Haulotte HA41PX Diesel Telescopic Boom Lift User Manual

Haulotte HA41PX Diesel Telescopic Boom Lift

Product Information

The product is a self-propelled lift with the model name HA 41 PX. The product is manufactured by Haulotte and is designed for various lifting applications. The product complies with the provisions of the Machinery Directive 89/392/EEC of June 14th 1989, as amended by the directives 91/368/EEC of June 21st 1991, 93/44/EEC of June 14th 1993, 93/68/EEC of July 22nd 1993, and 89/336/EEC of May 3rd 1989, directive 2000/14/CE, directive EMC/89/336/CE, and the provisions of the Australian Standards AS1418.10-1996.

Product Usage Instructions

1. Before using the product, carefully read and follow the operating and maintenance instructions provided in this manual.
2. For any service or assistance, contact our Local Agent or our Factory After-Sales Department, providing them with the exact type of machine and its serial number.
3. When ordering consumables or spares, refer to this documentation and the Spares catalogue to ensure you receive original parts for guaranteed interchangeability and perfect operation.
4. It is recommended to use only Haulotte original spare-parts for the following reasons
   • Recalling the EEC Declaration of Conformity: Components, substitutions, or modifications other than the ones recommended by Haulotte may question the initial security conditions of our Haulotte equipment. The EEC declaration will become null and void, and Haulotte will disclaim regulation responsibility.
   • End of the Warranty: The contractual warranty offered by Haulotte for its equipment will no longer be applied after spare-parts other than original ones are used.
   • Availability: Using Haulotte original spare-parts allows you to take advantage of 40,000 references available in our permanent stock and a 98% service rate.
5. Follow the general operating and maintenance instructions provided in this manual to ensure the safe and proper use of the HAULOTTE self-propelled platform.
6. For any additional information or support, please refer to the contact details provided in the user manual.

OPERATING AND MAINTENANCE INSTRUCTIONS

SELF-PROPELLED LIFT HA 41 PX
242 032 9720 – E 07.06 AUS

Distribué par / Distributed by/ Distribuito da

Haulotte France Tél / Phone Fax / Fax

+33 (0)4 72 88 05 70 +33 (0)4 72 88 01 43

Haulotte Hubarbeitsbühnen

Tél / Phone

+ 49 76 33 806 920

Fax / Fax

+ 49 76 33 806 82 18

Haulotte UK Tél / Phone Fax / Fax

+ 44 (0) 1952 292753 + 44 (0) 1952 292758

Haulotte Singapore Pte Ltd

Tél / Phone

+ 65 6536 3989

Fax / Fax

+ 65 6536 3969

Haulotte Australia PTY Ltd

Tél / Phone

+ 61 3 9706 6787

Fax / Fax

+ 61 3 9706 6797

Haulotte Do Brazil

Tél / Phone

+ 55 11 3026 9177

Fax / Fax

+ 55 3026 9178

Haulotte Iberica – Madrid

Tél / Phone

+ 34 91 656 97 77

Fax / Fax

+ 34 91 656 97 81

Centre Mondial Pièces de Rechange

Spare Parts International Centre

Tél / Phone

+33 (0)4 77 29 24 51

Fax / Fax

+33 (0)4 77 29 98 88

Haulotte Portugal

Tél / Phone

+ 351 21 955 98 10

Fax / Fax

+ 351 21 995 98 19

Haulotte U.S. Inc.

Main tool free

1-877-HAULOTTE

Service tool free 1-877-HAULOT-S

Haulotte Netherlands BV

Tél / Phone

+ 31 162 670 707

Fax / Fax

+ 31 162 670 710

Haulotte Italia Tél / Phone Fax / Fax

+ 39 05 17 80 813 + 39 05 16 05 33 28

Haulotte Scandinavia AB u.b.

Tél / Phone

+ 46 31 744 32 90

Fax / Fax

+ 46 31 744 32 99

Haulotte Iberica – Sevilla

Tél / Phone

+ 34 95 493 44 75

Fax / Fax

+ 34 95 463 69 44

Why use only Haulotte original spare-parts ?
1. RECALLING THE EEC DECLARATION OF CONFORMITY IN QUESTION Components, substitutions, or modifications other than the ones recommended by Haulotte may recall in question the initial security conditions of our Haulotte equipment. The person who would have intervened for any operation of this kind will take responsibility and recall in question the EEC marking validity granted by Haulotte. The EEC declaration will become null and void and Haulotte will disclaim regulation responsibility.
2. END OF THE WARRANTY The contractual warranty offered by Haulotte for its equipment will no longer be applied after spare-parts other than original ones are used.
3. PUBLIC AND PENAL LIABILITY The manufacture and unfair competition of fake spare-parts will be sentenced by public and penal law. The usage of fake spare-parts will invoke the civil and penal liability of the manufacturer, of the retailer, and, in some cases, of the person who used the fake spareparts. Unfair competition invokes the civil liability of the manufacturer and the retailer of a “slavish copy” which, taking unjustified advantage of this operation, distorts the normal rules of competition and creates a “parasitism” act by diverting efforts of design, perfection, research of best suitability, and the know-how of Haulotte.
FOR YOUR SECURITY, REQUIRE HAULOTTE ORIGINAL SPARE-PARTS

4. QUALITY Using Haulotte original spare-parts means guarantee of : · High quality partsl · The latest technological evolution · Perfect security · Peak performance · The best service life of your Haulotte equipment · The Haulotte warranty · Haulotte technicians’ and repair agents’ technical support
5. AVAILABILITY Using Haulotte original spare-parts allows you to take advantage of 40 000 references available in our permanent stock and a 98% service rate.
WHY NOT TAKE ADVANTAGE ?

GENERAL

You have just taken delivery of your HAULOTTE self-propelled platform.
It will give you complete satisfaction if you follow the operating and maintenance instructions exactly.
The purpose of this instruction manual is to help you in this.
We stress the importance: · of complying with the safety instructions relating to the machine itself, its use and its environment, · of using it within the limits of its performances, · of proper maintenance upon which its service life depends.
During and beyond the warranty period, our After-Sales Department is at your disposal for any service you might need.
Contact in this case our Local Agent or our Factory After-Sales Department, specifying the exact type of machine and its serial number.
When ordering consumables or spares, use this documentation, together with the “Spares” catalogue so as to receive original parts, the only guarantee of interchangeability and perfect operation.
Caution ! This manual is supplied with the machine and is included
on the delivery note.
REMINDER:You are reminded that our machines comply with the provisions of the “Machinery Directive” 89/392/EEC of June 14th 1989 as amended by the directives 91/368/EEC of June 21st 1991, 93/44/ EEC of June 14th 1993, 93/68/EEC of July 22nd 1993 and 89/336/ EEC of May 3rd 1989, directive 2000/14/CE, directive EMC/89/336/ CE and the provisions of the Australian Standards AS1418.10-1996.
Caution ! The technical data contained in this manual cannot involve
our responsibility and we reserve the right to proceed
with improvements or modifications without amending this manual.
i

Operating and maintenance instructions ii

Operating and maintenance instructions

GENERAL RECOMMENDATIONS – SAFETY

1.1 – GENERAL WARNING
Caution ! To attract the reader’s attention instructions are signalled by this
sign.

1.1.1 – Manual
This manual is designed to familiarise the operator with HAULOTTE selfpropelled platforms in order to ensure efficient and safe use. However, it cannot replace the basic training required by any user of site equipment. The site manager is bound to inform the operators of the instructions contained in the manual. He is also responsible for applying the user regulations in force in the country of use. Before using the machine, it is essential to understand all these instructions in order to ensure safe and efficient operation. This manual must be kept available for all operators. Additional copies can be supplied by the manufacturer on request
1.1.2 – Labels
Potential dangers and machine instructions are indicated on labels and plates. All instructions on such plates must be read. All labels conform to the following colour code:
· Red indicates a potentially fatal danger. · Orange indicates a danger of causing serious injury. · Yellow indicates a danger that may cause material damage or slight
injury. The site manager must ensure that these labels are in good condition and remain legible. Additional copies can be supplied by the manufacturer on request.
1.1.3 – Safety
Ensure that any persons entrusted with the machine are fit to meet the safety requirements that its use imposes. Avoid any working method that may jeopardise safety. Any use not compliant with the instructions may cause risk and damage to persons and property.
This manual must be kept by the user throughout the machine’s service life, including in the case of loan, lease and resale. Ensure that all plates or labels relative to safety and hazards are complete and legible.

1

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. Always cheek for specific requirements in the countrf of use.

Caution !
Only trained operators can use Haulotte self-propelled platforms.

Y km/h

X km/h
Y>X

°C 0
-15

There must always be at least two operators present, so that one of them at ground level can:
· Take fast action if necessary. · Take over the controls in case of accident or malfunction. · Monitor and prevent movement of vehicles and people near the plat-
form. · Guide the platform operator if required.
1.2.2 – Environment
Never use the machine:
· On ground that is soft, unstable, congested. · On ground that has a slope greater than permissible limit. · In winds greater than the permissible limit. If used outside, use an an-
emometer or refer to the beafort scale ref. clause 1-7 to ensure that the wind speed does not exceed the permissible limit. · Near power lines (check minimum safe approach distances according to voltage carried). · In temperatures less than -15°C (especially in refrigerated chambers). Consult us if it is necessary to work below -15°C. · In explosive atmospheres. · In poorly- ventilated areas, since the exhaust fumes are toxic. · During storms (risk of lightning). · In the dark, unless the optional floodlight is fitted. · In the presence of intense electromagnetic fields (radar, moving and high currents).
DRIVING ON PUBLIC ROADS IS PROHIBITED.

1.2.3 – Using the machine
In normal service (i.e. operating from the platform), the platform/turntable control select key must be removed and kept at ground level by a person who is present and trained in rescue/emergency assistance manoeuvres.
Do not use the machine: · with a load greater than allowed load, · if wind speed exceeds the maximum · with more than maximum authorised number of occupants in platform, · with a side load in the platform greater than permissible limit.

2

Operating and maintenance instructions

To reduce the risks of serious falls, operators must respect the following instructions:
· Hold the guardrail firmly when moving the platform. · Remove any traces of oil or grease from the platform steps, floor or
guardrails. · Wear personal protective equipment suited to working conditions and
conform to local regulations, particularly when working in hazardous areas. · Never disable the limit switches of the safety devices. · Avoid contact with stationary or moving obstacles. · Do not increase the platform operating height by means of ladders or other accessories. · Never use the guardrails to climb into or out of the platform (use the steps provided). · Never climb on the guardrails when the platform is elereted. · Avoid driving the machine at high speed in narrow or congested areas. · Never use the machine without putting in place the platform safety bar or closing the safety gate. · Never climb on the covers.

Caution !
Never use the platform as a crane, hoist or lift.
Never use the machine to pull or tow.
Never use the boom as a ram or thruster or to raise the wheels.

To reduce the risks of tipping over, operators must follow these instructions:
· Never disable the limit switches of the safety devices. · Never move the control handles from one direction to the other with-
out stopping in the «O» position. (To stop when travelling, gradually move the handle to «O», keeping your foot down on the pedal.). · Do not exceed the maximum load or the number of occupants allowed in the platform. · Spread the load and if possible place in the centre of the platform. · Check that the ground resists the pressure and load per wheel.
· Avoid contact with stationary or moving obstacles. · Do not drive the platform at high speed in narrow or congested areas. · Do not drive the platform in reverse gear at high speed (poor visibility). · Do not use the machine with a congested platform. · Do not use the machine with equipment or objects hanging from the
guardrails or boom. · Do not use the machine with items liable to increase the wind load
(e.g. panels). · Never carry out maintenance on the machine with the platform raised,
without first installing the required safety provisions (overhead crane, crane). · Perform the daily checks and monitor the machine’s good working order during periods of use. · Protect the machine from any vandalism when it is not in use.

NOTE :

Do not tow the platform. (It has not been designed to be tower and must be transported on a trailer).

3

Operating and maintenance instructions

1.3 – RESIDUAL RISKS

1.3.1 – Risks of jerky movements and tipping over

Caution !
The direction of travel can be reversed after a 180° turntable rotation. Take account of the colour of the arrows on the chassis compared with the direction of travel (green = forward, red =
reverse) Thus, moving the manipulator in the direction of the green arrow on the control panel will move the machine according to the direction indicated by the green arrow on the chassis. Similarly, moving a joystick in the
direction of the red arrow on the control panel, will move the
machine in the direction of the red arrow on the chassis

Risks of jerky movement and instability are high in the following situations: – Sudden action on the controls. – Overloading of the platform. – Uneven ground (Be careful during thaw periods in winter). – Gusts of wind. – Contact with an obstacle on the ground or at a height. – Work on floors or over drains or culverts, etc.
Allow sufficient stopping distances: – 3 meters at high speed, – 1 meter at low speed.
Do not alter or neutralise any components connected in any way to the machine’s safety or stability.
Do not place or fasten a load so that it overhangs the machine’s parts.
Do not touch adjacent structures with the elevator arm.
1.3.2 – Electrical risk

Caution !
If the machine has a 220 V 16A max. plug, the extension must be connected to a mains socket
protected by a 30 mA differential circuit breaker.

Electrical risks are high in the following situations: – Contact with a live line (check safety distances before operation near electricity lines). – Use during storms.
1.3.3 – Risk of explosion or burning
The risks of explosion or burning are high in the following situations: – Working in explosive or inflammable atmosphere. – Filling the fuel tank near naked flames. – Contact with the hot parts of the motor. – Use of a machine generating hydraulic leakage.

1.3.4 – Risks of collision
– Risk of crushing people in the machine operation zone (when travelling or manoeuvring equipment).
– The operator must assess the risks above him before using the machine.
– Pay attention to the position of the arms during turntable rotation. – Adapt movement speed to conditions related to the ground, traffic,
slope and movement of people, or any other factor that may cause a collision. – When driving down the ramp of a truck, ensure sufficient space is available for safe unloading. – Check brake pad wear regularly to avoid all risk of collision.

4

Operating and maintenance instructions

1.4 – INSPECTIONS

Comply with the national regulations in force in the country of machine use.

NOTE : For AUSTRALIA: .refer to AS2550.10.

For FRANCE: Order dated 1st March 2004 + 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.
These inspections are performed by an organisation or personnel specially designated by the site manager and under his responsibility (whether or not they belong to the company) Articles R 233-5 and R 233-11 of the French Labour Code, for Australia refer to AS 2550.10.
The results of these inspections are recorded in a log book kept on the machine.
Moreover, before each use, check the following: · the operator’s manual is in the storage compartment on the platform, · the stickers are placed according to the section concerning “Labels and their positions”, · oil level and any items in the maintenance operation table · look out for any damaged, incorrectly installed, modified or missing parts.

NOTE :

This register can be obtained from trade organisations, and in some cases from the OPPBTP or private prevention agencies.

The designated persons must be experienced in risk prevention (Articles R 233-11 or order n° 93-41)..
No person is allowed to perform any check whatsoever during machine operation (Article R 233-11 of the French Labour Code). Unless under controlled conditions and supervision by a competent persons

1.4.2 – Examination of machine suitability
The manager of the site where the machine is operated must ensure the machine is suitable, i.e. capable of performing the work in complete safety, and in compliance with the operating manual. Furthermore, the French order of 1st March 2004 addresses problems relative to leasing, examination of the state of conservation, checking upon operation after repairs, and test conditions (static test coefficient 1.25; dynamic test coefficient 1.1). All users must consult this order’s requirements and comply with them.

1.4.3 – State of conservation
Detect any deterioration liable to cause hazardous situations (concerning safety devices, load limiters, tilt sensor, cylinder leaks, deformation, welds, bolt tightness, hoses, electrical connections, tyre state, excessive mechanical gaps).

NOTE :

If the machine is rented/leased, the user responsible for the machine must examine its state of conservation and suitability. He must obtain assurance from the leaser that general periodic inspections and pre-operation inspections have been performed.

5

Operating and maintenance instructions

1.5 –

REPAIRS AND ADJUSTMENTS
These cover major repairs, and work on or adjustments to safety systems or devices (of a mechanical, hydraulic or electrical nature).
These must be performed by personnel from or working for PINGUELYHAULOTTE who will use only original parts.
Any modification not controlled by PINGUELY-HAULOTTE is unauthorised.
The manufacturer cannot be held responsible if non-original parts are used or if the work specified above is not performed by PINGUELY-HAULOTTEapproved personnel.

1.6 –

CHECKS BEFORE RETURNING UNIT INTO SERVICE
To be performed after: · extensive disassembly-reassembly operation, · repair affecting the essential components of the machine, · any accident caused by the failure of an essential component.
It is necessary to perform a “state of conservation” examination (see Chap 1.4.2, page 5), a stability (static overload) test and a functional (dynamic) test.

Caution !
These tests must be performed by a competent person.

1.7 – BEAUFORT SCALE

The Beaufort Scale of wind force is accepted internationally and is used when communicating weather conditions. It consists of number 0 – 17, each representing a certain strength or velocity of wind at 10m (33 ft) above ground level in the open.

Description of Wind

0

Calm

1

Light Air

2

Light Breeze

3

Gentle Breeze

4 Moderate Breeze

5

Fresh Breeze

6 Strong Breeze

7

Near Gale

8

Gale

9

Strong Gale

Specifications for use on land Calm; smoke rises vertically Direction of wind shown by smoke Wind felt on face; leaves rustle; ordinary vanes moved by wind Leaves and small twigs in constant motion; wind extends light flag Raises dust and loose paper; small Branches are moved Small trees in leaf begin to sway; crested wavelets form on inland waterways Large branches in motion; whistling heard in telephone wires; umbrellas used with difficulty Whole trees in motion; inconvenience felt when walking against wind Breaks twigs off trees; generally impedes progress Slight structural damage occurs (chimney pots and slates removed)

MPH 0-1 1-5 6-11
12-19
20-28 29-38
39-49
50-61
62-74 75-88

m/s 0-0.2 0.3-1.5 1.6-3.3
3.4-5.4
5.5-7.9 8.0-10.7
10.8-13.8
13.9-17.1
17.2-20.7 20.8-24.4

6

Operation and Maintenance

IDENTIFICATION

2 – PRESENTATION
The model HA 41PX motorised platforms is designed for all work at heights within the limit of their characteristics (see chap. 2.3, page 9, and chap. 2.4, page 10) and respecting all the security instructions specific to the materials and the places of use. The principal control station is on the platform. The operator’s position in the turret is a rescue station.
A plate (Fig. 1, page 7), fixed on the turret, carries all the marks (engraved) making it possible to identify the machine.
A3

Fig. 1 – Manufacturer’s Plate
RECALL : For any request for information, service or spare parts, specify the type and serial number.
7

2.2 – PRINCIPAL COMPONENTS

7

8

Operation and Maintenance 9
22

13

6

5

4

21

17

16

19 23

24

11

18 3

14

20

25

15

1

10 14

2 12

1 – Rolling frame 2 – Driving wheels and forward steering
3 – Driving wheels and rear steering
4 – Suspension platform 5 – Rotary Jack 6 – Platform 7 – Control panel platform 8 – Compensation jack 9 – 3 fly jib elements 10 – Steering crown 11 – Turret 12 – Caps

13 – Part of connection arm/beam 14 – Hydraulic motors for transfers + reduction gear 15 – Right Compartment (hydraulic reservoirs and diesel, control panel) 16 – Arm 3 elements 17 – Left Compartment (driving + pump + starter battery) 18 – Right Counterweight 19 – Left Counterweight 20 – Anchor points 21 – Compensation jack linkage component 22 – Fly jib lifting jack 23 – Arm lifting jack 24 – Fixed extensible Axle 25 – Turning extensible Axle

Fig. 2 – Site principal components

8

Operation and Maintenance
2.3 – WORKING AREA

ft in

-13ft 1in

0

13ft 1in 26ft 2in 39ft 4in 52ft 5in 65ft 7in

42

137ft 9in

40

131ft 2in

38

124ft 8in

36

118ft 1in

34

111ft 6in

32

104ft 11in

30

98ft 5in

28

91ft 10in

26

85ft 3in

24

78ft 8in

22

72ft 2in

20

65ft 7in

18

59ft

16

52ft 5in

14

45ft 11in

12

39ft 4in

10

32ft 9in

8

26ft 2in

6

19ft 8in

4

13ft 1in

2

6ft 6in

0

0

-2

-6ft 6in

-4

-13ft 1in

m -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20 22

9

2.4 – TECHNICAL CHARACTERISTICS 2.4.1 – Design features

Operation and Maintenance

DESIGNATIONS Overall length Overall width Overall height Ground clearance Height in transport position Length in folded position Height in folded position Working Height Floor Height Maximum Offset Maximum Range Turret rotation angle Fly jib clearance angle Suspension platform clearance angle Length of the platform Width of the platform Rotation angle of the platform External steering radius without chocks, axles retracted Interior steering radius without chocks, axles retracted Distance between centres of the wheels Overall width without extended axles Tilt Maximum forward speed Front axle loading Rear axle loading Total weight Maximum load capacity Engine Engine Power Idling engine power Consumption during idle Sound Level at 10 m Vibrations to hands Vibrations to feet Reserve fuel tank capacity Hydraulic reserve tank capacity Starting battery Differential gearing Maximum climbing slope Tyres
Tightening torque of the wheel nuts Tightening torque of directional crowns Maximum ground pressure -hard ground -soft ground Speed of transfer -Micro speed -Top speed

HA41PX

12,60 m

41 ft 4 in

2,53 m

8 ft 3 in

2,99 m

9 ft 9 in

0,38 m

1 ft 2 in

3,70 m

12 ft 1 in

12,60 m

41 ft 4 in

2,99 m

9 ft 9 in

41,50 m

136 ft 1 in

39,50 m

129 ft 7 in

19,80 m

64 ft 11 in

19,30 m

63 ft 3 in

360°

+ 70° / -40°

+ 65° / -65°

0,80 m

2 ft 7 in

2,44 m

8 ft

+ 87° / -87°

5,10 m

16 ft 8 in

2,70 m

8 ft 10 in

3,50 m

11 ft 5 in

3,30 m

10 ft 9 in

4°

45 km/h

28 mph

16530 kg

36442 lb

6570 kg

14484 lb

23100 kg

50927 lb

230 kg

507 lb

Diesel – Perkins

64 kW

34 kW

240 g/kwh

108 db (A)

< 2,5 m/s²

< 0,5 m/s²

140 l

37 gallons

240 l

63 gallons

12V – 135 Ah

Hydraulic

40%

Inflated foam tyres OTR – 445 / 65D22,5

57 mdaN 21,5 mdaN

12,5 daN/cm² 6,1 daN/cm²

181,29 PSI 88,4 PSI

0,5 km/h 5 km/h

0.31 mph 3.10 mph

10

Operation and Maintenance
2.5 – OBSTRUCTIONS

2.5.1 – Obstruction characteristics

A B C D E F X G H J

HA41PX 12,6 m 2,53 m 2,99 m 3,5 m 0,294 m 2,44 m X 0,8 m

41 ft 4 in 8 ft 3 in 9 ft 9 in 11 ft 48 in 0,96 ft 8 ft X2 ft 62 in

3,7 m

12 ft 1 in

A H

JC

HA41PX
E

HAULOTTE
D

G

B

F

11

2.6 – LABELS
J1

2.6.1 – “Yellow” Labels

J2

J3

Operation and Maintenance J4

J5

J7

J6

J8

2.6.2 – “Orange” labels
O1

12

Operation and Maintenance

R10

R14

R7

R4

2.6.3 – “Red” labels

R6

.F

Composant spÈcifique cette machine.

NE PAS INTERCHANGER.

.GB

Component specific to this machine.

DO NOT INTERCHANGE.

Komponenten nur f¸r

.D

diese maschine geeignet. BITTE AUF EINE ANDERE

MASCHINE NIGHT

MONTIEREN.

N MACHINE – MASCHINE N

7814 518

R2

R3

R8

R1

R12 R15

R9

R11

R16

13

A9 A14

A11
7814-393
A12
7814-394

2.6.4 – Other labels

A8

A1

Operation and Maintenance

A13

A2

A7

A15

2.6.5 – Optional biodegradable oil
A8

14

Operation and Maintenance

2.6.6 – Optional 240V plug
J10

Rep
R1 A7 R2 A1 J10 A4 R3 J5 A8 A8 A5 R7 J4 A2 J6 A3 O1 A16 A15 R8 A9 J3 R6 A11 A12 J2 J1 R4 A6 J7 A14 A13 J8 R11 R12 R9 R10 R14 R15 R16 A28

Code
2420329660 2420329720 307P218830 3078143680 3078145070 307P216910 3078143540 307P216940 3078143620 3078150770 3078143520 3078148890 307P217080 3078151420 3078143600 307P217060 3078144650 307P218080 3078143450 2421808660 307P216290 3078153510 3078143590 3078143640 3078145180 3078143930 3078143940 3078143530 3078143570 3078143630 307P217220 3078151730 3078153600 307P215120 3078152530 307P216930 307P220220 307P219490 307P219880 3078144510 3078144520 3078144490 3078144430

2.6.7 – Machine label references

Qua
ntity
2 1 2 1 1 1 1 1 2 4 1 1 1 1 2 1 1 1 1 1 2 1 1 2 1 4 4 1 1 2 1 1 1 1 1 2 2 4 4 1 1 4 1

Designation
PR Catalogue EC Handbook Floor + load height Refer to the Instruction manual Danger lateral movement direction Platform lectern Catch must be connected (optional) Graphics Risk of crushing (hands and fingers) Disengagement Hydraulic oil Biodegradable oil (optional) Haulotte Do not wait in the working area Do not wash… do not use machine… Turret lectern Tilt Manufacturer’s plate Operating instructions Yellow and black adhesive marking Restraining harnesses Close the barrier Hydraulic oil “high and low level” Do not to climb on the cover Do not interchange Front green arrow Rear red arrow Front orientation, remove the pin Greasing of the steering crown Risk of being crushed Haulotte Rotating platform Exit/entry point of the rear axle Exit/entry point of the front axle Restore jacks to zero Safety Components Active Safety measures Wheel Load Max. impact on stabiliser Fuel tank filling for Australia Harness load for Australia Sling load capacity for Australia Danger for electrocution for Australia

15

16

A16

R1 – R2

2.6.8 – Positioning of the labels

R11

A4

A6

R4 J3 J7

159P267300 a

R9 – R10

A12

J1 J4

A10

R1 – R5 A3

J8 J3 R6

R14 Only for Australia

J5 R9 – R10

A8 – A9

J2 J4 R7 J6 O1 A2

R3 R4

A15
R11
R9 – R10 A12 A13 A14

A28Only for Australia A1

A11 A12 J5

HAULOTTE

R5 – R8 – R12

J10 A7

A28 – R15Only for Australia

A11 J5

A11

A5

Operation and Maintenance

Operation and Maintenance

3 – OPERATING PRINCIPLES

3.1 – HYDRAULIC SYSTEM

All the movements of the machine are ensured by the hydraulic power provided by a power pack.
3.1.1 – Lateral movement
3.1.1.1 -Lateral (displacement of the machine)
The lateral movement is fed by a hydraulic pump with closed loop, variable flow and electric drive. Four hydraulic motors with two cylinders mounted in the wheels ensure the drive of the wheels via dampeners The break release is automatic with electric drive. As soon as movement stops, the brake springs back into position. The two speeds (high or low) are controlled by a switch. .

Low transfer speed The four motors have a large cubic capacity..

Top speed of traverse The four motors are controlled by an electro-valve with low cubic capacity.

The control handle proportionally controls the cubic capacity of the transfer pump.
The four motors are supplied in parallel.
There is hydraulic differential gearing on each axle. They each receive a quarter of the pump throughflow.

3.1.1.2 -Equipment
The movement of the equipment are ensured by an open circuit hydraulic pump with ‘LOAD SENSING’ regulation.
3.1.2 – Movements for telescoping, orientation, lifting of the arm and raising of the fly jib
are carried out through proportional distribution compensated by pressure. The flow of the pump changes automatically on request through “LOAD SENSING” drains. In neutral, there is no flow from the pump.
3.1.3 – Movements for raising the suspension platform, platform rotation, platform compensation and direction
are controlled by 4 way electro-valves, with all or zero flow. A slide-valve in the proportional distributor provides the flow necessary to these movements.
3.1.4 – The telescoping jacks for raising the fly jib, and lifting the arm and suspension platform
are equipped with watertight sealed safety valves.

17

Operation and Maintenance

Caution !
Their adjustment can be carried out only by specialised personnel.

3.1.5 – Platform Compensation
Compensation works by transfer of oil between 2 appropriate jacks. The compensatory recipient jack for the fly jib and platform is equipped with safety valves.
The user can adjust the starting levels from the control panel on the platform.

NOTE :

For the safety of the user, the slope of the platform is limited to approx. 10°.

3.1.6 – Arm/fly jib compensation linkage

Caution !
A shift of several degrees every 10 cycles of lift and descent, or an
inopportune shift during a cycle is the sign of a major malfunction. In
this case, fold up the machine immediately, reset the
compensation circuit, then redo cycles of tests from the turret station: if the problem persists,
forbid the use of the machine until this is repaired by Haulotte After
Sales Service.

For extra comfort, the machine is equipped with a hydraulic compensation system, which is used to maintain the linkage assembly and the fly jib at the same angle whatever the position of the arm. This system is based on a transfer of oil between the hydraulic arm jack and the compensatory linkage jack. (For the re-levelling of the linkage, See “Check jacking of the compensation arm”, page 32.
For the whole length of the arm, the top edge of the linkage must remain clearly horizontal.
In order to purge the circuit following maintenance or to compensate for a micro-leakage which may create a shift/slip, the machine is equipped with a device to facilitate the re-levelling of the linkage.
3.1.7 – Lifting chassis and axle extension
These functions are fed by the open circuit pump of the equipment. They are controlled by a distributor with four elements with hand drive operation, located on the chassis. The supply of these distributors is ensured by a side- valve in the proportional distributor located in the turret.

3.2 – ELECTRIC CIRCUIT AND SAFETY MEASURES FOR USE

3.2.1 – General information
The electric power used for the controls and the ignition of the thermal engine, is provided by a 12 V battery.
In order to prevent the use of the machine over and above its capabilities, the safety measures are provided in order to protect personnel and the machine. They immobilise the machine or disable its movements.

Caution !
Do not to carry out operations before having read and understood the instructions in chap. 4, page 23.

In this case, insufficient knowledge of the characteristics and operation of the machine can make one believe there is a breakdown, when it is only a correct operation of the safety measures. It is thus essential to read and understand all of the instructions in the following chapters.
When you need to carry out a breakdown or rescue operation, the safety measures are disabled.

3.2.2 – Automatic engine stop
The engine is automatically cut off when: – the alternator does not function any more, – the engine temperature is too high, – the oil pressure is too low, – a malfunction of the machine is detected.

18

Operation and Maintenance

Caution !
In the event of a malfunction of the safety measures, only specialised
personnel may carry out the necessary adjustments.

3.2.3 – Control of the platform load
If the platform load exceeds the maximum authorised load, no movement is not possible from the platform control unit. The overload indicator is an alarm which alerts the operator.
To return to normal configuration, it is necessary either:
– lighten the platform to return to a permitted working load
– use the turret control unit, knowing that the movements will be slowed down

3.2.4 – Slope Control
If the machine is located on a slope greater than the acceptable cant, the tilt indicator on the platform lectern/panel and the alarm alert the operator and any movement is cut. Nevertheless, the controls of the upper lectern/ control panel are not all cut.
Only movements making it possible to fold the machine are allowed in order to recover from the transfer:
– retrieve the telescopic fly jib – raise/lower the arm/fly jib to recover the horizontal position, – lower the arm, – lower the suspension platform until just below the horizontal.
Move the machine to a flat and horizontal surface.
.

NOTE :

When the machine is deployed, the slippage control box emits an audible signal as long as the slope is higher than the acceptable threshold, indicating to the operator that it will be impossible to deploy the platform any further

3.2.5 – Lateral movement speed
The two lateral movement speeds are useable when the platform is completely folded up. .

Caution !
When the machine is at the limit of its range, lateral movement is
prohibited (the range limit indicator is lit). It is necessary to bring in the
telescope to recover the lateral movement function.

When the fly jib is raised, or the arm deployed, or the telescope extended, or the suspension platform above the horizontal, only the micro speed is possible for lateral movement.
3.2.6 – Hour meter
An hour meter indicates the operating life of the thermal engine.

3.2.7 – Equipment Operating Rules
· The lowering of the fly jib below the horizontal is authorised only when the arm is raised at more than 60°.
· The arm cannot be lowered below 60° when the beam is below the horizontal.

19

Operation and Maintenance

Whilst raising the arm, the system automatically manages the necessary combination the movements for lifting and telescoping the arm. The machine itself carries out a complementary movement to the controlled movement, in order to keep the machine within the limits of the stability zone. The arm and the fly jib are equipped with length and angle sensors to fulfil these functions.
3.2.8 – Defects

Caution !
When the machine is deployed, it must always remain under power so that the safety systems are active.

ft in

-13ft 1in

0

13ft 1in 26ft 2in 39ft 4in 52ft 5in 65ft 7in

42

137ft 9in

40

131ft 2in

38

124ft 8in

36

118ft 1in

34

111ft 6in

32

104ft 11in

30

98ft 5in

28

91ft 10in

26

85ft 3in

24

78ft 8in

22

72ft 2in

20

65ft 7in

18

59ft

16

52ft 5in

14

45ft 11in

12

39ft 4in

10

32ft 9in

8

26ft 2in

6

19ft 8in

4

13ft 1in

2

6ft 6in

0

0

-2

-6ft 6in

-4

-13ft 1in

m -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20 22

The machine is equipped with internal defect detection systems. The number of flashes (1 to 9) of the defect indicator indicates to the user the nature of the anomaly: refer to the table “Operating incidents” in chap. 6, page 49 for the description of each type of defect. According to the nature of the anomaly, the machine may switch to BASIC MODE: certain movements may be limited or prohibited by the system to keep the user safe.
.
Procedure : · note the number of flashes emitted by the defect indicator, if any other indicators are lit, and the state of the machine at the time that the defect occurs · use the controls to retract the telescope and fly jib lift to bring the platform back inside the grey zone (see diagramme). · fold the machine. · forbid its use until the defect is repaired · refer to chap. 6, page 49 “Operating incidents ” to remedy the defect.

NOTE :

If the user presses on the emergency stop during a movement of the telescopic arm or fly jib, this may be in BASIC MODE upon restarting the machine. In this case, fold the machine completely, switch it off, and restart to re-initialise the machine.

NOTE :

If lowering is carried out with the sealed electric safety pump, refer to chap. 4.6.1, page 36.

3.2.9 – Range limits
The range limit indicator (orange) on the platform lectern is there for your use as a visual indicator.
· This indicator flickers to indicate that the machine is executing a movement complementary to a required movement in order to keep the platform within the limits of the stability zone. For example: the machine may retract the telescope when you ask for the fly jib to be lowered. For extra safety, any accumulation of other movements is prohibited during these phases. Lateral movement is prohibited within this zone.
· This indicator remains lit when the operator asks for a movement which would make the platform extend beyond its working area. .

HA41PX

HAULOTTE

3.2.10 -Transport positioning control switch
This switch (control no. 12, Photo 1, page 27) located on the turret lectern/ panel when activated, allows the platform to be folded back under the fly jib. It is active only when the arm is lowered, the fly jib retracted and raised less than 5°. The platform must be empty of personnel and material when this command is carried out.

Transport positionning Folded position

20

Operation and Maintenance

3.2.11 -HEAD Calculator

Caution !
It is forbidden to exchange the calculator of your machine with that
of another machine.

Each machine is equipped with a specific calculator calibrated for the functions of this machine. Replacing or exchanging this calculator without the prior agreement of a HAULOTTE technician can generate serious malfunctions of the machine.
A tamper-proof seal is affixed on the calculator. If we notice that the seal is torn off or that it is defective or that it does not correspond to this machine when the machine is returned to After Sales Service, or when a technician or Haulotte agent service it, we will not be able to apply the manufacturer’s guarantee for the calculator nor for the machine.

3.2.11.1 -HEAD calculator battery

Caution !
The flickering of each indicator may stop if this must resume its initial
function and indicate a malfunction.

The wear on the HEAD calculator battery is indicated by simultaneous flickering of the 3 indicators on the lower control panel, as soon as the machine is powered up.
These indicators are: · Engine oil pressure · Engine temperature · Warping indicator
As soon as the battery is flat, please contact our After Sales Service immediately.

3.2.12 -Length and angle sensors

Caution !
Do not use the machine as long as the calibrations have not been carried out.

Each machine is equipped with sensors (angle, length, pressure) for which the calculator was specifically gauged. Any work on these components requires calibration carried out by a HAULOTTE technician. All new calibration must be mentioned in the “inspection and repair register” of the machine.

21

Operation and Maintenance 22

Operation and Maintenance

4 – USE

4.1 – SAFETY MEASURES

To prevent use of the machine over and above its limits, safety measures are provided in order to protect personnel and the machine.

WHEN THE MACHINE IS DEPLOYED, IT MUST ALWAYS REMAIN ON POWER SO THAT THE SAFETY SYSTEMS ARE ACTIVE.

Caution !
These immobilise the machine, modify or disable its movements.

In this case, insufficient knowledge of the characteristics and operation of the machine can make one believe there is a breakdown whereas it is a correct operation of the safety measures. It is thus essential to read and understand all of the instructions of the following chapters.

4.1.1 – Displacement (controlled from the platform panel)

Caution !
Do not carry out operations before having read and understood the instructions in chap. 4.3, page 26.

To move the machine, it is necessary to activate the “dead man” safety by keeping your foot pressed on the pedal.

NOTE :

If the user presses the pedal for more than 8 seconds without making any movement, the system will become inoperative. It is then necessary to release the pedal and press it again.

· The release of the “dead man” pedal causes any lateral movement to stop.
· Lateral movement is possible with the machine unfolded on a level area only (or a slope lower than 4°).

Caution !
During lateral movement, movements such as raising the fly jib, raising the arm or turning the
turret are not possible.

NOTE :

The high and low speed of lateral movement are only possible if the telescope is retracted and the fly jib lowered to its horizontal position. Otherwise, its micro speed is automatically selected.

Caution !
It is forbidden to drive on the public highway.

· Firmly adhere to traffic regulations and instructions in working areas. · On rough ground, make a preliminary reconnaissance of the area be-
fore beginning work at height · always drive while maintaining a sufficient distance from unstable ed-
ges or slope · make sure that nobody is in immediate vicinity of the machine before
carrying out a movement or displacement.

4.1.2 – Filling the fuel tank
· Before any filling operation, make sure that the fuel is clearly what recommended and that it is properly stored in order not to be polluted

23

Operation and Maintenance

· Do not draw from a barrel if this has not been decanted and never use fuel at its bottom.
Because of fire hazard during the filling of the tank, take the following precautions:
· do not smoke · turn off the engine if it is on · stand upwind so as not to be sprinkled with fuel · touch the outside of the opening of the tank with the spout of the pump
before starting to fill the tank in order to avoid the risk of static electricity sparks · close the stopper of the tank properly and clean off any fuel which may have run out from the tank.

4.2 – UNLOADING – LOADING – DISPLACEMENT – PRECAUTIONS

NOTE :

When starting up a machine which has been slung and transported, it is possible that the safety system will detect a “false overload”, and prohibit all high level movements. In this case, raise the suspension platform a few centimetres from the low position in order to re-initialise the system.

Caution !
A wrong movement can bring about the complete breakdown of the machine and cause very serious personal and material injuries.

NOTE :

Before any handling, check the condition of the machine in order to ensure that it was not damaged during transport. If not, put in writing, the necessary reservations to the conveyor.

Carry out unloading operations on a stable surface which is sufficiently firm (chap. 2.4, page 10), flat and unobstructed..

Caution !
During transportation of the machine, the turret must be chocked using the rotation pin stop located under the turret Photo 3,
page 29.

4.2.1 – Unloading with ramps
Precautions: make sure that the ramps can support the load, that they are correctly fixed and that there is sufficient grip to avoid any risk of slippage during the manoeuvre.

Caution !
Never get under or too close to the machine during the manoeuvres.

NOTE :

As the slope of the ramp is almost always higher than the maximum slope of work (4°), it is necessary to have the fly jib and arms lowered to allow the movement. In this case, the sound-effects function but movement is possible.

If the slope is higher than the maximum slope during movement (voir chap. 2.4, page 10), use a winch in addition to traction.

Caution !
This method requires the starting up of the machine. Refer to
chap. 4.4, page 30 to avoid any risk of false manoeuvres.

4.2.2 – Loading
The precautions are identical to those for unloading. Stowing must be ensured in accordance with the sketch below:
· the machine must be in its folded position

24

Operation and Maintenance

· the anchoring points provided for this purpose must be used · the turret must be blocked with the pin. To climb the ramps of a truck, select low movement speed. .

Pmax

Pmax

3,8 m 12 ft 5 in

16,5 T 36.376 lb

3,5 m 11 ft 5 in

6,6 T 14.551 lb

Fig. 3 – Loading

25

4.3 – OPERATIONS BEFORE FIRST USE

Operation and Maintenance

IMPORTANT: before each use of the machine or after a period of storage, it is necessary to refer to the start-up operations of (chap. 5.3, page 42) in order to check the various levels, and to check various machine maintenance points.
RECALL : Before any operation, look over the machine while referring to these notes, engine notes and instructions given on the various plates.

Caution !
When washing under high pressure, do not direct the jet directly on the casings and electrical equipment
boxes.

26

Operation and Maintenance

4.3.1 – Familiarisation with the control units
4.3.1.1 -Turret lectern/control panel Photo 1 Turret control panel

1

2

3

4

5

6

8

9

7

12 11

10 13

14

15

16

17

18

19

20

21

22

1- Electrical pre-heating indicator 2 – Oil pressure indicator 3 – Engine temperature indicator 4 – Battery load meter 5 – Overload Indicator 6 – Range limit indicator 7 – Suspension platform control 8 – Telescopic fly jib control 9 – Raising beam control 10 – Arm lifting control 11 – Turret turning control

12- Platform compensation /transport position 13 – Emergency stop button 14 – Electrical pre-heating 15 – Turret/axle/platform control panel selector 16 – Machine power 17 – Emergency power unit control 18 – Hour meter 19 – Engine acceleration control 20 -Ignition control 21 – Fuel Selector- LPG 22 – Gyro- light control

27

Operation and Maintenance

4.3.1.2 -Platform control panel

NOTE :

When you wish to move, it is important to raise the suspension platform a few meters in order to prevent the platform touching the ground during displacement

Photo 2 Platform control panel

4

5

6

7

8

9

1

10

11

12

2

3

13

14

15

16

17

18

19

20

21

1 – Arm or fly jib position selector 2 – Arm lifting, fly jib raising and turret turning control 3 – Arm and fly jib telescopic control 4 – Power indicator 5 – Fuel level indicator 6 – Overload indicator 7 – Range limit Indicator 8 – Warp/slope Indicator 9 – Error indicator 10 – Emergency stop key 11 – Emergency safety control

12 – Movement control, forward axle direction 13 – Horn 14 – Low and high speed movement selector 15 – Rear axle direction control 16 – Differential jacking control 17 – Suspension platform control 18 – Platform rotation control 19 – Correction and compensation control 20 – Fuel Selector /LPG 21 – Ignition

NOTE :

When there is a problem on the machine, the operator in the platform is warned by the defect indicator (rep. 9, Photo 2, page 28) qui émet des flashes. which emits flashes. The number of flashes identifies the problems (See “OPERATING INCIDENTS”, page 49.)

28

Operation and Maintenance

4.3.2 – Controls before use

4.3.2.1 -Evolution Zone
· make sure that the machine is resting on flat ground which is stable and able to support the weight of the machine (see chap. 2.4, page 10 – pressure on the ground).

NOTE :

See table of characteristics in chap. 2.4, page 10 for maximum acceptable slope

· Make sure that no obstacle may obstruct the movements for: – axle extension, – lateral movement (displacement of the machine), – turning of the turret, – raising the arm (see chap. 2.3, page 9), – telescoping and raising the fly jib (see chap. 2.3, page 9).

4.3.2.2 -General

Caution ! When transporting the machine, the
turret must be blocked using the rotation stop pin located under the
turret (photo 3, page 29).
Photo 3
Caution ! Adhere to the security instructions
of the battery manufacturer .
Caution ! These machines are not insulated and must not be operated close to
power lines.

· make sure that the turret rotation jacking pin is removed (photo 3, page 29).
· inspect the whole of the machine visually: splashes of paint or leakages of battery acid will catch your eye
· check that there are not loosened bolts, nuts, connections and flexible components, no oil leaks, no cut or disconnected electrical wires.
· check the arms, the fly jib and the platform for traces of visible damage, traces of wear or deformation
· check for leakages, traces of wear, blows, scratches, rust or foreign bodies on the stems of the jacks
· check for leakage on the wheel retractors · check that there are no leaks on the pump and the hydraulic centre,
that components are tightened and that the two aspiration valves are completely open · check that the reduction gear is not damaged. · check the tightness of the wheel nuts and the degree of wear on the tires. · check the cleanliness and the tightness of the battery terminals: loose terminals or corrosion may cause a loss of power · control the level of electrolyte in the batteries: the level must be at approximately 10 mm above the plates. Supplement if necessary with distilled water.
· check the good state of the electric cable of the principal control panel · check the correct operation of the three emergency shutdowns · check the correct operation of the emergency power unit.
· check the cleanliness of the air filter – see engine note · check the levels:
– of engine oil: if necessary supplement the level (see note engine); – coolant; – of hydraulic oil (rep 1, Photo 4, page 30), if necessary supplement
the level using the stopper (rep. 2, Photo 4, page 30). Before checking the hydraulic oil level, check that the machine is completely folded and the axles retracted; – -of diesel (rep. 1, Photo 5, page 30) : refill if necessary (stopper rep. 2, Photo 5, page 30).

29

Photo 4
2

Operation and Maintenance
Photo 5
2

1

1

Caution !
When refilling, use products recommended in the ingredients
chapter (chap. 5.2.1, page 40).

· Check the clogging indicators of the hydraulic oil filters. If the red tester is visible, replace the filter cartridge (see chap. 5.3.2, page 43) and re-arm the clogging indicator by simply putting pressing it.

NOTE :

When starting up at low temperatures, the clogging indicator may give a false reading due to increased viscosity. Wait for the machine to warm up and rearm the clogging indicator. If the red tester continues to show, replace the cartridge.

· with the machine unfolded, check the correct operation of the cant control box (Photo 6, page 30) by tilting the support plate. Beyond 4° of incline, the slope warning signal should emit an audible signal.
Photo 6

4.4 – BRINGING INTO SERVICE

Caution !
Start up should only begin once all operations of the preceding chapter
are scrupulously carried out.

RECALL : The main control panel is in the platform
To familiarise oneself with the machine, you should perform the first operations on the ground, leaving the machine in the transport position, with the counterweight in front and the fly jib lowered.

30

Operation and Maintenance

Caution !
In normal use the turret control panel is a rescue station or
breakdown service and should be used only when absolutely necessary.

4.4.1 – Operations starting from ground
4.4.1.1 -Motor Ignition: Photo 1, page 27
· Make sure that the emergency stop keys are pulled out · Switch the machine power key (control rep. 16, Photo 1, page 27) to
ON · Turn the control panel selector key (contro rep. 15, Photo 1, page 27)
) to the “turret” position (pictograms – orange round). In this position the “platform” panel and “axles” controls are cancelled. · Engine oil pressure (control rep. 2, Photo 1, page 27) and battery load (control rep. 4, Photo 1, page 27) indicators are lit · Press the starter button (control rep. 20, Photo 1, page 27), the engine starts, the indicators (control rep. 2 and 4, Photo 1, page 27) switch off
– If the ambient temperature is lower than 0°C, proceed to preheat the engine by pressing the selector (control rep. 14, Photo 1, page 27). The corresponding indicator (control rep. 1, Photo 1, page 27) ignites and cuts out after ten seconds. You can then start the engine by pressing the starter button (control rep. 20, Photo 1, page 27).

NOTE :

If the engine does not start, switch it off by pressing on the emergency stop key and start the operation again .

· allow the engine to warm up, and check the correct operation of the hour meter (control rep. 18, Photo 1, page 27) and of the engine while it warms up.

4.4.1.2 -Extending the axles
In order to increase the stability of the machine, it is necessary to extend its width by extending the axles. This operation is only possible if the machine is completely folded, the suspension platform is below horizontal and the turret is aligned along the axis.
If the axles are retracted, the capabilities of the machine are reduced. Only the following movements are possible:
– rotation of the turret with the fly jib horizontal – raising the fly jib if the turret is aligned along the axis.
All the other movements are disabled.
If the axles are extended, all movements are possible.
The levers for extending the axles are located at the rear of the machine (photo 7, page 32).
The long levers, rep. 1 and 2, Photo 7, page 32, correspond to the solid axle (rear of the machine) and the short levers, rep. 3 and 4, Photo 7, page 32, correspond to the swivelling axle (front of machine).
Levers rep. 1 and 3, Photo 7, page 32 cause the jacks to descend and thus the frame to rise.

Caution !
If the axles are not completely extended or retracted, the buzzer
will sound continuously and movement will be disabled. .

Levers rep. 2 and 4, Photo 7, page 32 control the extension and retraction of the axles.
.

31

Caution !
If the two chock jacks are extended, the axle extension controls are temporarily disabled.

Operation and Maintenance

Photo 7

1

4

2

3

Caution ! Make sure that the platform cannot
touch the ground when the front axles are raised (lever rep. 3, Photo 7, page 32).
0,5 m mini 1,7 ft mini

Axles extension:
· Start the machine, switch the control panel position selector key (control rep. 15, Photo 1, page 27) to “axles” (pictograms – black circle). In this position, the controls of the “platform” and “turret” panels are disabled
· lower lever rep. 1, Photo 7, page 32, to make raise the rear of the chassis
· When the axle wheels do not touch the ground anymore, lower lever rep. 2, Photo 7, page 32 to activate the extension of the axle, while holding lever rep. 1, Photo 7, page 32 abaissée.
· Once the axle is completely extended (the alarm stops sounding), release lever rep. 2, Photo 7, page 32 then raise lever rep. 1, Photo 7, page 32until the chassis hydraulic jack is completely retracted
· proceed in the same way with levers rep. 3 and 4, Photo 7, page 32.

Caution !
Make sure before proceeding with the retraction of the axles that the machine is completely folded, that the suspension platform is below
horizontal and that the turret is aligned along the axis.

Retracting the axles: · With the machine folded, switch the control panel position selector key (control rep. 15, Photo 1, page 27) ) to “axles” (pictograms – black circle). In this position, the “platform” and “turret” controls panels are disabled · lower lever rep. 3, Photo 7, page 32, page 34, to raise the front chassis. · When the wheels of the axle do not touch the ground anymore, raise lever rep. 4, Photo 7, page 32 thus activating the retraction of the axle, while keeping lever rep. 3, Photo 7, page 32 lowered · Once the axle is completely retracted (the alarm stops sounding), release lever rep. 4, Photo 7, page 32 puis lever la manette rep. 3, Photo 7, page 32 then to raise the lever No. 3, Photograph 7, page 34 until the chassis hydraulic jack is completely retracted · proceed in the same way with levers rep. 1 and 2, Photo 7, page 32.
4.4.1.3 -Check jacking of the compensation arm

Caution !
Make sure before any movement that no obstacle will obstruct the
manoeuvres.

With the arm in its lowered position, check that the linkage component is correctly positioned: when the machine is positioned on horizontal ground, the higher stop of the linkage component must be horizontal.

32

Operation and Maintenance

If the connector piece is unlocked, the machine should not be used until this has been correctly repositioned

Drawing 1: connector piece at front

Drawing 2: connector piece at rear

Photo 8

If the linkage component is unlocked in AR (sketch 2), relocking is automatic when the machine is entirely folded, at the end of the descent of the arm.
If the linkage component is unfurled in AV (sketch 1), apply the following procedure from the turret:
1° lower the arm to mechanical thrust. 2° lift the beam by approximately 10°. 3° activate the descending arm control while simultaneously pres-
sing on the black button on the top of the PVG (see Photo 8) : this action effectively corrects the linkage component at the same time as the arm goes down. 4° Repeat operations 2 and 3 as many times as necessary until the compensating jack is clearly in its mechanical thrust. 5°° carry out a raising-lowering cycle of the arm to check correct purging of the circuit. .

Caution !
If correct repositioning is not be possible, forbid further use of the machine until repaired by Haulotte
After Sales Service.

Photo 9

4.4.1.4 -Procedure for checking the fly jib control system:
– With the machine folded, check the extension of the telescope from the turret controls.
– Check that the extension of the telescope stops in accordance with Photo 9, page 33.
– If telescope continues to extend, immediately shut off the telescopic extension control. The system must be repaired by Haulotte maintenance personnel before the machine may be used.

33

Operation and Maintenance
4.4.1.5 -Main movement controls
· test the movement by raising the fly jib in the direction it is mounted then lowering it (control rep. 9, Photo 1, page 27).
· stop the descent of the fly jib when it is in the horizontal position · then test the turret orientation movement in both directions (control
rep. 11, Photo 1, page 27) and the fly jib’s telescopic extension and retraction (control rep. 8, Photo 1, page 27). · test the movement of the suspension platform (control rep. 7, Photo 1, page 27) then lower the arm completely again (so that the platform is close to the ground).

4.4.2 – Operations starting from the platform

NOTE :

When you wish to move, it is important to raise the suspension platform in order to prevent the platform from touching the ground during movement.

(Photo 2, page 28) · Get on the platform, respecting the instructions on maximum load, and, if necessary, redistribute the load across the whole platform.

Caution !
MAXIMUM LOAD: HA41PX: 230 kg (i.e. 2 people)

NOTE :

If the load on the platform exceeds the authorised maximum load, no movement is possible from the platform control unit. The overload indicator on the platform control panel and the alarm will alert the operator. It is then necessary to lighten the load. There is no load restriction within the range.

4.4.2.1 -Control Panel Test

Caution !
High and low speeds are only possible if the machine is folded. When even slightly deployed, only
micro speed is possible.

· make sure before all manoeuvres that the green indicator (control rep. 4, Photo 2, page 28) is lit, check that the machine is under power and that the selector is in the “platform” position
· make sure that the emergency stop key (control rep. 10, Photo 2, page 28) is unlocked
· make sure that the error indicator (control rep. 9, Photo 2, page 28) is switched off
· check the correct operation of the warning signal (control rep. 13, Photo 2, page 28).
Work can then start.
4.4.2.2 -Test of the movements
To carry out a movement, it is necessary to press on the “dead man” pedal to activate the desired control.
The selector (control rep. 1, Photo 2, page 28) makes it possible to choose the control assignment (control rep. 3, Photo 2, page 28) to raise the arm or operate the fly jib’s telescopic functions
The speed and the angle of inclination of the controls correspond to its direction, speed of movement and acceleration. If the floor is not horizontal, correct the position of the platform by activating the compensation selector of the platform (control rep. 19, Photo 2, page 28).
Test the movements of the telescopic function, suspension platform and platform rotation with the associated selector.
Test the rotational movement of the turret by activating the control handle (control rep. 2, Photo 2, page 28) towards the left then towards the right.

34

Operation and Maintenance

Test the directional movement of the front axle using the selector placed on the handle of the movement control (contr rep. 12, Photo 2, page 28), ), and test that of the rear axle by using the selector located on the platform control panel (control rep. 15, Photo 2, page 28). The direction of movement is indicated by blue arrows. Test the 2 movement speeds by activating the low or high speed selector.
4.4.2.3 -Managing reach limitations :
A -FRONT Limitation:

Caution !
When the machine is at the limit of its reach, lateral movement is
forbidden (the reach limit light will light). The telescopic arm must be lowered to regain the use of lateral
movement.

With the fly jib at a descending angle and the telescopic arm extended:
· When the platform approaches the limit of its reach, the control system automatically returns the telescopic arm to keep the user within the stable operation range.

NOTE :

The reach limit indicator (orange) flashes to indicate the change in trajectory to the user. Movement speeds are automatically reduced.

Caution !
If an anomaly is detected in the reach limit management system, the
ERROR indicator lights and the machine switches to basic mode
(see chap. 3.2.8, page 20).

Extending the telescopic arm : · The movement of the telescopic arm is automatically stopped when it approaches its reach limit.

NOTE :

The reach limit indicator (orange) lights to indicate to the user that he is requesting a forbidden movement.

B – REAR Limitation :
With the fly jib at an upward angle, regardless of the length of the telescopic fly jib:
· When the arm is raised to an angle of less than 60°, the lift angle of the fly jib is limited to 48°. The reach limit indicator lights if the lifting the fly jib is requested.
· As soon as the arm lift angle exceeds 60°, the fly jib can then be raised to 70°.
Raising the arm at a descending angle : · If the fly jib is raised at an angle exceeding 48°, when the arm reaches and angle of 60°, the descent will stop: the reach limit indicator lights. The fly jib must be lowered to an angle of less than 48° before continuing lowering the arm. · If the fly jib is raised at an angle of less than 48°, the arm lowering control acts directly on the arm hydraulic jack

35

Operation and Maintenance

4.5 – EMERGENCY DESCENT
Photo 10
There may be cases where the operator in the platform is no longer able to control its movement, even through the machine is functioning normally. An able-bodied operator on the ground can use the “turret” lectern with main diesel power source to retrieve the operator on the platform.

Procedure :

· Switch the driving position selector key (rep. 1, Photo 10) to the “tur-

1

ret” position (orange circle). In this position the controls in the “plat-

form” lectern are disabled.

· Carry out the desired movements using the controls as you would nor-

mally.

4.6 – BREAKDOWN DESCENT

Caution !
Use of the emergency set is only for the rescue of personnel if there is a
breakdown in the main power supply. Any other usage many
cause damage to it.

4.6.1 – Breakdown rescue with the emergency electropump set
There is a way to carry out movements when there is a malfunction of the main power source. This is the electro-pump set power by the starter battery. This can be controlled equally from the turret lectern or the platform lectern.
Operating time using the emergency set is limited, so you are advised to return to the ground by the most direct means possible (see drawing).

Caution !
If an operator at height must abandon the platform for a solid and safe structure, the transfer should
only be done with the following recommendations: – The operator must secure himself using 2 belts. One belt must be fastened to the platform, the other to the structure. – The operator must only leave the
platform through the access trapdoor. – The operator must not unfasten the belt fastened to the
platform before the transfer is completed, or if there is still a risk of
danger.

· Procedure :
· Using the selected control position, press and hold down the emergency control positioning interrupter (control rep 17, Photo 1, page 27 and control rep 11, Photo 2, page 28). – If required, move away from obstacles using platform and direction movements.
· Press and hold down the interrupters for the movements required in the following order: – Partially retract the telescopic arm and fly jib (so that no red area is visible on the side), – Lower the fly jib fully, – Lower the arm to return the platform to the ground

36

Operation and Maintenance

Caution !
It is prefereable to carry out this operation on a flat and horizontal area of ground. At the very least, you should chock the wheels to
ensure that the machine is immobilised.

4.6.2 – Disengagement
Operating mode:
· Remove the transmission panel (rep. 1, Photo 11) by unscrewing the 2 holding screws (rep. 2, Photo 11).
1

2
Photo 11
· The central axle will then be visible(rep. 3, Photo 12).

Caution !
In this configuration the machine no longer has brakes. When towing the machine, always use a rigid towbar
and do not exceed 5 km/h.

3
Photo 12
· Replace the transmission panel, in such a way that its bulged surface faces into the interior of the gearbox. The machine is then disengaged.

Photo 13

37

Operation and Maintenance 38

Operation and Maintenance

5 – MAINTENANCE

5.1 –

GENERAL RECOMMENDATIONS
The maintenance operations given in this manual are intended for normal usage conditions.
In difficult conditions: extreme temperatures, high levels of humidity, polluted air, high altitude, etc… Certain operations must be carried out more frequently and particular precautions must be taken: consult the engine manufacturer’s notice and your local HAULOTTE agent on this subject.
Only competent HAULOTTE trained personnel should work on the machine and these should follow safety requirements for the protection of Personnel and the Environment.

Caution !
Refer to the instructions on the manufacturer’s notice covering the
engine section.

Thoroughly check the proper operation of the safety mechanisms as shown in bold in the summary table in chap. 5.3.1, page 42.

Caution !
Do not use the machine as a welding weight. Do not carry out welding without disconnecting the (+) and (-) terminals of the batteries. Do not start other vehicles with the
batteries connected.

39

Operation and Maintenance

5.2 – MAINTENANCE PLAN

The plan (following page) indicates the frequency, the maintenance points (main body), and the tools to be used.
· The number inscribed in the symbol indicates the maintenance point as well as its frequency.
· The symbol represents the tool to be used (or the operation to be carried out).
5.2.1 – Consumer items

ITEM

SPECIFICATION

Engine oil

SAE 15W40

Gearbox oil
Hydraulic oil
Biodegradable hydraulic oil (optional) High pressure grease with lithium

SAE 80W-90 AFNOR 48602
ISO VG 46 category HV
KP 2 K

Unleaded grease

Grade 2 ou 3

Replacement or specific operation

SYMBOL

Lubricants used by
PINGUELY HAULOTTE
SHELL RIMULAX
SHELL SPIRAXA EP80W90
SHELL T46
SHELL Natural HF-E46
ESSO Beacon EP2
BARDAL Super Teflub +
PTFE

ELF
TRANSELF EP 80 W 90 HYDRELF
DS 46
Epaxa 2 Multimove 2

TOTAL
TM 80 W/90 EQUIVIS ZS
46
MULTIS EP 2

40

Operation and Maintenance
30

5.2.2 – Maintenance diagramme

13

14 15

Hours
500 50

3

27

9 18 19 13

17

31 9 18

35

32

34 21

22

12

23 22

21

34

25

26

25

27

36

29

28

33

10 50 100 250 500 1 000 2 000

18 9 34
25

6

51

16 8

20

24

47 17 23

18 9 25

11 34

10 50 250 500 1 000 2 000

41

Operation and Maintenance

5.3 – OPERATIONS

5.3.1 – Summary table

FREQUENCY Daily or before each use
Every 50 hrs
50 first hours 100 first hours Every 250 h

OPERATIONS
· Check the levels of the: – engine oil – coolant – hydraulic oil – fuel – electric batteries
· Check the cleanliness of the: – fuel pre-filter – engine air filter – machine (specifically check the water-tightness of the connections and flexible components), and take the opportunity to check the state of the tyres, cables and all accessories and equipment.
– Check the status of the hydraulic oil filters; there is an indicator to show this, change the cartridge if the visible indicator appears.
– Check the degree of usage of the articulated axles. – Check the main safety items:
– When the machine is powered up, all of the indicator lights should light momentarily
– Tilt: with the machine unfolded, tilt the support panel beyond an angle of 4°, at which point the alarm will sound, and any lateral movements or extension of the telescopic arms will be prohibited
– Speed limiter: only slow speeds are possible if the arm or fly jib are raised, the telescopic arms extended or if the suspension platform is beyond the horizontal
– Check and if required readjust the setting of the connection point (see the procedure in chap. 4.4.1.3, page 32)
– After a complete deployment of the arm and fly jib of the machine, the error indicator should remain unlit
· Engine: see manufacturer’s notice · Check the level of the reduction gear of the powered wheels (see
chap. 5.3.2.2, page 44) · Check the level of the steering reduction gear (see chap. 5.3.2.2,
page 44) · Grease the:
– steering axle, central pivot and clevis pin: 10 points – steering crown wheel: the teeth (with a brush) – pendular articulation axle: 2 points – pendular articulation axle connecting piece: 4 points – fly jib base axle: 1 point · Clean the fuel pre-filter: · Change the hydraulic filter cartridges (see 250 hr frequency) · Drain the reduction gears of the powered wheels (see 500 hr frequency) · 4 points on the 4×4 model · Check the tightness of the steering crown wheel screws (torque 21.5 mdaN) · Check the tightness of the fly jib telescopic action chains. · Drain the steering gear (see 2000 hr frequency) · Engine: see manufacturer’s notice · Grease the chafing portions of the telescopic arms · Grease the steering crown wheel: 2 rolling points · Check the state of the telescopic action friction pads · Check the tightness of the wheel bolts (torque 57 mdaN) · Changer the hydraulic filter cartridge · Grease the chafing portions of the telescopic axles (with a spatula)

NUMBERS
1 2 3 4 5 6
7
8 9 31
11 13 14 15 30 16 17 18 19 35 32 20 21 12 22 23 34

42

Operation and Maintenance

Every 500 hours or every 6 months
OPTIONAL: Every 500 hours or every 6 months Every 1000 hours or every year

· Engine: see manufacturer’s notice

24

· Drain the wheel reduction gear. Refill: 4 x 1,4l capacity.

25

· Check the play between crown wheel and reduction gear teeth (this

should be between 0.3 and 0.6 mm)

· Check the tightness of the crown wheel screws (torque 21.5 mdaN)

26

· Check the proper calibration of the weighing system in different suspen-

sion positions.

· Carry out a static test of the jacks (rod movement < 3mm / 30 min)

· Drain : hydraulic oil reservoir (if optional biodegradable oil is used)

27

· Engine: see manufacturer’s notice

· Drain : hydraulic oil reservoir

27

· Check the tightness of the fly jib telescopic action chains.

36

· Using the Optimiser console, in the Failures menu, check that the record

of errors is 100% OK (consult the After Sales Service)

· Check the play in the crown wheel roll path (< 1.6mm

RECALL : All of these frequencies should be reduced when working in difficult conditions (consult the After Sales Service if necessary).

5.3.2 – Operating mode

Caution !
For all refills and greasing, use only the lubricants recommended in the
table in chap. 5.2.1, page 40.

NOTE :

Recycle the drained oils in order not to pollute the environment.

5.3.2.1 -Hydraulic oil filters

Photo 14 Hydraulic oil filter equipment circuit 2

Photo 15 Hydraulic oil filter lateral movement circuit 2

1 3

1

3

· Change the cartridge (1) if the red light appears on the indicator (2). · Unscrew the base (3), remove the cartridge and screw in a new car-
tridge. · Rearm the chock indicator (2) by pressing this so that it turns back to
green.

NOTE :

The jacking check must be done when warm – in cold conditions the indicator may light due to the viscosity of the oil.

43

Operation and Maintenance

Caution !
Before dismantling, ensure that the oil circuit is not pressurised and that the oil is not too hot.

5.3.2.2 -Powered wheel reduction gear

Photo 16 Wheel reduction gear
1 2

· Checking the level: – Rotate the wheel so that you place 1 stopper (1) on a horizontal line and 1 stopper (2) on a vertical line. – Unscrew the stopper (1) and check the level, which should be at the height of the orifice, and if necessary refill the level after unscrewing stopper (2). – Retighten the stopper.
· Drainage : – Rotate the wheel until stopper (2) faces downward. Unscrew the 2 stoppers and allow the oil to drain. – Replace the wheel in the position indicated above to check the level and refill. – Retighten the stoppers

5.3.2.3 -Steering reduction gear

Photo 17 Steering reduction gear
1

Checking and drainage require that the machine is positioned on smooth horizontal ground.
· Checking the level: – Unscrew the refill stopper (rep. 1, Photo 17). – Remove this and check that the oil level is between the minimum and maximum levels indicated.

MAXI

MINI
2
– Refill the level if required. – Retighten the refill stopper.
– Drainage: – Unscrew the refill stopper (rep. 1, Photo 17). – Unscrew the drainage stopper (rep. 2, Photo 17). – Allow the oil to drain. – Retighten the drainage stopper, and refill as
shown above. – Retighten the refill stopper

44

Operation and Maintenance

Caution !
Check the correct jacking of the machine, that you have sufficient capacity and the good condition of
the lifting equipment.

5.3.2.4 -Steering crown wheel
The periodic inspection of the condition of the steering crown wheel is essential to ensure safe use and the machine’s lifespan..

Caution !
The service operation of a machine with a crown wheel which is badly
maintained or in bad condition creates dangerous operating conditions which can cause serious or fatal injury and damage to
components.

Greasing:
· Grease the teeth of the crown wheel using a paintbrush, while visually checking the wear on the teeth.
· Grease the travel path using the 2 greasers accessible through the holes in the turret until the grease comes out of the crown wheel lip seal. Carry out complete rotations of the crown wheel before and after greasing. Any hard point or squeaking during the rotation, or metallic particles in the drained grease are signs of abnormal use of the travel path: contact Haulotte service.

The tasks below must be carried out by trained competent personnel: contact Haulotte Services..

Tightening screws: · Tightening torque: check the values given in Table 5.3.1, “Summary table”, page 42.
Checking play : · Gear teeth play: Check that the play between teeth meets the values given in Table 5.3.1, “Summary table”, page 42. · Travel path play: Check that the play meets the values given in Table 5.3.1, “Summary table”, page 42.
5.3.2.5 -Static checks of the jacks
The periodic inspection of the condition of the jacks is essential to ensure safe use and the machine’s lifespan.
After carrying out any work on any part of the hydraulic circuit of the machine, a static test should always be carried out before returning the machine into service. The tasks below must be carried out by trained competent personnel: contact Haulotte Services.

Caution !
The service operation of a machine with one or more jacks in bad condition creates dangerous operating conditions which can
cause serious or fatal injury and damage to components.

NOTE :

Periodic testing of the jacks is a regulatory requirement in certain countries.

Before starting the static tests, check that the hydraulic circuit is correctly purged (run several cycles for each movement) and that the jacking of the connecting piece is correct (chap. 4.4.1.3, page 32). All of the operations below must be carried out on flat ground, in an open area, with a 290 kg load in the platform (1, 25x of the nominal permitted load).

45

Fig. 4 – Configuration 1

Operation and Maintenance
Configuration 1 (Fig. 4, page 46) : · With the arm gently raised, the fly jib raised to its cutoff point, with the fly jib telescopic arm extended. · oMeasure side X1 between the underside of the arm and the turret reinforcement (Photo 18).
Photo 18

X

Fig. 5 – Configuration 2 Fig. 6 – Configuration 3

· Leave the machine to stand for 30 min. · oMeasure side X2 between the underside of the arm and the turret
reinforcement. · oIf X2-X1 is > 13 mm, the hydraulic jack should be replaced. · oMake a telescopic movement with the fly jib extended: the telescopic
arms should not extend.
Configuration 2 (Fig. 5, page 46) : · With the arm in its lowered position, the fly jib raised a few degrees, with the telescopic arms retracted, and the suspension platform horizontal. Attach a lead line approx. 17.5m in length along the axis to the extremity of the telescopic arms to be able ot measure any variation in height when the machine is deployed. – Length of the extended fly jib hydraulic jack rod: B1 – Length of the extended platform compensation receptor jack rod: C1 – Length of the extended suspension platform hydraulic jack rod: D1
· Raise the arm then extend the telescopic fly jib until the cutoff point (without making any other movement): configuration 3 (Fig. 6, page 46) :
· Measure the height between the lead line and the ground: F1 – Leave the machine to stand for 60 min
· Measure the height between the lead line and the ground: F2 – Retract the fly jib telescopic arm
· Lower the arm to its lowered position (Fig. 5, page 48), then raise it again: – Length of the extended fly jib hydraulic jack rod: B2 – Length of the extended platform compensation receptor jack rod: C2 – Length of the extended suspension platform hydraulic jack rod: D2

46

Operation and Maintenance

Report the measured values in a copy of the table below:

Measu- Measu- Displacement = 2-1 Max ac- Corresponds to the positioning of

red va- red va-

ceptable

the jacks

lues 1 lues 2

value in

mm

X

dX

13

Arm raised

B

dB

6

Fly jib raised

C

dC

6

Platform compensation receiver

D

dD

6

Suspension platform

F

dF

170

Télescopic arm and/or connector

piece and /or fly jib raised compen-

sation

If one of the values measured is higher than the maximum acceptable value, contact Haulotte Services for repair of the affected jack(s) before returning the machine to service..
5.3.3 – List of consumer items
· Hydraulic filter cartridge. · Air filter element. · Fuel pre-filter. · Fuel filter. · Engine oil filter. · Fuses.

5.4 – LOAD TESTING

The tests below are to be performed after: · a major strip down operation. · an accident resulting from a critical component failure.

Caution !
The following tests must be carried out by a competent person under
controlled conditions with test results being fully documented.

5.4.1 – Overload Test
The structural overload test is 125% of the rated safe working load. See §1.12.3 of AS1418.10-1996 for details of the test.

· HA32PX :

overload test is 287,5 kg

The machine is to show no signs of permanent deformation.
5.4.2 – Functional test
These tests are to demonstrate that: · The machine can operate smoothly through all motions whilst carrying the rated safe working load. · All safety devices are working correctly. · The maximum permitted operating speeds are not exceeded.
5.4.3 – Stability test
Stability test is performed in order to demonstrate that the machine is stable in the least favorable position. The worst case overturning moment applied represents the least favorable loads and forces combined.

47

Operation and Maintenance

Caution !
In order to safeguard the elevating platform against tipping during the stability test, it is imperative that a
restraining device such as an anchor block and chain be used to restrain the unit during the stability
test.

This chain shall not assist in stabilising the platform prior ti it reaching a point of tipping should it occur for any reason i.e. uncontrolled application of test load.

$

Overturning moment applied is simulated by a load of W kg

applied at distance L from tipping line, with the elevating

work platform on a 4,5.

MACHINE HA41PX
Horizontal (1)

T (°)

W

L

OVERTURNING MOMENT

Pound (lb)

Kilogram

Feet inch (ft
in)

Meter Feet Pound Meter New-

(m)

(ft.lb)

ton (mN)

4,5

893 405 63,2 19,250 57473

77923

L1 W 1

T
See § 1.12.2 of AS1418.10-1996 for additional testing details. The elevating work platform must come to a stationary condition without overturning.

48

Operation and Maintenance

6 – OPERATING INCIDENTS

RECALL :

Obeying the machine’s usage and maintenance instructions will help to avoid the majority of incidents. Nevertheless these may happen, and before any work is carried out, it is vital to check the table in chap. 6, page 51 to see if these are reported. In this case, you simply need to follow the instructions.If not, you should contact your HAULOTTE agent or the After Sales Service of the manufacturer.

Before diagnosing the breakdown, you should check that: · the fuel tank is not empty, · the batteries are correctly charged, · the emergency stop punch buttons on the turret and the platform are unlocked, · the relays (platform control lectern – turret cabinet) are correctly inserted into their socket, · the fuses are not defective or incorrectly inserted.

NOTE :

In the turret cabinet, LEDs show the status of each extension to check that this is properly activated.

The engine stops

INCIDENTS

The engine stops

Fuel reserve light is on

Fuel reserve indicator

PROBABLE CAUSE
· Leak or air bubble in the fuel circuit
· Blocked fuel filter · Dead battery · Defective printed circuit
fuse (in the electrical cabinet) · Punch buttons are depressed · Engine in “safe” mode : oil pressure, overheating, alternator charging · Burnt-out load indicator bulb · Defective engine safety relays (KP1) · Bad battery and terminal cable contacts
· Fuel tank is empty

SOLUTIONS · Call in After Sales Service
· Change the fuel filter · Recharge the battery · Replace defective fuses
· Reset
· See the manufacturer’s notice or call in After Sales Service
· Change the bulb
· Replace the relay(s)
· Unscrew the terminals and clean these
· Fill the tank

49

Operation and Maintenance

The engine stops

INCIDENTS Error indicator flashes in 4 flash sequences
4 X

PROBABLE CAUSE
· Break in one of the fly jib telescopic arm chains

SOLUTIONS
· Evacuate the user from the machine and call in After Sales Service

The engine stops, no movement is possible, even using the emergency set
The engine stops during movement of the fly jib, and does not restart

Error indicator
Error indicator flashes in 5 flash sequences
5 X
Error indicator
Continuous alarm, error indicator flashes in 8 flash sequences and reach limit indicator lit
8 X

· Emergency stop line fault
· Extension 100 cm beyond the normal reach limit of the fly jib: serious failure in the jib fly raising or telescopic hydraulic controls

· Evacuate the user from the machine and call in After Sales Service
· Evacuate the user from the machine and call in After Sales Service

Error indicator

The engine stops while moving the arm, and does not restart.

Reach limit indicator
Continuous alarm, error indicator flashes in 8 flash sequences and reach limit indicator lit

· Serious failure in the arm raising or telescopic hydraulic controls

8 X

· Evacuate the user from the machine and call in After Sales Service

Error indicator

Low pressure or pump power

Reach limit indicator

No platform movement

· Weak engine power
· Leak or air bubble in the fuel circuit
· Blocked fuel filter · Hydraulic oil leak on a con-
nector, flexible or other component · Faulty accelerator bobine · Faulty accelerator relays and/or fuse
· Turret selector key in the wrong position
· “Dead man” safety switch not activated
· Control function error
· Error in the electro-valve of the requested movement
· Low hydraulic oil

· Adjust engine speed (see After Sales Service)
· Call in After Sales Service
· Change the fuel filter · Repair or replace (see After
Sales Service)
· Change the bobine (YA2) · Replace the accelerator re-
lays and/or fuse (KM6, FU14) · Switch to “platform” position
· Press the “dead man” pedal and hold this down during the entire movement
· Replace the control (see After Sales Service)
· Replace the electro-valve or its bobine (see After Sales Service)
· Refuel

50

Operation and Maintenance

No platform movement

INCIDENTS
Reach limit indicator lights when a movement is requested

PROBABLE CAUSE
· The movement requested is not permitted in this context

SOLUTIONS
· Return to the base position (retract the telescopic arms, lower the fly jib or arms) so that the the movement will be permitted again

No platform movement
No platform movement

Reach limit indicator
Alarm, overload indicator
Overload indicator
Alarm, tilt indicator lit

· Overloaded platform · Platform leaning on the
ground · Suspension platform jack
on high or low mechanical stop setting · Suspension platform is in “transport” position · Error in the weighing system
· Slope or tilt > 4° and the machine is deployed

· Lighten the load · Raise the suspension plat-
form from the turret position · Control the suspension plat-
form from the turret position
· Control the suspension platform from the turret position
· Call in After Sales Service
· Retract the machine and return to flat ground (see Ch 3.2.4)

No platform movement
No platform movement No platform movement
No platform movement

Tilt indicator
Alarm, overload indicator, error indicator flashes in 9 flash sequences
9 X

· Error in the platform overload circuit

· Restart · If the problem persists,
check the weighing electrical circuit (see After Sales Service)

Overload indicator Error indicator
Alarm
Error indicator flashes (1 flash) and the reach limit indicator remains lit.
1 X
Error indicator
Reach limit indicator
The error indicator flashes in 2 flash sequences

· Axles are not entirely extended or not entirely retracted
· Chocking jack not entirely retract
· Press the emergency stop button while carrying out a movement.
· Failure in one or several safety sensors controlling the base limits of the machine (SL1 to SL8, SQ11, SQ3, SQ9, SQ10, SQ43 to 45)
· Failure of one of the platform position controls

· Extend or retract the axles completely
· Retract the chocking jack completely
· Note the configuration of the machine then fold it
· From the turret control position, restart the machine
· If the error reappears on start-up or during a complete extension-retraction cycle controlled from the turret position, call in After Sales Service
· Replace the affected control (see After Sales Service)

2 X
Error indicator

51

Operation and Maintenance

No platform movement

INCIDENTS
The error indicator flashes in 6 flash sequences

Impossibility of lowering the telescopic arms to its resting point
arm compensator unlocks frequently

6 X
Error indicator

No movement of the telescopic arms or fly jib

Error indicator flashes in 7 flash sequences
7 X

PROBABLE CAUSE
· Failure of one or more fuses (FU7, 8, 5, 6 or 2)

SOLUTIONS
· Replace the defective fuse. If the problem persists, call in After Sales Service

· The arm compensator is unlocked

· fold the machine, then relock the compensation (see Ch 4.4.1.3)

· Watertightness or operating problem with the arm compensator raising circuit
· Error in the arm and fly jib function coordination relays: KA50

· Fold and immobilise the machine until a complete check of the circuit has been carried out (see After Sales Service)
· Replace the KA50 relays

No movement of the telescopic arms or fly jib

Error indicator
Error indicator flashes in 7 flash sequences
7 X

· Error in the arm and fly jib function coordination relays: KA51

· Replace the KA51 relays

No movement of the fly jib telescopic arms and the fly jib lowering action is disabled
Ditto, + the engine stops, and will not restart.

Error indicator
Continuous alarm and error indicator flashes in 8 flash sequences
8 X
Error indicator
Continuous alarm and reach limit indicator lit

· 70 cm extension beyond the normal fly jib reach limit range: serious malfunction of the fly jib lift or telescopic hydraulic controls
· Ditto, but more serious: 100 cm extension beyond the normal fly jib reach limit range

· Evacuate the user from the machine and call in After Sales Service
· Evacuate the user from the machine and call in After Sales Service

While running an arm command

Reach limit indicator
Continuous alarm and error indicator flashes in 8 flash sequences

· Serious malfunction of the arm lift or telescopic hydraulic controls

8 X

· Evacuate the user from the machine and call in After Sales Service

Error indicator

52

Operation and Maintenance

INCIDENTS

While running an arm command, the engine stops and will not restart.

Ditto + reach limit indicator lit
8 X

Error indicator

PROBABLE CAUSE · Ditto, but more serious

SOLUTIONS
· Evacuate the user from the machine and call in After Sales Service

Without making any request to the arm, or upon starting up the machine

Reach limit indicator
Discontinuous alarm, the reach limit indicator flashes, the error indicator flashes in 8 or 10 flash sequences.
8 X OR 10 X

· Arm maintenance error (problem with purging or watertightness)

Error indicator

· Fold the machine immediately and call in After Sales Service

La turret will not turn
The hydraulic pump is making noise

Reach limit indicator

No lateral mo- Reach limit indicator is lit vement

· The blocking tool is still inserted into the chassis
· Lack of oil in the reservoir · Aspiration pump vanes are
closed or not completely open · Oil too viscous
· The platform is at its reach limit

· Remove the tool
· Return to level position · Open completely the aspi-
ration vanes
· Drain the circuit and replace with recommended oil
· Gently retract the fly jib telescopic arm

No lateral movement

Reach limit indicator
Error indicator flashes in 3 flash sequences

3 X

· Error in the lateral movement control circuit (YV30a, YV30b, YV10)

· Check the components of the lateral movement control circuit (see After Sales Service)

Lateral movement disabled while at microspeed While making a lateral movement, the machine stops
No axle retraction/extension

Error indicator

· The platform is deployed
· Insufficient load on one wheel
· · No grip on a driving wheel · Wrong control position se-
lected · Emergency stop engaged

· Retrieve the telescopic arms, lower the fly jib and arm, lower the suspension platform
· Press the differential jacking button
· Switch the selector key to the “axle” position
· Check the three emergency stop buttons

53

INCIDENTS No axle retrac- Alarm tion/extension
Alarm is set off
Only the error indicator flashes (1 flash)
1 X
Error indicator

Operation and Maintenance

PROBABLE CAUSE · The machine is not in the ri-
ght configuration
· Chassis hydraulic jack is not completely retracted
· Hydraulic oil temperature too high.
· Malfunction of one or several safety sensors monitoring axle extension and the alignment of the turret (SQ30 to 33, SQ36 to 39, SQ40, SQ42)

SOLUTIONS
· Switch the selector key to the turret position, fold the machine completely, align the turret along the axis
· Completely insert the blockage jack
· Allow to cool
· Note the configuration of the machine then fold it. Check the condition of the sensors. If the problem persists, call in After Sales Service

54

Operation and Maintenance

7 – SAFETY SYSTEM

7.1 – TURRET CABINET RELAY AND FUSE FUNCTIONS
(see chap. 8, page 57)

FU1-10A FU2-3A FU3-80A FU4-30A FU5-3A FU6-3A FU7-20A FU8-5A FU9-20A FU10-3A FU11-25A FU13-250A FU14-15A FU15-25A KA2 KA37 KA43 KA50 KA51 KM4 KM5 KM6 KM8 KMG KP1

Engine power supply fuse “Chassis” position movement fuse Pre-heating fuse Weak power control fuse, calculators “Turret” position movement fuse “Platform” position movement fuse Electrical vane power supply Permanent power supply fuse Injection pump fuse LS valve fuse Optional cooler fuse Emergency pump fuse Accelerator fuse Optional rotating beacon/horn fuse Thermic engine ignition Accessories power supply Emergency pump cutoff relays Fly jib/arm raising relays Arm/fly jib raising telescopic function relays Emergency pump contact Preheating Accelerator Horn General power supply Engine power supply

7.2 –

SAFETY CONTACT FUNCTIONS

B2 B3 B4 B7 B8 SB0 SB1 SB2 SQ1 SQ2 SQ3 SQ9 SQ10 SQ11 SQ12 SQ13 SQ30/31 SQ32/33 SQ34

(see chap. 8, page 57) Engine overheating contact Engine oil pressure contact Hydraulic oil overheating contact Optional hydraulic oil overheating cooler contact Hydraulic high speed lateral movement contact Emergency stop punch button (chassis) Emergency stop punch button (turret) Emergency stop punch button (platform) Cant Raised suspension platform position switch Folded position switch Telescopic fly jib retraction position switch Telescopic arm retraction position switch Fly jib turret position switch Chain break no. 1 position switch Chain break no. 2 position switch Extended front track position switch Extended front track position switch ILS receivers – front jacking retracted

55

SQ35 SQ36/37 SQ38/39
SQ40 SQ41 SQ42 SQ43 SQ44/45 SL1/SL2 SL3/SL4 SL5/SL6 SL7/SL8
G1 G3 A1 A2

ILS receivers – rear jacking retracted ILS switches – axle track extended ILS switches – axle track retracted Turret chassis axis alignment position switch Fuel reserve position switch Turret chassis axis alignment position switch ILS detector – telescopic fly jib arms ILS detector – telescopic arms Fly jib angle gauge Fly jib length gauge Arm angle gauge Arm length gauge Small chamber pressure gauge Wide chamber pressure gauge Weight relative angle gauge Weight absolute angle gauge

Operation and Maintenance

56

152

Operation and Maintenance
8 – ELECTRICAL DIAGRAMME
8.1 – FOLIO 01/06
S hunt
57

101

101

FU4

FU3

30A

80A

F U14 15A

F U15

FU1

F U13

F U11

10A

250A

25A

25A

115

907

GB1

(04-13)

109

B atterie

108

B+ D+
~
B- W G2
(03-17)
Alternateur

120 119

(02-1)
KA2 (04-19)

166

100 160

KP1 (04-18)
116 (02-20)
116

K M4 (02-17)

909

K A37 (04-15)

103
M3 D1

142 161 906 910

K M5 (04-17)
104

K M6 (04-16)

(02-21)

B7

S A16

K M8 (04-20)

905

167

E S OS

KSB ALFB

YA2

YA1

YA3

R1

HL11

D27

M4

EV

D29

HL5

HL6 HA1

0 Démarreur

P réchauffage

Accélérateur

0
P ompe à carburant P ompeà injection

P ompe de s ec ours

0

R efroidis s eur

G yrophare P rojecteur K laxon

(02-1)

8.2 – FOLIO 02/06

58

(01-6)
Arrêt d’Urgence C hâs s is Châssis
Arrêt d’Urgence T ourelle
Arrêt d’Urgence P anier
Mis e s ous tens ion

121 216 203
405

120 CE1

K MG (02-3)

SB0 CE2
SB1
102

S A1

611

FU6

FU5

3A

3A

SB2
215

E _Cmd_Panier

E _Cmd_Tourelle

S A0

C hâs s is

S hunt

254

E _E lec_K MG

Masse

240 611D
FU2 3A

FU8

FU7

F U10

5A

20A

3A

4.9 E _Cmd_C hâssis

AlimeCnatalctuiolanteur

E _E lec_FU8

E _E lec_FU7

HE AD – Noeud A YV1

S _E v_ValveLS 20.2

303

302

FU9 20A
201 242 212 211

905 905

(01-14) (04-5)
(03-1) (03-1) (03-1) (04-1)

241

Operation and Maintenance

(01-21)

K MG

D8

Alimentation

0 S élection du
pos te de conduite

S A19

S A20
620

K A43 (04-14)
622
K M4 Horamètre

H P1

116 (01-14)
D5

D6
0 C ommande pompe de s ecours

(03-1)

Operation and Maintenance
8.3 – FOLIO 03/06
59

(05-1)

201

201

(02-21)

K A51

K A50

Y V 36

Y V 35

Y V 38

Y V 40

Y V 34

Y V 24

Y V 19B

YV15B YV19A

YV18B YV15A

Y V 18A

Y V 30B

Y V 30A

414A 263
407A 408A 401A 402A
304A 311A 306A 417A
309 814C
262 807B
903A 399

11.2

13.2

15.9

53.2

8.6

8.3

21.2

32.2

34.2

33.2

19.2

18.2

10.2

17.2

54.2

31.2

S _Pmp_TranslationA S _Pmp_TranslationB

S S

_E _E

v_D es centeP e ndula ire v_MontéeP endula ire

S S

_E _E

vv__MDeosnctéeenCteoCmopmepnesnastiaotnion

S S

_E _E

v_R v_R

otationP otationP

anierDroite anierG auche

S _E v_Génératrice

E _EECmCEEC_m_dETTmCC_dé_éOdmm_Cllee_rOEddmsisDer_ccEniedMooDCe_st_ppnaemocMCeettsneaidFFmoocntt_énillentoèèdReeGntccn_éFFtehahDSeellnèeeuèBBortocccrrrrhhtéhiaatieeeeeess
E _EC_mCdm_dD_eMsocnetnéteePPeenndduullaaiirree E _EC_mCdm_dD_eMsocnetnéteeCCoommppeennssaattiioonn

S S S S S S S

_E _E _E _E _E _S _S

v_D ébloc a geT oure lle

v_R v_S

ecalageC ompensation ecuLevage

v_T éles copa geB ra s F ut1

E _C md_Accélérateur E _C md_Démarrage E _Cmd_Préchauffage
E _Therm_AlternateurW

eve_ll__TTRééelelleessvccaoogppeaaFggleèeBcFhrlaèesc/TFhéuetl/e2LsecvoapgeeBBErr_aaTssherm_EM_ECa_npTqt_huSeeruPmrrce_hsSasuuiorfcfnehHHauuuifillefee

HE AD – Noeud A

27.3

27.4

40.2

27.7

4.6

4.12

28.7

30.6

30.5

30.8

30.9

28.9 28.4

28.6 28.3

28.2 28.1

4.15 4.14

(05-20)

(05-16)

411 412 505 504 511 510 517 516
410 409
401
402
605 117A
406
108
904 112 111

SB7

SB3

S A2

(05-21)

(05-16)

B

A

B

A

B

A

B

A

(01-3)

B

A

B

A

S A15

S A14

S A13

S A8

B2

B3

B4

S A21

S A6

410A 401B

D34

D32

(04-1) (04-1)

0 242 212

(02-21) (02-21) (02-21)

Operation and Maintenance

K M8
12V 25A
(05-1) (05-9) 0 (04-1)

211 242
0

211 242
0

(02-21)

HL7
(02-21) (04-21) (03-21)

Les contacts sont représentés machine repliée

(04-21)

P upitre panier s ous tens ion

O ption

220 Ohms 2W
905

R 104 HA2

R 28 HA4

D2

HL1

HL2

HL3

HL10 HL15 HL14 HL12 HL4

HL9

HL8

HL16

KA2

KP1

K M5

K M6

K A37

K A43

0

210A
698 260 310A 253 921A 699 914 398 112A 111A 110A
922A 415 305

(01-3) 109

(05-1)

12.1

27.1

4.3

4.2

4.1

56.2

28.15

9.2 16.2

49.2

35.2

52.2

16.3

14.2

S _S ig_BruiteurTourelle

S _S ig_BruiteurPanier

S _S ig_Feux à éclat

PSSSo_rSSStSéiiigggeS(PRDSigauéé_nrsfLacieeihumrravt)MiertgaCaetcia(ohPrnbinauneriaenr)t

P ortSé_eS(Tigo_uLreimlleit)a tion

E

S _S ig_Dévers HSSu__iSSlSeiiggT___ShSSeiguru_mrrMccihqhauaaneruqgfufeee(TTPhoreuerrsmesliiloqenu) e

E _Therm_AlternateurD+

S _Alim_Accessoires S _Therm_Accélérateur

E _C pt_REe_sCeprtv_eDCéavrebrusr_a4n°t _CEEptCCDppEtéttDeEDCcé_éptCtitEetoe_pcn_cEETttTCt_ié__ioEEoeTpCClnne_l_étZeT_ppTsCClsoeeFcttepcpnsollleoètRRetecpspcsoRuuePTcEhacpppFeooeeog_ettplpnuuupSèCeBladrrraicBupeereeguhgarrtmlCCeTlla_eeseaBhshFeoRRFAir_aanulrleeeèxèa2îîtrBnnénncecsttheeeha_lrrlee2é2é1se1

E _C pt_CapteurAngleFlèche1

E E

__CCEpp_tt__CCCpaat_ppCtteeauuprrtLLeoounnrAgguuneeguulerrFFFlllèèèccchhheee212

12.3

150 146

S _Therm_Préchauffage

S S

_T _T

herm_Alimentation herm_Démarreur

911

(05-9)

E _C pt_CapteurAngleB ras1

E E

__CCEpp_tt__CCCpaat_ppCtteeauuprrtLLeoounnrAgguuneeguulerrBBBrrraaasss221

HE AD – Noeud A

29.12

51.4

29.11 15ppm/°C 30.7 15ppm/°C 30.15

29.9

15ppm/°C 29.1 15ppm/°C 29.4

16.1

28.14

41.2

44.2

43.2

46.2

36.2

45.2

29.13

3.3

29.14

48.2

39.3

30.1 30.2

213 214

(05-15) (05-18)

205

252

918

206

917

204

S Q12

218B

250

S Q42

115A

115B

207

S Q44

915

485

R ad

R 105

301 Ohms

0.1% 0,25W 0.1% 0,25W

R 106

301 Ohms

R 107

301 Ohms

0.1% 0,25W 0.1% 0,25W

512
612 804 807
403
506 259 901

R 108

301 Ohms

S Q3 S Q10

0

S L8

S L7

S L6

S L5

S L4

S L3

S L2

S L1

S Q11 S Q45

S Q43

S Q13

S Q9

S Q2

S Q41

8.4 – FOLIO 04/06

(04-21) (03-21)
S Q1

(04-1) (04-1)

0 242

0 242

60

401 402

703 705

311 310
410 409 611C

919

419 420B (04-20) 911
920 117B
222 611A

805 606 708 707 611B 418 420A

Operation and Maintenance
8.5 – FOLIO 05/06
S hunt
61

(04-21) 211

(04-2)

0

(05-19)

2110

211
0 (05-1)

(04-21) 242 (05-16)

S B 6 P édale d’homme mort

2110

BN WH
S M4

WH/B K

BN

WH

S M31

BN

WH

S M2

A

B

Y

GY

G N Y E /B K G Y /B K

R100 470 1% 1/4W

XY

YE

GY

GN

R101 470 1% 1/4W

R102 470 1% 1/4W

Y

GY

GN

R103 470 1% 1/4W

S A18 SB5

D33

409B

S A9

SB4

S A11

S A3

S A4

S A7

A

B

A

B

(05-1) (05-18)
D35

390 391

(05-18) D36

401A 402A

S A5 S A12

A

B

A

B

29.10 29.2 29.8 29.7 E _C mdTranEsl_aCtiEomn_dC_mHdoDrsiNreecutitoEren_ACvmandt_GDairuecchtieonAvantDroite

29.15 30.10 30.12 E _C md_OrientatioEn_C md_LEe_vCagmed_HorsNeutre

S _P vg_TéleLsecvoapgaegBerFalsèche 23.3

S _P vg_Orientation 24.3

506A

500

3 (03-18)

K A50

5

4

512A

501

1

1

1

3 (05-8) 0 (03-21) 201

YV7
2

YV3

3

2

YV5

3

2

0

201

30.11 30.13 E _C md_TélescEo_pCagmed_HorsNeutre

S

_P

vg_T R

éelleesvcaogpeaFgleèBchraes

25.3

612A

3 (03-19)

28.10

3.2

38.2

29.3

28.13

30.4 30.3

E

_C

md_G

éné

ratrice

E

_C

md_Démarrage E _C

md_S

électionBSra_sPRvogt_aPtEieo_nnVCdPiutmaelnasdiis_ereeGr_TCrEraoaxnmntdespenleasntiiosoanntCEioa_nlCagmedD_iBreloctcioangeDifférentEie_lC

md_R

otEa_tiConmPda_nRieortDartioointeP

anierG

auche

22.3

(03-8) (03-9) 30.14

29.5 29.6

E _C md_PédaleHommeEM_Cormt d_DirectioEn_ACrmrièdr_eDGiareuccthioenArrièreDroite

(03-11)

(03-12)

(05-10) 242

(06-2)

S _S ig_Apprentissage 8.2

HE AD – Noeud A

214 (04-2) 607

403A 383
213 (04-1)

K A51

5

4

503

502

1

1

YV6

3

2

YV4

3

2

1

YV2

3

2

0 201

(06-2)

J 4. 5

J4.6 J4.1

J 4. 4

J 4. 3

J 10. 2

384

J7.R 379 1 G 2

J 15. 3
A1 C apteur d’angle
386

P etite chambre
J 7. B

380 G1

A2

J 7. G

U2 C arte P esage

J11.1 381 1 G 2

385
J15.1 Inclinomètre

G rande chambre
J 11. 3

382 G2

383

J 15. 2

–
J 4. 2

Alim_C ompensation

Desc.

Mont.

J 6. 2

J 6. 1

0

T éles copage F lèche K laxon

Levage B ras

O rie nta tion

T éles copage B ras

R elevage F lèche

C hâs s is et panier

(05-20) 390 (05-21) 391

Operation and Maintenance

Les contacts sont représentés machine repliée

201

(05-13)

242

Chassis

CE4

CE3

YV21B YV22A

Y V 22B

YV9

201 201
201 201 201 201 201 201 201 201

Y V 33

YV8 YV31

Y V 10

Y V 12

B8

242 242
242 242 242 242
455 242

S Q40 S Q32

S Q38 S Q36

S Q35

S Q34

453 452
454 456

S Q30

Y V 21A

307

S Q31

S Q33

S Q39 S Q37

CE 16

CE 19

CE 18

CE 17

CE 15

CE 14

CE 20

CE 12

CE7

S hunt CE8

CE 10

CE9

CE6

CE5

CE 13

CE 11

8.10

818 814B
304 306 807A 601

8.1

15.4

15.6

15.3

8.9

S S

_E _E

v_DirectionAva v_DirectionAva

ntDroite ntG a uche

S S

_E _E

vv__DDiirreeccttiioonnAArrrriièèrreeGDraouitcehe

S _E v_BlocageDifférentiel

E ssSie_uEOvs_cDilléabnltocage

15.8

307 308

15.7

C alaSg_eEDvi_reEcxttieonns ion

8.12

814A 813

8.11

S S

_E _E

v_G ra ndeV ites s eT ra ns vDéfreinageE ssieux

lation

50.3

255 232 218A 258 257 256 251

47.2

50.4

51.2

51.3

37.2

42.2

E _CTprta_nPsalastGiornandeVitesse

EE__ECC_ppCtt__pCtE_asClsaaigelaeugAxeRvAaernnrtitRèréreesnRtreéntré

E _C pt_E ssieuxNonE tendus

E

_C

E _Cpt_TourelleAxée1 pt_E ssieuAvantArriereNonE

tendu

8.6 – FOLIO 06/06

HE AD – Noeud A

242

(05-17)

62

Operation and Maintenance

8.7 – NOMENCLATURE

REP A1 A2 B2 B3 B4 B7 B8 EV FU1 FU2 FU3 FU4 FU5 FU6 FU7 FU8 FU9 FU10 FU11 FU13 FU14 FU15 G1 G2 GB1 HA1 HA2 HA4 HL1 HL2 HL3 HL4 HL5 HL6 HL7 HL8 HL9 HL10 HL11 HL12 HL14 HL15 KA2 KA37 KA43 KA50 KA51 KM4 KM5 KM6 KM8 KMG KP1

FOLIO-COL 05 – 14 05 – 14 03 -20 03 -19 03 -18 01 -17 06 -13 01 -17 01 -13 02 – 9 01 – 7 01 – 5 02 – 8 02 – 6 02 -12 02 -11 02 -15 02 -14 01 -17 01 – 16 01 – 9 01 -19 05 – 20 05 – 20 01 – 1 01 -20 04 – 7 04 – 2 04 -12 04 – 11 04 – 11 04 – 10 01 -19 01 -19 04 – 1 04 – 4 04 – 5 04 – 7 01 – 8 04 – 9 04 – 8 04 – 7 04 -19 04 -15 04 -13 05 -18 05 -19 02 -16 04 -17 04 -16 04 – 20 02 – 2 04 -18

DESIGNATION Weight relative angle gauge Weight absolute angle gauge Engine overheat manifold Engine low oil pressure manifold Hydraulic oil overheat manifold Optional hydraulic oil overheating cooler thermostat Hydraulic high speed lateral movement manifold Optional engine cooler Engine power supply fuse “Chassis” position movement fuse Pre-heating fuse Weak power control fuse, calculators “Turret” position movement fuse “Platform” position movement fuse Electrical vane power supply Electrical vane power supply Injection pump fuse LS valve fuse Optional cooler fuse Emergency pump fuse Accelerator fuse Accelerator fuse Small chamber pressure gauge Wide chamber pressure gauge 12V battery Alarm Platform alarm turret alarm Battery charge indicator Turret overload indicator Engine overheating indicator Oil pressure indicator Optional rotating beacon Optional work light Power on indicator Fuel reserve indicator Error indicator Platform overload indicator Pre-heating indicator Tilt indicator Turret reach limit indicator Platform reach limit indicator Ignition relays Accessories power supply relays Emergency pump cutoff relays Arm/fly jib raising telescopic function relays Fly jib/arm raising relays Emergency pump relays Preheating relays Accelerator relays Horn relays General relays Engine power supply relays
63

REP M3 M4 P1 R1 SA0 SA1 SA2 SA3 SA4 SA5 SA6 SA7 SA8 SA9 SA11 SA12 SA13 SA14 SA15 SA16 SA18 SA19 SA20 SA21 SB0 SB1 SB2 SB3 SB4 SB5 SB6 SB7 SL1/SL2 SL3/SL4 SL5/SL6 SL7/SL8 SM2 SM4 SM31 SQ1 SQ2 SQ3 SQ9 SQ10 SQ11 SQ12 SQ13 SQ30/31 SQ32/33 SQ34 SQ35 SQ36/37 SQ38/39 SQ40 SQ41
64

FOLIO-COL 01 – 3 01 -16 02 -18 01 – 7 02 – 2 02 – 7 03 -13 05 -13 05 -15 05 -20 03 – 8 05 -16 03 – 2 05 – 11 05 -12 05 -18 03 – 3 03 – 5 03 – 6 01 -18 05 – 10 02 -15 02 -17 03 -11 02 – 3 02 – 3 02 – 3 03 -14 05 – 11 05 – 9 05 -13 03 -15 04-13 04 – 15 04 – 17 04 – 18 05 – 7 06 -15 05 – 5 04 – 2 04 – 5 04 – 4 04 – 6 04 – 5 04 -11 04 -7 04 -8 06 -20 06 -19 06 -14 06 -15 06 -17 06 -16 06 -18 04 – 3

Operation and Maintenance
DESIGNATION Ignition Emergency pump Hour meter Preheating Resistor Power-on selector Position selector key Accelerator switch Differential jacking switch Platform rotation switch Platform compensation switch Turret suspension platform switch Platform suspension platform switch turret fly jib telescopic action switch Platform arm/fly jib selector switch Lateral movement high speed selector switch Platform forward direction switch Turret fly jib extension switch Turret arm extension switch Turret rotation switch Optional rotating beacon interrupter Optional generator ignition Turret emergency pump switch Platform emergency pump switch Turret compensation interrupter Chassis punch button Turret punch button Platform punch button Turret ignition switch Platform ignition switch Horn switch Dead Man Pedal Preheating switch Fly jib angle gauge Fly jib length gauge Arm angle gauge Arm length gauge Telescopic action manipulator Lateral movement manipulator rotation and lifting manipulator Tilt Suspension platform position switch Fly jib retraction area position switch Retracted telescopic fly jib arm position switch Retracted telescopic arm position switch Fly jib turret position switch Chain break no. 1 position switch Chain break no. 2 position switch Extended front track position switch Extended front track position switch ILS receivers – front jacking retracted ILS receivers – rear jacking retracted ILS receivers – axle track extended ILS receivers – axle track retracted Turret right-angle position switch Fuel reserve indicator

Operation and Maintenance

REP SQ42 SQ43 SQ44/45
U1 U2 YA1 YA2 YA3 YV1 YV2
YV3 YV4 YV5 YV6 YV7 YV8/31 YV9 YV10 YV12 YV15A/B YV18A/B YV19A/B YV21A/B YV22A/B YV24 YV30A
YV30B
YV33 YV34 YV35 YV35 YV36 YV38 YV40

FOLIO-COL 04 – 8 04 – 9 04 – 10
02/03/04/05/06 05 – 15 01 – 11 01 – 9 01 -13 02 – 14 05 -11
05 -4 05 -9 05 -5 05 – 7 05 – 1 06 – 9 06 – 6 06 – 10 06 – 11 03 – 7 03 – 4 03 – 9 06 – 2 06 – 4 03 – 11 03 – 2
03 – 2
06 -7 03 -12 03 – 14 03 – 13 03 – 16 03 – 13 03 – 13

DESIGNATION Turret right-angle redundant position receiver Fly jib telescopic arm ILS detector Telescopic arm ILS detector HEAD calculator Weighing card Fuel pump Accelerator Injection pump Load sensing solenoid valve Solenoid valve – PVG suspension platform, axle extension, jacking, direction Arm raising control solenoid valve Fly jib raising control solenoid valve Turret orientation solenoid valve Arm telescopic action control solenoid valve Fly jib telescopic action control solenoid valve Axle extension, jacking and direction solenoid valve Jacking differential control solenoid valve Lateral high speed movement control solenoid valve Brake release control solenoid valve Compensation control solenoid valve Suspension platform control solenoid valve Platform rotation control solenoid valve Forward direction control solenoid valve Rear direction control solenoid valve Optional generator control solenoid valve Section A lateral movement control pump solenoid valve Section B lateral movement control pump solenoid valve Oscillating axel unblocking control solenoid valve turret unblocking control solenoid valve Telescopic arm barrel 1 control solenoid valve Arm raising safety solenoid valve Telescopic arm barrel 2 control solenoid valve Arm raising safety solenoid valve Compensation jack solenoid valve

65

Operation and Maintenance 66

Operation and Maintenance
9.1 – SHEET 1/3

9 – HYDRAULIC DIAGRAMME

67

9.2 – SHEET2/3

Operation and Maintenance

68

Operation and Maintenance
9.3 – SHEET 3/3
69

9.4 – NOMENCLATURE

NUMBER
1 2 3 4 5 7 8 9 10 11 12 13 14 16 18 19 20 21
22
23 24 25 26 27 28 29 30 31 33 34 35 36 37 38 39 40 41 42 44 45 46 49 52

DESIGNATION
LATERAL MOVEMENT PUMP EQUIPMENT PUMP EMERGENCY GROUPE LATERAL MOVEMENT HYDRAULIC MOTOR DIRECTION REDUCTION MOTOR PLATFORM ROTATION JACK EQUIPMENT DISTRIBUTOR PLATFORM FUNCTIONS HYDRAULIC BLOCK LATERAL MOVEMENT DRIVING BLOCK LATERAL MOVEMENT BLOCK 2 DIVIDERS LATERAL MOVEMENT BLOCK 1 DIVIDERS ELECTRONIC PARALLEL DISTRIBUTOR BRAKE RELEASE CONTROL BLOCK PATH END HYDRAULIC ROLLER HYDRAULIC SWIVEL JOINT JACK COMPENSATION SAFETY BLOCK ARM LIFTING JACK SAFETY BLOCK ARM TELESCOPIC ACTION JACK SAFETY BLOCK FLY JIB TELESCOPIC ACTION JACK SAFETY BLOCK EQUIPMENT PUMP FLY JIB LIFTING JACK SAFETY BLOCK PILOT ANTI- RETURN VALVE BLOCK PILOT ANTI-RETURN VALVE BLOCK PILOT ANTI-RETURN VALVE BLOCK E BALANCING VALVE PILOT ANTI-RETURN VALVE (cartridge) ANTI-RETURN VALVE 5 b – 3/4″G ANTI-RETURN VALVE 0.5 b – 3/4″G ANTI-RETURN VALVE 0.5 b – 3/8″G HYDRAULIC RESERVOIR ASSEMBLY 250 L OPTIONAL HYDRAULIC REFRIGERATION PRESSURE FILTER WITH INDICATOR PRESSURE FILTER WITH INDICATOR MANUAL CONTROL DISTRIBUTOR LINE PRESSURE LIMITER 1/2″G LINE PRESSURE LIMITER 3/8″G ISOLATOR VALVE 1″1/2 ISOLATOR VALVE SOLENOID VALVE 2V/2P FLY JIB RAISING SAFETY VALVE CONTACT MANIFOLD 10 BARS / NF ELECTRO 2V/2P SOLENOID VALVE 3V/2P

Operation and Maintenance
SCHEMA SHEET No N° 2 1 1 2 1 1 1 1 2 2 2 3 3 3 1,2,3 1 1 1
1
1 1 3 3 1 1 1 1 1,3 1 2 2 1 1 1 1 1 2 1 1 2 1 3 1

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