Pinguely-Haulotte HA20PX Operating instructions

L'ACCES A L'ESPACE
CISEAUXARTICULEES TELESCOPIQUESMATS TRACTEES
ISO 9001
PINGUELY HAULOTTE • LA PERONNIERE - BP 9 - 42152 L'HORME • Tél. [phone] • Fax SAV [phone]
email [email protected] • Web www.haulotte.com
REPAIR MANUAL
SELF PROPELLED LIFT
HA20 PX - HA26PX
242 031 9530 - E 02.03 GB

Repair manual 1
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Caution!
GENERAL
This manual gives the information required for youto perform servicing and repair
operations on certain pieces of equipment yourself.
However, we would like to bring your attention to the importance of:
• respecting the safety instructions concerning the machine itself, its use and
its environment,
• use within the limits of its performance,
• correct servicing to ensure long service life.
During and after the guarantee period, our After-Sales service is available to
perform any servicing operations you may require.
In this case, contact our local agency or our Plant After-Sales service, specifying
the exact type of machine and its serial number.
To order consumables or spare parts, use the "Instructions for use and
maintenace" manual and the "Spare parts" catalogue to order original parts, the
only guarantee of interchangability and perfect operation.
REMINDER:We would like to remind you that our machines comply with the
clauses of the "Machines Directive", 89/392/CEE, dated June 14th
1989, modified by directives 91/368/CEE, dated June 21st 1991, 93/
44/CEE, dated June 14th 1993, 93/68/CEE (98/37/CE) dated July
22nd 1993 and 89/336 CEE, dated May 3rd 1989; to directive 2000/
14/CE and directive EMC/89/336/CE.
The technical data in this
manual is not binding and we
reserve the right to make
improvements or
modificationswithoutaltering
this manual.

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SUMARY
GENERAL.................................................................................................................... 1
1 - GENERAL RECOMMENDATIONS - SAFETY............................................................ 5
1.1 - GENERAL WARNING................................................................................................. 5
1.1.1 - Manual..................................................................................................................................... 5
1.1.2 - Labels ...................................................................................................................................... 5
1.1.3 - Safety....................................................................................................................................... 5
1.2 - GENERAL SAFETY RECOMMENDATIONS.............................................................. 6
1.2.1 - Operators................................................................................................................................. 6
1.2.2 - Environment............................................................................................................................. 6
1.2.3 - Using the machine................................................................................................................... 6
1.3 - RESIDUAL RISKS....................................................................................................... 8
1.3.1 - Risks of jerky movements and tipping over ............................................................................. 8
1.3.2 - Electrical risk............................................................................................................................ 8
1.3.3 - Risk of explosion or burning..................................................................................................... 8
1.3.4 - Risks of collision ...................................................................................................................... 8
1.4 - INSPECTIONS ............................................................................................................ 9
1.4.1 - Periodic inspections................................................................................................................. 9
1.4.2 - Examination of machine suitability........................................................................................... 9
1.4.3 - State of conservation............................................................................................................... 9
1.5 - REPAIRS AND ADJUSTMENTS............................................................................... 10
1.6 - VERIFICATIONS WHEN RETURNING TO SERVICE.............................................. 10
1.7 - BEAUFORT SCALE .................................................................................................. 10
2 - SPECIFICATIONS ..................................................................................................... 11
2.1 - TECHNICAL CHARACTERISTICS ........................................................................... 11
2.1.1 - HA 20PX technical characteristics......................................................................................... 11
2.1.2 - HA 26PX technical characteristics......................................................................................... 12
2.2 - OVERALL DIMENSIONS .......................................................................................... 14

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2.2.1 - HA 20PX overall dimensions..................................................................................................14
2.2.2 - HA 26PX overall dimensions..................................................................................................15
2.3 - TIGHTENING TORQUE.............................................................................................16
2.3.1 - Tightening torque for large thread..........................................................................................16
2.3.2 - Tightening torque for fine thread............................................................................................ 16
2.3.3 - Tightening torque for hydraulic hoses....................................................................................17
2.3.4 - Pressure values (in bar).........................................................................................................18
2.3.5 - Adjustment time......................................................................................................................19
3 - SAFETY SYSTEM......................................................................................................21
3.1 - FUNCTIONS OF THE TURRET CABINET FUSES AND RELAYS...........................21
3.2 - FUNCTION OF THE SAFETY SWITCHES ...............................................................21
4 - WIRING DIAGRAM.....................................................................................................23
4.1 - WIRING DIAGRAM E 448 - FOLIO 01/05..................................................................23
4.2 - WIRING DIAGRAM E 448 - FOLIO 02/05..................................................................24
4.3 - WIRING DIAGRAM E 448 - FOLIO 03/05..................................................................25
4.4 - WIRING DIAGRAM E 448 - FOLIO 04/05..................................................................26
4.5 - WIRING DIAGRAM E 448 - FOLIO 05/05..................................................................27
4.6 - PART LIST.................................................................................................................28
5 - MACHINES ELEMENTS ............................................................................................31
5.1 - MOTOR......................................................................................................................31
5.2 - FUSES.......................................................................................................................31
5.3 - INPUT ........................................................................................................................31
5.3.1 - Control inputs :.......................................................................................................................31
5.3.2 - Safety inputs :.........................................................................................................................33
5.4 - OUTPUT ....................................................................................................................33
5.4.1 - Relay......................................................................................................................................33
5.4.2 - "On/Off" electrovalves............................................................................................................33
5.4.3 - Proportional electrovalves......................................................................................................34

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5.4.4 - Buzzer and light indicators..................................................................................................... 34
6 - OPERATING EQUATIONS........................................................................................ 35
6.1 - START....................................................................................................................... 35
6.2 - STOP MOTEUR ........................................................................................................ 35
6.3 - ACCELERATOR........................................................................................................ 35
6.4 - COMPENSATION...................................................................................................... 35
6.5 - ROTATION................................................................................................................ 35
6.6 - JIB.............................................................................................................................. 36
6.7 - ROTATION................................................................................................................ 36
6.8 - ARM LIFTING............................................................................................................ 36
6.9 - BOOM LIFTING......................................................................................................... 37
6.10 - TELESCOPING......................................................................................................... 37
6.11 - TRAVEL..................................................................................................................... 37
6.12 - STEERING ................................................................................................................ 37
6.13 - DIFFERENTIAL BLOCKING...................................................................................... 38
6.14 - HORN - BUZZER....................................................................................................... 38
6.15 - INDICATORS............................................................................................................. 38
6.16 - OTHER FUNCTIONS : OVERLOAD, DEAD MAN, SLOPE...................................... 39
6.16.1 - Overload ................................................................................................................................ 39
6.16.2 - Dead man .............................................................................................................................. 39
6.16.3 - Slope...................................................................................................................................... 39
6.17 - HA26P REACH LIMIT................................................................................................ 39
7 - SAFETY LOCATION.................................................................................................. 41
8 - POSITIONS OF ELECTRIC COMPONENTS ............................................................ 43
8.1 - MOTHER BOARD ..................................................................................................... 43
8.1.1 - Description............................................................................................................................. 43

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8.1.2 - Positions of screws, connectors and relays ........................................................................... 44
8.1.3 - Positions of fuses...................................................................................................................45
8.1.4 - Positions of diagnosis help LEDs...........................................................................................46
9 - HYDRAULIC DIAGRAMS ..........................................................................................47
9.1 - HYDRAULIC DIAGRAM FOR HA20/26PX AND HA61/80JRT MODELS (B1539)0..47
10 - HYDRAULICS COMPONENTS DESCRIPTION........................................................49
10.1 - TRAVEL BLOCK........................................................................................................49
10.1.1 - Location..................................................................................................................................49
10.1.2 - Input and output .....................................................................................................................51
10.2 - PVG 32 DANFOSS BLOCK.......................................................................................52
10.2.1 - Location..................................................................................................................................52
10.2.2 - Input and output .....................................................................................................................53
10.3 - CETOP 3 AUXOLIARY BLOCK.................................................................................54
10.3.1 - Location..................................................................................................................................54
10.4 - EMERGENCY PUMP UNIT .......................................................................................55
10.4.1 - Location..................................................................................................................................55
10.5 - TELECOPING BLOCK...............................................................................................56
10.5.1 - Location..................................................................................................................................56
10.6 - STEERING BLOCK CONTROL.................................................................................57
10.6.1 - Location..................................................................................................................................57
10.6.2 - Input and output .....................................................................................................................57
11 - HYDRAULIC EQUATIONS.........................................................................................59
11.1 - TRAVEL.....................................................................................................................59
11.2 - TURNTABLE ROTATION ..........................................................................................59
11.3 - ARM LIFTING ............................................................................................................59
11.4 - BOOM LIFTING .........................................................................................................59
11.5 - TELESCOPING..........................................................................................................59
11.6 - OTHER MOVEMENT.................................................................................................59

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12 - MAINTENANCE......................................................................................................... 61
12.1 - GENERAL RECOMMENDATIONS........................................................................... 61
12.2 - PARTICULAR RECOMMENDATIONS...................................................................... 61
12.2.1 - Specific tools.......................................................................................................................... 61
12.2.2 - Replacing an element............................................................................................................ 62
12.2.3 - Locating the breakdown......................................................................................................... 62
12.3 - MAINTENANCE SYSTEM......................................................................................... 62
12.4 - ELECTRIC POWER SUPPLY................................................................................... 63
12.5 - MAINTENANCE PLAN.............................................................................................. 64
12.6 - OPERATIONS........................................................................................................... 66
12.6.1 - Summary table....................................................................................................................... 66
12.7 - PRESENCE OF LABELS .......................................................................................... 67
12.7.1 - Common "yellow" label .......................................................................................................... 67
12.7.2 - Commom "orange" label........................................................................................................ 68
12.7.3 - Common "red" label............................................................................................................... 69
12.7.4 - Other common label............................................................................................................... 70
12.7.5 - Model-specific labels.............................................................................................................. 71
12.7.6 - Description............................................................................................................................. 72
12.7.7 - Label positioning.................................................................................................................... 73
12.8 - PRESENCE OF MANUALS....................................................................................... 74
13 - PREVENTIVE MAINTENANCE SHEET .................................................................... 75
14 - OPERATING INCIDENTS.......................................................................................... 83
14.1 - INCIDENT TABLE ..................................................................................................... 83
14.1.1 - General operation.................................................................................................................. 84
14.1.2 - Lifting system......................................................................................................................... 86
14.1.3 - Travel system......................................................................................................................... 87
14.1.4 - Steering system..................................................................................................................... 88
14.1.5 - Turntable rotation system ...................................................................................................... 88
14.2 - BREAKDOWN DETECTION FLOW CHART............................................................. 88

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15 - CORRECTIVE MAINTENANCE PROCEDURES.....................................................177