Haulotte H23TPX Installation guide

T
TE EC CH HN NI IC CA AL L T TR RA AI IN NI IN NG G
D
DI IA AG GN NO OS ST TI IC C L LE EV VE EL L I II I
H
H2 21 1T TX X- -H H2 23 3T TP PX X- -H H2 25 5T TP PX X
H
HB B6 62 2- -H HB B6 68 8J J- -H HB B7 76 6J J

TRAINING MANUAL DIAGNOSTIC Level 2 H21TX - H23TPX and H25 TPX
2420339100 E07-14
2/78
H
Ho ow w t to o u us se e t th hi is s d do oc cu um me en nt t? ?
Y
Yo ou u h ha av ve e b be et tw we ee en n t th he e h ha an nd ds s t th he e s su um mm ma ar ry y g gi iv ve en n d du ur ri in ng
g t th he e H HA AU UL LO OT TT TE E t te ec ch hn ni ic ca al l t tr ra ai in ni in ng g I It t w wi il ll l
e
en na ab bl le e y yo ou
u t to o f fi in nd d i in nf fo or rm ma at ti io on n n ne ec ce es ss sa ar ry y f fo or r t th he e m ma ai in nt te en na an nc ce
e a an nd d t th he e r re ep pa ai ir r o of f y yo ou ur r H HA AU UL LO OT TT TE E
m
ma ac ch hi in ne e . .
T
Th ha an nk ks s t
to o t th he e g gu ui id de e b be el lo ow w y yo ou u w wi il ll l r re ea ac ch h t th he e r re eq qu ui ir re ed d c ch ha ap
pt te er r q qu ui ic ck kl ly y. .
C
Ch ha ap pt te er r 1 1:
:M Ma ai in n f fe ea at tu ur re es s a an nd d f fu un nc ct ti io on ns s
I
It t i is s a a r re es su um me e o of f t th he e
i in nf fo or rm ma at ti io on n c co on nt ta ai in ne ed d i in n t th he e u us se er r m ma an nu ua al l d de el li iv ve er re ed
d w wi it th h t th he e m ma ac ch hi in ne e: : c co om mp po on ne en nt ts s, ,
o
ov ve er ra al ll l d di im me en ns si io on ns s, , w
wo or rk ki in ng g z zo on ne e , , c co om mm ma an nd ds s, , e et tc c… …
C
Ch ha ap pt te er r 2 2:
:S St tu ud dy y o of f t th he e e el le ec ct tr ri ic c s sc ch he em ma at ti ic cs s
Y
Yo ou u w wi il ll l f fi in nd d t th he
er re e t th he e e el le em me en nt ts s a as s f fo ol ll lo ow wi in ng g: :
-
- A A s su um mm ma ar ry y o of f t th he e s
st ta an nd da ar rd di iz ze ed d s sy ym mb bo ol ls s u us se ed d b by y H HA AU UL LO OT TT TE E G Gr ro ou up p
-
- T Th he e c co
om mp pl le et te e w wi ir ri in ng g d di ia ag gr ra am m o of f t th he e s st tu ud di ie ed d m mo od de el l
-
- T Th he e n
no on n e ex xh ha au us st ti iv ve e l li is st t o of f t th he e e el le ec ct tr ri ic c l lo oo om ms s a an nd d e el le ec ct tr
ro on ni ic c b bo oa ar rd ds s
-
- L Lo oc ca al li iz za at ti io on n o of f t th he e m ma ai in n s sa af fe et ty y u un ni it
ts s ( (t ti il lt t , , l li im mi it t s sw wi it tc ch he es s, , s se en ns so or rs s, ,t tr ra an ns sd du uc ce er rs s… …) )
-
- L
Lo og gi ic ca al l e eq qu ua at ti io on ns s o of f o op pe er ra at ti io on n: : b by y f fu un nc ct ti io on n, , t to o d di ia ag
gn no os se e t th he e m ma ai in n d dy ys sf fu un nc ct ti io on ns s
C
Ch ha ap pt te er r 3 3:
:S St tu ud dy y o of f t th he e h hy yd dr ra au ul li ic c s sc ch he em ma at ti ic cs s
Y
Yo ou u w wi il ll l f fi in nd d t th
he er re e t th he e e el le em me en nt ts s a as s f fo ol ll lo ow wi in ng g: :
-
- a a s su um mm ma ar ry y o of f t th he e
s st ta an nd da ar rd di iz ze ed d s sy ym mb bo ol ls s u us se ed d b by y H HA AU UL LO OT TT TE E G Gr ro ou up p
-
- t th he e c
co om mp pl le et te e h hy yd dr ra au ul li ic c d di ia ag gr ra am m o of f t th he e s st tu ud di ie ed d m mo od de el l
-
- a
a l lo oc ca al li iz za at ti io on n o of f t th he e m ma ai in n h hy yd dr ra au ul li ic cs s m ma an ni if fo ol ld d ( (p pr ro op
po or rt ti io on na al l b bl lo oc ck k , , o on n/ /o of ff f m mo ov ve em me en nt ts s b bl lo oc ck k) )
C
Ch ha ap pt te er r 4
4:
:A Ad dj ju us st tm me en nt ts s
T
Th hi is s i is s t th he e a ad dj ju us st tm me en nt ts s a an nd d c ca al li ib br ra at ti io
on ns s, , h hy yd dr ra au ul li ic cs s a an nd d e el le ec ct tr ri ic c, , n ne ec ce es ss sa ar ry y t to o t th he e g go oo od
d m ma ai in nt te en na an nc ce e o of f
t
th he e m ma at te er ri ia al l. . Y Yo ou u w wi il ll l f fi in nd d a as s w we el ll l
t th he e m me et th ho od ds s o of f a ad dj ju us st tm me en nt t w wi it th h t ta ab bl le e v va al lu ue es s. .
C
Ch ha ap
pt te er r 5 5:
:G Gu ui id de e o of f b br re ea ak kd do ow wn n
Q
Qu ui ic ck k s su um mm ma ar ry y o of f t th he e s st te ep p t to o b
be e f fo ol ll lo ow we ed d f fo or r p po os ss si ib bl le e s so ou ur rc ce es s o of f b br re ea ak kd do ow wn n. .
I
In n c
ca as se e o of f a an ny y d de ef fe ec ct t o or r a an ny y d dy ys sf fu un nc ct ti io on n y yo ou u w wi il ll l b be e a ab
bl le e t to o i id de en nt ti if fy y t th he e e el le em me en nt ts s i in n q qu ue es st ti io on n; ; w wh ha at te ev ve er r
t
th he ey y a ar re e e el le ec ct tr ri ic c o or r h hy yd dr ra au ul li ic c. .
C
Ch ha ap pt te er r 6 6:
:S Su um mm ma ar ry y o of f t th he e v ve er rs si io on ns s
T
Th hi is s m ma an nu ua al l t tr re ea at ts s o of f t th he e
l la at te es st t v ve er rs si io on n, , h ho ow we ev ve er r t th hi is s s su um mm ma ar ry y t ta ab bl le e e en na ab bl le es
s y yo ou u t to o f fi in nd d t th he e f fo or rm me er r
v
ve er rs si io on ns s o of f t th he e m ma at te er ri ia al l ( (e
el le ec ct tr ri ic c a an nd d h hy yd dr ra au ul li ic cs s) ). .
C
Ch ha ap pt te er r 7 7:
:S Sp pe ec ci ia al l f fu un nc ct ti io on ns s
T
Th hi is s c ch ha ap pt te er r g ga at th he er rs s a al ll l t th he e f fu un
nc ct ti io on ns s a an nd d a ad dj ju us st tm me en nt t s sp pe ec ci if fi ic c t to o c ca ar rr ry y o ou ut t o on n t th he
e m ma ac ch hi in ne e. . T Th he er re e d do oe es s
n
no ot t e ex xi is st t f fo or r a al ll l t th he e m ma at te er ri ia al ls
s a an nd d d de ep pe en nd ds s o on n t th he e s st tu ud di ie ed d m mo od de el l. .
I
It t m mu us st t b be e t th he e
s su ub bj je ec ct t o of f a a s sp pe ec ci ia al l a at tt te en nt ti io on n o of f y yo ou ur r s sh ha ar re e b be ec ca au us
se e a an n i in nt te er rv ve en nt ti io on n b ba ad dl ly y c ca ar rr ri ie ed d o ou ut t c ca an n
d
de et te er ri io or ra at
te e t th he e g go oo od d p pe er rf fo or rm ma an nc ce e o of f t th he e m ma ac ch hi in ne e a an nd d t th hu us s c co on ns
se eq qu ue en nt tl ly y t th he e s sa af fe et ty y o of f t th he e u us se er rs s. .
O
On nl ly y a a t te ec ch hn ni ic ci ia
an n H HA AU UL LO OT TT TE E o or r a ap pp pr ro ov ve ed d b by y H HA AU UL LO OT TT TE E S Se er rv vi ic ce es s i is s a ab bl le
e t to o c ca ar rr ry y o ou ut t t th hi is s k ki in nd d o of f
i
in nt te er rv ve en nt ti io on n. .
O
On n t th hi is s c
ch ha ap pt te er r, , s so om me e s sp pe ec ci ia al l a ad dj ju us st tm me en nt t ( (s se en ns so or rs s) ) a ar re e a al ls so o
e ex xp pl la ai in ne ed d p pr ri io or r t to o c ca al li ib br ra at ti io on n ( (d de ep pe en nd ds s o on n
t
th he e m mo od
de el l) )
C
Ch ha ap pt te er r 8 8
: : L Li is st t o of f s sc ch he em ma at ti ic cs s
T
Th hi is s c ch ha ap pt te er r l li is st ts s a al ll l s sc ch he em ma
at ti ic cs s ( (e el le ec ct tr ri ic c/ /h hy yd dr ra au ul li ic c) ) o of f a al ll l m mo od de el ls s a an nd d s so om me e l la
ay yo ou ut t i if f r re eq qu ui ir re ed d
M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R O OP PE ER RA AT TI IO ON NS S O ON N Y YO OU UR R H HA AU UL LO OT TT TE
E M MA AC CH HI IN NE E
M MU US ST T B BE E D DO ON NE E O ON NL LY Y B BY Y T TR RA AI IN NE ED D , ,E EX XP PE ER RI IE EN NC CE
ED D A AN ND D A AU UT TH HO OR RI IZ ZE ED D T TE EC CH HN NI IC CI IA AN NS S

TRAINING MANUAL DIAGNOSTIC Level 2 H21TX - H23TPX and H25 TPX
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R
RE EV VI IS SI IO ON N
Revision Edition Subject Created
by Validated by Modified by Translated by Language
00 03-11 creation MGD FLH MGD FR/EN
01 07-13 Add new overload
adjustment and
accelerator engine
coil
MGD FLH MGD EN/FR
04 12-13 Add Diag Pad info +
console alarm list
MGD Central
R&D
MGD MGD EN
05 02-14 Add chapter
schematics
MGD EN
06 07- 14 Add latest tips on
options like ASB
(Active Shield Bar)
MGD EN

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SUMMARY
1.MAIN FEATURES AND FUNCTIONS........................................................................................................................6
1.1.CHARACTERISTICS .....................................................................................................................................................6
1.1.1.main components..............................................................................................................................................6
1.1.2.Overall dimensions...........................................................................................................................................7
1.1.3.working zones...................................................................................................................................................9
1.1.4.technical datas................................................................................................................................................12
1.2.OVERALL DIMENSIONS .............................................................................................................................................15
1.3.COMMANDS CONTROL BOX.......................................................................................................................................16
2.ELECTRICAL PART...................................................................................................................................................18
2.1.SYMBOLS USED........................................................................................................................................................18
2.2.METHODOLOGY OF CONTROL...................................................................................................................................23
2.2.1.electric continuity control...............................................................................................................................23
2.2.2.Control of an on/off valve...............................................................................................................................23
2.2.3.Control of components ...................................................................................................................................25
2.3.THE ELECTRICAL SHEMATICS...................................................................................................................................27
2.3.1.The main printed circuit (lower box)..............................................................................................................27
2.4.SLIP RING (2440309100)..........................................................................................................................................27
2.5.LOCALIZATION OF THE MAIN SAFETY COMPONENTS ................................................................................................28
2.6.LIST OF COMPONENTS ..............................................................................................................................................29
2.6.1.engine.............................................................................................................................................................30
2.6.2.Fuses...............................................................................................................................................................31
2.6.3.inputs..............................................................................................................................................................31
2.6.4.Outputs...........................................................................................................................................................33
2.7.LOGICAL EQUATIONS OF OPERATION........................................................................................................................36
2.7.1.engine.............................................................................................................................................................36
2.7.2.drive................................................................................................................................................................37
2.7.3.Steering...........................................................................................................................................................38
2.7.4.boom...............................................................................................................................................................39
2.7.5.Telescoping.....................................................................................................................................................39
2.7.6.Turret slewing.................................................................................................................................................39
2.7.7.jib....................................................................................................................................................................40
2.7.8.Compensation.................................................................................................................................................40
2.7.9.basket rotation................................................................................................................................................40
3.THE HYDRAULIC PART............................................................................................................................................41
3.1.SYMBOLS USED........................................................................................................................................................41
3.2.THE HYDRAULIC SCHEMA 149P234040....................................................................................................................45
3.3.MAIN MANIFOLD.......................................................................................................................................................45
3.3.1.Detail of the drive block.................................................................................................................................46
3.3.2.Detail of on/off block......................................................................................................................................47
3.3.3.Detail of pvg block..........................................................................................................................................49
4.ADJUSTMENTS............................................................................................................................................................51
4.1.ADJUSTMENTS WITH OPTIMIZER CONSOLE...............................................................................................................51
4.1.1.Parameter settings..........................................................................................................................................54
4.1.2.alarms on upper control box ..........................................................................................................................55
4.2.CONSOLE DIAG PAD ..................................................................................................................................................57
4.3.PRESSURES ADJUSTMENT .........................................................................................................................................58
4.3.1.Table of pressures...........................................................................................................................................58
4.3.2.Plug socket of the pressures ...........................................................................................................................59
4.3.3.Adjustment......................................................................................................................................................60
4.4.OVERLOAD ADJUSTMENT.........................................................................................................................................64

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5.BREAKDOWN SERVICE GUIDE..............................................................................................................................66
5.1.NO START .................................................................................................................................................................66
5.2.NO MOVEMENT.........................................................................................................................................................66
5.3.NO MOVEMENT >3M ...............................................................................................................................................66
5.4.NO BOOM LIFT ..........................................................................................................................................................66
5.5.NO TELESCOPIC BOOM EXTENSION ...........................................................................................................................67
5.6.NO TURRET ROTATION..............................................................................................................................................67
5.7.NO ON/OFF MOVEMENTS ........................................................................................................................................67
5.8.NO DRIVE .................................................................................................................................................................67
5.9.ONLY LOW SPEED .....................................................................................................................................................67
5.10.NO STEERING............................................................................................................................................................67
6.SUMMARY OF THE VERSIONS H21 H23 H25.......................................................................................................68
7.SPECIAL FUNCTIONS................................................................................................................................................69
7.1.REACH LIMITATION (H25TPX)................................................................................................................................69
7.2.ADJUSTMENT OF REACH LIMITATION SWITCHS.........................................................................................................70
8.LIST OF SCHEMATICS..............................................................................................................................................70

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1
1. . M MA AI IN N F FE EA AT TU UR RE ES S A AN ND D F FU UN NC CT TI IO ON NS S
1
1. .1 1. . C
CH HA AR RA AC CT TE ER RI IS ST TI IC CS S
1
1. .1 1. .1 1. . M
MA AI IN N C CO OM MP PO ON NE EN NT TS S

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1
1. .1 1. .2 2. . O OV
VE ER RA AL LL L D DI IM ME EN NS SI IO ON NS S
H21TX
H23TPX

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H25TPX

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1
1. .1 1. .3 3. . W
WO OR RK KI IN NG G Z ZO ON NE ES S
H21 TX

TRAINING MANUAL DIAGNOSTIC Level 2 H21TX - H23TPX and H25 TPX
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H23 TPX

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H25 TPX

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1
1. .1 1. .4 4. . T
TE EC CH HN NI IC CA AL L D DA AT TA AS S

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TRAINING MANUAL DIAGNOSTIC Level 2 H21TX - H23TPX and H25 TPX
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TRAINING MANUAL DIAGNOSTIC Level 2 H21TX - H23TPX and H25 TPX
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1
1. .2 2. . O OV VE ER RA AL LL L D DI IM ME EN NS SI IO ON NS S

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1
1. .3 3. . C CO OM MM MA AN ND DS S C CO ON NT TR RO OL L B BO OX X

TRAINING MANUAL DIAGNOSTIC Level 2 H21TX - H23TPX and H25 TPX
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TRAINING MANUAL DIAGNOSTIC Level 2 H21TX - H23TPX and H25 TPX
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2
2. . E EL LE EC CT TR RI IC CA AL L P PA AR RT T
2
2. .1 1. . S SY YM MB BO OL LS S U US SE ED D
Battery with one element
Alternator
Fuse (Here 10 amps)
Coil winding roll
Electric motor
light
Diode
Hourmeter

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Standard push-button of safety “mushroom-headed
button”
Rotary knob
Push-button
Limit switch
Pressure switch
Key selector with 3 positions (T turret, O neutral, N
platform)
Toggle switch with 2 positions
Electrovalve
relay
horn

TRAINING MANUAL DIAGNOSTIC Level 2 H21TX - H23TPX and H25 TPX
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Proportional electrovalve
Controller/joysticks
Foot pedal switch
buzzer
“light”
Electrovalve “ON/OFF » ( bang-bang)
Tilt sensor ( ramp detection)
Angle sensor (reach limitation)