OPERATING AND MAINTENANCE INSTRUCTIONSARTICULEES TELESCOPIQUESMATS TRACTEESCISEAUX L'ACCES A...

L ' A C C E S A L ' E S P A C ECISEAUXARTICULEES TELESCOPIQUESMATS TRACTEES

I S O 9 0 0 1

PINGUELY HAULOTTE • LA PERONNIERE - BP 9 - 42152 L'HORME • Tél. +33 (0) 4 77 29 24 24 • Fax SAV +33 (0) 4 77 29 98 88email [email protected] • Web www.haulotte.com

OPERATING AND MAINTENANCEINSTRUCTIONS

SELF-PROPELLED SCISSOR PLATFORMCOMPACT 8, 10, 12 DX

242 032 0440 - E 06.03 GB

Operating and maintenance instructions

i

Caution !

GENERAL

You have just taken delivery of your mobile elevating work platform

It will give you complete satisfaction if you follow the operating and maintenanceinstructions 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 yourdisposal 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 ofinterchangeability and perfect operation.

This manual is supplied with the machine and is included on the deliverynote.

REMINDER:You are reminded that our machines comply with the provisions ofthe «Machines Directive» 89/392/EEC of June 14th 1989 asamended 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 and directive EMC/89/336/CE.

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.


ii

Operation and Servicing - Compact 8, 10, 12 DX

CONTENTS

1 - GENERAL RECOMMENDATIONS - SAFETY ............................................................ 1

1.1 - GENERAL WARNING ................................................................................................. 11.1.1 - Manual ..................................................................................................................................... 1

1.1.2 - Labels ...................................................................................................................................... 1

1.1.3 - Safety....................................................................................................................................... 1

1.2 - GENERAL SAFETY INSTRUCTIONS......................................................................... 21.2.1 - Operators ................................................................................................................................. 2

1.2.2 - Environment............................................................................................................................. 2

1.2.3 - Using the machine ................................................................................................................... 2

1.3 - RESIDUAL RISKS....................................................................................................... 41.3.1 - Risks of jolting - Overturning.................................................................................................... 4

1.3.2 - Electrical risks .......................................................................................................................... 4

1.3.3 - Risks of explosion or burning................................................................................................... 4

1.3.4 - Risks of collision ...................................................................................................................... 4

1.3.5 - Abnormal noise ........................................................................................................................ 4

1.4 - VERIFICATIONS ......................................................................................................... 41.4.1 - Routine verifications................................................................................................................. 4

1.4.2 - Examination of suitability of a machine.................................................................................... 5

1.4.3 - State of conservation ............................................................................................................... 5

1.5 - REPAIRS AND ADJUSTMENTS................................................................................. 5

1.6 - VERIFICATIONS AT THE TIME OF PUTTING BACK INTO SERVICE...................... 5

1.7 - BEAUFORT SCALE .................................................................................................... 6

2 - PRESENTATION ......................................................................................................... 7

2.1 - IDENTIFICATION ........................................................................................................ 7

2.2 - MAIN COMPONENTS................................................................................................. 8

2.3 - DESCRIPTION ............................................................................................................ 8

2.4 - WORKING AREA ...................................................................................................... 102.4.1 - Compact 8 DX........................................................................................................................ 10

iii


2.4.2 - Compact 10 DX...................................................................................................................... 11

2.4.3 - Compact 12 DX...................................................................................................................... 12

2.5 - SIZE ...........................................................................................................................132.5.1 - COMPACT 8 DX size ............................................................................................................ 13

2.5.2 - COMPACT 10 DX size .......................................................................................................... 14

2.5.3 - COMPACT 12 DX size .......................................................................................................... 14

2.6 - TECHNICAL DATA ....................................................................................................152.6.1 - COMPACT 8 DX technical data ............................................................................................. 15

2.6.2 - COMPACT 10 DX technical data ........................................................................................... 16

2.6.3 - COMPACT 12 DX technical data ........................................................................................... 17

2.7 - LABELS......................................................................................................................182.7.1 - Common "yellow" labels......................................................................................................... 18

2.7.2 - Common "orange" labels........................................................................................................ 18

2.7.3 - Common "red" labels.............................................................................................................. 19

2.7.4 - Other labels ............................................................................................................................ 19

2.7.5 - Model-specific labels .............................................................................................................. 20

2.7.6 - Specific labels : Option........................................................................................................... 21

2.7.7 - Machine label references ....................................................................................................... 22

2.7.8 - Label positions ....................................................................................................................... 23

3 - OPERATION...............................................................................................................25

3.1 - HYDRAULIC CIRCUIT..............................................................................................253.1.1 - Travel movement, steering movement ................................................................................... 25

3.1.2 - Scissor lifting cylinder............................................................................................................. 25

3.2 - ELECTRIC CIRCUIT..................................................................................................25

3.3 - SAFETY SYSTEMS ...................................................................................................263.3.1 - Details of the main safety systems......................................................................................... 26

3.3.2 - Load / overload control........................................................................................................... 26

3.3.3 - Tilt control............................................................................................................................... 26

3.3.4 - Low, Medium and High travel speed...................................................................................... 26

4 - USE.............................................................................................................................27

4.1 - GENERAL INSTRUCTIONS ......................................................................................274.1.1 - General................................................................................................................................... 27

iv


4.1.2 - Manual extensions ................................................................................................................. 27

4.1.3 - Filling the fuel tank ................................................................................................................. 28

4.2 - LOADING, UNLOADING ........................................................................................... 284.2.1 - Unloading with ramps ............................................................................................................ 28

4.2.2 - Loading .................................................................................................................................. 29

4.2.3 - Transport instructions. ........................................................................................................... 29

4.3 - BEFORE THE FIRST OPERATION .......................................................................... 294.3.1 - Getting to know the control stations....................................................................................... 29

4.3.2 - Pre-operation check............................................................................................................... 31

4.4 - OPERATION.............................................................................................................. 334.4.1 - General recommendations..................................................................................................... 33

4.4.2 - Operation from the ground..................................................................................................... 34

4.4.3 - Operation from the platform ................................................................................................... 35

4.5 - RESCUE LOWERING - EMERGENCY PLATFORM OPERATION .......................... 38

4.6 - BRAKE RELEASE..................................................................................................... 39

4.7 - STABILISERS............................................................................................................ 39

5 - MAINTENANCE ......................................................................................................... 41

5.1 - GENERAL RECOMMENDATIONS ........................................................................... 41

5.2 - MAINTENANCE SYSTEM......................................................................................... 41

5.3 - MAINTENANCE PLAN .............................................................................................. 425.3.1 - Consumables ......................................................................................................................... 42

5.3.2 - Maintenance diagram ............................................................................................................ 43

5.4 - OPERATIONS ........................................................................................................... 445.4.1 - Summary table....................................................................................................................... 44

5.4.2 - Operating instructions ............................................................................................................ 45

5.4.3 - List of consumables ............................................................................................................... 45

6 - OPERATING INCIDENTS.......................................................................................... 47

6.1 - PLATFORM LIFTING SYSTEM................................................................................. 47

6.2 - TRAVEL SYSTEM .................................................................................................... 48

v


6.3 - STEERING SYSTEM .................................................................................................48

7 - SAFETY SYSTEM ......................................................................................................49

7.1 - CHASSIS BOX RELAY AND FUSE FUNCTION .......................................................49

7.2 - SAFETY CONTACT FUNCTION ...............................................................................49

8 - HYDRAULIC DIAGRAMS ..........................................................................................51

8.1 - COMPACT 8, 10 DX ..................................................................................................51

8.2 - COMPACT 12 DX ......................................................................................................52

9 - WIRING DIAGRAM.....................................................................................................53

9.1 - COMPACT 8, 10, 12 DX FOLIO A-001......................................................................53





vi


Caution !

1 - GENERAL RECOMMENDATIONS - SAFETY

1.1 - GENERAL WARNING

1.1.1 - ManualThe purpose of this manual is to help the operator to get to know HAULOTTE self-propelled lifts so as to use them efficiently and SAFELY. It cannot, however,replace the basic training necessary for any user of site plant.

The head of establishment has an obligation to ensure that operators know theinstructions in the instruction manual. The head of establishment is alsoresponsible for the implementation of the "user regulations" in force in the countryof use.Before using the machine, it is essential for safe use of the platform and itsefficiency to familiarise yourself with all these instructions.This instruction manual must be kept available to any operator. Additional copiescan be supplied by the manufacturer on request.

1.1.2 - LabelsThe potential dangers and instructions concerning the machine are indicated bylabels and plates. It is necessary to read the instructions appearing on them.All of the labels comply with the following colour code:

• The colour red indicates a potentially mortal danger.• The colour orange indicates a danger which may cause serious injury.• The colour yellow indicates a danger which may cause material damage or

slight injury.The head of the establishment must make sure that these labels are in goodcondition, and must take the necessary steps to keep them legible. Additionallabels can be supplied on request by the manufacturer.

1.1.3 - SafetyEnsure that any person to whom you entrust the machine is capable of assumingthe safety requirements of its use.Avoid any working mode liable to jeopardise safety. Any use not compliant withthe instructions could lead to risks and injury to people and damage to property.

In order to attract the reader's attention, the instructions will

be preceded by this standardized sign.

The operating manual must be kept by the user throughout the machine's lifeincluding in the event of loan, hiring-out or re-sale.Make sure that all the plates or labels relating to safety and danger are completeand legible.

1


Caution !

1.2 - GENERAL SAFETY INSTRUCTIONS

1.2.1 - OperatorsThe operators must be over 18 and must hold an operating permit issued by theemployer after he has checked their medical fitness and after they have passeda practical lift driving/operating test.

Only trained operators can use Haulotte self-propelled

lifts.

There must be at least two operators so that one of them can:• Intervene quickly if necessary.• Take the controls in the event of an accident or breakdown.• Monitor and prevent machines and pedestrians going round the lift.• Guide the lift's operator if required.

1.2.2 - EnvironmentNever use the machine:

• On soft, unstable, cluttered ground.• On ground with a bank greater than the permissible limit.• With exposure to a wind greater than the permissible threshold. If used out-

side, make sure, using an anemometer, that the wind speed is less than orequal to the permissible threshold.

• Near power lines (find out the minimum distances depending on the volta-ge). In temperatures below -15°C (particularly in cold stores). Consult us if itis necessary to work below -15°C.

• In explosive areas.• In an area not properly ventilated, since the exhaust gases are toxic.• During storms (risk of lightning).• At night if it is not equipped with the optional light.• When there are very strong electromagnetic fields (radar, mobiles and high

currents).DO NOT TRAVEL ON PUBLIC HIGHWAYS.

1.2.3 - Using the machineIt is important to ensure that in normal use, that is lift operation, the lift postselection key remains in the lift position so as to be able to control the lift from theplatform. In the event of a problem on the platform, a person present and trainedin emergency/standby manoeuvres can assist by putting the key in the groundcontrol position.

Do not use the machine with:• A load greater than the nominal load.• More people than the authorized number.• A lift lateral force greater than the permissible value.• A wind greater than the permissible speed.

X km/h

Y km/h Y>X

-15

0

˚C

2


Caution !

In order to avoid any risk of a serious fall, it is essential for operators to complywith the following instructions:

• Hold on to the guard rails firmly when the lift is being raised or driven.• Wipe any traces of oil or grease off the steps, floor and hand rails.• Wear individual protective equipment suited to the working conditions and

local regulations in force, particularly when working in a dangerous area. • Do not neutralise the limit switches on the safety devices. • Avoid hitting fixed or moving obstacles.• Do not increase the working height by using ladders or other accessories.• Do not use the guard rails as a means of access for getting onto and off the

platform (use the steps provided for this purpose on the machine).• Do not climb onto the guard rails when the platform is in the raised position.• Do not drive the lift at high speed in areas which are narrow or not cleared.• Do not use the machine without fitting the lift's protective bar or without clo-

sing the safety gate.• Do not climb onto the covers.

Never use the platform as a crane, goods lift or lift. Never

use the platform to pull or tow.

In order to avoid risks of overturning, it is essential for operators to comply withthe following instructions:

• Do not neutralise the limit switches on the safety devices.• Avoid operating the control levers for one direction in the opposite direction

without stopping in the " 0 " position (in order to stop during travelling, movethe manipulator's lever gradually).

• Comply with the maximum load as well as the number of people authorizedon the lift.

• Distribute the loads and place them if possible in the centre of the lift.• Verify that the ground can take the pressure and load per wheel.• Avoid hitting fixed or moving obstacles.• Do not drive the lift at high speed in areas which are narrow or not cleared.• Do not drive the lift in reverse (lack of visibility).• Do not use the machine with a cluttered lift.• Do not use the machine with equipment or objects suspended from the

guard rails.• Do not use the machine with elements which could increase the wind load

(e.g.: panels).• Do not carry out machine maintenance operations when it is raised without

having put in place the necessary safety devices (travelling crane, crane).• Carry out the daily checks and monitor proper operation during periods of

use.• Protect the machine from any unsupervised intervention when it is not in ser-

vice.

NOTE : Do not tow the lift (it has not been designed for that and must betransported on a trailer).

3


Caution !

1.3 - RESIDUAL RISKS

1.3.1 - Risks of jolting - OverturningThe risks of jolting or overturning are considerable in the following situations:

- sudden operation of the control levers,- overload of the lift,- ground weakness (Beware of thawing in winter),- gusting wind,- hitting an obstacle on the ground or high up,- working on quays, bays, pavements, etc...

Allow a sufficient stopping distance: - 3 metres at high speed,- 1 metre at low speed.

1.3.2 - Electrical risks

If the machine has a 220 V power point, max. 16 A, it is essential for the extension lead to be connected to a

mains outlet protected by a 30 mA quick-trip circuit-

breaker.

The electrical risks are considerable in the following situations:- hitting a power line,- use in stormy weather.

1.3.3 - Risks of explosion or burningThe risks of explosion or burning are considerable in the following situations:

- work in an explosive or flammable atmosphere,- filling the fuel tank near to flames,- contact with the hot parts of the engine,- using a machine with hydraulic leaks.

1.3.4 - Risks of collision- Risks of crushing people present in the area in which the machine is

operating (during travelling or operation of the equipment).- Evaluation by the operator, before any use, of the risks above him.

1.3.5 - Abnormal noiseWhen the platform is started, the user must listen for abnormal noise :

- seizure,- discharge of an equilibrium valve,- discharge of a pressure limiter, etc.

If abnormal noise is detected, the user must stop using the equipmentimmediately and contact the PINGUELY HAULOTTE After-Sales department todetect the source of the problem.

1.4 - VERIFICATIONSComply with the national regulations in force in the country of use.For FRANCE: Order of June 9th 1993 + circular DRT 93-22 September 1993specifying:

1.4.1 - Routine verificationsThe machine must be the subject of routine inspections every 6 months so thatany defect liable to cause an accident is detected.These inspections must be carried out by an organisation or personnel speciallydesignated by the head of establishment and under the latter's responsibility(company's personnel or not) (Articles R 233-5 and R 233-11 of the Code duTravail).The result of these inspections must be entered in a safety register opened by thehead of establishment and kept constantly available to the works inspector and

4


safety committee of the establishment, if there is one, as well as a list of thespecially designated personnel (Article R 233-5 of the Code du Travail).

NOTE : Such register can be obtained from the trade organisations andsome of them can be obtained from the OPPBTP or private preven-tion organisations.

The people designated must be experienced in the field of risk prevention(Articles R 233-11 of Decree n° 93-41).It is forbidden to allow any worker to proceed, during the operation of the machine,with any verification whatsoever (Article R 233-11 of the Code du Travail).

1.4.2 - Examination of suitability of a machineThe head of the establishment in which this equipment is put into service mustmake sure of the suitability of the machine, that is, that it is appropriate for theworks to be carried out safely and that it is used in accordance with the instructionmanual. In addition, in the above-mentioned French order of June 9th 1993,problems associated with hiring, the examination of the state of conservation,verification at the time of putting back into service after repair, as well ascoefficient 1.25 static test and coefficient 1.1 dynamic test conditions arementioned. Each person responsible using the machine must acquaint himselfand follow the requirements of this decree.

1.4.3 - State of conservationDetect any damage liable to be the cause of dangerous situations (safety devices,load limiters, tilt monitor, leaks from cylinders, deformation, condition of welds,tightness of bolts, hoses, electrical connections, condition of tyres, excessivemechanical play).

NOTE : In the case of hiring, the person responsible using the hired machinehas the responsibility of examining the state of conservation and forexamining suitability. He must check with the hirer that the routinegeneral verifications and verifications before putting into servicehave indeed been carried out.

1.5 - REPAIRS AND ADJUSTMENTSMajor repairs, maintenance work or adjustments on the safety elements orsystems (concerns mechanics, hydraulics and electricity).They must be carried out by PINGUELY-HAULOTTE personnel or personnelworking on behalf of PINGUELY-HAULOTTE who must use original parts only. Any modification outside PINGUELY-HAULOTTE's control is not authorised. The manufacturer is not liable if original parts are not used or if the work specifiedabove is not carried out by PINGUELY-HAULOTTE approved personnel.

1.6 - VERIFICATIONS AT THE TIME OF PUTTING BACK INTO SERVICETo be carried out after:

• major removal/refitting, • a repair involving the machine's essential parts,• any accident caused by the failure of an essential part.

It is necessary to proceed with an examination of suitability, an examination of thestate of conservation, a static test, a dynamic test (see coefficients, § 1.4.2,page 5).

5


1.7 - BEAUFORT SCALEThe Beaufort Scale of wind force is accepted internationally and is used whencommunicating weather conditions. It consists of number 0 - 17, eachrepresenting a certain strength or velocity of wind at 10m (33 ft) above groundlevel in the open.

Description of Wind Specifications for use on land MPH m/s0 Calm Calm; smoke rises vertically. 0-1 0-0.21 Light Air Direction of wind shown by smoke. 1-5 0.3-1.52 Light Breeze Wind felt on face; leaves rustle; ordinary vanes moved by

wind.6-11 1.6-3.3

3 Gentle Breeze Leaves and small twigs in constant motion; wind extends light flag.

12-19 3.4-5.4

4 Moderate Breeze Raises dust and loose paper; small Branches are moved. 20-28 5.5-7.95 Fresh Breeze Small trees in leaf begin to sway; crested wavelets form

on inland waterways.29-38 8.0-10.7

6 Strong Breeze Large branches in motion; whistling heard in telephone wires; umbrellas used with difficulty.

39-49 10.8-13.8

7 Near Gale Whole trees in motion; inconvenience felt when walking against wind.

50-61 13.9-17.1

8 Gale Breaks twigs off trees; generally impedes progress. 62-74 17.2-20.79 Strong Gale Slight structural damage occurs (chimney pots and slates

removed).75-88 20.8-24.4

6


2 - PRESENTATION

The self-propelled platform is designed for all overhead work, within thelimits of its characteristics.The main operating station is on the platform extension. The backup stationand emergency control are on the ground.

2.1 - IDENTIFICATIONA plate on the chassis bears all the indications (engraved) for machineidentification.

Fig. 1 - Manufacturer’s plate

REMINDER: For all information, intervention or spare parts requests,please specify the machine type and serial number.

7


2.2 - MAIN COMPONENTSFig. 2 - Position of the main components

2.3 - DESCRIPTION"HAULOTTE SCISSOR" platforms are work platforms surrounded byprotective barriers. They can be lifted or lowered by a hydraulic cylinderacting on scissors with three, four or five sections, depending on the model,which support the work platform. The chassis has two braked drive and steering wheels at the front and twobraked drive wheels at the back, equipped with puncture-proof tyres(inflated with polyurethane foam) with a cross-country tread.Each motor is supplied with power by a thermal diesel engine. All controland power devices are installed in two side boxes, including:

• the hydraulic tank and filters,• the air-cooled thermal motor and hydraulic pump,• the fuel tank,• the hydraulic distribution set,• the thermal motor ignition battery,• the electric control cubicle.

The tilt detector is between the scissor arms.The electric cubicle on the chassis controls:

• station selection,• motor fault light indicators,• hour counter,• platform up and down movement,• start and stop of the thermal motor,• emergency stop of all movements.

3

2

15

1

10

4 53

7

811

12

13

9

14

10

10

6

1- Front steering wheels 9- Rear wheels2- Platform 10- Anchoring points3- Extension 11- Hydraulic tank4- Document case 12- Frame5- Platform control desk 13- Platform access bar6- Safety barrier 14- Cover locking tab7- Platform access ladder 15- Motor box8- Chassis control desk

8


The three movements: travel, steering and platform lifting are controlled byhydraulics.Travel and lifting are in proportional command.Steering is activated by a double-action cylinder.

Option:• Stablisers: a set of four cylinders fixed to the chassis, controlled from

the platform control panel, enables the machine to be levelled (section§ 4.7, page 39).

9


2.4 - WORKING AREA

2.4.1 - Compact 8 DX

9

(m)

8

7

6

5

4

3

2

1

0- 4 - 3 - 2 - 1 0 1 2 (m)

- 1 0 1

10



11

(m)

10

9

8

7

6

5

4

3

2

1

0- 4 - 3 - 2 - 1 0 1 2

(m)- 1 0

11



(m)

12

11

10

9

8

7

6

5

4

3

2

1

0- 4 - 3 - 2 - 1 0 1 2

(m)- 1 0 1

12


2.5 - SIZE

2.5.1 - COMPACT 8 DX size

1440

11

50

23

00

2650

1870

25

0

1200

2500

1800

1540

3060

13




2500

1200

2370

2650

1870

25

0

1220

1500

1540

1800

3060

14

00

16

80

2500

25

40

1200

2650

1870

25

0

1800

1540

3060

14


2.6 - TECHNICAL DATA

2.6.1 - COMPACT 8 DX technical data

CHARACTERISTIC COMPACT 8 DXWorking height 8,38 mMax./min floor height 6,38 m / 1,15 mOverall width - base 1,80 mOverall width - table 1,54 mPlatform dimensions 1,54 m x 2,50 mOverall length 2,65 mOverall length with stabilising option 3,06 mOverall height 2,30 mExtension dimensions 1,20 mGround clearance 0,25 mWheelbase 1,87 mOutside turning radius 3,73 mLoad capacity with one extension 565 kg (3 people) including

150 kg on the extensionMaximum lateral force 40 daNMax. wind speed 45 kphSlope and tilt indicator with audible alarm at 3°Travel speed 1,6 kph PV, 3 kph MV, 5,5 kph GVMaximum travel slope 40%Lifting time 33 sLowering time 37 sHydraulic reservoir capacity 75 lGeneral hydraulic set pressure 240 bar PV, 170 bar GVTravel hydraulic set pressure 220 barLifting hydraulic set pressure 125 barHydraulic pump capacity 11 + 11 cm3/revLifting and travel delivery 26 l/minSecure and steer delivery 13 l/minSilent Pack diesel thermal motor DEUTZ-power 18 kW at 2400 rpm-idling power 8 kW at 1150 rpm-consumption 235 g/kW/h-idling consumption 235 g/kW/hDiesel tank capacity 30 lNumber of steer wheels 2Number of drive wheels 4Differential lock yesHydraulic brakes yesFreewheeling yesStarting battery 1x12 V - 70 AhSupply voltage 12 VSolid tyres - dimension 26 x 12 - 12PRWheel nut tightening torque 19 daN.mMax. force on one wheel with nominal load 1750 daNMax. ground pressure with 565 kg- hard ground (concrete) - loose ground (mud)

7,8 daN/cm2

3,23 daN/cm2

Weight of machine with one extension 3120 kgWeight of machine with stabiliser option 3320 kgAcoustic power 106 dB(A)Vibration level at feet < 0,5 m/s²Vibration level at hands < 2,5 m/s²

15





8,1 daN/cm2

3,42 daN/cm2

Weight of machine with one extension 3330 kgWeight of machine with stabiliser option 3530 kgMax. force on one stabiliser with nominal load 1470 daNGround pressure on one stabiliser 4,6 daN/cm2

Acoustic power 106 dB(A)Noise level at 10 meters 71,9 dB(A)Vibration level at feet < 0,5 m/s²Vibration level at hands < 2,5 m/s²

16





8,1 daN/cm2

3,82 daN/cm2

Weight of machine with one extension 3830 kgWeight of machine with stabiliser option 4030 kgMax. force on one stabiliser with nominal load 2350 daNGround pressure on one stabiliser 7,5 daN/cm2

Acoustic power 106 dB(A)Vibration level at feet < 0,5 m/s²Vibration level at hands < 2,5 m/s²

17


2.7 - LABELS

2.7.1 - Common "yellow" labels

2.7.2 - Common "orange" labels

41 23 43 25

17

28

18


2.7.3 - Common "red" labels

2.7.4 - Other labels

.F

.GB

.D

7814 518

Composant spØcifique � cette machine.

NE PAS INTERCHANGER.

Component specificto this machine.

DO NOT INTERCHANGE.

Komponenten nur f�rdiese maschine geeignet. BITTE AUF EINE ANDERE

MASCHINE NIGHT MONTIEREN.

N� MACHINE - MASCHINE N�

22 5 10

21 44

4 19 42

45

19


2.7.5 - Model-specific labels

2.7.5.1 - Compact 8 DX

2.7.5.2 - Compact 10 DX

2.7.5.3 - Compact 12 DX

3

3

3

20


2.7.6 - Specific labels : Option

2.7.6.1 -240V plug

2.7.6.2 -Stabilization of cylinders

2.7.6.3 -Biodegradable hydraulic oil

a

8

18

19

21


2.7.7 - Machine label references

Ref Code Qty Description1 2420320550 1 SP catalogue Compact 8DX1 2420320560 1 SP catalogue Compact 10DX1 2420320570 1 SP catalogue Compact 12DX2 2420320440 2 CE manual3 3078146290 2 COMPACT 8 DX floor height + load 3 3078146300 2 COMPACT 10 DX floor height + load3 3078146310 2 COMPACT 12 DX floor height + load4 3078143680b 1 Read the manual5 3078145100 2 Travel direction7 3078148180b 1 Top control desk7 3078146110a 1 Emergency stop8 3078143540a 1 Connect to a 220V socket (option)9 3078146350 2 "Compact 8 DX" label9 3078146360 2 "Compact 10 DX" label9 3078146370 2 "Compact 12 DX" label10 3078143620 2 Danger: Risk of hand crushing 17 3078150670 1 Brake release18 3078144670 4 Danger : Risk of foot crushing (option)19 3078143520a 1 Hydraulic oil19 3078148890 1 Biodegradable hydraulic oil (option)20 3078148770 3 Haulotte design21 3078143800 2 No stopping in the working area22 3078143810 1 Danger: Risk of electrocution23 3078143600 2 Do not use as a welding station24 3078145660a 1 Bottom control desk25 3078144650 1 Risk of overturning : check tilt26 3078143270a 1 Manufacturer’s plate (English)28 3078143450 1 Operating instructions (English)30 2421808660 1 Yellow and black adhesive marking41 3078144970 1 Heat burn danger42 3078143590a 1 High and low level hydraulic oil 43 3078143640 2 Do not stand on the cover44 3078145180 1 Do not interchange45 3078148710 1 Acoustic power50 3078146330 2 4WD design

22


2.7.8 - Label positions

43

21

15

9 50

10

30

41

49

20

8

5

29

15

3

18 24

50

28

23

25

19

17

42

9

44

26 45

18

2110

20

30

3

7

48

474641 2

5

22

29

23

18

18

18

18

20

21

23


24


Caution!

3 - OPERATION

3.1 - HYDRAULIC CIRCUITAll machine movements are controlled by hydraulic power, supplied by twogear pumps driven by a thermal motor.In the event of a breakdown, manual emergency action enables loweringof the scissors.A return filter on the return line protects the installation againstcontamination. Only one movement is possible at a time.

3.1.1 - Travel movement, steering movementTravel is controlled by on/off distributing valves. Gradual movement iscontrolled by a proportional command distributing valve.

Steering only is controlled by an on/off distributing valve.

Only specialised personnel can make adjustments. Incorrect

adjustment may cause malfunction of the machine’s safety systems,

generating a risk of serious accidents.

3.1.2 - Scissor lifting cylinderThe cylinder is equipped with a flap electrovalvemounted on the body.The lifting movement is controlled by an on/off electrovalve and gradualmovement is controlled by the proportional electrovalve.The lowering movement is controlled by one (2 for the twelve metreversion) on/off electrovalve mounted on each cylinder.

3.2 - ELECTRIC CIRCUITThe electric power used for the controls and thermal motor ignition issupplied by a 12V battery (Photo 2, page 25).

Photo 1 Photo 2 Photo 3

Supply motor

4 x 4 version

Four hydraulic motors drive the wheels. Three speeds (high, medium and low) are con-trolled by a switch.High speed: the two motors on the fixed axle are supplied in parallel by the two pump bodies; the steering axle is in freewheel.Medium speed: the four motors are supplied in parallel, by the two pump bodies Low speed: Each side receives half the output supplied by one pump body. All the motors are supplied in parallel. A hydraulic differential blockage on each side can be used in low and high speed.

25


3.3 - SAFETY SYSTEMS

3.3.1 - Details of the main safety systemsAutomatic motor stop :

• insufficient oil pressure,• motor oil temperature too high,• generator or fan belt breakage.

Light indicator warning :• clogged air filter.

Audible warning :• hydraulic oil overheating.

3.3.2 - Load / overload controlIf the platform load reaches the maximum authorised load, the buzzerwarns the operator.The control circuit disables all movements except lifting. Load must bereduced to reset.

3.3.3 - Tilt control Photo 4

When the machine is unfolded, the tilt control detector (Photo 4, page 26)emits an audible signal as long as the slope remains greater than themaximum tilt allowed (Table 3.3.3.1, “Maximum tilt table”, page 26),informing the operator that the scissors and travel movement cannot beused.If the situation persists, after a time delay of 1-2 seconds, the scissor liftingmovement command and travel command are disabled as long as themachine remains extended. To restore use of the travel movement, thewhole scissor assembly must be folded.

3.3.3.1 - Maximum tilt table.

3.3.4 - Low, Medium and High travel speedThese travel speeds are only authorised when the machine is completelyfolded. When the platform is lifted, only micro-speed is possible.

Maximum tiltCOMPACT 8DX 3°COMPACT 10DX 3°COMPACT 12DX 3°

26


Caution!

4 - USE

4.1 - GENERAL INSTRUCTIONS

4.1.1 - GeneralYour scissor-type platform is mobile. All movements are controlled from a control box on the platform extension:this is the main operating station. The control box on the chassis is abackup or emergency station.

Do not use the machine if wind speed exceeds 45 km/h.

Caution!Do not attempt any movements

before reading and understanding the instructions in chapter 4.3

To avoid all risk of accident, safety devices are provided to prevent use ofthe machine beyond its capacity in order to protect personnel and themachine. These systems immobilise the machine or neutralise the movements. Inthis case, insufficient knowledge of the machine’s characteristics andoperation may lead an operator to believe a breakdown has occurredwhereas in fact, it is merely the safety system coming into operation. It is therefore essential to fully understand all the instructions in the next fewchapters.

4.1.2 - Manual extensionsPhoto 5

The platforms are equipped with a single manual extension with severalpossible positions.Conditions of use:To extend or retract the extension:

• take hold of the two handles provided, • lift them by 90° • push them in the direction of movement required. Lifting the handles

by 90° automatically releases the extension’s position holding lock(Ref 1, Photo 5, page 27)

During trailer or vehicle transport, as well as during work and movement,the manual extension must be fastened and locked.Check that the locks are properly engaged when the handles return to theirinitial position in order to avoid unwanted extension or retraction of theextension.

1

27


Caution!

Caution!

4.1.3 - Filling the fuel tank (Photo 7, page 28)Before any filling operation, ensure that the fuel is of the recommendedtype and that it has been properly stored to avoid contamination. Do not draw from a barrel without decanting and never use the dregs.

Photo 6

Photo 7To protect against the fire hazard during tank filling, the followingprecautions should be taken:

• do not smoke,• stop the thermal motor if it is in operation,• stand upwind to avoid being sprayed with fuel,• touch the filling hole before starting to fill with the pump spout in order

to avoid the risk of sparking due to static electricity,• take care to close the tank plug properly and clean any fuel that may

have spilled from the tank.

4.2 - LOADING, UNLOADING

IMPORTANT: Before any operation, check the overall condition of themachine to make sure that it has not been damaged during transport. Ifnecessary, make any reserves in writing to the transport company.

A false movement may cause the machine to fall and cause very

serious bodily injury or material damage. Perform unloading manoeuvres on a sufficiently

resistant (section § 2.6, page 15), stable, flat surface in a clear area.

4.2.1 - Unloading with ramps The following precautions should be taken:

• the machine is totally folded,• the ramps can bear the load and are properly fixed,• adhesion must be sufficient to prevent all risk of sliding during ma-

noeuvre.IMPORTANT: this method requires the machine to be started,see section § 4.3, page 29 to prevent all risk of false manoeuvre.Select low travel speed.

Never stand under or too close to the machine during manoeuvres.

NOTE: The ramp slope is almost always greater than the maximumworking slope (3°), causing the buzzer to sound, but travel re-mains possible. If the slope is greater than the maximum trav-el slope (see section § 2.4, page 10), use a winch asadditional traction or retention means.

28


Caution!Do not go down ramps at high

speed.4.2.2 - LoadingThe precautions are the same as for unloading.Stowage must be conform to the diagram below.To climb the ramps of a truck, select the low travel speed.

4.2.3 - Transport instructions.• When transporting the machine, ensure that the vehicle capacity,

loading surfaces, straps and links are sufficient to bear the weight ofthe machine.

• The machine should be on a level surface or fastened before thebrakes are released.

• Attach the extension with straps to prevent it extending during trans-port.

4.3 - BEFORE THE FIRST OPERATIONEach platform is subjected to permanent quality checks during itsmanufacture.Transport may cause damage, which must be reported to the transportcompany for any claim before the first operation.

REMINDER:Before any operation, learn about the machine by reading thismanual and the instructions on the various plates.

4.3.1 - Getting to know the control stationsAll movements are controlled from a control box on the platform extension. This is the main operating station, it must not be moved to another area onthe platform or the "FORWARD" and "REVERSE" controls may beinverted. The control box on the chassis is a backup or emergency station.

NOTE: Do not perform any movements until you have read the in-structions in section § 4.4, page 33.

You must be familiar with the machine’s characteristics and operation ascertain machine reactions may cause you to think a breakdown hasoccurred, whereas it is simply the safety systems coming into operation.

4WD

ompact C

Haulotte

29


4.3.1.1 - Chassis control panelPhoto 8

Photo 9

4.3.1.2 - Platform control panelPhoto 10

1- Emergency stop button 7- Oil light indicator2- Hour counter 8- Oil pressure3- Chassis/platform control station selection 9- Battery charge light indicator 4- Flashing light (option) 10- Air filter clogged light indicator 5- Up/down selection switch 11- Key to open the control desk 6- Thermal motor ignition

5

6 7 58 109

114

32 1

30


Photo 11

4.3.2 - Pre-operation checkBefore operation, the machine must be visually inspected.

4.3.2.1 - Safety bar Ensure that the safety bar (Ref.1 Photo 12, page 31) slides freely enablingaccess to the platform.

Photo 12

1A

1B

2

3

4

5

6

7

8 9

11

10

12

13

13

1A- Stabiliser extend control 7 - Differential blocking1B- Stabiliser retract control 8 - Emergency stop button2 - Audible warning control 9 - Movement control manipulator3 - Travel speed selection 10 - Fail-safe4 - Power on indicator 11 - Centralised stabiliser control (option)5 - Thermal motor ignition 12 - Indicators : Movement selection6 - Up / down selector switch 13 - Indicators : Stabiliser state

1

31


4.3.2.2 -Overall mechanical appearance of the machine• Visual inspection of the whole machine: paint chips, missing or slack

parts, or battery acid leaks should be noted.• Check that there are no slack bolts, nuts, connections or hoses, no

hydraulic leaks, no cut or disconnected electric conductors.• Check the wheels: no missing or slack nuts.• Check the tyres: not tears or wear.• Check the lifting and steering cylinder: no sign of deterioration, oxida-

tion or foreign matter on the rod.• Inspect the platform and scissor arms: no visible damage, wear or de-

formation.• Check the steering axle: no visible excessive wear of the pivot pins,

missing or slack parts, deformation or cracks.• Check the condition of the control box power cable.• Check the presence of the manufacturer’s plate, warning labels and

operating manual.• Check the condition of the safety barriers and access bar.

4.3.2.3 - Machine environment• Check that an extinguisher in working order is available and at hand.• Always work on hard ground, able to bear the maximum load per

wheel.• Do not use the machine at temperatures of less than -15°C, in partic-

ular in cold rooms.• Wipe any traces of oil or grease from the floor, ladder and handrails.• Ensure that no-one is in the immediate proximity of the machine be-

fore lifting or lowering the platform.• Ensure that there are no obstacles that could affect the following

movements:- travel (machine movement).- platform lifting.

NOTE: See "working area" diagram (section § 2.4, page 10).

4.3.2.4 - Hydraulic systemPhoto 13

Photo 14 • Check the hydraulic pump: no leaks, components properly fixed.• Check the level of hydraulic oil (Ref 1, Photo 14, page 32).

1

32


Caution!

4.3.2.5 -Thermal motor • Raise the cover held by 2 tabs (Ref 1, Photo 15, page 33).• Check the level of fuel in the tank (Ref 1, Photo 17, page 33).

Check the level of motor oil: maximum mark on the gauge (Ref 1, Photo 16,page 33).

Photo 15

Photo 16Photo 17

4.3.2.6 - Safety devices• Check that the top and bottom emergency stop buttons work properly.• Check proper operation of the tilt sensor (Photo 4, page 26) by :

- unlocking the platform emergency stop button,- selecting platform position with the chassis control desk key (Ref.

3, Photo 9, page 30),- from the chassis control desk, raise the platform (Ref. 5, Photo 9,

page 30),- push the tilt sensor. The buzzer should sound when the machine’s

maximum angle is reached.• Check that the end of stroke contacts are free of all foreign matter.• Check the visual and audible alarms.

If the machine has a 220 volt current plug, the extension must be connected to a mains socket

protected by a 30mA differential circuit breaker.

4.4 - OPERATION

IMPORTANT: The machine should only be put into operation after all thechecks have been completed.

4.4.1 - General recommendations• Before all movement or overhead work, check that the passage is free

of persons, obstacles, holes or slopes, that the slope does not exceedthe maximum allowed, that the surface is hard, firm and able to bearthe wheel load.

• Always drive well away from unstable edges or banks.• Ensure that there is no-one in the immediate proximity of the machine

before making any movements. Be particularly careful while the ex-

1

1

1

33


tension is out as visibility is reduced.

REMINDER:It is prohibited to drive on public highways.

• To move the machine, it must not be overloaded. In the case of over-load, the machine is immobilised.

• Travel movement can only be controlled from the platform control sta-tion.

• It is impossible to make travel movements and lift the platform at thesame time.

4.4.2 - Operation from the ground(Photo 9, page 30)

4.4.2.1 - RecommendationsDanger of crushing:

• Keep hands and limbs away from the scissors.• Use common sense and prepare machine movement when using the

bottom controls. Keep a safe distance between the machine and fixedobstacles.

• From the chassis control station, only lifting and lowering controls areavailable.

4.4.2.2 -Operating instructionsMotor ignition (Photo 18, page 34):

NOTE: Hour counter: Each time the machine operates, the hoursare counted, causing the "hourglass" to flash.

Photo 18

• Ensure that the stop button (Ref 1) is pulled.• Put the control station selection key switch (Ref 3) in the "ground con-

trol" position and hold it in this position to enable other operations onthis control station. In this position, the "platform" controls are can-celled.

• The motor oil pressure light indicators (Ref 8) and battery charge lightindicators (Ref 2) are on. The air filter light indicator (Ref 6) is off.

• Press the ignition button (Ref 6), the motor starts, the light indicatorsgo out.

5

6 7 8 109

11

4

32 1

34


Caution!

Caution!

NOTE: If the motor does not start, switch off and repeat the operation.

• Allow the motor to warm up, using the time to check proper opertionof the hour counter (Ref 2), motor and pump.

Do not use ignition assistance products. Leave the motor to warm up for a few minutes before loading

the platform.

Movement test:Holding the ignition key (Ref 3) in the chassis position (right side), make thefollowing movements:

• Lift- Hold the Up/down control switch (Ref 5) upwards to make this

movement.• Lower

- Hold the Up/down control switch (Ref 5) downwards to make thismovement.

Motor stop:• Press the emergency stop button (Ref 1). When this button locks, the

thermal motor is stopped and all platform controls are disabled.• The button must be unlocked to re-enable the controls.

The motor may also stop if the chassis control desk key is put in the"platform" position instead of the "chassis" position.Passage to "platform" control:

• Put the key selection switch (Ref 5) in the "platform" position.

4.4.3 - Operation from the platform

Before any operation, check that the required movement has been

selected.

4.4.3.1 - Recommendations• Do not move the machine unless the safety barriers are correclty in-

stalled and the safety access bar is lowered.• Pay attention to reduced visibility conditions and blind spots when

driving and moving.• Be careful of the correct positioning of the extended platform when

moving the machine.• We strongly recommend that operators wear approved helmets when

moving the machine.• Inspect the working area to identify overhead obstructions or other

possible dangers.• Do not perform acrobatic movements or straddle the outer barrers.• Adapt movement speed according to the condition of the floor, traffic,

slope position of people or any other factor that may cause a collision.• Do not move the machine in the passageway of a crane or any other

overhead machine unless the crane’s controls have been locked and/or precautions have been taken to avoid collisions.

First, check that the on-board load is within the maximum load limits andthat it is evenly distributed..

Platform ExtensionCOMPACT 8 DX PLATFORM 565 Kg - 3 occupants i.e. 325 Kg 150 Kg - 1 occupant, i.e. 70 Kg

COMPACT 10 DX PLATFORM 565 Kg - 3 occupants i.e. 325 Kg 150 Kg - 1 occupant, i.e. 70 Kg

COMPACT 12 DX PLATFORM 450 Kg - 3 occupants i.e. 210 Kg 150 Kg - 1 occupant, i.e. 70 Kg

35


NOTE: During platform use, the motor will be started and stoppedfrom the platform control desk.

Ensure that the protective bar is properly closed and that the green powerlight indicator is on.

4.4.3.2 -Operating instructionsPhoto 19

Motor start - stopStart :

• Unlock the palm button (Ref. 8) by turning it 90°,• Press the ignition selector switch (Ref. 5).

Stop :• Push the palm button (Ref. 8).

Control station test• Ensure that the palm button (Ref. 8) is unlocked,• Ensure that the green light (Ref. 4) is on before making any move-

ment. This means that the machine power is on and that the selectorswitch is in the "plaform" position,

• Check that the buzzer (Ref. 2) works properly.Travel

• Press the required travel speed selector (Ref. 3). The correspondinglight indicator (Ref. 12) comes on.

• Press the fail-safe (Ref. 10) and activate the manipulator (Ref. 9) inthe required direction of movement within 10 seconds of making theselection. After 10 seconds, the light indicator goes out and travel isno longer validated.

NOTE: Move the manipulator slowly : gradual manipulation = gradualmovement.

Do not go through neutral without pausing. Any action on the manipulatorautomatically causes acceleration of the motor regime.

1A

1B

2

3

4

5

6

7

8 9

11

10

12

13

13

36


Caution!

Caution!

Steering After selecting travel, left/right steering is controlled by activating thecorresponding buttons on the manipulator.

Differential blocking (after selecting low and medium speed travel)Press the selector switch (Ref. 7) to block the differential. Releasing thebutton releases the blockage.

NOTE: Do not make large movements with the differential blocked.Do not steer with the differential blocked.

Lifting • Press the up selector switch (Ref. 6). The corresponding pilot light

(Ref. 12) comes on.• Activate the manipulator in the required direction of movement within

10 seconds of making the selection.• Do not go through neutral without pausing.

Any action on the manipulator causes automatic acceleration of the motorregime, except for the down movement.

REMINDER:In the event of overload, platform lowering is impossible..

At the end of the down movement, an "anti-shearing" protection system eliminates the risk of

shearing when the scissors fold up fully.

Platform lowering is mainly controlled by the manipulator to a positioncorresponding to a minimum space between the arms of 50 cm, thusavoiding the risk of "crushing".

To continue lowering:• Release the manipulator for four seconds, then continue the move-

ment.• During this period, the buzzer sounds for safety reasons.• During lowering, there is no motor acceleration.

Any movement selected is cancelled automatically if the user

does not use the function for 10 seconds.

Stabilisers (option): see section § 4.7, page 39

37


Caution!

4.5 - RESCUE LOWERING - EMERGENCY PLATFORM OPERATIONRescue lowering In the event of breakdown, put the selection key (Ref 1, Photo 20, page 38)on the chassis side in the chassis position and use the emergency controlon the chassis control box (Ref 2).

Photo 20

Emergency lowering If machine power fails, there is a manual control behind the access ladderat the back of the machine, enabling the platform to be lowered (Ref 1,Photo 21, page 38).

Photo 21

It is forbidden to lower overloads using the emergency lowering

operation.

REMINDER:During emergency and backup operations from the groundwith the extension out, it is essential to ensure that there areno obstables under the platform (wall, cross rail, electric line,etc.).

12

1

38


Caution!

4.6 - BRAKE RELEASEThe brakes are released manually. (Photo 22, page: 39)Operating instructions:

• Close valve N1 (Ref 2).• Activate the hand pump until the brakes are fully released (Ref 1).• Open valve N2 (Ref 3).• Tow the machine at low speed.• Once in position:

- Close valve N2 (Ref 3).- Open valve N1 (Ref 2).

Photo 22

4.7 - STABILISERSA set of four cylinders fixed to the chassis, controlled from the platformcontrol panel, enables the machine to be levelled. A spirit level in theplatform enables the operator to check machine horizontality.The selector switches (Ref. 1A, Photo 19, page 36) control stabilisercylinder extension.The selector switches (Ref. 1B, Photo 19, page 36) control stabilisercylinder retraction.These selector switches can be used to control 1, 2, 3 or 4 cylinders at thesame time for a same movement (up or down).

The stabilisers must always be adjusted while the platform is in the

low position. The four cylinders must be in position on the ground.

Stabiliser extension:• Activate the stabiliser buttons (Ref.1A, Photo 19, page 36).• Activating the four buttons at the same time slows down stabiliser ex-

tension.• When an cylinder is extended, the buzzer sounds. The light indicator

corresponding to the stabiliser (ref. 13):- flashes quickly if the cylinder is extended but not in contact with the

ground,- remains on if the cylinder is extended in contact with the ground,- flashes slowly if the cylinder is totally extended.

• Platform lifting is authorised if the machine is stabilised (all four lightindicators on fixed).

2

3

1

39


Caution!

Stabiliser retraction:• Activate the stabiliser buttons (Ref. 1B, Photo 19, page 36).• Hold selection 1B down until the light indicator corresponding to sta-

biliser 1A (Ref. 13) goes out. Extinction of this light indicator meansthat the cylinder is fully retracted.

• Activating the four buttons at the same time slows down stabiliser re-traction.

NOTE: Stabilisers are lowered with the motor accelerated. Stabilisersare raised with the motor slowed down.

Travel movement is disabled unless all four stabiliser cylinders are

retracted (all four light indicators are out).

Caution!If one of the cylinders is fully extended without coming into contact with the ground, it is

impossible to raise the platform.

The machine is equipped with 3 safety systems:• Travel functions are deactivated until all four cylinders are fully retract-

ed.• To change the position of a cylinder, the platform must be lowered.• The platform "lift" function is only possible if the four cylinders are in

contact with the ground or all retracted (all light indicators on or all off).

CENTRALISED STABILISER OPTION (Ref. 11, Photo 19, page 36)

This option enables automatic stabilising and levelling of the platform in thelowered position by simply pressing the "Centralised stabiliser" selectorswitch (Ref. 11, Photo 19, page 36).

Stabiliser lowering• Hold down the centralised stabiliser selector switch until the motor ac-

celerator and buzzer stop, which corresponds to a correct stabilisedposition, visualised by the four light indicators of the stabilisers com-ing on fixed (Ref.13).

Stabiliser raising• Activate the stabilser buttons (Ref. 1B, Photo 19, page 36).• Hold selector switch 1B down until the light indicator corresponding to

stabiliser 1A (Ref. 13) goes out. Extinction of this light indicator meansthat the cylinder is fully retracted.

• Activating the four buttons at once means that the stabilisers risemore slowly.

At any time, the operator can stop or continue the centralised stabilisingcycle by holding down or releasing the control button (Ref. 11).

On rough terrain, it is sometimes preferable to stabilise manually.

40


Caution!

5 - MAINTENANCE

5.1 - GENERAL RECOMMENDATIONS The servicing operations described in this manual are given for normaloperating conditions.In difficult conditions: extreme temperatures, high humidity, polluted at-mosphere, high altitude, etc. certain operations should be performed moreoften and specific precautions taken: consult PINGUELY HAULOTTE’s Af-ter-Sales department for such cases.Only approved and skilled personnel may intervene on the machine andmust respect the safety instructions concerning Personnel andEnvironment protection.For the motor part, consult the manufacturer’s manual.

Regularly check that safety systems work properly:• Tilt: buzzer + stop (travel and lifting disabled).• Platform overload - load > 200 kg, buzzer + total stoppage of all

movements (lowering and travel disabled).

Do not use the machine as a welding earth.

Do not weld without disconnecting the (+) and (-) terminals of the

batteries.Do not start other vehicles with the

batteries connected.

5.2 - MAINTENANCE SYSTEMPhoto 23

Operating instructions: These operations are to be carried out on both sides of the platform.Positioning of the maintenance stands:

• Park the lifting platform on firm, horizontal ground.• Ensure that the two emergency stop buttons are "ON".• Turn the ignition keyon the chassis control desk to "chassis" (Ref 3,

Photo 18, page 34).• Move the chassis control desk lifting switch upwards to lift the platform

(Ref 5, Photo 18, page 34).• Unscrew, turn the maintenance stand and allow it to hang vertically

(Photo 23, page 41).• Push the lifting switch (Ref 5, Photo 18, page 34) to the bottom posi-

tion to gradually lower the platform until the maintenance stand is incontact with the two fixing points (top and bottom).

41


Removing the maintenance stand:• Push the chassis lifting switch up and gradually lift the platform until

the maintenance stand is free (Ref 5, Photo 18, page 34).• Turn the maintenance stand until it is in contact in its storage position

and screw back into place (Photo 23, page 41).• Push the chassis control desk lifting switch down and lower the plat-

form completely (Ref 5, Photo 18, page 34).

5.3 - MAINTENANCE PLANThe maintenance plan shows the frequency, maintenance points (device)and ingredients to be used.

• The reference shown in the symbol shows the maitnenance point ac-cording to the frequency.

• The symbol represents the consumable to be used (or the operationto be carried out).

5.3.1 - Consumables

INGREDIENT SPECIFICATION SymbolLubrifiers used by PINGUELY -

HAULOTTEELF TOTAL

Motor oil SAE 15W40 SHELL RIMULA-X

Hydraulic oil

Biodegradable hydraulic oil

(option)

AFNOR 48602 ISO VG 46

BIO ISO 46

BP SHF ZS 46 HYDRELF DS 46 EQUIVIS ZS 46

Extreme pressure lithium grease ISO - XM - 2

Lead-free grease Grade 2 ou 3 ESSO GP GREASE MULTIMOTIVE 2 MULTIS EP 2

Exchange or spe-cific operations

Lithium grease ENS / EP 700

42


5.3.2 - Maintenance diagram

10

50

250

500

1 000

2 000

500

1 000

2 000

10

50

250

6

12

9 910

13

6

7

8

11

4 1

2

6

6 6

3

43


5.4 - OPERATIONS

5.4.1 - Summary table

REMINDER:All these frequencies should be reduced in the case of work indifficult conditions (consult the After-Sales department ifnecessary).

FREQUENCY OPERATIONS Ref

Every day or before each start of operation

• Check levels:- motor oil,- hydraulic oil,- diesel,- electric batteries,

• Check cleanliness:- diesel pre-filter, replace if water or impurities are

found,- machine (in particular, check the tightness of

connections and hoses), also check tyre condition,cables and all other acecssories and equipment.

1234

Every 50 hours

• Grease:- wheel pivot pin axles: 2 x 2 points.

• Check diesel pre-filter, replace if water or impurities arefound.

CAUTION: after the first 50 hours: • Change the hydraulic filter cartridge (see 250 hour fre-

quency).• Check the tightness:

- of screws, nuts and bolts in general,- of wheel nuts (torque 19 daNm).

67

Every 250 hours

Motor: see Manufacturer’s manual.• Change the hydraulic filter cartridge.• Grease:

- the steering wheel pivot pints- the friction parts of the slides (spatula)- the battery terminals

8

910

Every 500 hoursMotor: see Manufacturer’s manual.

• Fill up: capacity 2 x 0.7 l for 4x2 - 4 x 0.7 l for 4x4.• Oil change : biodegradable hydraulic oil tank (option)

Every 1000 hours or every year Motor: see Manufacturer’s manual.• ·Oil change: hydraulic oil tank 11

Every 2000 hoursMotor: see Manufacturer’s manual.

• Oil change: hydraulic tank and whole oil circuit.• Empty and clean diesel tank.

1213

Every 3000 hours or every 4 years

• Check:- the condition of the slides,- the condition of the electric cables and hydraulic

hoses etc.

44


Caution!

5.4.2 - Operating instructionsIMPORTANT:Only use the lubrifiers recommended in the table in section§ 5.3, page 42 for filling up and greasing operations. Collect emptied oil to avoid environment contamination.

Check that the machine is stabilised, and that the lifting means

are of sufficient capacity and in good condition.

5.4.2.1 - Greasing the steering wheel pivot pins

Photo 24 Grease the pivot pins (Ref.1) with lead-free grease.

5.4.2.2 - Greasing the slides (Photo 25, page 45)

Photo 25Grease with lithium grease using a spatula.

5.4.3 - List of consumables• Hydraulic filter cartridge• Air filter element• Diesel pre-filter• Diesel filter • Motor oil filter

1

45


46


6 - OPERATING INCIDENTS

The next few pages will give you a starting point for solving any problemsthat may occur during scissor platform operation.If a problem arises that is not mentioned in this section or if it is not solvedby the solutions proposed, consult qualified technical personnel beforeperforming any maintenance operations. Most problems encountered onthis machine occur mainly in the hydraulic and electric systems.

Before anything else, check that:• The two emergency stop buttons on the chassis control box and on

the platform control box are unlocked and the key is in the chassis orplatform position.

6.1 - PLATFORM LIFTING SYSTEMANOMALY CHECK PROBABLE CAUSE SOLUTION

No movement when the lifting switch on the box and the manipula-tor are activated.

Check that movement occurs when the lifting switch on the on the chassis control box is activated.

Control switch does not work. Replace the switch (After-Sales department).

Manipulator does not work. Replace the manipulator (After-Sales department).

Insufficient oil in the hydraulic circuit. Fill up with oil as necessary.

The platform does not go up.

Load on the platform too heavy (personnel or material) Reduce load.


Tilt.Check the position of the machine and ensure that it is not tilted.

The platform does not go down.

Load on the platform too heavy (personnel or mate-rial).

Reduce load.

The platform moves up and down with a jolty movement.


47


6.2 - TRAVEL SYSTEM

6.3 - STEERING SYSTEM

* CAUTION:

• CAVITATION = BUBBLES• BUBBLES + PRESSURE = SERIOUS PROBLEM

(OLEOPNEUMATIC SYSTEM) • BUBBLES + PRESSURE + HEAT = DANGEROUS

SITUATION.

NOTE: It takes approximately 4 hours for the oil emulsified under theeffects of cavitation to return to its normal appearance.

ANOMALY CHECK PROBABLE CAUSE SOLUTION

No movement when the switch is in the travel position and the manipulator on the platform control box is activated.

The manipulator does not work.

Repair or replace the manip-ulator (After-Sales depart-ment).


Tilt.

Check the position of the machine and ensure that it is not tilted.

Overload. Reduce load.The machine goes into runaway during lower-ing.

Balancing valve incorrectly adjusted or not working prop-erly.

Adjust or replace the balanc-ing valve (After-Sales depart-ment).

ANOMALY CHECK PROBABLE CAUSE SOLUTION

No movement when the manipulator is acti-vated.


The control manipulator does not work.

Replace the manipulator (After-Sales department).

Noisy hydraulic pump. Insufficient oil in the tank. Fill up with oil as necessary.Hydraulic pump cavi-tation (vacuum in the pump due to insuffi-cient oil).*

The hydraulic oil becomes cloudy, opaque and white (bubbles observed).

Oil viscosity too high. Empty the circuit and fill with the recommended oil.

Hydraulic circuit over-heating.

Oil viscosity too high. Empty the circuit and fill with the recommended oil.

Insufficient hydraulic oil in the tank. Fill up with oil as necesary.

The system works irregularly.

The hydraulic oil is not at optimal operating tempera-ture.

Make a few movements with-out load to allow the oil to heat up.

48


7 - SAFETY SYSTEM

7.1 - CHASSIS BOX RELAY AND FUSE FUNCTION(see wiring diagram)

7.2 - SAFETY CONTACT FUNCTION(see wiring diagram)

KA2 Thermal motor ignition. FU5–3 A Circuit fuse on movement control from chassis.

KP1 Thermal motor stoppage. FU6–3 A Circuit fuse on movement control from platform.

KT2 Movement acceleration (electro-motor). FU7–20 A Electrovalve supply circuit fuse.

KMG Mains power. FU8–5 A Control circuit fuse.

FU3–80 A Accelerator circuit fuse. FU9–20 A Accessory circuit fuse.

FU4–30 A Mains circuit fuse (motor). FU10–3 A Circuit fuse.

SB1 Emergency stop push button. SQ10 Rear right stabiliser.

SB2 Emergency stop push button. SQ12 12 meter travel disable

SQ1 Tilt box. Disables platform lifting and travel. B2 Motor oil temperature.

SQ3 Tilt reset, if machine folded. B1 Air filter contact. Light indicator on if air filter clogged.

SQ4 Top end of travel sensor. B3 Oil pressure contact. Motor cut off if insufficient pressure.

SQ7 Front left stabiliser. B4 Hydraulic oil temperature contact.Audible alert if temperature too high.

SQ8 Front right stabiliser. B6 Overload.Audible alert if overloaded.

SQ9 Rear left stabiliser. B7 to B10 Machine stabilised detection.

49


50


8 - HYDRAULIC DIAGRAMS

8.1 - COMPACT 8, 10 DX

FRO

NT

SHAF

TES

SIEU

AVA

NT

FRO

NT

LEFT

ENG

INE

FRO

NT

RIG

HT

ENG

INE

MO

TEU

RAV

ANT

GAU

CH

E

MO

TEU

RAV

ANT

DR

OIT

44

2

3

1

1

44

6 5

DIR

ECTI

ON

STEE

RIN

G

FRO

NT

RIG

HT

AVAN

TD

RO

ITFR

ON

T LE

FT

AVAN

TG

AUC

HEOPT

ION

CAL

AGE

BLO

CKI

NG

OPT

ION

BAC

K LE

FT

ARR

IER

EG

AUC

HE

BAC

K R

IGH

T

ARR

IER

ED

RO

IT

ENG

INE

2400

rpm

�17

.9 k

W

ENG

INE

3200

rpm

�17

.8 k

W

ESSI

EU A

RR

IER

EBA

CK

SHAF

T

OPT

ION

GAS

OLI

NE

/ LPG

MO

TEU

RAR

RIE

RE�

DR

OIT

MO

TEU

RAR

RIE

RE�

GAU

CH

E

BAC

KLE

FTEN

GIN

E

BAC

KR

IGH

TEN

GIN

E

LIFTIN

G

LEVAGE

OPT

ION

GEN

ERAT

OR

300

bar

4350

PSI

175

bar

2540

PSI 22

0 ba

r31

90 P

SI

240

bar

3480

PSI

140

bar

2030

PSI

300

bar

4350

PSI

B165

79 c

51


8.2 - COMPACT 12 DX

BAC

K SH

AFT

MO

TEU

RAR

RIE

RE

GAU

CH

E

MO

TEU

RAR

RIE

RE�

DR

OIT

BAC

K LE

FTEN

GIN

EBA

CK

RIG

HT

ENG

INE

ESSI

EU A

RR

IER

E

ENG

INE

2400

rpm

�17

.9 k

W

OPT

ION

GAS

OLI

NE

/ LPG

ENG

INE

3200

rpm

�17

.8 k

W

300

bar

4350

PSI

300

bar

4350

PSI

175

bar

2540

PSI 22

0 ba

r31

90 P

SI

240

bar

3480

PSI

140

bar

2030

PSI

FRO

NT

SHAF

TES

SIEU

AVA

NT

FRO

NT

LEFT

ENG

INE

FRO

NT

RIG

HT

ENG

INE

MO

TEU

RAV

ANT

GAU

CH

E

MO

TEU

RAV

ANT

DR

OIT

44

6 5

3

1

1

44

2

OPT

ION

CAL

AGE

BLO

CKI

NG

OPT

ION

DIR

ECTI

ON

STEE

RIN

G

FRO

NT

LEFT

BAC

K LE

FTBA

CK

RIG

HT

FRO

NT

RIG

HT

AVAN

TG

AUC

HE

ARR

IER

EG

AUC

HE

ARR

IER

ED

RO

IT

AVAN

TD

RO

IT

LIFTIN

G

LEVAGE LIF

TING

LEVAGE

OPT

ION

GEN

ERAT

OR

B165

80 b

52


9 - WIRING DIAGRAM

9.1 - COMPACT 8, 10, 12 DX FOLIO A-001

12

34

56

78

91

01

11

21

31

41

51

61

71

81

92

0

A B C D E F G H I J K L M

01

VIS

AM

OD

IFIC

AT

ION

IND

DA

TE

PIN

GU

ELY

-HA

ULO

TTE

La P

Øro

nniŁ

reB

P 9

42152 L

’HO

RM

E

DA

TE

DE

CR

EA

TIO

N

DA

TE

DE

VE

RIF

ICA

TIO

N

DE

SS

INE

PA

R

VE

RIF

IE P

AR

Laur

ent D

I FLO

RIO

FrØ

dØric

DE

NE

ZE

08-0

4-19

99

30-0

4-19

99

5N

BR

E T

OT

AL

DE

FO

LIO

S

TE

L: 04 7

7 2

9 2

4 2

4

E56

0

SCHE

MAS

b12

-09-

2002

GØ

nØra

tric

eLD

Fa

09-0

7-20

02B

7 �

BB

10 N

OLD

F

H

D+ WB-B+

~

P1

YA2

G2

80A

10A

YA1

Star

ter

Alte

rnat

orAc

cele

rato

rEn

gine

Sto

p

120

115

0

109

103

101

101

101

119119

108

0

118

00

242

120

116

109

242

M3

KA2

D1

KT2

D3

FU3

FU1

KP1

D5D4

HL1

(02-

2)

(02-

13)

(02-

2)

(02-

2)

(04-

20)

(04-

21)

(04-

18)

(04-

19)

(04-

20)

GB1

CO

MPA

CT

8 10

12

DX

CO

MPA

CT

2068

RT

2668

RT

3368

RT

53



23

45

67

89

10

11

12

13

14

15

16

17

18

19

20


02

VIS

AM

OD

IFIC

AT

ION

IND

DA

TE

PIN

GU

ELY

-HA

ULO

TTE

La P

Øro

nniŁ

reB

P 9

42152 L

’HO

RM

E

DA

TE

DE

CR

EA

TIO

N

DA

TE

DE

VE

RIF

ICA

TIO

N

DE

SS

INE

PA

R

VE

RIF

IE P

AR

Laur

ent D

I FLO

RIO

FrØ

dØric

DE

NE

ZE

08-0

4-19

99

30-0

4-19

99

5N

BR

E T

OT

AL

DE

FO

LIO

S

TE

L: 04 7

7 2

9 2

4 2

4

E56

0

SCHE

MAS

TO

NSA

1

U1

F8F7

F5F6

30A

3A3A

20A

5A20

A

ES T

urre

t

ES G

antry

Beac

onSp

ot L

ight

ON

/ OFF

Lig

ht

(31)

(32)

N�2

242

152

201

216

203

101

102

241

120

120

102

240

240

212

212

215

240

215

00

905

905

211

905

241

0

240

906

211

SB1

SB2

KMG

KMG

FU5

FU6

FU7

FU8

FU9

(01-

20)

(01-

20)

(01-

20)

(01-

20)

(02-

10)

FU4

SA16

HL5

HL6

(03-

2)

(03-

2)

(03-

2)(0

3-2)

HL7

(04-

13)

(03-

2)

CO

MPA

CT

8 10

12

DX

CO

MPA

CT

2068

RT

2668

RT

3368

RT

54



23

45

67

89

10

11

12

13

14

15

16

17

18

19

20


03

VIS

AM

OD

IFIC

AT

ION

IND

DA

TE

PIN

GU

ELY

-HA

ULO

TTE

La P

Øro

nniŁ

reB

P 9

42152 L

’HO

RM

E

DA

TE

DE

CR

EA

TIO

N

DA

TE

DE

VE

RIF

ICA

TIO

N

DE

SS

INE

PA

R

VE

RIF

IE P

AR

Laur

ent D

I FLO

RIO

FrØ

dØric

DE

NE

ZE

30-0

6-20

00

30-0

6-20

00

5N

BR

E T

OT

AL

DE

FO

LIO

S

TE

L: 04 7

7 2

9 2

4 2

4

E56

0

SCHE

MAS

U1

1710

1819

3534

15.8

15.7

15.3

8.3

8.10

8.9

8.6

8.12

8.11

31

BlockingFront Left

BlockingFront Right

BlockingRear Left

BlockingRear Right

BlockingFront Left

BlockingFront Right

BlockingRear Left

Steeringwithout Traction

Blocking

Steering

Forward /Reverse

DifferentialLock

DifferentialLock

TractionLifting

HS

MS HS

HS

Bloc

king

Bloc

king

21

Steeringwithout Traction

BlockingRear Right

B10

B8B7

B9

43.2

44.2

45.2

37.2

28.9

28.4

28.6

28.3

28.2

28.1

28.1

328

.10

F R

LR

B14

B12

B11

B13

28.1

428

.750

.350

.4

RF

LR

Floor DetectionFront Left

Floor DetectionFront Right

Floor DetectionRear Left

Floor DetectionRear Right

No Floor DetectionFront Left

NoFloor DetectionFront Right

No Floor DetectionRear Left

No Floor DetectionRear Right

Level Sensor

212

517

211

510

511

242

242

115A

204

813

115B

218A

814A

814B

814C

818

309

304B

306B

308

307

504

505

919

920

242

242

00

516

915

605

255

407A

408A

402A

401A

310A

414A

703

705

311A

201

0

304

201

417A

256

304

0

YV14

B

SQ10

(02-

20)

(02-

20)

(02-

20)

(04-

1)

(04-

1)

SQ7

YV18

BYV

15A

YV15

BYV

19A

YV19

BYV

21A

YV21

BYV

11YV

12YV

8

(02-

20)

(04-

1)

YV18

A

(04-

1)

(05-

2)

SQ8

SQ9

YV23

YV14

A

(02-

20)

YV22

AYV

22B

(05-

7)

(05-

8)

KAD

KAG (03-

13)

KAG

(03-

12)

KAD

YV17

YV10

(03-

11)

(03-

6)

CO

MPA

CT

8 10

12

DX

CO

MPA

CT

2068

RT

2668

RT

3368

RT

55



23

45

67

89

10

11

12

13

14

15

16

17

18

19

20


04

VIS

AM

OD

IFIC

AT

ION

IND

DA

TE

PIN

GU

ELY

-HA

ULO

TTE

La P

Øro

nniŁ

reB

P 9

42152 L

’HO

RM

E

DA

TE

DE

CR

EA

TIO

N

DA

TE

DE

VE

RIF

ICA

TIO

N

DE

SS

INE

PA

R

VE

RIF

IE P

AR

Laur

ent D

I FLO

RIO

FrØ

dØric

DE

NE

ZE

08-0

4-19

99

30-0

4-19

99

5N

BR

E T

OT

AL

DE

FO

LIO

S

TE

L: 04 7

7 2

9 2

4 2

4

E56

0

SCHE

MAS

B4B3

B1

260

261

U1

39.3

41.2

42.2

46.2

40.2

27.4

27.3

27.2

27.1

15.9

15.4

98.

28.

152

.252

.314

4.1

4.2

4.3

Horn

Buzzer

B6

38.2

1311

Tilt Detector

Lower Position

Upper Position

Weighing

Dplus

Filter

Oil Pressure

Oil Temp

8M Cut OffCE Only

Lowering > SQ3

Lowering

Lifting

LoweringCompact12SDX

Oil Pressure

Oil Temp

Air Filter

Engine Stop

Accelerator

Start up

27.7

B2

Oil Temp

3332

4.12

4.6

4.9

LiftingLowering

Startup

Generator

15.6

111A

222

242

207

0

607

601

304A

807A

306A

807B

0

232

250

201

399

92

1B

903A

904

111

109

112

921A

110

205

0

117A

108

905

212

405

406

112A

210

110A

150

242

605A

146

(05-

4)

SQ3

(03-

20)

SQ4

HL3

SQ12

(01-

13)

SQ1

(05-

2)

(01-

12)

HA1

YV25

YV13

YV9

YV20

(03-

20)

HL4

HL2

HA4

KP1

KT2

KA2

(02-

20)

SA6

SB3

(03-

20)

(03-

20)

YV24

(05-

2)

YV24

’

KA20

(04-

9)

KA20

(04-

4)

(04-

7)

CO

MPA

CT

8 10

12

DX

CO

MPA

CT

2068

RT

2668

RT

3368

RT

56



23

45

67

89

10

11

12

13

14

15

16

17

18

19

20


05

VIS

AM

OD

IFIC

AT

ION

IND

DA

TE

PIN

GU

ELY

-HA

ULO

TTE

La P

Øro

nniŁ

reB

P 9

42152 L

’HO

RM

E

DA

TE

DE

CR

EA

TIO

N

DA

TE

DE

VE

RIF

ICA

TIO

N

DE

SS

INE

PA

R

VE

RIF

IE P

AR

Laur

ent D

I FLO

RIO

FrØ

dØric

DE

NE

ZE

20-0

4-19

99

30-0

4-19

99

5N

BR

E T

OT

AL

DE

FO

LIO

S

TE

L: 04 7

7 2

9 2

4 2

4

E56

0

SCHE

MAS

YSM4

U1

29.4

29.2

29.3

29.5

29.6

12.3

12.1

16.3

5449

28.1

5

Translation

Neutral Position

Dead Man

Steering

ProportionnalValve

LS

MS

HS

Movement

16.2

5620

29.1

130

.630

.530

.430

.330

.930

.830

.11

30.1

029

.829

.729

.10

29.9

3.2

29.1

2

(27)

(27)

(28)

(28)

(25)

(20)

(18)

(21)

(12)

(14)

(15)

(13)

(14)

(12)

(15)

(13)

(8)

(2)

(10)

(5)

(9)

(3)

(11)

(6)

(9)

(6)

(10)

(2)

(5)

(8)

(3)

(14)

(13)

(15)

(12)

(13)

(14)

(12)

(30)

(17)

(27)

(28)

(20)

(29)

(23)

(17)

N�2

N�2

N�1

N�1

(12) (1)

30.2

36.2

Generator

Horn

Movement

Start up

LS

MS

HS

Diffential Block

BlockingFront Left

BlockingFront Right

BlockingRear Left

BlockingRear Right

General Blocking

BlockingFront Left

BlockingFront Right

BlockingRear Left

BlockingRear Right

201

415

0

699

0

611A

606

612

401

402

117B

804

263

805

703

305

253

914

0

698

398

303

211

211

242

211

0

807

418

211

310

410

409

708

707

419

901

311

214

705

218B

SB4

SA7b

HL14

HL11

SA4a

SA4b

PWM

1

(04-

10)

HL15

HL13

HL12

HL10

HL16

HL17

HM4

SA7a

SB5

SA9a

SA5b

SA3

SA5a

SA11

aSA

11b

SA12

aSA1

2bSA

9b

(03-

20)

(04-

21)

SA1

SA2

(04-

14)

(03-

13)

(03-

13)

CO

MPA

CT

8 10

12

DX

CO

MPA

CT

2068

RT

2668

RT

3368

RT

57

OPERATING AND MAINTENANCE INSTRUCTIONSARTICULEES TELESCOPIQUESMATS TRACTEESCISEAUX L'ACCES A...

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Transcript of OPERATING AND MAINTENANCE INSTRUCTIONSARTICULEES TELESCOPIQUESMATS TRACTEESCISEAUX L'ACCES A...