [ev x Td levT R TX] ———YERSIONA WD [yve Tyver [vy via Tvvie] TRAVELLING ELECTROVALVES _PlakFar em ms cm Panduler corre : ‘ {Turret Haste. PlatForm rolabion control PhL?orm ratakion control I Compensation contro! [pate pump co rol Raising control ‘| | L Timer [with Pendular W257 | without Peodviar HAT / H2BT Steering electrovalve | a i reeeriee eee tneeteeee aneeeeee tteeeeeeEEa ee aeeeeeenneeeeey aeeeeenent 7 7 eae fet) aetietict OE ~ rn cae CSRS geet ane HAPS et tv eta eT atv PH EE Ee aH | eI \ | ‘le ME fT | LE £ | HiFU30 IF § ' nse fe-<4sas " | | 1 j ee st | F pbo---- 4 | 1 \ | i } r | ‘ i | ane i | ; i i : 546 5 ' 51! KAI KANT J m | | He \ aid \ 33 \ KA22 1 7 Vv age | | | : i [eee 54 564 546 56¢ | r =o + i = \ i. a See See |-———-- Sree eet eee + | | ! 1 | Vie _V15 i [aes nt ee) veo | ' i a ; eee $—Dr 94+ + | Z| lee Std 46 48 i faui 48) 48 | 3 | SSPE eo Fo EE ceC eee CPeSeeee cere +7 | —__ | - 4+] -_ ---_--—_— I -—| { 3 Lea | i" : ! \ we | i “| of 4 (Neu2 “BE et \ Heeae! 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KAA KA21 KA23 KAI KLZ KU Sate pa rac Ae — | bs ee ae sla ose 60 ; on hal I ie wy oO sowewn E338 : Te ST : =e haulotte% Here 1X bt H25 TP.