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Pinguely-Haulotte H21T Repair Manual

Self-propelled telescopic platform
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REPAIR MANUAL
SELF-PROPELLED TELESCOPIC PLATFORM
H21T(X) - H23T(X) - H23TP(X) - H25TP(X)
242 031 9590 - E 10.02
GB
I S O 9 0 0 1
ARTICULEES
MATS
TELESCOPIQUES
CISEAUX
TRACTEES
L ' A C C E S
A
L ' E S P A C E
PINGUELY HAULOTTE • LA PERONNIERE - BP 9 - 42152 L'HORME • Tél. +33 (0) 4 77 29 24 24 • Fax SAV +33 (0) 4 77 31 28 11
email haulotte@haulotte.com • Web www.haulotte.com

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  • Page 1 REPAIR MANUAL SELF-PROPELLED TELESCOPIC PLATFORM H21T(X) - H23T(X) - H23TP(X) - H25TP(X) 242 031 9590 - E 10.02 I S O 9 0 0 1 ARTICULEES MATS TELESCOPIQUES CISEAUX TRACTEES L ' A C C E S L ' E S P A C E PINGUELY HAULOTTE •...
  • Page 3 Repair manual GENERAL This manual gives the information required for you to perform servicing and repair operations on certain pieces of equipment yourself. However, we would like to bring your attention to the importance of: • respecting the safety instructions concerning the machine itself, its use and its environment, •...
  • Page 4 Repair manual...

  • Page 5: Table Of Contents

    VERIFICATIONS WHEN RETURNING TO SERVICE ..........6 1.7 - BEAUFORT SCALE ....................6 SPECIFICATION......................7 2.1 - TECHNICAL DATA..................... 8 2.1.1 - H21T(X) and H23TP(X) technical data ..................8 2.1.2 - H23T(X) and H25TP(X) technical data ................... 9 2.2 - DIMENSIONS ......................10...
  • Page 6 4.2.3 - Positions of fuses ........................28 4.2.4 - Positions of diagnosis help LEDs ................... 29 HYDRAULIC DIAGRAMS ..................31 5.1 - DIAGRAM H21T / H23T REFERENCE B15714 ............31 5.2 - DIAGRAM H21TX / H23TX REFERENCE B15713 ...........32 5.3 - DIAGRAM H23TP / H25TP REFERENCE B15330 ...........33 5.4 -...
  • Page 7 Repair Manual 5.5.1 - "On/off" electrovalves......................35 5.5.2 - Proportional electrovalves...................... 35 MAINTENANCE ......................37 6.1 - GENERAL RECOMMENDATIONS ................37 6.2 - SPECIFIC RECOMMENDATIONS................37 6.2.1 - Specific tools.......................... 37 6.2.2 - Replacing an element ......................37 6.2.3 - Locating the breakdown......................38 6.2.4 - Environment protection ......................
  • Page 8 Repair Manual OPERATING INCIDENTS ..................57 8.1 - INCIDENT TABLE ......................57 8.1.1 - General operation........................58 8.1.2 - Lifting system ......................... 60 8.1.3 - Travel system ......................... 61 8.1.4 - Steering system........................61 8.1.5 - Turntable rotation system....................... 62 8.2 - BREAKDOWN DETECTION FLOW CHARTS............62 CORRECTIVE MAINTENANCE PROCEDURE ............139...

  • Page 9: General

    Operating and maintenance instructions GENERAL RECOMMENDATIONS - SAFETY 1.1 - GENERAL WARNING 1.1.1 - Manual This manual aims to help maintenance personnel service and repair the machine. It cannot, however, replace the basic training required by any person working on the site equipment. The site manager must inform operators of the recommendations in the instruction manual.

  • Page 10: General Safety Instructions

    Operating and maintenance instructions 1.2 - GENERAL SAFETY INSTRUCTIONS 1.2.1 - Operators Operators must be aged over 18, and hold an operating permit issued by their employer after undergoing a medical check and a practical test that prove they are apt to operate the machine. Caution ! Only trained operators can use There must always be at least two operators present, so that one can...
  • Page 11 Operating and maintenance instructions To reduce the risks of serious falls, operators must respect the following instructions: • Hold the guardrail firmly when lifting or driving the platform. • Remove any traces of oil or grease from the platform steps, floor or guardrails.

  • Page 12: Residual Risks

    Operating and maintenance instructions 1.3 - RESIDUAL RISKS Caution ! 1.3.1 - Risks of jerky movements and tipping over Operation direction may be inverted on a turntable machine after 180° Risks of jerky movement and tipping over are high in the following rotation.

  • Page 13: Inspections

    Operating and maintenance instructions 1.4 - INSPECTIONS Comply with the national regulations in force in the country of machine use. For FRANCE: Order dated 9 June 1993 + circular DRT 93 dated 22 September 1993 which specify: 1.4.1 - Periodic inspections The machine must be inspected every 6 months in order to detect any defects liable to cause an accident.

  • Page 14: Repairs And Adjustments

    PINGUELY-HAULOTTE 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. 1.6 - VERIFICATIONS WHEN RETURNING TO SERVICE To be performed after: • extensive disassembly-reassembly operation, •...

  • Page 15: Specification

    Repair manual SPECIFICATION The self-propelled elevating work platforms, models H21T(X), H23T(X), H23TP(X), H25TP(X), are designed to carry out all kinds of overhead work within the limits imposed by their characteristics (see "Operation and maintenance instruction manual", and Chapitre 2.1, page 8) and provided that all safety instructions relating to the equipment and environment of use are respected.

  • Page 16: Technical Data

    Repair manual 2.1 - TECHNICAL DATA 2.1.1 - H21T(X) and H23TP(X) technical data DESCRIPTION H21T H21TX H23TP H23TPX Load 360 kg including 3 people 250 kg including 2 people Maximum side manual force 40 kg Max. wind speed 60 km/h Floor height 18.8 m...

  • Page 17: H23T(X) And H25Tp(X) Technical Data

    Repair manual 2.1.2 - H23T(X) and H25TP(X) technical data DESCRIPTION H23T H23TX H25TP H25TPX Nominal load 250 kg including 2 people Maximum side manual force 40 kg Max. wind speed 60 km/h Floor height 21.3 m 21.3 m 23 m 23 m Working height 23.3 m...

  • Page 18: Dimensions

    Repair manual 2.2 - DIMENSIONS 2.2.1 - H21T(X) dimensions haulotte 2490 8908 2478 2084 Haulotte...

  • Page 19: H23Tp(X) Dimensions

    Repair manual 2.2.2 - H23TP(X) dimensions H23TP Haulotte 10241 Haulotte 2084 2478...

  • Page 20: H23T(X) Dimensions

    Repair manual 2.2.3 - H23T(X) dimensions haulotte 2490 11052 Haulotte 2084 2478...

  • Page 21: H25Tp(X) Dimensions

    Repair manual 2.2.4 - H25TP(X) dimensions H 25TP Haul ot t e 2490 10777 12871 2478 2084 Haul ot t e...

  • Page 22: Tightening Torque Values

    Repair manual 2.3 - TIGHTENING TORQUE VALUES 2.3.1 - Tightening torque values for large threading Tightening torque in N.M Nominal diameter 10.9 12.9 M 6*1 9 to 11 13 to 14 15 to 17 M 7*1 15 to 19 21 to 24 26 to 28 M 8*1.25 22 to 27...

  • Page 23: Tightening Torque Values For Hydraulic Hoses

    Repair manual 2.3.4 - Tightening torque values for hydraulic hoses Description Torque to apply (Nm) Spanner to use turning equal elbow JIC37 90 (10) turning equal elbow JIC37 90 (12) turning equal elbow JIC37 90 (18) turning equal elbow JIC37 90 (25) nut F JIC37 (25) nut FJIC37 (12) nut FJIC37 (18)

  • Page 24: Pressure Values (In Bar)

    Repair manual 2.3.5 - Pressure values (in bar) • Pump: - flow cancellation: 240 b - load sensing, standby pressure: 30b • PVG Danfoss distributor: - entry pressure protection: 270 b - rotation pressure limiter: 100 b • Telescoping: - output pressure: 100 b - large chamber braking valve: 210 b - small chamber braking valve: 210 b •...

  • Page 25: Safety System

    Repair manual SAFETY SYSTEM 3.1 - FUNCTION OF RELAYS AND FUSES IN TURNTABLE BOX (see wiring diagram) Ref. Description Thermal motor start Thermal motor stop Motor speed acceleration (electromotor) Main supply Electropump contactor FU01–10 A Motor stop circuit fuse FU03–80 A Accelerator circuit fuse FU04–30 A Main circuit fuse...

  • Page 26: Positions Of Electric Contacts

    Repair manual 3.3 - POSITIONS OF ELECTRIC CONTACTS SQ11 SQ10 Zone a: no break Zone b: movements slowed Zone c: telescope out disabled Zone d: boom lowering disabled Zone e: telescope out cut Zone f: motor cut...

  • Page 27: Operating Equations

    Repair manual 3.4 - OPERATING EQUATIONS • Start If (SB3=1 or SB4=1) and U3=0 and D+=0 and YV1 not supplied then KA2=1 If (SB3=1 or SB4=1) then module-frequency 1=1 then module-frequency 2=1 (two signals are sent at a one second interval to 698 then 699; in return, the frequency module sends 12V to 485 if the motor is running).
  • Page 28 Repair manual 1°Out If SA8a=1 then YV1=1 and YV4=1 2°Down If SA8b=1 then YV1=1 and YV4=1 - Platform 1°Out If HM2=1 and SM2ab=0 followed by SM2ab=1 thenYV1=1 and YV4=1 2°In If HM2=1 and SM2ab=0 followed by SM2ab=1 then YV1=1 and YV4=1 •...

  • Page 29: Wiring Diagrams

    Repair manual WIRING DIAGRAMS 4.1 - DIAGRAM E 455 - FOLIO 01/05...
  • Page 30 Repair manual FOLIO 02/05...
  • Page 31 Repair manual FOLIO 03/05...
  • Page 32 Repair manual FOLIO 04/05...
  • Page 33 Repair manual FOLIO 05/05...

  • Page 34: Positions Of Electric Components On The Mother Board

    Repair manual 4.2 - POSITIONS OF ELECTRIC COMPONENTS ON THE MOTHER BOARD 4.2.1 - Description SCREW Connector + Battery Flashing light + Bi-energy machine - option Bottom box door + Main Top control panel Starter Bottom box door Accelerator control KMG main relay Main supply after contactor Emergency pump KM4 contactor...

  • Page 35: Positions Of Screws, Connectors And Relays

    Repair manual 4.2.2 - Positions of screws, connectors and relays...

  • Page 36: Positions Of Fuses

    Repair manual 4.2.3 - Positions of fuses...

  • Page 37: Positions Of Diagnosis Help Leds

    Repair manual 4.2.4 - Positions of diagnosis help LEDs YV20 YV2A YV11 YV18B YV10 YV18A YV2B YV15B YV12 YV15A YV21B YV23 YV21A YV14B YV13A YV14A YV22B YV22A YV16B YV16A YV19B YV19A...
  • Page 38 Repair manual...

  • Page 39: Hydraulic Diagrams

    Repair manual HYDRAULIC DIAGRAMS 5.1 - DIAGRAM H21T / H23T REFERENCE B15714...

  • Page 40: Diagram H21Tx / H23Tx Reference B15713

    Repair manual 5.2 - DIAGRAM H21TX / H23TX REFERENCE B15713...

  • Page 41: Diagram H23Tp / H25Tp Reference B15330

    Repair manual 5.3 - DIAGRAM H23TP / H25TP REFERENCE B15330...

  • Page 42: Diagram H23Tpx / H25Tpx Reference B15331

    Repair manual 5.4 - DIAGRAM H23TPX / H25TPX REFERENCE B15331...

  • Page 43: Functions Of Electrovalves

    Repair manual 5.5 - FUNCTIONS OF ELECTROVALVES 5.5.1 - "On/off" electrovalves 12v = electro controlled / 0v = electro not controlled Load Sensing 303, time delayed for 2 seconds YV2a Jib305 YV2b Compensation, rotation, steering 415 High speed vitesse 813 Differential blocking 807A YV10 MediumSpeed HighSpeed 814A...
  • Page 44 Repair manual...

  • Page 45: Maintenance

    Incorrect use of a tool (incorrect adjustment after a reading error) may lead to premature deterioration of the elevating platform (or more seriously, an accident), for which PINGUELY-HAULOTTE cannot be held responsible. 6.2.2 - Replacing an element Before replacing an element, the machine must be put in the maintenance configuration (see Chapitre 6.3, page 38) and the electric power supply cut...

  • Page 46: Locating The Breakdown

    Repair manual To preserve the integrity of the safety systems and the technical characteristics of the elevating platform, it is essential to use original parts and to respect the initial setting and tightening torque values (see Chapitre 2, page 7). 6.2.3 - Locating the breakdown Certain checks require the elevating platform to be switched on.

  • Page 47: Maintenance Plan

    The reference shown in the symbol shows the area maintained based on the frequency. The symbol represents the consumable to use (or the operation to be carried out). Lubricants used by Consumable Specification Symbol TOTAL Pinguely-Haulotte Motor oil SAE 15W40 SHELL RIMULA-X SHELL Tranself Gearbox oil SAE 90 TM 80 W/90...
  • Page 48 Repair manual HOURS Haulotte 17 18 1 000 2 000...

  • Page 49: Operations

    Repair manual 6.6 - OPERATIONS 6.6.1 - Summary table. Frequency Ref. Operation Test: • the horn • the tilt detector and safety systems Check the levels: • motor oil • hydraulic oil (see fiche P008) • diesel • electric batteries Every day or before Check the cleanliness: each use...

  • Page 50: Presence Of Labels

    Repair manual Frequency Ref. Operation Change the oil of the hydraulic tank and whole circuit Every 2000 hours Empty and clean the diesel tank Lubricate the rotation reducing gear: 1 point Check the condition of the safety cable, the telescoping cables and friction pads Every 3000 hours and the electric wires and hydraulic hoses.

  • Page 51: Yellow" Labels

    Repair manual 6.7.1 - "Yellow" labels 6.7.2 - "Orange" labels...

  • Page 52: Red" Labels

    Component specific to this machine. DO NOT INTERCHANGE. Komponenten nur f r diese maschine geeignet. BITTE AUF EINE ANDERE MASCHINE NIGHT MONTIEREN. N MACHINE - MASCHINE N 7814 518 H21T(X) H23T(X) 20 b 20 a H23TP(X) H25TP(X) 20 d 20 c...

  • Page 53: Other Labels

    Repair manual 6.7.4 - Other labels 7814-394 7814-393 7814-312 7814 922 6.7.5 - Option...

  • Page 54: Positions Of Labels

    3078139010 «H25TP» 1250127590 «Haulotte» 3070029541 «Haulotte» 3078136770 «X» 3078144310 Floor height + load capacity H21T(X) 3078144320 Floor height + load capacity H23T(X) 3078144330 Floor height + load capacity H23TP(X) 3078144340 Floor height + load capacity H25TP(X) 3078143120 Turntable box label...

  • Page 55: Positionnement Des Étiquet

    Repair manual 6.7.7 - é...

  • Page 56: Presence Of Manuals

    Repair manual 6.8 - PRESENCE OF MANUALS Check that the manuals supplied with the machine are in good condition and stored in the document holder provided on the platform. An illegible manual may result in incorrect or dangerous use of the machine.

  • Page 57: Preventive Maintenance Sheets

    Repair manual PREVENTIVE MAINTENANCE SHEETS List of preventive maintenance sheets Sheet no. Description FICHE P007 Checking - changing the oil of a wheel reducing gear FICHE P008 Checking - filling the hydraulic oil tank FICHE P009 Changing the hydraulic filter cartridge...
  • Page 58 Repair manual...
  • Page 59 PREVENTIVE MAINTENANCE SHEET Sheet P007 Folio 1/1 CHECKING - CHANGING THE OIL OF A WHEEL REDUCING GEAR 1 - Preliminary operations Caution! • Put the machine in the maintenance configuration (see § 6.3, page 32). • Switch off electric power (see § 6.4, page 32). Use a container to collect oil to prevent pollution of the environment.
  • Page 60 PREVENTIVE MAINTENANCE SHEET...
  • Page 61 PREVENTIVE MAINTENANCE SHEET Sheet P008 Folio 1/1 CHECKING - FILLING THE HYDRAULIC OIL TANK 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3 -). Caution! • Switch off electric power (see § 6.4 -). Put the machine in the folded 2 - Checking - filling the hydraulic oil tank position.
  • Page 63 PREVENTIVE MAINTENANCE SHEET Sheet P009 Folio 1/1 CHANGING THE HYDRAULIC FILTER CARTRIDGE 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3 -). Caution! • Switch off electric power (see § 6.4 -). Use a container to collect oil 2 - Replacing the hydraulic filter cartridge to prevent pollution of the environment.

  • Page 65: Operating Incidents

    Repair manual OPERATING INCIDENTS 8.1 - INCIDENT TABLE Before diagnosing a failure, check that: • the fuel tank is not empty, • the batteries are properly charged, • the turntable and platform "palm button" emergency stop buttons are unlocked, • the relays (platform control panel - turntable box) are correctly pushed into their compartments, (see §...

  • Page 66: General Operation

    Repair manual 8.1.1 - General operation ANOMALY PROBABLE CAUSE SOLUTION • Diesel tank empty • Fuse FU1 defective • Diesel supply circuit defective The motor does not start, the Sheet DP015 starter is activated • Wiring defective • Module U1 defective •...
  • Page 67 Repair manual ANOMALY PROBABLE CAUSE SOLUTION • Fuse FU1 defective • Platform control panel defective No movement available from Sheet DP024 the platform control panel • Fail-safe pedal defective • Wiring harness defective • Oil non-conform • Obstruction of the tank air vent •...

  • Page 68: Lifting System

    Repair manual 8.1.2 - Lifting system ANOMALY PROBABLE CAUSE SOLUTION • Electrovalve YV19 or YV2 defective • Coil defective • Electronic module U1 defective No platform up and/or down compensation movement • Wiring harness defective Sheet DP050 • Printed circuit defective •...

  • Page 69: Travel System

    Repair manual 8.1.3 - Travel system ANOMALY PROBABLE CAUSE SOLUTION • Connectors disconnected • Manipulator HM4 defective • Wiring harness defective No machine travel movement Sheet DP032 • Electronic module U1 defective • Coils of electrovalve YV6 or YV7 defective •...

  • Page 70: Turntable Rotation System

    Repair manual 8.1.5 - Turntable rotation system ANOMALY PROBABLE CAUSE SOLUTION • Electrovalve YV5 defective No turntable rotation move- • Electronic module U1 defective ment (right and/or left) from • Wiring harness defective the platform (or turntable) Sheet DP042 • Printed circuit defective control panel •...
  • Page 71 BREAKDOWN DETECTION FLOW CHART Sheet DP015 Folio 1/2 THE MOTOR DOES NOT START, THE STARTER IS ACTIVATED The motor does not start, the starter is activated Check the level of the diesel tank Diesel OK Fill the diesel tank Open the turntable control panel and check the state of fuse FU1 Fuse Replace fuse FU1...
  • Page 72 BREAKDOWN DETECTION FLOW CHART Sheet DP015 Folio 2/2 THE MOTOR DOES NOT START, THE STARTER IS ACTIVATED Replace relay See Fiche Check wiring between the motor starter C062 switch SB3 or SB4 and the printed circuit of the turntable control box The fault persists Wiring...
  • Page 73 BREAKDOWN DETECTION FLOW CHART Sheet DP016 Folio 1/3 THE MOTOR DOES NOT START, THE STARTER IS NOT ACTIVATED The motor does not start, the starter is not activated Check the position of the platform and turntable emergency stop buttons Unlock the emergency stop button Position unlocked Check the state of battery charge...
  • Page 74 BREAKDOWN DETECTION FLOW CHART Sheet DP016 Folio 2/3 THE MOTOR DOES NOT START, THE STARTER IS NOT ACTIVATED Open the turntable control panel and check the state of fuses FU1, FU4 and FU8 Fuses OK Replace the defective fuse Check the 12V on line 242 of the turntable control panel Repair key switch SA1 wiring or replace the switch...
  • Page 75 BREAKDOWN DETECTION FLOW CHART Sheet DP016 Folio 3/3 THE MOTOR DOES NOT START, THE STARTER IS NOT ACTIVATED Activate the starter switch SB3 or SB4 and check for 12 V voltage between terminals 242 and 146 in the turntable control box Check wiring between switch SB3 or SB4 and the turntable control box...
  • Page 77 BREAKDOWN DETECTION FLOW CHART Sheet DP019 Folio 1/2 THE MOTOR DOES NOT START FROM THE PLATFORM PANEL BUT DOES START FROM THE TURNTABLE PANEL The motor does not start from the platform but does start from the turntable - Place the key switch in the platform position - Check that the platform panel power light indicator is on...
  • Page 78 BREAKDOWN DETECTION FLOW CHART Sheet DP019 Folio 2/2 THE MOTOR DOES NOT START FROM THE PLATFORM PANEL BUT DOES START FROM THE TURNTABLE PANEL Activate SB4 and check for 12V voltage at terminal 117B of the printed circuit Repair wiring or replace the wiring harness between the platform control panel and the turntable control panel...
  • Page 79 BREAKDOWN DETECTION FLOW CHART Sheet DP020 Folio 1/1 THE MOTOR DOES NOT START FROM THE TURNTABLE CONTROL PANEL BUT DOES START FROM THE PLATFORM CONTROL PANEL The motor does not start from the turntable control panel but does start from the platform control panel - Open the turntable control panel - Activate switch SB3 and check continuity...
  • Page 81 BREAKDOWN DETECTION FLOW CHART Sheet DP021 Folio 1/1 MOTOR ACCELERATION FOR ANY MOVEMENT CONTROLLED FROM THE PLATFORM (ACCELERATION, TRAVEL, LIFTING, TURNTABLE ROTATION, TELESCOPE) No motor acceleration regardless of the movement controlled from the platform (acceleration, travel, lifting, turntable rotation, telescope) Place the key switch in the turntable position and activate the accelerator switch (SA2) on the...
  • Page 83 BREAKDOWN DETECTION FLOW CHART Sheet DP022 Folio 1/2 NO MOTOR ACCELERATION ON ACTIVATING THE ACCELERATOR SWITCH SA2 FROM THE TURNTABLE CONTROL PANEL No motor acceleration on activating the accelerator switch SA2 from the turntable control panel - Place the key switch in the platform position - Press the pedal and make a telescoping movement from the platform.
  • Page 84 BREAKDOWN DETECTION FLOW CHART Sheet DP022 Folio 2/2 NO MOTOR ACCELERATION ON ACTIVATING THE ACCELERATOR SWITCH SA2 FROM THE TURNTABLE CONTROL PANEL Voltage - Maintain activation of the accelerator switch SA2 of the turntable control panel. - Check for 12V voltage on terminal 605A of the printed circuit.
  • Page 85 BREAKDOWN DETECTION FLOW CHART Sheet DP023 Folio 1/5 NO MOVEMENT AVAILABLE (FROM TURNTABLE OR PLATFORM CONTROL PANELS) No movement available (from turntable or platform panels) Check the level of hydraulic See Fiche P005 or P008 Level Fill up See Fiche Open the turntable control P005 or P008 panel.
  • Page 86 BREAKDOWN DETECTION FLOW CHART Sheet DP023 Folio 2/5 NO MOVEMENT AVAILABLE (FROM TURNTABLE OR PLATFORM CONTROL PANELS) Movement - Open the turntable control panel - Press the pedal and activate the boom lifting manipulator SM31. - Check that the LED associated with electrovalve YV1 is on.
  • Page 87 BREAKDOWN DETECTION FLOW CHART Sheet DP023 Folio 3/5 NO MOVEMENT AVAILABLE (FROM TURNTABLE OR PLATFORM CONTROL PANELS) Pressure 25 to 32 bars Adjust the «load See Sheet C073 or C111 sensing» pressure Pressure Check the coupling See Fiche between the hydraulic C042 or C091 pump and the thermal...
  • Page 88 BREAKDOWN DETECTION FLOW CHART Sheet DP023 Folio 4/5 NO MOVEMENT AVAILABLE (FROM TURNTABLE OR PLATFORM CONTROL PANELS) - Replace the pressure limiter of the PVG input module - Clean the protective filter screen. The fault persists Replace the PVG input See Fiche C076 or C094 module...
  • Page 89 BREAKDOWN DETECTION FLOW CHART Sheet DP023 Folio 5/5 NO MOVEMENT AVAILABLE (FROM TURNTABLE OR PLATFORM CONTROL PANELS) - Place the key switch in the turntable position - Check for 12V voltage between points «0» and «240» of the turntable panel printed circuit Replace relay KMG See Fiche Replace the U1 module...
  • Page 91 BREAKDOWN DETECTION FLOW CHART Sheet DP024 Folio 1/2 NO MOVEMENT AVAILABLE FROM THE PLATFORM CONTROL PANEL No movement available from the platform control panel - Open the turntable control panel - Check the state of fuse FU6 Replace the Fuse fuse - Place the key switch in the platform position - Open the platform control panel...
  • Page 92 BREAKDOWN DETECTION FLOW CHART Sheet DP024 Folio 2/2 NO MOVEMENT AVAILABLE FROM THE PLATFORM CONTROL PANEL - Open the turntable control panel - Check for 12V voltage on terminal 211 Check wiring of wire 211 inside the platform control panel Replace the wiring harness between the turntable control panel and the platform control...
  • Page 93 BREAKDOWN DETECTION FLOW CHART Sheet DP025 Folio 1/2 NOISY HYDRAULIC PUMP The hydraulic pump makes a noise Check the oil level in the circuit Oil level Top up with oil See Fiche P005 or P008 Check that the oil used is the recommended oil (problem of oil viscosity being too high) Change the...
  • Page 94 BREAKDOWN DETECTION FLOW CHART Sheet DP025 Folio 2/2 NOISY HYDRAULIC PUMP Valves Open the open suction valves Check the state of the suction pipes (clogging, etc.) Pipes Replace the hydraulic pump suction pipes See Fiche Incorrect operation of the C042 or hydraulic pump: replace it C091...
  • Page 95 BREAKDOWN DETECTION FLOW CHART Sheet DP028 Folio 1/5 NO JIB MOVEMENT (UP AND / OR DOWN) FROM THE PLATFORM (OR TURNTABLE) CONTROL PANEL No jib movement (up and/or down) from the platform (or turntable) control panel - Place the key switch in the platform position - Press the pedal and activate the basket rotation switch on the platform control panel The basket...
  • Page 96 BREAKDOWN DETECTION FLOW CHART Sheet DP028 Folio 2/5 NO JIB MOVEMENT (UP AND / OR DOWN) FROM THE PLATFORM (OR TURNTABLE) CONTROL PANEL Press the pedal and activate the jib switch. Check for 12V at the terminals of the PVG connector YV2a - Open the turntable control panel - Press the pedal and activate the jib switch.
  • Page 97 BREAKDOWN DETECTION FLOW CHART Sheet DP028 Folio 3/5 NO JIB MOVEMENT (UP AND / OR DOWN) FROM THE PLATFORM (OR TURNTABLE) CONTROL PANEL - Invert the coils of the jib electrovalve YV18A and YV18B - Press the pedal and activate the platform (or turntable) jib switch The defective movement up (1) or...
  • Page 98 BREAKDOWN DETECTION FLOW CHART Sheet DP028 Folio 4/5 NO JIB MOVEMENT (UP AND / OR DOWN) FROM THE PLATFORM (OR TURNTABLE) CONTROL PANEL Platform jib fault Turntable jib fault Maintain the control Maintain the control activated and check for activated and check for 12V voltage at terminals 12V voltage at terminals 410 (up) and 409 (down) of...
  • Page 99 BREAKDOWN DETECTION FLOW CHART Sheet DP028 Folio 5/5 NO JIB MOVEMENT (UP AND / OR DOWN) FROM THE PLATFORM (OR TURNTABLE) CONTROL PANEL Replace the double flow See Fiche limiter C083 The fault persists Replace the electrovalve See Fiche YV18 C067...
  • Page 101 BREAKDOWN DETECTION FLOW CHART Sheet DP032 Folio 1/4 NO MACHINE TRAVEL MOVEMENT No machine travel movement - Place the key switch in the platform position - Press the pedal and make an arm lifting movement Movement See Fiche DP023 Put the machine on wedges so that the wheels are not touching the ground - From the platform control panel, select low speed.
  • Page 102 BREAKDOWN DETECTION FLOW CHART Sheet DP032 Folio 2/4 NO MACHINE TRAVEL MOVEMENT Open the turntable control panel and check connection of PVG travel connectors (25 and 26) Connections Reconnect the connectors Check operation of the travel manipulator Activate the fail-safe HM4 alone and check for voltage at HM4 output and no voltage at SM4ab output Setpoints:...
  • Page 103 BREAKDOWN DETECTION FLOW CHART Sheet DP032 Folio 3/4 NO MACHINE TRAVEL MOVEMENT Check setpoint at output 26.3 and 25.3 of U1 electronic module Setpoint: Replace the U1 electronic See Fiche Output 26.3 and 25.3: C058 or C107 module Forward = 6 to 9V Reverse = 6 to 3V The fault...
  • Page 104 BREAKDOWN DETECTION FLOW CHART Sheet DP032 Folio 4/4 NO MACHINE TRAVEL MOVEMENT Setpoints: 29.2 = exc. neutral 29.3 = 12V Replace defective wiring har- 29.4 = forward 2.5 to 4.5V nesses no. 612, 606 and 611A Reverse 2.5 to 0.5V See Fiche Replace the U1 module C058 or C107...
  • Page 105 BREAKDOWN DETECTION FLOW CHART Sheet DP034 Folio 1/4 MACHINE TRAVEL SPEED DOES NOT CORRESPOND TO THE SELECTOR SPEED Machine travel speed does not correspond to the selector - Do not press the pedal - Open the turntable control panel and check that the LEDs associated with electovalves YV8, YV10 and YV12 are off All the LEDs...
  • Page 106 BREAKDOWN DETECTION FLOW CHART Sheet DP034 Folio 2/4 MACHINE TRAVEL SPEED DOES NOT CORRESPOND TO THE SELECTOR SPEED - Place the key switch in the platform position. - Place the speed selector in the «High speed» position. - Press the pedal and make a forward travel movement. - Check for 12V voltage at the terminals of the connector of the electrovalve in question (YV8, YV10 and YV12).
  • Page 107 BREAKDOWN DETECTION FLOW CHART Sheet DP034 Folio 3/4 MACHINE TRAVEL SPEED DOES NOT CORRESPOND TO THE SELECTOR SPEED - Press the pedal and make a forward travel movement. - Check for 12V voltage at the terminals of the connector of electrovalve YV10 12V OK - Open the turntable control panel.
  • Page 108 BREAKDOWN DETECTION FLOW CHART Sheet DP034 Folio 4/4 MACHINE TRAVEL SPEED DOES NOT CORRESPOND TO THE SELECTOR SPEED Open the platform control panel Place the speed selector SA11 Place the speed selector SA11 Place the speed selector SA11 on «low speed» on «medium speed»...
  • Page 109 BREAKDOWN DETECTION FLOW CHART Sheet DP036 Folio 1/3 NO DIFFERENTIAL BLOCKING WHEN SWITCH SA3 IS ACTIVATED No differential blocking when switch SA3 is activated - Place the key switch in the platform position - Do not press the pedal - Open the turntable control panel and check that the LEDs associated with electovalves YV9 and YV13 are off All the LEDs are Note the LED that is on...
  • Page 110 BREAKDOWN DETECTION FLOW CHART Sheet DP036 Folio 2/3 NO DIFFERENTIAL BLOCKING WHEN SWITCH SA3 IS ACTIVATED - Press the pedal and make a forward travel movement. - Check for 12V voltage at the terminals of the connector of the electrovalve in question (YV9 and YV13) 12V OK - Open the turntable control panel.
  • Page 111 BREAKDOWN DETECTION FLOW CHART Sheet DP036 Folio 3/3 NO DIFFERENTIAL BLOCKING WHEN SWITCH SA3 IS ACTIVATED - Open the platform control panel - Press the pedal, activate switch SA3 and check the setpoint at the output of switch SA3 (807) Setpoint Replace See Fiche...
  • Page 113 BREAKDOWN DETECTION FLOW CHART Sheet DP041 Folio 1/1 THE MOTOR STARTS THEN STOPS AFTER 5 SECS The motor starts, then stops after 5 seconds Check the level of the diesel tank Diesel Fill the diesel tank Check the diesel supply circuit See motor manufacturer’s manual Circuit Repair the diesel supply circuit...
  • Page 115 BREAKDOWN DETECTION FLOW CHART Sheet DP042 Folio 1/4 NO TURNTABLE ROTATION MOVEMENT (RIGHT AND/OR LEFT) FROM THE PLATFORM (OR TURNTABLE) CONTROL PANEL No turntable rotation movement (right and/or left) from the platform (or turntable) control panel - Place the key switch in the turntable (or platform) position - Activate the rotation switch from the turntable control panel SA15 (or the rotation manipulator SM31 from the platform con- trol panel - pedal activated)
  • Page 116 BREAKDOWN DETECTION FLOW CHART Sheet DP042 Folio 2/4 NO TURNTABLE ROTATION MOVEMENT (RIGHT AND/OR LEFT) FROM THE PLATFORM (OR TURNTABLE) CONTROL PANEL Activate the rotation movement in manual: - Put the emergency lever into place on the platform control of the rotation distributor (YV5) - Activate the lever right / left while pressing the emergency control of the safety valve (YV1), or activate the emergency unit.
  • Page 117 BREAKDOWN DETECTION FLOW CHART Sheet DP042 Folio 3/4 NO TURNTABLE ROTATION MOVEMENT (RIGHT AND/OR LEFT) FROM THE PLATFORM (OR TURNTABLE) CONTROL PANEL Maintain the control activated and Voltage check for 3V or 9V voltage (depen- ding on the movement direction) on terminal 512A of the printed circuit See Fiche Replace the PVG control head...
  • Page 118 BREAKDOWN DETECTION FLOW CHART Sheet DP042 Folio 4/4 NO TURNTABLE ROTATION MOVEMENT (RIGHT AND/OR LEFT) FROM THE PLATFORM (OR TURNTABLE) CONTROL PANEL Activate the boom lifting movement in manual: - Put the emergency lever into place on the manual control of the boom lifting distributor (YV3).
  • Page 119 BREAKDOWN DETECTION FLOW CHART Sheet DP050 Folio 1/5 NO COMPENSATION MOVEMENT (UP AND/OR DOWN) No compensation movement (up and/or down) - Place the key switch in the platform position - Press the pedal and activate the jib switch on the platform control panel movement - Stop the movement and release the pedal...
  • Page 120 BREAKDOWN DETECTION FLOW CHART Sheet DP050 Folio 2/5 NO COMPENSATION MOVEMENT (UP AND/OR DOWN) Press the pedal and activate the compensation switch and check for 12V voltage at the terminals of the PVG YV2a connector - Open the turntable control panel - Press the pedal and activate the compensation switch and check for 12V voltage on terminal 305 of the printed circuit...
  • Page 121 BREAKDOWN DETECTION FLOW CHART Sheet DP050 Folio 3/5 NO COMPENSATION MOVEMENT (UP AND/OR DOWN) - Invert the coils of the compensation electrovalve YV19A and YV19B - Press the pedal and activate the compensation switch The defective movement, up (1) or down (2), is made in response to a control for the opposite movement down (1) or...
  • Page 122 BREAKDOWN DETECTION FLOW CHART Sheet DP050 Folio 4/5 NO COMPENSATION MOVEMENT (UP AND/OR DOWN) Maintain the control activated and check for 12V voltage at terminals 401 (up) and 402 (down) of the printed circuit Open the platform control panel and check the wiring of the compensation switch SA5 Wiring Replace the U1 module...
  • Page 123 BREAKDOWN DETECTION FLOW CHART Sheet DP050 Folio 5/5 NO COMPENSATION MOVEMENT (UP AND/OR DOWN) Replace the double flow See Fiche limiter C083 The fault persists Replace the balancing See Fiche valve C082 The fault persists Replace electrovalve See Fiche YV19 C067...
  • Page 125 BREAKDOWN DETECTION FLOW CHART Sheet DP051 Folio 1/2 THE COMPENSATION MOVEMENT IS MADE WHEN PLATFORM ROTATION IS ACTIVATED When platform rotation is activated, the compensation movement is made - Do not press the pedal - Open the turntable control panel and check that the LED associated with electrovalve YV24 is off - Press the pedal and activate the compensation switch...
  • Page 126 BREAKDOWN DETECTION FLOW CHART Sheet DP051 Folio 2/2 THE COMPENSATION MOVEMENT IS MADE WHEN PLATFORM ROTATION IS ACTIVATED The fault persists Replace See Fiche electrovalve YV24 C067 - Open the turntable control panel - Press the pedal and activate the compensation switch and check for 12V voltage on terminal 399 of the printed circuit Replace the U1...
  • Page 127 BREAKDOWN DETECTION FLOW CHART Sheet DP053 Folio 1/5 NO TELESCOPING MOVEMENT (IN AND/OR OUT) FROM THE PLATFORM (OR TURNTABLE) CONTROL PANEL No telescoping movement (out and/or in) from the platform (or turntable) control panel - Fold the machine except for the boom - Place the key switch in the turntable (or platform) position - Activate the telescoping switch from the turntable control panel SA8 (or the telescoping manipulator SM2 from the platform control...
  • Page 128 BREAKDOWN DETECTION FLOW CHART Sheet DP053 Folio 2/5 NO TELESCOPING MOVEMENT (IN AND/OR OUT) FROM THE PLATFORM (OR TURNTABLE) CONTROL PANEL Check the setpoint at the outputs of limit detectors SQ7, SQ10 and SQ11. Setpoint SQ10=0V SQ7=12V SQ11=0V Check the continuitéy of wiring harnesses 115A, 218A and 218B.
  • Page 129 BREAKDOWN DETECTION FLOW CHART Sheet DP053 Folio 3/5 NO TELESCOPING MOVEMENT (IN AND/OR OUT) FROM THE PLATFORM (OR TURNTABLE) CONTROL PANEL Activate the telescoping movement in manual - Put the emergency lever into place on the manual control of the telescoping distributor (YV4) - Activate the lever up/down while pressing the emergency control of the safety valve (YV1), or activate the emergency unit Movement OK...
  • Page 130 BREAKDOWN DETECTION FLOW CHART Sheet DP053 Folio 4/5 NO TELESCOPING MOVEMENT (IN AND/OR OUT) FROM THE PLATFORM (OR TURNTABLE) CONTROL PANEL Maintain the control activated and Voltage check for 3V or 9V (depending on movement direction) on terminal 506A of the printed circuit Replace the PVG YV4 control See Fiche Voltage...
  • Page 131 BREAKDOWN DETECTION FLOW CHART Sheet DP053 Folio 5/5 NO TELESCOPING MOVEMENT (IN AND/OR OUT) FROM THE PLATFORM (OR TURNTABLE) CONTROL PANEL Activate the rotation movement in manual: - Put the emergency lever into place on the manual control of the rotation distributor (YV5) - Activate the lever right/left while pressing the emergency control of the safety valve (YV1), or activate the emergency unit...
  • Page 133 BREAKDOWN DETECTION FLOW CHART Sheet DP054 Folio 1/5 NO BOOM LIFTING MOVEMENT (UP AND/OR DOWN) FROM THE PLATFORM (OR TURNTABLE) CONTROL PANEL No boom lifting movement (up and/or down) from the platform (or turntable) control panel - Fold the machine except for the boom - Place the key switch in the turntable (or platform) position - Activate the lifting switch from the turntable control panel SA13 (or the lifting manipulator SM31 from the platform control panel)
  • Page 134 BREAKDOWN DETECTION FLOW CHART Sheet DP054 Folio 2/5 NO BOOM LIFTING MOVEMENT (UP AND/OR DOWN) FROM THE PLATFORM (OR TURNTABLE) CONTROL PANEL Check the setpoint at the outputs of limit detectors SQ7, SQ8 and SQ11. Setpoint SQ7=0V SQ8=12V SQ11=0V Check the continuity of harnesses 115A, 115B and 218B.
  • Page 135 BREAKDOWN DETECTION FLOW CHART Sheet DP054 Folio 3/5 NO BOOM LIFTING MOVEMENT (UP AND/OR DOWN) FROM THE PLATFORM (OR TURNTABLE) CONTROL PANEL Activate the boom lifting movement in manual: - Put the emergency lever into place on the manual control of the boom lifting distributor (YV3) - Activate the lever up/down while pressing the emergency control of the safety valve (YV1), or activate the emergency unit...
  • Page 136 BREAKDOWN DETECTION FLOW CHART Sheet DP054 Folio 4/5 NO BOOM LIFTING MOVEMENT (UP AND/OR DOWN) FROM THE PLATFORM (OR TURNTABLE) CONTROL PANEL Maintain the control activated and Voltage check for 3V or 9V voltage (depen- ding on the movement direction) on terminal 403A of the printed circuit Replace the PVG YV3 control See Fiche...
  • Page 137 BREAKDOWN DETECTION FLOW CHART Folio 5/5 Sheet DP054 NO BOOM LIFTING MOVEMENT (UP AND/OR DOWN) FROM THE PLATFORM (OR TURNTABLE) CONTROL PANEL Activate the rotation movement in manual: - Put the emergency lever into place on the manual control of the rotation distributor (YV5) - Activate the lever right/left while pressing the emergency control of the safety valve (YV1), or activate the emergency unit...
  • Page 139 BREAKDOWN DETECTION FLOW CHART Sheet DP056 Folio 1/2 ONLY TRAVEL MICRO-SPEED IS AVAILABLE ON THE MACHINE REGARDLESS OF THE SPEED SELECTED Only travel micro-speed remains available on the machine, regardless of the selected speed Check that the machine is folded SQ2 = 1, SQ3 = 1 and SQ9 = 1 Machine Fold the machine...
  • Page 140 BREAKDOWN DETECTION FLOW CHART Sheet DP056 Folio 2/2 ONLY TRAVEL MICRO-SPEED IS AVAILABLE ON THE MACHINE REGARDLESS OF THE SPEED SELECTED The fault persists Replace the printed circuit See Fiche C063...
  • Page 141 BREAKDOWN DETECTION FLOW CHART Sheet DP058 Folio 1/1 SUDDEN STOP OF TRAVEL MOVEMENT DURING A PLATFORM LIFTING OPERATION Sudden stop of travel movement during a platform lifting operation Check the setpoint at the output of detectors SQ3, SQ2 and SQ9 Adjust the detector(s), See Fiche replace the defective...
  • Page 143 BREAKDOWN DETECTION FLOW CHART Sheet DP060 Folio 1/4 NO STEERING MOVEMENT (RIGHT OR LEFT) No steering movement (right or left) - Place the key switch in the platform position - Press the pedal and activate the basket rotation switch on the platform control panel The basket rotates - Stop the movement and release the pedal...
  • Page 144 BREAKDOWN DETECTION FLOW CHART Sheet DP060 Folio 2/4 NO STEERING MOVEMENT (RIGHT OR LEFT) Press the pedal and activate the REAR steering manipulator SM4 and check for 12V voltage at the terminals of the PVG YV2a connector - Open the turntable control panel - Press the pedal and activate the REAR steering manipulator SM4 and check for 12V voltage on terminal 305 of the printed circuit...
  • Page 145 BREAKDOWN DETECTION FLOW CHART Sheet DP060 Folio 3/4 NO STEERING MOVEMENT (RIGHT OR LEFT) - Invert the coils of the jib electrovalve YV16A and YV16B - Press the pedal and activate the REAR steering manipulator SM4 The defective movement, right (1) Replace electrovalve See Fiche or left (2), is made in response to a...
  • Page 146 BREAKDOWN DETECTION FLOW CHART Sheet DP060 Folio 4/4 NO STEERING MOVEMENT (RIGHT OR LEFT) Maintain the control activated and check for 12V voltage at terminals 703 and 705 of the printed circuit Open the platform (or turntable) control panel and check the wiring of the manipulator SM4 Wiring...

  • Page 147: Corrective Maintenance Procedure

    Repair manual CORRECTIVE MAINTENANCE PROCEDURE List of corrective maintenance sheets: Sheet no. Description FICHE C010 Changing a hose FICHE C034 Changing a wheel FICHE C035 Changing a wheel reducing gear or a hydraulic travel motor FICHE C036 Changing a steering pivot FICHE C039 Changing the tilt sensor FICHE C040...
  • Page 148 Repair manual Sheet no. Description FICHE C099 Changing the turntable rotation hydraulic motor FICHE C100 Changing the swing joint FICHE C101 Changing a counterweight FICHE C103 Dismantling / re-assembling the jib FICHE C104 Changing the basket rotation gearing FICHE C106 Changing the turntable slew ring FICHE C107 Changing the U1 electronic module...
  • Page 149 CORRECTIVE MAINTENANCE SHEET Sheet C010 Folio 1/1 CHANGING A HOSE 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3, page 32). • Switch off electric power (see § 6.4, page 32). Caution! • Close the shut-off valve, if any; if not, empty the hydraulic tank. Ensure that the oil is not too hot.
  • Page 151 CORRECTIVE MAINTENANCE SHEET Folio 1/1 Sheet C034 CHANGING A WHEEL 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3, page 32). • Switch off electric power (see § 6.4, page 32). 2 - Removing a wheel •...
  • Page 153 CORRECTIVE MAINTENANCE SHEET Sheet C035 Folio 1/2 CHANGING A WHEEL REDUCING GEAR OR A TRAVEL HYDRAULIC MOTOR 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3, page 32). • Switch off electric power (see § 6.4, page 32). •...
  • Page 154 CORRECTIVE MAINTENANCE SHEET Sheet C035 Folio 2/2 CHANGING A WHEEL REDUCING GEAR OR A TRAVEL HYDRAULIC MOTOR Figure 1 Figure 2...
  • Page 155 CORRECTIVE MAINTENANCE SHEET Sheet C036 Folio 1/2 CHANGING A STEERING PIVOT 1 - Preliminary operations Caution! • Put the machine in the maintenance configuration (see § 6.3, page 32). Ensure that the oil is not too • Switch off electric power (see § 6.4, page 32). hot.
  • Page 156 CORRECTIVE MAINTENANCE SHEET Sheet C036 Folio 2/2 CHANGING A STEERING PIVOT A - A Figure 1...
  • Page 157 CORRECTIVE MAINTEANCE SHEET Sheet C039 Folio 1/1 CHANGING THE TILT SENSOR 1 - Preliminary operations • Put the machine on a flat surface with zero slope. • Put the machine into the maintenance configuration (see § 6.3, page 32). Caution! •...
  • Page 159 CORRECTIVE MAINTENANCE SHEET Sheet C040 Folio 1/1 CHANGING THE HORN 1 - Preliminary operations Caution! • Switch off electric power (see § 6.4, page 32). Do not use the machine during maintenance 2 - Removing the horn operations. • Mark and disconnect the electric connections from the horn (1). •...
  • Page 161 CORRECTIVE MAINTENANCE SHEET Sheet C041 Folio 1/1 CHANGING THE TILT SENSOR BUZZER 1 - Preliminary operations Caution! • Switch off electric power (see § 6.4, page 32). Do not use the machine during maintenance 2 - Removing the buzzer operations. •...
  • Page 163 CORRECTIVE MAINTENANCE SHEET Sheet C043 Folio 1/1 CHANGING AN ELECTRIC COMPONENT ON THE TOP CONTROL PANEL 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3, page 32). • Switch off electric power (see § 6.4, page 32). Caution! •...
  • Page 165 CORRECTIVE MAINTENANCE SHEET Sheet C044 Folio 1/1 CHANGING AN ELECTRIC COMPONENT ON THE BOTTOM CONTROL PANEL 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3, page 32). • Switch off electric power (see § 6.4, page 32). Caution! •...
  • Page 167 CORRECTIVE MAINTENANCE SHEET Sheet C045 Folio 1/1 CHANGING A MANIPULATOR 1 - Preliminary operations Caution! • Put the machine in the maintenance configuration (see § 6.3, page 32). Do not use the machine • Switch off electric power (see § 6.4, page 32). during maintenance •...
  • Page 169 CORRECTIVE MAINTENANCE SHEET Sheet C046 Folio 1/1 CHANGING THE STARTER BATTERY 1 - Preliminary operations Caution! • Put the machine in the maintenance configuration (see § 6.3, page 32). Wear protective goggles and • Switch off electric power (see § 6.4, page 32). gloves for any operation on the batteries.
  • Page 171 CORRECTIVE MAINTENANCE SHEET Sheet C047 Folio 1/1 CHANGING A COVER GAS SPRING 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3, page 32). • Switch off electric power (see § 6.4, page 32). Caution! Do not use the machine 2 - Removing a gas spring during maintenance...
  • Page 173 CORRECTIVE MAINTENANCE SHEET Sheet C052 Folio 1/1 CHANGING THE BASKET ROTATION HYDRAULIC MOTOR 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3, page 32). • Switch off electric power (see § 6.4, page 32). Caution! Ensure that the oil is not too 2 - Removing the hydraulic motor...
  • Page 175 CORRECTIVE MAINTENANCE SHEET Sheet C053 Sheet C053 Folio 1/3 CHANGING THE BASKET 1 - Preliminary operations Caution! • Put the machine in the maintenance configuration (see § 6.3, page 32). • Switch off electric power (see § 6.4, page 32). It is essential to put the •...
  • Page 176 CORRECTIVE MAINTENANCE SHEET Sheet C053 Sheet C053 Folio 2/3 CHANGING THE BASKET • If necessary, put the platform’s electric plug back into place and fix using its fixing bolts equipped with new toothed washers. • Reconnect the « + » then « - » terminals of the starter battery. •...
  • Page 177 Sheet C053 Folio 3/3 CHANGING THE BASKET Figure 3 HA16/18PX - HA46/51JRT = 108 mm / 4.25 in H21T - HB62 = 103 mm / 4.055 in H23T/TP - H25TP - HB68J - HB76J = 108 mm / 4.25 in...
  • Page 179 CORRECTIVE MAINTENANCE SHEET Sheet C054 Folio 1/1 CHANGING A WEIGHING SYSTEM ROLLING BEARING 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3, page 32). • Switch off electric power (see § 6.4, page 32). •...
  • Page 181 CORRECTIVE MAINTENANCE SHEET Sheet C056 Folio 1/1 CHANGING THE HYDRAULIC FILTER Caution! 1 - Preliminary operations Ensure that the oil is not too • Put the machine in the maintenance configuration (see § 6.3, page 32). hot. • Switch off electric power (see § 6.4, page 32). •...
  • Page 182 CORRECTIVE MAINTENANCE SHEET Folio 2/2...
  • Page 183 CORRECTIVE MAINTENANCE SHEET Sheet C059 Folio 1/1 CHANGING A COIL 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3, page 32). • Switch off electric power (see § 6.4, page 32). 2 - Removing a coil •...
  • Page 185 CORRECTIVE MAINTENANCE SHEET Sheet C062 Folio 1/2 CHANGING A RELAY 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3, page 32). • Switch off electric power (see § 6.4, page 32). • Disconnect the « - » then « + » terminals of the starter battery. 2 - Removing a relay •...
  • Page 186 CORRECTIVE MAINTENANCE SHEET Sheet C062 Folio 2/2 CHANGING A RELAY...
  • Page 187 CORRECTIVE MAINTENANCE SHEET Sheet C063 Folio 1/1 CHANGING THE PRINTED CIRCUIT 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3, page 32). • Switch off electric power (see § 6.4, page 32). • Disconnect the « - » then « + » terminals of the starter battery. 2 - Removing the printed circuit •...
  • Page 189 CORRECTIVE MAINTENANCE SHEET Sheet C064 Folio 1/1 CHANGING THE FAIL-SAFE PEDAL 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3, page 32). • Switch off electric power (see § 6.4, page 32). • Disconnect the « - » then « + » terminals of the starter battery. 2 - Removing the fail-safe pedal •...
  • Page 191 CORRECTIVE MAINTENANCE SHEET Sheet C067 Folio 1/1 CHANGING AN ELECTROVALVE 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3, page 32). Caution! • Switch off electric power (see § 6.4, page 32). Ensure that the oil is not too hot.
  • Page 193 CORRECTIVE MAINTENANCE SHEET Sheet C079 Folio 1/1 CHANGING A FLOW SEPARATOR 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3, page 32). • Switch off electric power (see § 6.4, page 32). Caution! Ensure that the oil is not too 2 - Removing a flow separator hot.
  • Page 195 CORRECTIVE MAINTENANCE SHEET Sheet C082 Folio 1/1 CHANGING A BALANCING VALVE FOR THE COMPENSATION FUNCTION 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3, page 32). • Switch off electric power (see § 6.4, page 32). Caution! Ensure that the oil is not too 2 - Removing a balancing valve...
  • Page 197 CORRECTIVE MAINTEANCE SHEET Sheet C083 Folio 1/1 CHANGING A DOUBLE FLOW LIMITER FOR THE COMPENSATION FUNCTION 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3, page 32). Caution! • Switch off electric power (see § 6.4, page 32). Ensure that the oil is not too hot.
  • Page 199 CORRECTIVE MAINTENANCE SHEET Sheet C085 Folio 1/2 CHANGING A STEERING PIVOT ON A NON-DRIVE WHEEL 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3 -). Caution! • Switch off electric power (see § 6.4 -). •...
  • Page 200 CORRECTIVE MAINTENANCE SHEET Sheet C085 Folio 2/2 CHANGING A STEERING PIVOT ON A NON-DRIVE WHEEL A - A...
  • Page 201 CORRECTIVE MAINTENANCE SHEET Sheet C086 Folio 1/2 DISMANTLING AND RE-ASSEMBLING THE STEERING SYSTEM 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3 -). • Switch off electric power (see § 6.4 -). Caution! 2 - Removing a steering bar Ensure that the oil is not too •...
  • Page 202 CORRECTIVE MAINTENANCE SHEET Sheet C086 Folio 2/2 DISMANTLING AND RE-ASSEMBLING THE STEERING SYSTEM B - B A - A...
  • Page 203 CORRECTIVE MAINTENANCE SHEET Sheet C087 Folio 1/1 CHANGING THE STEERING CYLINDER 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3 -). Caution! • Switch off electric power (see § 6.4 -). Ensure that the oil is not too 2 - Removing the steering cylinder hot.
  • Page 204 CORRECTIVE MAINTENANCE SHEET Sheet C087 Folio 2/2 CHANGING THE STEERING CYLINDER...
  • Page 205 CORRECTIVE MAINTENANCE SHEET Sheet C091 Folio 1/2 CHANGING THE HYDRAULIC PUMP Caution! Ensure that the oil is not too 1 - Preliminary operations hot. • Put the machine in the maintenance configuration (see § 6.3 -). • Switch off electric power (see § 6.4 -). •...
  • Page 206 CORRECTIVE MAINTENANCE SHEET Sheet C091 Folio 2/2 CHANGING THE HYDRAULIC PUMP...
  • Page 207 CORRECTIVE MAINTENANCE SHEET Sheet C092 Folio 1/2 CHANGING THE HYDRAULIC BLOCK (TRAVEL / ON-OFF MOVEMENT / STEERING) 1 - Preliminary operations Caution! • Put the machine in the maintenance configuration (see § 6.3 -). Ensure that the oil is not too •...
  • Page 208 CORRECTIVE MAINTENANCE SHEET Sheet C092 Folio 2/2 CHANGING THE HYDRAULIC BLOCK (TRAVEL / ON-OFF MOVEMENT / STEERING)
  • Page 209 CORRECTIVE MAINTENANCE SHEET Sheet C093 Folio 1/2 CHANGING THE DISTRIBUTION HYDRAULIC BLOCK 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3 -). Caution! • Switch off electric power (see § 6.4 -). Ensure that the oil is not too 2 - Removing the distribution hydraulic block hot.
  • Page 210 CORRECTIVE MAINTENANCE SHEET Sheet C093 Folio 2/2 CHANGING THE DISTRIBUTION HYDRAULIC BLOCK...
  • Page 211 CORRECTIVE MAINTENANCE SHEET Sheet C094 Folio 1/1 INTRINSIC DISMANTLING / RE-ASSEMBLY OF THE DISTRIBUTION HYDRAULIC BLOCK 1 - Preliminary operations • Remove the distribution hydraulic block (see corresponding sheet). Caution! Ensure that the oil is not too 2 - Dismantling the distribution hydraulic block (1) hot.
  • Page 213 CORRECTIVE MAINTENANCE SHEET Sheet C097 Folio 1/1 CHANGING A TURNTABLE COVER 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3 -). Caution! • Switch off electric power (see § 6.4 -). Do not use the machine during maintenance 2 - Removing a cover operations.
  • Page 215 CORRECTIVE MAINTENANCE SHEET Sheet C098 Folio 1/2 CHANGING THE THERMAL MOTOR Caution! 1 - Preliminary operations Leave the motor and exhaust • Put the machine in the maintenance configuration (see § 6.3 -). to cool sufficiently before • Switch off electric power (see § 6.4 -). performing any maintenance •...
  • Page 216 CORRECTIVE MAINTENANCE SHEET Sheet C098 Folio 2/2 CHANGING THE THERMAL MOTOR Caution! If the motor installed is new, follow the first commissioning instructions (see motor manufacturer’s manual).
  • Page 217 CORRECTIVE MAINTENANCE SHEET Sheet C099 Folio 1/2 CHANGING THE TURNTABLE ROTATION HYDRAULIC MOTOR 1 - Preliminary operations Caution! • Lift the boom sufficiently to enable access to the turntable rotation hydrau- Put the turntable rotation lic motor. blocking pin into place. •...
  • Page 218 CORRECTIVE MAINTENANCE SHEET Sheet C099 Folio 2/2 CHANGING THE TURNTABLE ROTATION HYDRAULIC MOTOR...
  • Page 219 CORRECTIVE MAINTENANCE SHEET Sheet C100 Folio 1/2 CHANGING THE SWING JOINT ASSEMBLY 1 - Preliminary operations Caution! • Lift the boom sufficiently to enable access to the swing joint. • Place wedges under the boom to bear its weight. Put the turntable rotation •...
  • Page 220 CORRECTIVE MAINTENANCE SHEET Sheet C100 Folio 2/2 CHANGING THE SWING JOINT ASSEMBLY Figure 1...
  • Page 221 CORRECTIVE MAINTENANCE SHEET Sheet C101 Folio 1/1 CHANGING A COUNTERWEIGHT 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3 -). • Switch off electric power (see § 6.4 -). • Put the boom in slings (1) to prevent tipping when the counterweight(s) is(are) removed.
  • Page 223 CORRECTIVE MAINTENANCE SHEET Sheet C103 Folio 1/2 DISMANTLING / RE-ASSEMBLING THE JIB 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3 -). • Switch off electric power (see § 6.4 -). Caution! • Remove contactor (7) (see corresponding sheet). Ensure that the oil is not too 2 - Removing the platform+support assembly hot.
  • Page 224 CORRECTIVE MAINTENANCE SHEET Sheet C103 Folio 2/2 DISMANTLING / RE-ASSEMBLING THE JIB 6 - Installing the jib • Put the jib and its cylinder into place and put back the articulation pins. • Put back the upper pin stop clevis (8). •...
  • Page 225 CORRECTIVE MAINTENANCE SHEET Sheet C104 Folio 1/2 CHANGING THE BASKET ROTATION GEARING 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3 -). • Switch off electric power (see § 6.4 -). • Remove the basket (see corresponding sheet). •...
  • Page 226 CORRECTIVE MAINTENANCE SHEET Sheet C104 Folio 2/2 CHANGING THE BASKET ROTATION GEARING A - A...
  • Page 227 CORRECTIVE MAINTENANCE SHEET Sheet C106 Folio 1/3 CHANGING THE SLEW RING 1 - Preliminary operations Caution! • Move the turntable to the locking position. • Put the machine in the maintenance configuration (see § 6.3 -). Ensure that the oil is not too •...
  • Page 228 CORRECTIVE MAINTENANCE SHEET Fiche C106 Folio 2/3 CHANGING THE SLEW RING • Make several turntable rotation, steering and travel movements using all possible travel speeds to purge the hydraulic circuit. • Check that the electric controls work properly. • Check the level of the hydraulic oil tank. Figure 1 Figure 2...
  • Page 229 CORRECTIVE MAINTENANCE SHEET Sheet C106 Folio 3/3 CHANGING THE SLEW RING...
  • Page 231 CORRECTIVE MAINTENANCE SHEET Sheet C107 Folio 1/2 CHANGING THE U1 ELECTRONIC MODULE 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3 -). • Switch off electric power (see § 6.4 -). • Disconnect the « - » then « + » terminals of the starter battery to isolate the electric circuit.
  • Page 232 CORRECTIVE MAINTENANCE SHEET Sheet C107 Folio 2/2 CHANGING THE U1 ELECTRONIC MODULE...
  • Page 233 CORRECTIVE MAINTENANCE SHEET Sheet C108 Folio 1/1 CHANGING A CONTROL UNIT OF THE DISTRIBUTION BLOCK 1 - Preliminary operations Caution! • Put the machine in the maintenance configuration (see § 6.3 -). Ensure that the oil is not too • Switch off electric power (see §...
  • Page 235 CORRECTIVE MAINTENANCE SHEET Sheet C109 Folio 1/2 CHANGING THE EMERGENCY ELECTROPUMP UNIT 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3 -). • Switch off electric power (see § 6.4 -). Caution! • Disconnect the « - » then « + » terminals of the starter battery. Ensure that the oil is not too hot.
  • Page 236 CORRECTIVE MAINTENANCE SHEET Sheet C109 Folio 2/2 CHANGING THE EMERGENCY ELECTROPUMP UNIT...
  • Page 237 CORRECTIVE MAINTENANCE SHEET Sheet C110 Folio 1/2 CHANGING A LIMIT CONTACT 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3 -). • Switch off electric power (see § 6.4 -). 2 - Removing a limit contact •...
  • Page 238 CORRECTIVE MAINTENANCE SHEET Sheet C110 Folio 2/2 CHANGING A LIMIT CONTACT 5 - Adjusting and testing SQ7 (see chapter on positioning the safety ele- ments) • In the telescope in position, check that there is 2 mm between the contact lever and the telescope tube as shown in figure 2.
  • Page 239 CORRECTIVE MAINTENANCE SHEET Sheet C111 Folio 1/2 ADJUSTING A PRESSURE LIMITER Before an adjustment operation, operate the machine so that the oil Caution! in the tank is at a temperature of around 50°. Ensure that the oil is not too hot.
  • Page 240 CORRECTIVE MAINTENANCE SHEET Sheet C111 Folio 2/2 ADJUSTING A PRESSURE LIMITER • Put the machine back in the operational configuration. • Make several turntable rotation movements to check machine operation. 4 - Adjusting the emergency unit pressure limiter (5 - fig. 4) •...
  • Page 241 CORRECTIVE MAINTENANCE SHEET Sheet C112 Folio 1/1 CHANGING A BALANCING BLOCK BOOM LIFTING FUNCTION 1 - Preliminary operations Caution! • Lift the boom and wedge it. The boom MUST be wedged • Switch off electric power (see § 6.4 -). (support the boom on wedges) 2 - Removing the balancing block...
  • Page 243 CORRECTIVE MAINTENANCE SHEET Sheet C114 Folio 1/2 CHANGING THE EMERGENCY HYDRAULIC CIRCUIT PRESSURE LIMITER 1 - Preliminary operations Attention ! • Put the machine in the maintenance configuration (see § 6.3 -). Ensure that the oil is not too • Switch off electric power (see §...
  • Page 244 CORRECTIVE MAINTENANCE SHEET Sheet C114 Folio 2/2 CHANGING THE EMERGENCY HYDRAULIC CIRCUIT PRESSURE LIMITER...
  • Page 245 CORRECTIVE MAINTENANCE SHEET Sheet C115 Folio 1/2 CHANGING THE JIB CYLINDER 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3 -). • Switch off electric power (see § 6.4 -). Caution! • Anchor the basket on the ground. Ensure that the oil is not too hot.
  • Page 246 CORRECTIVE MAINTENANCE SHEET Sheet C115 Folio 2/2 CHANGING THE JIB CYLINDER...
  • Page 247 CORRECTIVE MAINTENANCE SHEET Sheet C116 Folio 1/2 CHANGING THE BOOM LIFTING CYLINDER 1 - Preliminary operations • Position the self-propelled telescopic platform on a firm, horizontal sur- Caution! face. Ensure that the oil is not too • Put the turntable rotation blocking pin into place. hot.
  • Page 248 CORRECTIVE MAINTENANCE SHEET Sheet C116 Folio 2/2 CHANGING THE BOOM LIFTING CYLINDER...
  • Page 249 CORRECTIVE MAINTENANCE SHEET Sheet C117 Folio 1/2 CHANGING THE TURNTABLE ROTATION REDUCING GEAR 1 - Preliminary operations • Lift the boom to enable access to the turntable rotation reducing gear (1). • Wedge the boom to take its weight (place on firm supports). •...
  • Page 250 CORRECTIVE MAINTENANCE SHEET Sheet C117 Folio 2/2 CHANGING THE TURNTABLE ROTATION REDUCING GEAR...
  • Page 251 CORRECTIVE MAINTENANCE SHEET Sheet C118 Folio 1/2 CHANGING A CIRCUIT SELECTOR OF THE TRAVEL HYDRAULIC BLOCK 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3 -). Caution! • Switch off electric power (see § 6.4 -). Ensure that the oil is not too hot.
  • Page 252 CORRECTIVE MAINTENANCE SHEET Sheet C118 Folio 2/2 CHANGING A CIRCUIT SELECTOR OF THE TRAVEL HYDRAULIC BLOCK...
  • Page 253 CORRECTIVE MAINTENANCE SHEET Folio 1/13 Sheet C119 DISMANTLING / RE-ASSEMBLING THE BOOM 1 - Preliminary operations • Put the machine in the maintenance configuration (see § 6.3 -). Caution! • Switch off electric power (see § 6.4 -). Ensure that the oil is not too •...
  • Page 254 CORRECTIVE MAINTENANCE SHEET Sheet C119 Folio 2/13 DISMANTLING / RE-ASSEMBLING THE BOOM plate under the boom. • Free the slings (13) after noting the length of the free threaded part. • Take the cable and hoses from the side chutes of the large drum and allow to hang freely from the flap.
  • Page 255 CORRECTIVE MAINTENANCE SHEET Folio 3/13 Sheet C119 DISMANTLING / RE-ASSEMBLING THE BOOM Figure 3 4 - Removing the receiver compensation cylinder (Figure 4, Figure 5) • Put the receiver compensation cylinder in slings (1). • Remove the top cap (2). •...
  • Page 256 CORRECTIVE MAINTENANCE SHEET Sheet C119 Folio 4/13 DISMANTLING / RE-ASSEMBLING THE BOOM 5 - Removing the large drum (Figure 6) • Put the large drum (16), emitting compensation cylinder (35) and boom lif- ting cylinder (36) in slings. • Mark and disconnect the hydraulic hoses of the emitting compensation cylinder and boom lifting cylinder.
  • Page 257 CORRECTIVE MAINTENANCE SHEET Folio 5/13 Sheet C119 DISMANTLING / RE-ASSEMBLING THE BOOM 6 - Installing the large drum Before re-installing, check the condition of all the articulation pin rings, and replace if necessary. Lubricate all bores before re-instal- ling the pins. Only use lubricants recommended by the manufactu- rer.
  • Page 258 CORRECTIVE MAINTENANCE SHEET Sheet C119 Folio 6/13 DISMANTLING / RE-ASSEMBLING THE BOOM Spurs to be removed on the first link Figure 7 7 - Installing the receiver compensation cylinder • Bring the receiver compensation cylinder to the end of the head element (1) to reconnect the two hydraulic hoses of the cylinder, according to the marks made during dismantling.
  • Page 259 CORRECTIVE MAINTENANCE SHEET Folio 7/13 Sheet C119 DISMANTLING / RE-ASSEMBLING THE BOOM Figure 9 9 - Re-assembling and adjusting a 3-element telescopic boom Head element equipment • Bind together the two electric cables (31, Figure 10) with adhesive tape, on the side on which they will be inserted. Mark a length of 3m on the 42- wire cable.
  • Page 260 CORRECTIVE MAINTENANCE SHEET Sheet C119 Folio 8/13 DISMANTLING / RE-ASSEMBLING THE BOOM C2: cylinder in R1: cylinder rotation R2: cylinder rotation Stick the ring (31) with loctite 648. Compensation Basket rotation Figure 11 • Attach the cables and hoses inside the element with HB20 collars (32) for hoses C1 and R1 and HB33 collars (33) for hoses C2, R1, 4-wire and 42- wire cables (shown from F-Figure 12).
  • Page 261 CORRECTIVE MAINTENANCE SHEET Folio 9/13 Sheet C119 DISMANTLING / RE-ASSEMBLING THE BOOM 2 operators required. Preparation of the head element before insertion: • Attach the slings to the element with adhesive tape (such as masking tape) (Figure 13) • Prepare the slings on the head element. •...
  • Page 262 CORRECTIVE MAINTENANCE SHEET Sheet C119 Folio 10/13 DISMANTLING / RE-ASSEMBLING THE BOOM Figure 14 • Assemble the front pulleys from inside the element. • Finish inserting the head element to its mechanical stop. • Pull the out slings taut to place them in the front pulley groove, then put in the Hc screws to keep them in place.
  • Page 263 CORRECTIVE MAINTENANCE SHEET Folio 11/13 Sheet C119 DISMANTLING / RE-ASSEMBLING THE BOOM Free sling Figure 15 • Bring the head element + intermediary element assembly into alignment with the large drum. • Insert the cables, hoses and chain in the large drum, bringing them out through the flap.
  • Page 264 CORRECTIVE MAINTENANCE SHEET Sheet C119 Folio 12/13 DISMANTLING / RE-ASSEMBLING THE BOOM 12 - Finishing • Put back contactors SQ3, SQ7, SQ8, SQ9, SQ10 and SQ11 (see corres- ponding sheet). • Put back the jib, if applicable (see corresponding sheet). •...
  • Page 265 CORRECTIVE MAINTENANCE SHEET Folio 13/13 Sheet C119 DISMANTLING / RE-ASSEMBLING THE BOOM cam placed on the intermediary drum. No adjustment is necessary. Simply check that the contactor does not touch the intermediary drum and that contact with the cam is made correctly. •...

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