Manual Reparacion Haulotte 8-12 Bis

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Repair Manual
GENERAL .................................................................................................................... 11
-GENERAL RECOMMENDATIONS - SAFETY ............................................................ 51.1
-GENERAL WARNING ................................................................................................. 51.2
-GENERAL SAFETY RECOMMENDATIONS .............................................................. 61.3
-RESIDUAL RISKS ....................................................................................................... 81.4
-VERIFICATIONS ......................................................................................................... 81.5
-REPAIRS AND ADJUSTMENTS................................................................................. 91.6 -
VERIFICATIONS BEFORE RESTARTING WORK ..................................................... 92
-SPECIFICATION........................................................................................................ 112.1
-TECHNICAL CHARACTERISTICS ........................................................................... 122.2
-SIZE........................................................................................................................... 142.3
-TIGHTENING TORQUE ............................................................................................ 163
-SAFETY SYSTEMS ................................................................................................... 173.1 -
RELAY AND FUSE FUNCTIONS.............................................................................. 173.2
-SAFETY CONTACT FUNCTIONS ............................................................................ 174
-WIRING DIAGRAMS.................................................................................................. 194.1 -
WIRING DIAGRAM E 501 C...................................................................................... 195
-HYDRAULIC DIAGRAMS.......................................................................................... 215.1 -
HYDRAULIC DIAGRAM FOR COMPACT 8, 8W AND 10 (B16187) MODELS......... 215.2 -
HYDRAULIC DIAGRAM FOR COMPACT 12 (B16188) MODEL .............................. 226
-MAINTENANCE ......................................................................................................... 23i
Repair Manual6.1 -GENERAL
RECOMMENDATIONS............................................................................ 236.2 -MAINTENANCE
DEVICE........................................................................................... 236.3 -ELECTRICITY
SUPPLY............................................................................................. 246.4 -MAINTENANCE
PLAN............................................................................................... 256.5
-OPERATIONS............................................................................................................ 276.6
-PRESENCE OF LABELS........................................................................................... 286.7
-PRESENCE OF MANUALS ....................................................................................... 357
-PREVENTIVE MAINTENANCE SHEETS .................................................................. 378
-OPERATING INCIDENTS .......................................................................................... 478.1
-TABLE OF INCIDENTS ............................................................................................. 478.2 -
FAILURE DETECTION FLOW CHARTS ................................................................... 529
-CORRECTIVE MAINTENANCE PROCEDURES....................................................... 91
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Repair manual
1 - GENERAL RECOMMENDATIONS - SAFETY

1.1 - GENERAL WARNING
1.1.1 - Manual
This manual aims to help maintenance personnel service and repair the
machine. It cannot, however, replace the basic training required by any person
working on the site equipment.
The site manager must inform operators of the recommendations in the
instruction manual. He is also responsible for application of current "user
regulations" in the country of use.
Before operating on the machine, it is essential to be familiar with all the
recommendations in this manual and the user manual to ensure personnel and
equipment safety.
1.1.2 - Labels
Potential dangers and recommendations for the machine are indicated on labels
and plates. Read the instructions on them.
All labels conform to the following colour code:
• Red indicates a potentially fatal danger.
• Orange indicates a danger that may cause serious injury.
• Yellow indicates a danger that may cause material damage or slight injury.
Maintenance pesrsonnel must ensure that these labels and plates are in good
conditions and keep them legible. Spare labels and plates can be supplied by
the manufacturer on request.
1.1.3 - Safety
Ensure that any person entrusted with the machine is take the safety measures
implied by its use.
Avoid any working mode that may affect safety. Any use that does not comply with
the recommendations may generate risks and damage to people and equipment.
After intervention, maintenance personnel must check that the operator manual
is present. This must be kept by the user throughout the machine’s service life,
even if it is loaned, rented or sold.
Ensure that all the plates or labels related to safety and danger are complete
and legible.
Caution!
To attract the reader’s
attention, instructions
are indicated by this
standardised sign.
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Repair manual
1.2 - GENERAL SAFETY RECOMMENDATIONS

Repair manual
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Repair manual
1.3 - RESIDUAL RISKS
1.3.1 - Risks of jolting - tipping over

The risks of jolting or tipping over are high in the following situations:
- sudden action on the control levers,
- platform overload,
- uneven floor (pay attention to thaw periods in winter),
- gusts of wind,
- contact with obstacles on the ground or in the air,
- working on quays, pavements, etc.
Allow sufficient stopping distances:
1.3.1 3 metres at high speed,
1.3.2 1 metre at low speed.
1.3.3 - Electric risks
Caution!
If the machihe has a 220 V Electric risks are high in the following situations:
plug, with max. 16A, the 1.3.2 contact with a live line,
extension must be 1.3.3 use during stormy weather.
connected to a mains socket
protected by a 30mA 1.3.4 - Risks of explosion or burning
differential circuit breaker. The risks of explosion or burning are high in the following situations:
- work in an explosive or inflammable atmosphere,
- filling the fuel tank near a naked flame,
- contact with the hot parts of the motor,
- use of a machine with hydraulic leaks.
1.3.4 - Risks of collision
1.3.5 Risks of crushing people present in the machine’s movement area
(travel or when manoeuvring the equipment).
1.3.6 The operator must assess any overhead risks before use.
1.4 - VERIFICATIONS
Comply with current national legislation in the country of use.
In FRANCE: Order dated June 9th 1993 + circular DRT 93-22 dated September
1993, specifying:
1.4.1 - Regular checks

The devices must be regularly inspected every 6 months to detect any defect
liable to cause an accident.
These inspections are to be carried out by an organisation or person specially
appointed by the site manager and under his responsibility (company personnel
or otherwise) Articles R 233-5 and R 233-11 of the Labour Code.
The result of these inspections is recorded in a safety register updated by the
site manager and constantly available to the Works Inspector and the
company’s safety committee, if any, and the list of specially appointed personnel
(Article R 233-5 of the Labour Code).
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Repair manual
NB:This register can be obtained from professional organisations andfor some, from the OPPBTP or private
prevention organisations.
The appointed people must be experienced in the field of risk prevention (Article
R 233-11 of decree no. 93-41).
It is forbidden to allow anyone to perform any checks during machine operation
(Article R 233-11 of the Labour Code).
1.4.2 - Examination of device suitability

The manager of the site on which the equipment is used must ensure that the
machine is suitable, i.e. appropriate to the work to be carried out safely and that it is
used in accordance with the instruction manual. Moreover, the French order, dated
June 9th 1993, refers to problems asosciated with rental, examination of the
condition, verifications before starting work after repair, and conditions of static test
coefficient 1.25 and dynamic test coefficient 1.1. All responsible users should find
out about and respect the requirements of this decree.
1.4.3 - Condition
Detect any deterioration liable to cause dangerous situations (safety devices, load
limiters, tilt detector, cylinder leaks, deformation, weld condition, tightness of bolts,
hoses and electric connections, tyre condition, excessive mechanical play).
NB:In the case of rental, responsible users of the rented machine mustexamine the condition and check suitability.
They must check withthe rental company that the general regular checks and checks be-fore starting work have
been performed.
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Repair manual
2.1 - TECHNICAL CHARACTERISTICS
2.2 - Compact 8, Compact 8W technical data
DescriptionCompact 8Compact 8WLoad (indoor use)350 kg, including 2 people450 kg,

including 3 peopleLoad (outdoor use)120 kg, including 1 person120 kg, including 1 personManual
lateral force (indoor use)40 daN40 daNManual lateral force (outdoor use)20 daN20 daNMaximum
wind speed (indoor use)0 Km/h0 Km/hMaximum wind speed (outdoor use)45 km/h45 Km/hFloor
height6.18 m6.27 mWorking height8.18 m8.27 mFolded length2.31mFolded length with steps2.42
mOverall width0.81 m1.20 mFolded height (hand rails)1.99 m2.14 mFolded height (platform)0.87
m1.02 mWheel base1.86mmFloor clearance130 mmFloor clearance with pothole system
extended25 mmPlatform dimension2.3 m x 0.8 m2.3 m x 1.2 mExtension
dimension0.92mExtension capacity150 KgTravel speed, machine folded0/3.5 km/hTravel speed,
machine raised0/1 km/hInterior turning radius0 m0.2 mExterior turning radius2.1 m2.5
mMaximum slope during travel25%23%Maximum tilt permitted2°3°Hydraulic tank25 lTotal
mass1730 Kg1950 KgMax. load on one wheel1350 daN1600 daNMaximum pressure on the
2 2
floor6.7 daN/cm 7.9daN/cm Number of drive wheels22Number of steering wheels22TyresNon-
marking- solid rubberWheel diameter380 mmFreewheelYESMovementsProportional
commandBatteries24 V - 180 Amp/h C524 V - 250 Amp/h C5General hydraulic
pressure200barsTravel200 barsSteering150 barsLifting165 barsRaising time37 s44 sLowering
time41 s56 sCE standardsYES
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Repair manual
2.1.2 - Compact 10, Compact 12 technical data
DescriptionCompact 10Compact 12Load (indoor use)450 kg, including 3

people300 kg, including 3 peopleLoad (outdoor use)120 kg, including 1 person120 kg,
including 1 personManual lateral force (indoor use)40 daN40 daNManual lateral force
(outdoor use)20 daN20 daNMaximum wind speed (indoor use)0 km/h0 km/hMaximum
wind speed (outdoor use)45 km/h45 km/hFloor height8.14 m10 mWorking height10.14
m12 mFolded length2.31mFolded length with steps2.42 mOverall width1.20 mFolded
height (hand rails)2.26 m2.38 mFolded height (platform)1.14 m1.26 mWheel
base1.86mFloor clearance130 mmFloor clearance with pothole system extended25
mmPlatform dimension2.3 m x 1.2 mExtension dimension0.92 mExtension capacity150
kgTravel speed, machine folded0/3.5 km/h (variable)Travel speed, machine raised1
km/hInterior turning radius0 mExterior turning radius2.5 mMaximum slope during
travel23%Maximum tilt permitted3°3°Hydraulic tank25litresTotal mass2330 kg2630
kgMax. load on one wheel1350 daN1600 daNMaximum pressure on the floor7.65
2 2
daN/cm 10.15 daN/cm Number of drive wheels22Number of steering
wheels22Tyressolid rubber 38 x 13 x 5 cmWheel diameter380
mmFreewheelYESMovementsProportional commandBatteries24 V - 250 Amp/h C524
V - 250 Amp/h C5General hydraulic pressure220 bars240 barsTravel220 bars240
barsSteering150 bars150 barsLifting165 bars150 barsRaising time51 s85 sLowering
time42 s50 sCE standardsYES
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Repair manual
2.2.3 - Compact 10 size
2.29 m1.19 m
2.26 m
1.86 m1.20 m
1 m
2.2.4 - Compact 12 size
2.29 m1.19 m
2.38 m1.86 m1.20 m2.42 m
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Repair manual
2.3 - TIGHTENING TORQUE
2.4 - Tightening torque for large thread
Nominal diameterTightening torque in N.M8.810.912.9 M 6*19 to 1113 to 1415 to 17M 7*115 to

1921 to 2426 to 28M 8*1.2522 to 2731 to 3437 to 41M 10*1.543 to 4561 to 6773 to 81M 12*1.7575 to 94110 to
120130 to 140M 14*2120 to 150170 to 190200 to 220M 16*2190 to 230260 to 290320 to 350M 18*2.5260 to
320360 to 400440 to 480M 20*2.5370 to 450520 to 570620 to 680M 22*2.5500 to 620700 to 770840 to 930M
24.3*3630 to 790890 to 9901070 to 1180M 27*3930 to 11501300 to 14001560 to 1730M 30*3.51260 to
15701770 to 19602200 to 23502.3.2 - Tightening torque for fine threadNominal
diameterTightening torque in N.M8.810.912.9M 8*124 to 2933 to 3740 to 44M 10*1.2546 to 5764 to
7177 to 85M 12*1.2583 to 100120 to 130140 to 150M 14*1.5130 to 160180 to 200220 to 240M 16*1.5200 to
250280 to 310340 to 370M 18*1.5290 to 360410 to 450490 to 540M 20*1.5410 to 510570 to 630690 to 760M
22*1.5550 to 680780 to 870920 to 1000M 24*1.5690 to 860970 to 10701160 to 1290M 27*21000 to 13001400
to 15601690 to 1880M 30*21400 to 17001960 to 21802350 to 2610
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Repair manual
3 - SAFETY SYSTEMS
3.1 - RELAY AND FUSE FUNCTIONS
ReferenceDescriptionFU1Motor-pump fuseFU2Speed variator output protective

fuseFU3Speed variator intput protective fuseFU4Flashing light and working light (optional)
protective fuse
3.2 - SAFETY CONTACT FUNCTIONS
ReferenceDescriptionSB1Line contactor / Chassis emergency stop buttonSB2Platform

emergency stop buttonSQ1Tilt reset position switchSQ3Top position switchSQ48 meter
breaking position switchSQ5/6Pothole extensionSQ10Tilt indicatorHL1Speed variator fault light
indicatorPT1Speed variator fault numeric indicator
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Repair manual
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-1.4Repair123456789101112131415161718192021WIRINGmanualARCH11220V(1)910011SM1 41316 B1SB3501EDIAGRAM SA3GDUHMSB2 168(2)3634 11109514136 C62353937404134515238FU310A B8B4B2A7A9A6B5B13B1B12 T O NDKlaxonHL5HL4SA158C2 B-9C1
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17 77100PINGUELY-HAULOTTEDESSINE PARDATE DE CREATIONE501INDDATEMODIFICATIONVISANBRE TOTAL DE FOLIOSLaurent DI FLORIO25-06-1999c18-05-2001Rajout entrÈe PF/CHLDF1La PÈronniËreTEL: 04 77 29 24 24COMPACT 8 - 8W -
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Repair manual
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5
-1.5Repair55HYDRAULICmanualPOTHOLESDIRECTIONSTEERINGFREIN ESSIEU ARRIERE6aREAR AXLE BRAKEESSIEU AVANTFRONT AXLE66b4YV7FORDIAGRAM6c
YV38W8,COMPACTHYDRAULICYV6YV4YV9YV2aYV2bYV5aYV5bCOMPACT 8 - COMPACT 2032E 200 bar150 barYV1COMPACT 8W-10220
-
bar(B16187)10ANDDIAGRAMSCOMPACT 2247E - 2747E32MODELS M3000W5,51 27 LB16187RESERVOIR - TANK
24V
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Repair manual
5.2 - HYDRAULIC DIAGRAM FOR COMPACT 12 (B16188) MODEL

6b6aYV86 DIRECTIONSTEERING
5POTHOLES5ARRIEREBRAKE
FREIN ESSIEUREAR AXLE
FRONTAXLE ESSIEU AVANT
7b7dYV77c77a1YV5bYV9YV5aYV6227 LRESERVOIR - TANKYV2bYV3YV4YV2aYV13
B16188
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Repair manual
6 - MAINTENANCE
6.1 - GENERAL RECOMMENDATIONS
Caution!
Do not use the machine as Servicing oprations described in this manual are given for normal conditions of
a welding earth. use.
Do not weld without In difficult conditions: extreme temperatures, high hygrometry, polluted
disconnecting the (+) and atmosphere, high altitude, etc., certain operations must be carried out more
(-) battery terminals. frequently and specific precautions must be taken: consult the PINGUELY
Do not start other vehicles HAULOTTE After-Sales Service for information.
with the batteries connected. Only authorised and competent personnel may operate on the machine and
must comply with the safety instructions related to Personnel and Environment
protection.
Regularly check that the safety systems work properly:
1°) Tilt: buzzer + stop (travel and lifting disabled).
2°) Platform overload - load.
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Repair manual
Operating instructions: for the COMPACT 10, 12 (see: Photo 2, page 23)
These operations are to be carried out on both sides of the platform.
Putting the maintenance stand into place:
• Position the platform on a firm, horizontal floor.

• Ensure that the two emergency stop buttons are "ON".
• Turn the chassis ignition key to the "Chassis" position.
• Push the chassis lifting switch up to raise the platform.
• Unscrew and turn the maintenance stand and allow to hang vertically.
• Push the lifting switch down to lower the platform gradually until the mainte-
nance stand comes up against the two fixing points (top and bottom).
Removing the maintenance stand:
• Push the chassis lifting switch up and gradually raise the platform until the
maintenance stand is free.
• Turn the maintenance stand until it comes into its storage position and
screw back into place.
• Push the chassis lifting switch down and lower the platform completely.
6.3 - ELECTRICITY SUPPLY

Photo 3
Operating instructions:
Cutting off the electricity supply:

Press the chassis emergency stop.
Starting the electricity supply:

Reset the emergency stop.
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Repair manual
6.4 - MAINTENANCE PLAN
The plan (overleaf) indicates frequency, servicing points (device) and the
consumables to be used.
• The reference in the symbol indicates the servicing point according to the
frequency.
• The symbol represents the consumable to be used (or the operation to be
performed).
6.4.1 - Consumables
ConsumableSpecificationSymbolLubricants used byELFTOTALPinguely-HaulotteGearbox oilSAE
15W40SHELLRIMULA - XHydraulic oilAFNOR 48602BPHYDRELFEQUIVISISO VG 46SHF ZS 46DS 46ZS
46Organic hydraulic oilISO BIO 46(optional)Lithium greaseISO-XM-2CARDREXADC1Lithium greaseENS / EP
700EPEXA 2Lead-free greaseGrade 2 or 3ESSOMultimotive 2MultisGP GREASEEP 2Exchange or
specificoperation
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Repair manual
6.4.2 - Maintenance diagram

1711101281223161718 10
50
14 250
500
1 000
2 000
45210612119123
19
10
50
250
500
1 000
2 000
3 000
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Repair manual
6.5 - OPERATIONS
6.5.1 - Summary table
FREQUENCYOPERATIONSREF•Check the levels:-hydraulic oil (see paragraph 7 -, sheet P001 ),1-electric

batteries4-battery charge, using the indicator5Every day or before•Check cleanliness:each start of operation-
machine (in particular, check the tightness of connections andhoses), also check the condition of tyres, cables
and allaccessories and equipment.6-platform slide for extension• Check hydraulic oil filter clogging.7Pay attention
for the first 50 hours:8• Change the hydraulic oil cartridge (see 250 hours frequency).• Check the condition of
battery cables (replace if worn)9Every 50 hours•Check the tightness:-screws in general10-front motor fixing screw
9 daNm- rear brake fixing screws 9 daNm11- wheel nuts (torque 110 daNm)12•Change the hydraulic filter
cartridge (see paragraph 7 -,13sheet P002 )2•Grease:-steering wheel pivots (see paragraph 7 -, sheet P003 )
3Every 250 hours-the friction parts of the slides with a spatula (see paragraph 7 -, sheet P004 )14•Check:-battery
charger connection15-battery levelEvery 500 hours or•If using organic hydraulic oil, empty the hydraulic
tank.16every 6 monthsEvery 1000 hours or•Empty the hydraulic oil tank16every year•Clean the motor pump set
carbon17Every 2000 hours•Empty the hydraulic tank and whole hydraulic circuit.18Every 3000 hours or•Check:-
condition of the slides19every 4 years-condition of the electric cables, hydraulic hoses, etc.20
REMINDER:All these frequencies must be reduced if working in difficult condi-
tions (consult After-Sales if necessary).
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Repair manual6.6 - PRESENCE OF LABELSIt is important to check that the labels and
plates warning personnel of the variousdangers associated with using the machine are in good
condition.The labels providing operators with information on machine use and maintenancemust
also be checked.An illegible label may lead to incorrect or dangerous use of the
machine.Operating instructions:Check the presence of the labels:Check that all the labels
described below are legible and in the correct place.Replace if necessary (spare parts can be
supplied on request, if necessary).6.6.1 - Common "yellow"
labels1723249a101814STOP3 sPENDANT LA DESCENTE,3 SECONDES D'ARRETAUTOMATIQUE SONTNECESSAIRES
AFIN DESUPPRIMER LES RISQUESD'ECRASEMENT7814 464
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Repair manual
6.6.2 - Common "orange" labels
161312a
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Repair manual
6.6.3 - Common "red" labels

19
3
8
20
1 15
7
6.6.4 - Other common labels
226
21 25
30
• Cut off
the
electric
power
supply
(see §
6.3,
page
22).
PREVENTIVE MAINTENANCE SHEET
Sheet 1/1
SHEET P002REPLACING THE HYDRAULIC FILTER
CARTRIDGEPREVENTIVE MAINTENAPREVENTIVE
MAINTENANCE SHEET
Sheet 1/1
SHEET P004GREASING THE SLIDES
1 - Preliminary operations
•Put the machine in the maintenance configuration (see § 6.2, page

21). •Cut off the electric power supply (see § 6.3, page 22).
2 - Greasing the slides
•Grease the slides using a spatula.
NOTA : Only use the grease recommended by the manufacturer.
•Put the machine back into the operational configuration.

Repair manual
8 - OPERATING INCIDENTS
8.1 - TABLE OF INCIDENTS
Before anything else, check that:

• the batteries are charged; the green light indicators should be on.
• the two "palm button" emergency stops on the chassis control box and on
the platform control box are unlocked.
• the oil level in the tank is OK.
Caution!Bubbles + pressure + heat =NB:Cavitation (emulsified oil) may cause incorrect operation of
hydraulicunacceptable situation.components. It takes approximately 4 hours for oil that has beenRisk of
explosionemulsified under the effects of cavitation to get back to its normalcondition.
8.1.1 - General operation
ANOMALYCHECKPROBABLE CAUSESOLUTION•Defective batteries•Oil level low• Defective fusesNo

movement• Defective chassis emergency stopSHEET DP007• Defective platform emergency stop• Defective
wiring harness• Defective motorpump set•Defective printed circuit•Defective control unitHydraulic pump
noisy•Insufficient oil in the tankSHEET DP009• Defective pump• Defective speed variatorPothole system does•
Defective wiring harnessnot extend when the• Defective electrovalve YV6 coilSHEET DP013platform is raised•
Defective electrovalve YV6•Defective pothole cylinders• Defective key switch SA1No movement from
the•Defective electric wiring harness• Defective speed variatorSHEET DP014platform control station• Defective
manipulator•Defective printer circuit U2Hydraulic pumpThe hydraulic oil• Oil viscosity too high• Empty the circuit
andcavitationbecomes cloudyrefill with the recom-(Vacuum in the pumpand white (withmended oil.due to
insufficient oil).bubbles)
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Repair manual
ANOMALYCHECKPROBABLE CAUSESOLUTION•Oil viscosity too high•Empty the circuit

andOverheating of thereplace with the re-commended oil. Tophydraulic circuit•Insufficient hydraulic oil in the tankup
with oil as neces-sary.• The hydraulic oil is not at optimum• Make some move-The system worksoperating
temperaturements without load toirregularlyenable the oil to heatup 8.1.2 - Platform lifting
systemANOMALYCHECKPROBABLE CAUSESOLUTION• Defective wiring harnessNo up or down•
Defective printed circuit U2movement from the• Defective manipulatorSHEET DP001platform control• Defective
platform emergency stopbuttonNo up or down• Defective key switchmovement from the• Defective wire no.
10SHEET DP002chassis control• Defective switch SA2•Hydraulic leak• Defective wiring harnessNo up movement
from• Defective electrovalve YV1 coil•Defective lifting cylinderthe chassis or platformSHEET DP003• Defective
electrovalve YV1controls•Defective or badly adjusted limiter•Defective tilt detector• Defective speed variator•
Defective end of stroke contactor• Defective wiring harnessNo down movement• Badly adjusted or defective
pressurecontact SP1from the platform orSHEET DP004• Defective electrovalve YV7 coilchassis controls• Defective
electrovalve YV7• Defective speed variatorThe platform (above• Defective electrovalve YV8 or YV9coil1.5m) comes
down• Defective electrovalve YV8 or YV9SHEET DP005slowly by platform or•Defective electric wiring
harnesschassis controls• Defective speed variatorThe platform moves up•Insufficient oil in the hydraulic circuit•Top
up with oil as ne-and down with a jerkycessarymovement
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Repair manual
8.1.3 - Travel system
ANOMALYCHECKPROBABLE CAUSESOLUTION• No movement availableNo travel movement

in•Defective pothole cylinder•Defective wiring harnesseither direction,SHEET DP006• Defective pothole end of
stroke con-FORWARD ortactorBACKWARD•Defective brake•Defective motorNo travel in one•Defective speed
variatordirection, FORWARD• Defective wiring harnessSHEET DP010or BACKWARD• Defective YV2a or YV2b
coil• Defective electrovalve YV3 orYV4High speedcoil• Defective electrovalve YV3 or YV4unavailable belowSHEET
DP011•Defective wiring harness1.5m•Defective printed circuit U2• Defective speed selector switchSA3Only micro-
speed is•Defective speed variator• Defective electric wiring harnessSHEET DP012available below 1.5m• Defective
contactor SQ1The machine goes into•Balancing valve incorrectly set or not• Replace the balan-runaway
downhillworking properlycing valve.8.1.4 - Steering systemANOMALYCHECKPROBABLE
CAUSESOLUTION• Hydraulic leak• No lifting• Defective printed circuit U2• Defective electrovalve YV5a or
YV5bNo steeringcoilSHEET DP008• Defective electrovalve YV5• Defective wiring harness• Defective manipulator•
Defective steering cylinder• Defective steering pressure limiter
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Repair manual
8.1.5 - List of MDI codesNumericFlashDescriptionindicator00 on M.D.I + red led:Battery below 5% or

speed variator inoperativeAL 01Supply voltage of YV7, YV9 and wire no. 3 (input B+, check that wires 100 & 3
are3not inverted) /Incorrect connection of wire 26(see NB)if all light indicators are on and fault 01 speed variator
inoperativeAL 066Serial card or cable or supply plug of the top station (wire no. 58 / MDI cabling or MDI/ 7-wire
wiring harness (37 ; B5 / 38 ; B5 / 39. A 3 / 40 ; B1 / 41 ; B12 / 51 ; A7 / 52 ; A6 /AL 136EEPROM problem (Speed
variator inoperative)AL 323Low idle VMN or incoherent with the applied PWM (speed variator inoperative)AL
374Mains switch stuck (auxilliary contact of the battery set open or inoperative)AL 384Mains switch open by the
control microswitch (battery cut-off inoperative)AL 495I=0 A EVER Current always zero in operation (speed
variator inoperative)AL 535High idle current (speed variator inoperative)AL 603The capacitors do not start to
charge on key. ( 250A fuse / motor connections)AL 629Speed variator temperature too high (> 75° speed variator
inoperative)AL 668Discharged batteryAL 731Short-circuit on electrovalve, the mains switch or buzzerMains switch
pilot in short-circuit(switch coil or variator problem)AL 744(wire 19 on terminal 9 disconnected, MAV on hydraulic
block)(speed variator inoperative if the relay sticks immediately)(charger starter plug incorrectly connected)AL
754Mains switch pilot does not close(switch coil or speed variator problem)AL 782Accelerator up when idle
(joystick problem). Check the potentiometer supplied with51 / 52 output 39AL 792Incorrect start sequence (joystick
connection)AL 802Double start request (serial card or joystick)YV6 coil inoperative or incorrectly connectedAL
90(wires 25 / 7 theoretical resistance 75 ohms)(inversion of wires 25 & 27 at terminals 18 & 18)AL 93Drivers 2KO
SIC Problem with small wiring harness between MDI and bottom stationcontrol panelThe control microswitch does
not respond correctly to the SIEMENS micro (speedAL 946variator inoperative)If horn is quiet, change the coil
mains switch in DCAL 957Pressure switch alarm
50
Repair manual
NumericFlashDescriptionindicatorAL
980Disagreement between the speed variator and MDI
timers*Auxililary contact of chassis emergency stop
inoperativeAL 996Programmed handling requestNB:If
no situation and red and green (last) light indicators are
on,SPEED VARIATOR is INOPERATIVE.Alarm 01:- if
all the green light indicators are on = speed variator
ino-perative- Check YV7 connector
- Disconnect the plug on electrovalve
YV7 - Take YV1 coil for testing
- The fault disappears = replace coil / the fault does
not disappear
- Disconnect the plug connecting with the chassis
wiring harness
- Check the pin of wire 26 for incorrect
connection - Tests
Alarm 98 :- when replacing the speed variator or MDI, this code
may appear when restarting the machine. In this
case, leave the machine live for approximately 1/4
hour, to allow the speed variator to re-establish
communication with the M.D.I.
51
Repair manual
8.2 - FAILURE DETECTION FLOW CHARTS
52
FAILURE DETECTION FLOW CHARTSHEET DP001Sheet 1/2NO UP AND DOWN
MOVEMENTFROM THE PLATFORM CONTROLNo up and down movement from
theplatform control
Place the movement selector

switch (SA3) in the position
(HS) then in the up position.
Check that light indicators HL4
(up) and HL5 (HS) come on
Open the platformThecontrol panel and-NOLEDs comecheck for 24Vonbetween terminals (7)and (4)YESOpen
the platform controlpanel and activate24Vthe «fail-safe» and tilt theNOmanipulatorbetween (7)and (4)Check the
presence of a set-YESPresenceNOpoint value on input A9 ofof setpoint at C4printed circuit U2 and theRepair
cabling oroutput of printedpresence of 24V on input B5replace switch SA3circuit U2and B13 of printed circuit
U2YESRenovate cablingENDbetween terminal C4A9 setpointand output (5) of theNOvalue and 24V oncontrol
panel or changeB5 and B13the control panel linkContinuityNOwiring harnessYESbetween coils (1) and (2)of the
platformcontrol panelENDSee SHEETReplace printedC004circuit U2YESENDSee SHEETReplace theChange
theRenovate cabling orC013manipulatorcontrol panel linkchange PB SB2wiring harnessENDENDEND
MOVEMENTFROM THE PLATFORM CONTROL
FAILURE DETECTION FLOW CHARTSHEET
DP002Sheet 1/2NO UP AND DOWN
MOVEMENT FROM THECHASSIS CONTROLNo
up and down movementfrom the chassis control
Place the key switch in the

«chassis control» position and
check for 24V on its terminal
connected to wire no. 10
24V presentNOReplace theSee SHEETYESswitchC005ENDCheck for voltage on switch SA2 -wire no. 10
24VNOReplace wire no. 10present
YES
END
Check operation of switch SA2.
Change SA2 up/down
24V atNOReplace switch SA2See SHEETterminals 37 or 38 ofC003the speed variatorYESENDReplace speedSee

SHEETvariator U1C005
END
MOVEMENT FROM THECHASSIS CONTROL
FAILURE DETECTION FLOW CHARTSheet 1/4SHEET
DP003NO UP MOVEMENT FROM THECHASSIS OR PLATFORM
CONTROL
No up movement from the chassis or

platform control
Check that there are no hydraulic leaks
NORepair theNo leakshydraulic linksYESENDCheck supply of the electrovalveYV1 coil:- disconnect the coil
connector andmeasure supply voltage
NO24V coil supplyCheck electrical continuity ofYESthe wiring harness betwen coilYV1 and the speed
variatorCheck continuity ofcoil YV1ContinuityNOReplace thecorrectwiring harnessNOYESContinuityReplace
theSee SHEETENDcorrectcoilC007Check the speed variator’sYES«safety» inputs:- Tilt «SQ10» (input 27)END- High
position contactor«SQ3» (input 29)Connect a pressure gauge to the hy-- Potholes «SQ5» SQ6» (inputdraulic
block’s minimess pressure tap24) associated with positionActivate the up movement and noteswitch «SQ1» (input
25)pressure
B A
FAILURE DETECTION FLOW CHARTSHEET DP003Sheet 2/4NO UP MOVEMENT FROM
THECHASSIS OR PLATFORM CONTROLA
Pressure
= 165 barsNO(or 150 bars: compact 12)= 2393 psi(or 2175 psi : compact 3347EYESZeroNOpressureSee
SHEETReplace the liftingC001hydraulic cylinder(s)YESAdjust orSee SHEETC002 orreplace
theENDSHEETlimiterC012ReplaceSeeelectrovalveSHEETYV1C030END
END
THECHASSIS OR PLATFORM CONTROL
BCheck operation of tilt detector SQ10 :- Check supply, connectionNO- Check operationInput(27)- Check the
settingat +24VYESNOReplace theSeeInput (29)connector or theSHEETat +24Vtilt
detectorC006YESInputNOEND(25) at +24V(below 1.5mor 4ft92in)YESNOInputCheck operation of the end of
stroke(24) at +24Vcontactor SQ3:- Check supply, connection- Check operationYES- Check settingReplace the
speedSee SHEETvariator U1C003Check operation of end of strokecontactors SQ1, SQ5 and SQ6:END- Check
supply, connection- Check operation- Check setting
Adjust or replace theSee SHEETdefective detector or itsC018wiring
END
THECHASSIS OR PLATFORM CONTROL
FAILURE DETECTION FLOW CHARTSHEET DP004Sheet 1/2NO DOWN MOVEMENT FROM
THEPLATFORM OR CHASSIS CONTROL
No down movement from the chassis
or platform controls
Check the allowed load on

the platform
Load correctNO Reduce load

YES
Disconnect the wiring harness from

END
pressure contact SP1 (on up cylinder)
Check for 24V on one of the two

wiring harness terminals
24VNOpresentYES
Replace wiring harness
END
Place a shunt between the two
terminals of the wiring harness
NO The platform
comes down
YES
Adjust or replace pressureSee SHEET

Check for 24V on input 26 C033contact SP1
of the speed variator
END
24VNOReplace the wiringpresentharnessYESENDA
FAILURE DETECTION FLOW CHARTSHEET DP004Sheet 2/2NO DOWN MOVEMENT
FROM THEPLATFORM OR CHASSIS CONTROL
A
Check supply to electrovalve YV7:

disconnect the coil’s electric connector
and measure supply voltage
24VNOcoil supply Check electric continuity of the

YES wiring harness between the
electro-valve and speed variator
Check continuity of the coil
of electrovalveYV7
ContinuityNOReplace wi-correctring
harnessYESENDReplace theSee
Coil continuityNOReplace Fichespeed variatorC003
theSeecorrectSHEETcoilC007YESReplaceSeeENDelectrovann
eSHEETYV7C030
END
FAILURE DETECTION FLOW CHARTSHEET DP005Sheet 1/4PLATFORM (ABOVE 1.5M OR
4FT92IN) DESCENTIS SLOWFROM THE PLATFORM OR CHASSIS CONTROL
Platform (above 1.5m or 4ft92in) descent is slow
from the platform or chassis controls
Compact 12,NOCompact 3747E

YES
Disconnect the coil connector of

electrovalve YV9 and request
platform descent
Platform descentNOCheck for 24V at the terminals of the coilsupply connector of electrovalve YV9is even
slowerYESNO24VADisconnect the coil connector ofpresentelectrovalve YV8, request platform lowe-ring and check for
24V at the connector’sYESterminalsCheck electrovalve YV9 coilcontinuityBNOContinuitycorrectYES
Change electrovalveSee SHEETYV9 coilC007ChangeSee SHEETelectrovalve YV9C030
END
END
FAILURE DETECTION FLOW CHARTSHEET DP005Sheet 2/4PLATFORM
(ABOVE 1.5M OR 4FT92IN) DESCENTIS SLOWFROM THE PLATFORM OR
CHASSIS CONTROLA
Check for 24V absence on input

(25) of the speed variator
24VNOCheck absence of short-circuit in thewiring harness between pressureabsentcontact SP1 and speed
variator U1YESNOCheck electric continuity of the wiringAbsence ofharness between electrovalve
YV9short-circuitand the speed variatorYESNOReplace the electricContinuitywiring
harnesscorrectENDYESSee SHEETReplace theC003speed variatorReplace the speedSee SHEETReplace
the wiringvariatorC003harnessENDENDEND
FAILURE DETECTION FLOW CHARTSHEET DP005Sheet 3/4PLATFORM (ABOVE 1.5M OR
4FT92IN) DESCENTIS SLOWFROM THE PLATFORM OR CHASSIS CONTROL
24VNOCheck electric continuity of the wiringpresentharness between electrovalve YV8and the speed
variatorYESNOCheck continuity of electrovalveContinuityYV8 coilcorrectYESNOContinuityReplace the
wiringharnesscorrectYESENDSee SHEEReplace theT C003speed variatorReplaceSee SHEETelectrovalve
YV8C030END
END
ReplaceSee SHEETthe coilC007

END
FAILURE DETECTION FLOW CHARTSHEET DP005Sheet 4/4PLATFORM (ABOVE 1.5M
OR 4FT92IN) DESCENTIS SLOWFROM THE PLATFORM OR CHASSIS CONTROL
FAILURE DETECTION FLOW CHARTSHEET DP006Sheet 1/4NO TRAVEL MOVEMENT IN
BOTH DIRECTIONSFORWARD AND BACKWARD
No travel movement in either forward
or backward direction
Check platform loadLoadNOReduce loadcorrectYESENDMake a lifting movementfrom the chassisTheNONo

movement isSee SHEETplatformavailableDP007risesYESMake a lifting movement fromthe platform lifting
controlpanelTheplatformNONo movement is available from the See SHEETrisesplatformDP014YESMake a
lowering move-ment from the platformTheNOplatform goesSee SHEET DP014downYESLower the platform
below1.5m or 4ft92in
A
Request a travel movement
TheDisconnect the two coils a and b ofNOelectrovalve YV2travel movementRequest a travel movement and
check foroperates24V
YES
B Raise the platform above
1.5m or 4ft92in and check

that the
Pothole sys-NOSee SHEET DP013tem extends

YES
Check for 24V on input 24 of

the speed variator
24VNOCheck electric continuity of the wiringharness between the pothole end of stokepresentcontactor (SQ5 and
SQ6) and the variator.YESReplace theSee SHEEContinuityNOReplace the defective wiringvariator U1T
C003correctharnessYESENDENDAdjust or replace the defective potholeSee SHEETend of stroke contactor (SQ5
or SQ6)C018
END
24VNOCheck for 24V on input 36 ofthe speed variator (breaking atpresent8m or 26ft25in)YES
24VCheck continuity of the wiring harnessNObetween the top end
Close valve NV1 of the of strokepresentcontactor (SQ4) and the speed variator(breaking
hydraulic block and release at 8m or 26ft25in)YESCContinuityNOcorrectReplace theSee
the brakes manually SHEYESdefective motorET C014Replace theENDwiring
harnessENDSee SHEAdjust or replace thetop end of strokeET
C018contactor SQ4
Request a travel movement
The
travel movement NO occurs
YES
Replace theSee SHEdefective

brakeET C011
END
END
Disconnect the movement selector

switch on the platform control panel
and activate the travel control
Traveloccurs at lowNOReplace printedSee SHEspeedcircuit U2ET C004YESENDCheck cabling of

theSee SHEETmovement selectorC004switch SA3 or replace itEND
FAILURE DETECTION FLOW CHARTSHEET DP007Sheet 1/4NO MOVEMENT
No movement
Check battery charge
ChargeNOOKYES Recharge or replace

Check the oil level in defective batteries
the hydraulic tank
END
LevelNOOK
YES
Check the state of fuses

FU1, FU2, FU3 and FU4 Top up with oilSee SHEETP001
END
FusesNOReplace defectiveOKfuses
YES
END Request a
platform lifting
movement and check motor-
pump operation (audible)
The motorMaintain the activated lifting control andNOcheck for setpoint

voltage betweenpump setterminals B+ and VMNP of the
speedworksvariatorYESVoltageNOCApresent
YES
B
A
Check electric continuity of chassis

emergency stop contacts SB1
Replace the chassisSee
ContinuityNOOKYES
SHEETemergency stopC031
Check for 24V at key switch (SA1)
END
input on the chassis control panel
24VNOCheck electric continuity of plat-form emergency stop contactspresent(SB2)YESPlace the
chassis control panel keyContinuityNOswitch (SA1) in the «chassis»OKposition and check for
24Vbetween terminals (13) and (2); (4)YESand (2); (34) and (2) of the speedvariator U1Replace the
wiring harnessbetween the platform controlpanel and the chassisENDReplace the
platformSeeSHEETemergency stopC00424VNOpresentENDYESRepair electric cabling betweenkey switch
SA1 on the chassisCcontrol panel and the speed va-riator U1
END
Check electric continuity of the

motor pump set connection to
the speed variator
ContinuityNOOKYESSee SHEEReplace the motorT C019pump set

Restore the electric connection
between the motor pump set and
the speed variator
END
END
C
Check
cablin
g of
the
electro
valve
supply
line
(line 7
at fuse
FU2
output)
Re
pla
ce
CablingNOOK ca
YESSee blin
SHEEReplace g
speedT
C003variator
U1 E
END N
D
FAILURE DETECTION FLOW CHARTSHEET DP008Sheet 1/2NO STEERING No steering
Check for absence of hydraulic leaks
Absence ofNOleaksYES Repair hydraulic
Make a lifting movement connectors
END
Lifting
NO
movement occurs
YES
SHEET DP007
- Disconnect electrovalve YV5 electric
connectors
- Activate steering and check for 24V on
connector YV5a (left) or YV5b (right)
Make a
steering
movem
4V
ent
(right
pre
and
sen
left)and
t
check
for 24V
YES
on input
B1 or
B12
ofNOpri
Check nted
co circuit
nti U2 of
nui the
platfor
ty
m
of
controlp
coi
anel
ls 24V24VNOpr
esent
onpresentout
puts 3 or 6 of
themanipulat
orNOYESYE
YV SHEET SSee
Replac
e
printedRepair
cabling
between
5a the C004 circuit
U2manipulat
or and the
circuitNOimpr
or imé
U2ENDEND
Replace
theSee
SHEET Replac
e theSee
YV SHEEcoil defective
pulator Tmani
C007 C013
5b E
N
D
END
C
o
n
t
i
n
u
i
t
y
O
K
YES
A
FAILURE DETECTION FLOW CHARTSHEET DP008Sheet 2/2NO STEERING A
Connect a pressure gauge to the minimess tapping on the hydraulic block

Activate steering and note the pressure value (value disappears after 5s)
PressureNOZero pressureNO= 150 bars or2175 psiYESYESReplace the steeringSee SHEETReplaceSee

SHEEcylinderC023electrovalveYV5T C030ENDEND
See SHEETAdjust or replace the steeringC012pressure limiter
END
FAILURE DETECTION FLOW CHARTSHEET DP009Sheet 1/2NOISY HYDRAULIC PUMP
The hydraulic pump

makes a noise
Check the oil level in the circuit
Oil levelNOTop up with oilSee SHEETis OKP001
YES
Incorrect operation of the hydraulicSee SHEETpump; replace the pumpC032
END
FAILURE DETECTION FLOW CHARTSHEET DP002Sheet 2/2NOISY HYDRAULIC PUMP
FAILURE DETECTION FLOW CHARTSHEET DP010Sheet 1/2NO TRAVEL IN JUST ONE
DIRECTION
No travel in just one travel direction
Disconnect the connector YV2a

(AV) or YV2b (AR) concerned by
the fault
Request the defective travel

movement and check for 24V at
the connector’s terminals
Check for 24V between outputs:
24V presentNO - (8) and (34) for FORWARD
- (9) and (34) for BACKWARD
YES
Invert coils YV2a and YV2b
NO
Voltage present
The fault is still on

NO YES
the same travel
direction
Replace the wiring harness
between the electrovalve
YESReplaceSee SHEEelectrovalve and the speed variator
YV2T C008
END
END
Replace theSee SHEETspeed
variatorC003END
Replace coil YV2a orSee SHEETYV2b

corresponding toC007the defective
traveldirection
END
FAILURE DETECTION FLOW CHARTSHEET DP002Sheet 2/2NO TRAVEL IN JUST ONE
DIRECTIONFORWARD or BACKWARD
FAILURE DETECTION FLOW CHARTSHEET DP011Sheet 1/2HIGH SPEED
UNAVAILBLEBELOW 1.5M OR 4FT92IN
High speed unavailable below
1.5m or 4ft 92 in
Disconnect the connector of electrovalve

YV3. Request a high speed travel
movement and check for 24V on the
disconnected wiring harness connector
Check electric continuity of the coil of
24V presentYES
electrovalve YV3
NO
Check for 24V between terminals (7)

and (34) of the speed variator U1
Contin
Disconnect the connector E
uityNO 24V present of electrovalve YV4. N
Replac D
Request a high speed travel
e the YES movement and check for 24V
on the disconnected wiring
coil
harness connector
ofSee
SHEele
ctroval
ve
YV3ET
C007O
KYES
NO
between electrovalve YV3 and
speed variator U1
NO Check for 24V between
24V present terminals (6) and (34) of
speed variator U1
END
YES
Check electric
continuity of the coil of
NO24V presentYES
electrovalve YV4
between electrovalve YV3
and speed variator U1
NOContinuity OKYESReplace the coil ofSee
SHEETelectrovalve YV4C007
B END C B END
FAILURE DETECTION FLOW CHARTSHEET DP011Sheet 2/2HIGH SPEED
UNAVAILBLEBELOW 1.5M OR 4FT92INB
Check for 24V on input B2 of
printed circuit U2 of the
platform control
Repair cabling between the

speed selector switch SA3 and
NO printed circuit U2 of the
24V present platform control or replace the
speed selector switch SA3
YES (see SHEET C004 )
Replace printedSee SHEETENDcircuit U2C004
END
ReplaceSee SHEETelectrovalve YV4C007
The faultNOENDpersistsYESReplaceSee SHEETelectrovalve YV3C007

END
FAILURE DETECTION FLOW CHARTSHEET
DP012Sheet 1/2ONLY MICRO-SPEED IS
AVAILABLE BELOW 1.5MOR 4FT92INOnly micro-
speed is available below1.5m or 4ft92inRaise the platform
above 1.5m or 4ft92in
Lower the platform below 1.5m or
4ft92in. Check that the lowering
movement stops (normal procedure
with lowering restarted after
releasing the manipulator for 3s)
The platformNOCheck electric continuity of thewiring harness between

the end ofstops its descentstroke contactor SP1 (1.5m orat 1.5m
or4ft92in) and speed variator U14ft92inYESReplace the speedSee
SHEEContinuityNOvariator U1T C003OKYESENDAdjust or replace
theSee SHEETend of stroke contac-C018tor SQ1 (1.5m or4ft92in)
Replace the wiring

harness
END
END
FAILURE DETECTION FLOW CHARTSHEET DP012Sheet 2/2ONLY MICRO-SPEED IS
AVAILABLE BELOW 1.5MOR 4FT92IN
FAILURE DETECTION FLOW CHARTSHEET DP013Sheet 1/2THE POTHOLE SYSTEM IS
NOT EXTENDED WHENTHE PLATFORM IS LIFTED
The pothole system is not extended
when the platform is lifted
- Disconnect the electric connector

of electrovalve YV6
- Check 24V supply to
the electrovalve
VoltageNOReplace theSee SHEEpresent on output24V presentvariatorT C00318 of the

speedYESvariatorYESENDCheck coil continuityReplace the wiringharness (ref 25)ENDContinuityNOReplacer the
coil ofSee SHEETelectrovalve YV6C007OK
YES
END
Check
electrovalve
operation
ElectrovalveNOReplaceSee SHEETworks properlyelectrovalve
YV6C030YES
END
A
FAILURE DETECTION FLOW CHARTSHEET DP013Sheet 2/2THE POTHOLE SYSTEM IS
NOT EXTENDED WHENTHE PLATFORM IS LIFTED
Check operation of the

pothole system cylinder(s)
Cylinder(s) workNOReplace defectiveSee SHEETproperlycylinder(s)C024YESENDEND

FAILURE DETECTION FLOW CHARTSHEET DP014Sheet 1/4NO MOVEMENT FROM THE
PLATFORM CONTROL PANEL
No movement from the platform
control panel
Place the key switch SA1 in the

«platform» position and check for
24V at terminals 9 and 11 of SA1
NO
24V present
YES
Check for 24V on wires 9 and 11

of the platform control panel
Replace the keySeeswitch SA1SHEETC004END
24V presentNOReplace the electric wiring harnessbetween the platform

control paneland the chassisYESENDCheck for 24V between terminals C1B+
and C2B- of printed circuit U2
24V presentNOCheck for 24V between terminals 34and 2 of the speed

variatorYES
Reque
st a
travel
or
lifting
move
ment
from
the
platfor
m and
measu
re
voltag
e at
the
manip
ulator’
s
output
termin
als:
• 9:
-10
V
• 11:
+10
V
• 10:
bet
we
en
-10
V
and
+10
V
• 5:
24
V
• 14
or
1:
24
V
A
24V presentNOReplace speedSee SHEEvariator U2T C003YESENDReplace the electric wiring harnessbetween
the platform control paneland the chassisENDFAILURE DETECTION FLOW CHARTSHEET
DP014Sheet 2/4NO MOVEMENT FROM THE PLATFORM CONTROL PANEL
VoltageNOReplace theSee SHEEOKmanipulatorT C013YES

END
Check voltage on the inputs

of printed circuit U2:
• A6: -10V
• A7: +10V
• A9: between -10V and +10V
• B5 and B13: 24V
Repair cabling between the
Voltage NO
manipulator SM1 and printed
OK
circuit U2
YES
END
Check for variable setpoint
voltage between terminals C2B-
and C4 of printed circuit U2
Presence of aNOReplace printedSee SHEEsetpoint
voltagecircuit U2T C004YESEND
Check for setpoint voltage
between terminals 2 and 21 of
the speed variator U1
B
Setpoint voltageNOReplace the wiring harnessbetween the platform controlpresentpanel and the speed
variatorYESENDReplace speedSee SHEEvariator U1T C003
END
Repair manual
9 - CORRECTIVE MAINTENANCE PROCEDURES

List of corrective maintenance sheets:Sheet no.DescriptionFICHE C001Replacing a lifting
cylinderFICHE C002Adjusting a hydraulic block pressure limiterFICHE C003Replacing a
variable speed driveFICHE C004Replacing a component on the platform control
stationFICHE C005Replacing a component on the chassis control stationFICHE
C006Replacing the tilt detectorFICHE C007Replacing a coilFICHE C008Replacing the travel
eletrovalveFICHE C009Replacing the hydraulic filterFICHE C010Replacing a hoseFICHE
C011Replacing a vacuum brakeFICHE C012Replacing a hydraulic block pressure
limiterFICHE C013Replacing a manipulatorFICHE C014Replacing a hydraulic travel
motorFICHE C015Replacing the buzzerFICHE C016Replacing the distribution blockFICHE
C017Replacing the remote control systemFICHE C018Replacing the end of stroke
sensorFICHE C019Replacing the motor pump setFICHE C020Replacing a hydraulic block
valveFICHE C021Replacing a wheelFICHE C022Replacing the brake release pullFICHE
C023Replacing the steering cylinderFICHE C024Replacing a pothole cylinderFICHE
C025Replacing the platform extensionFICHE C026Replacing the platformFICHE
C027Replacing the scissors (and pads)FICHE C028Replacing a scissor ring or axleFICHE
C029Replacing the balancing valvesFICHE C030Replacing a cartridge electrovalveFICHE
C031Replacing the chassis emergency stop buttonFICHE C032Replacing the hydraulic
pumpFICHE C033Replacing and adjusting the pressure switch 91
Repair manual
92
CORRECTIVE MAINTENANCE SHEETSHEET C001Sheet 1/1REPLACING A LIFTING
CYLINDER
CORRECTIVE MAINTENANCE SHEETSHEET C002Sheet 1/2ADJUSTING A HYDRAULIC
BLOCKPRESSURE LIMITER
Caution!
Ensure that oil temperature is not too high.
2 1
3
NB:Steering is disabled after a certain period when at the maximum in
onedirection, and only the other direction is possible and can re-authorisesteering
in the initial direction. The steering pressure measurement timeis therefore
limited.
• If necessary, adjust the hexagonal hollow head screw on the steering

pres-sure limiter (2) to disable movement at the pressure indicated in the
table below.
• Put the machine in the maintenance configuration (see § 6.2, page 21).
• Cut off the electric power supply (see § 6.3, page 22).
• Unscrew the pressure gauge and put the cap back on the hydraulic
pressure tap.
• Put the machine back in the operational configuration.
• Make several steering movements to check that the machine works properly.
CORRECTI
VE
MAINTENA
NCE
SHEETSHE
ET
C002Sheet
2/2NCE
SHEET
Sheet 2/2
CORRECTIVE MAINTENANCE SHEETSHEET C004Sheet 1/1REPLACING A COMPONENT
ON THEPLATFORM CONTROL PANEL
Caution! 2 - Removing a component from the platform control panel
Do not use the • Remove the closing plate (1) by unscrewing the four fixing screws.
machine during • Mark and disconnect the electric connections of the component to
maintenance be replaced.
operations. • Remove the component.
3 - Replacing a component on the platform control panel

• Put a new component and seal into place on the front of the platform con-
trol panel.
NB:If it is a lever switch, adjust the position of the fixing nut and counternut so that the switch
lever joint axle is on the same level as the seal,to ensure tightness.
• Reconnect the electric connections according to the marks made

when dismantling.
• Fix the closing plate with the four fixing screws.
• Perform the function corresponding to the replaced component to check
1that it works
properly.CORRECTIVE
MAINTENANCE SHEET
CORRECTIVE MAINTENANCE SHEETSHEET C005Sheet 1/1REPLACING A COMPONENT
ON THECHASSIS CONTROL PANEL
Caution!
Do not use the 2 - Removing a component from the chassis control panel (1)
machine during • Remove the protective plate (2) from the chassis control panel.
maintenance • Mark and disconnect the electric connections of the component requiring
operations. replacement.
• Remove the component.
3 - Replacing a component in the chassis control panel

• Put the new component and seal on the front of the chassis control panel.
NB:If it is a lever switch, adjust the position of the fixing nut and counternut so
that the switch lever joint axle is on the same level as the seal,to ensure
tightness.

when dismantling.
• Put back the chassis control panel protective plate.
4 - Test
1
• Put the machine back into the operational configuration.
• Perform the function corresponding to the replaced component to check
that it works properly.
2
CORRECTIVE MAINTENANCE SHEET
CORRECTIVE MAINTENANCE SHEETSHEET C006Sheet 1/1REPLACING THE TILT
DETECTOR
to align
the tilt
1 - Preliminary detector.
operations
• Place the
Cau platform on a
tion flat, level floor NB: A spirit
! with no slope. level is built into
Do not • Put the certain tilt detectors.
use machine in
the the
machi maintenance • Put the
configuration machine back
ne du-
(see § 6.2, into the
ring operational
page 21).
mainte • Cut off the configuration.
nance electric power
operat supply (see § 4 - Operating test
ions. 6.3, page 22). of the tilt detector
• Lift the
2 - Removing the platform to a
tilt detector height of 2m.
• Mark and • Tilt the tilt
disconnect detector (see
the tilt photo) and
detector’s check that a
electric signal is given
connections (the signal
• Remove the should be
tilt detector audible from
by the platform).
unscrewing • Check that
the three after 1-2
fixing bolts. seconds, it is
no longer
3 - Replacing the
tilt detector possible to
raise the
• Put a new tilt
detector into platform by
place and activating the
secure with manipulator.
the three
fixing bolts.
• Reconnect
the electric
connections
, according
to the
marks
made when
dismantling.
• Place a
spirit
level on
the top
of the
tilt
detector
and
adjust
the
fixing
screws
CORRECTIVE MAINTENANCE SHEETSHEET C007Sheet 1/1REPLACING A COIL
• 42 - Removing a coil5• Unscrew the two fixing screws (1) from the fixing
lug and take out thehydraulic block.Disconnect the relevant coil’s electric
connector (2).
• Unscrew the nut (3) or (4) and remove the coil (5).
3 - Replacing a coil
• Put a new coil (5) into place and secure with the nut (3) or (4).
• Reconnect the electric connector (2) on the coil.
• Put the hydraulic block back into place and secure with the screws (1)
equipped with new flat and toothed washers.
• Check that the coil works properly by performing the movement corres-1ponding to the
replaced coil.
2 3 5
CORRECTIVE MAINTENANCE SHEETSHEET C008Sheet
1/1REPLACING THE TRAVEL ELECTROVALVE1 - Preliminary
operationsCaution!Ensure that oil temperature is• Put the machine in
the maintenance configuration (see § 6.2, page 21).not too high.• Cut off
the electric power supply (see § 6.3, page 22).2 - Removing the travel
electrovalve• Unscrew the two screws (1) on the fixing lug and take out the
hydraulic2block.• Mark and disconnect the coil’s electric connections (2).•
Unscrew the four fixing screws (3) of the electrovalve (4) and remove it.
3 - Replacing the travel electrovalve

• Put a new electrovalve equipped with its seal into place and secure
using the four screws.
• Reconnect the electric connections (2) on the coils.
• Put back the hydraulic block and secure using the screws (1)
equipped with new flat and toothed washers.
• Make several travel movements to check that it works properly.
1 4
3
CORRECTIVE MAINTENANCE SHEETSHEET C009Sheet 1/1REPLACING THE
HYDRAULIC FILTER
Caution!
Ensure that oil temperature 2 - Removing the hydraulic filter
is not too high. • Disconnect the two hydraulic filter hoses.
• Fit caps on the hoses.
• Unscrew the fixing screws (1) and remove the hydraulic filter.
• Remove the two hydraulic filter connections (2).
3 - Replacing the hydraulic filter

1 • Put the two connections (2) on a new hydraulic filter.
• Put the equipped hydraulic filter into place, respecting the oil flow
direc-tion; secure with the fixing screws.
• Reconnect the hydraulic hoses.
• Perform several lifting cycles to purge the hydraulic circuit.
2
CORRECTIVE MAINTENANCE SHEETSHEET C010Sheet 1/1REPLACING A HOSE
into the
operation
1- al
Preliminary configura
operations tion.
C • Put the • Make
a machine several
u in the moveme
t mainten
i nts using
ance the
o configur
n replaced
ation hose to
! (see § purge the
Ensure 6.2, hydraulic
th page circuit.
at 21). • Check
oil • Cut off the oil
te the level in
m electric the
power hydraulic
pe
supply oil tank.
rat
(see §
ur 6.3,
e page
is 22).
no
t 2 - Removing
to a hose
o • Disconn
hi ect the
hose
gh
from the
. equipme
nt it
connect
s.
NB:Unscrew
the hose
slowly to
allow
residual
hydraulic
pressure
todissipate.
• Fit caps
to the
equipme
nt holes
to
protect
them.
3 - Replacing
a hose
• Reconn
ect a
new
hydrauli
c hose.
• Put the
machine
back
CORRECTIVE MAINTENANCE SHEETSHEET C011Sheet 1/1REPLACING A VACUUM
BRAKE
• Put the machine in the low configuration.
Caution!
• Raise the machine using a jack or hoist.
Ensure that oil temperature
is not too high. 2 - Removing a vacuum brake (see figure 1)
• Remove the pin (3) and nut (4) fixing the wheel and remove the wheel (1).
• Place a wedge under the vacuum brake.
• Disconnect the vacuum brake’s hose.
• Fit a cap to the hose.
• Remove the vacuum brake (2) by removing its four fixing bolts (5) (6) (7).
3 - Replacing a vacuum brake

• Put the new vacuum brake (2) into place.
• Secure the vacuum brake using the four fixing bolts equipped with
new elastic washers (5).
• Reconnect the hydraulic hose.
• Put the wheel (1) into place and secure using the fixing nut and pin.
• Perform several brake/release operations to purge the hydraulic circuit.
• Check the oil level in the hydraulic oil tank.
3
5 7 1
Fig. 1
CORRECTIVE MAINTENANCE SHEETSHEET C012Sheet 1/1REPLACING A PRESSURE
LIMITERON THE HYDRAULIC BLOCK
Caution!
Ensure that oil temperature 2 - Removing a pressure limiter from the hydraulic block
is not too high. • If necessary, unscrew the two fixing screws (1) from the fixing lug and
remove the hydraulic block.
• Unscrew the pressure limiter (2) and take it out of the hydraulic block.
3 - Replacing a pressure limiter in the hydraulic block

2 • Screw a new pressure limiter equipped with its seal onto the
hydraulic block.
• Put the hydraulic block back into place, if applicable, and secure
with screws (1) equipped with new flat and toothed washers.
• Set the limiter to the required pressure.
• Perform several movements using the replaced pressure limiter to
check that it works properly.
1
MANIPULATOR
Caution! • Cut off the electric power supply (see § 6.3, page 22).
Do not use the machine du-
ring maintenance operations. 2 - Removing the manipulator (2)
• Remove the closing plate (1) by removing the four fixing screws.
• Mark and disconnect the manipulator’s electric connections.
• Remove the manipulator by removing its fixing screws.
3 - Replacing the manipulator

• Fix a manipulator, equipped with new seals, to the platform control panel.
• Reconnect the electric connections, according to the marks made when
dismantling.
• Put the closing plate back into place and secure with the four fixing
screws.
• Make several up and down movements from the plaform to check that
the manipulator works properly.
2 1
CORRECTIVE MAINTENANCE SHEETSHEET C014Sheet 1/1REPLACING A HYDRAULIC
TRAVEL MOTOR
hydraulic • Make several travel movements to purge the
motor (4) hydraulic circuit.
1- by • Check the oil level in the hydraulic oil tank.
Preliminary removing
C operations its four
a • Put the fixing
u machine bolts (3)
t in the (5) (6).
i low
o configur 3 - Replacing a
n ation hydraulic
! (see § travel motor
Ensure 6.2, • Put a
th page new
21). hydraulic
at
• Cut off motor
oil into
the
te place.
electric
m power • Secure
pe supply the
rat (see § hydrauli
ur 6.3, c motor
e page using
is 22). the four
no • Raise fixing
t the bolts,
machine equippe
to
using a d with
o jack or new
hi hoist. elastic
gh washers
. 2 - Removing .
a hydraulic • Recon
travel motor nect
(see figure 1) the
• Remove hydrau
the pin lic
(2) and hoses
nut (1) accordi
fixing the
ng to
wheel
and the
remove marks
the made
wheel when
(7). dis-
• Mark mantlin
and g.
disconn • Put the
ect the wheel
two back and
hydrauli secure
c motor with the
hoses. fixing nut
• Fit caps and pin.
to the • Put the
hoses. machine
• Place a back into
wedge the
under operation
the al
hydrauli configura
c motor. tion.
• Remove
the
7125643Fig.
1CORRECT
IVE
MAINTENA
NCE
SHEET
BUZZER
Caution! 1 - Preliminary operations
Do not use the • Cut off the electric power supply (see § 6.3, page 22).
machine during
2 - Remove the buzzer
maintenance
• Mark and disconnect the buzzer’s electric connections (1).
operations.
• Remove the buzzer by unscrewing the fixing bolt.
3 - Replacing the buzzer

• Put the new buzzer into place and secure with the fixing bolt.
• Reconnect the electric conections according to the marks made when
dis-mantling.
4 - Test
• Check that the buzzer gives a signal below 1.5 metres (or 4ft92in) during
lowering.
1
DISTRIBUTION BLOCK
Caution!
2 - Removing the distribution block
• Remove the fixing lug (1) securing the distribution block to the chassis,
is not too high.
and take out the distribution block (2) to access its components.
• Mark and disconnect the distribution block’s electric connections.
• Mark and disconnect the distribution block’s hydraulic hoses.
N
2 B
• F
i
• R
e
2
• P
u
• R
• e
R
• e
S
• e
P
u
1 • P
• e
C
h
REMOTE CONTROL
2 - Removing the remote control

• Remove the protective plate (2) of the chassis control station.
• Release the manual control cable (3) of the covered distributing valve on the
lifting cylinder.
• Unscrew the plate sheath stop (4) supporting the cable.
• Mark the cable route in the scissor ducts and remove the cable from the
ducts.
• Unscrew the blocking nut of the emergency pull (1) and remove the pull
and cable assembly.
3 - Replacing the remote control

• Put the remote control cable back into place in the scissor ducts, according to
2 the route marked when dismantling.
• Put the emergency pull in place on the front of the chassis control panel
and secure with the blocking nut.
• Screw the sheath stop onto the cable support plate at the distributing
valve level.
• Secure the cable to the distributing valve manual control.
• Put the chassis control panel protective plate back into place.
• Raise the platform to a height of 2m (or 6ft56in) and activate the
emergency pull to check that it works properly.
3 4
Sheet 2/2
CORRECTIVE MAINTENANCE SHEETSHEET C018Sheet 1/1REPLACING AN END OF
STROKE CONTACTOR
Cau 1- back to the
tion! Preliminary position
Do operations marked when
• Put the dismantling.
no
machine in • Put the
t
the end of
us maintenance stroke
e configuration contactor
th (see § 6.2, into place
e page 21). in the
m • Cut off the
position
ac electric
marked
hi power supply
(see § 6.3, when dis-
ne
page 22). mantling
du
and
rin
2- secure
g
Removing with bolts
m
an end of (3)
ai
stroke without
nt contactor tightening.
en
• Mark the
an position of 4 - Test
ce the end of • Put the
op stroke machine into
er contactor (1) the operational
ati and its lever configuration.
on (2). • Perform the
s. • Remove the movement,
end of stroke using the
contactor. contactor
• Open the concerned
end of (see table)
stroke and check
contactor, that it works
mark and properly.
disconne • Adjust the
ct the contactor
electric position if
connec- necessary and
tions. tighten the
fixing bolts.
1 3-
3 Replacing
2 an end of
stroke
contactor
• Open the
new end of
stroke
contactor,
reconnect
the electric
connections
and close
the end of
stroke
contactor.
• Move the
end of
stroke
contactor’s
lever (2)
CONTACTORMOVEMENT TOCHECKBE
MADELifting end of strokeLiftingLifting
disabled in the high posi-(SQ3)tion• Extension
of the potholesLiftingwhen the platform
reaches1.5m.Pothole end of stroke•
Microspeed present(SQ5 and SQ6)•
Disconnect YV6• Lifting impossible beyond•
Lifting1.5m• Travel impossible beyond1.5mTilt
reset end ofLifting beyondCheck that the
lowering move-ment is correct with an
interrup-stroke (SQ1)1.5m and loweringtion at
1.5m.8m end of strokeTravel impossible
(microspeedswitch (SQ4)Lifting beyond
8mdisabled)(H12SN only)CORRECTIVE
MAINTENANCE SHEET
MOTOR PUMP SET
• Put
the
machin
e in the2 - Removing the motor pump set
mainten • Remove the upper inspection flap.
ance • Mark and disconnect the motor’s electric connections (1).
configur • Mark and disconnect the hydraulic pump’s two hoses (3).
ation • Fit caps to the hoses.
(see
6.2, • Remove the fixing collars (2) from the motor pump set and remove the
page motor pump set.
21) • Remove the hydraulic pump’s suction and backflow flanges (4).
Cut off
the3 - Replacing the motor pump set
electric
power • Put the suction and backflow flanges equipped with new seals on a
supply motor pump set.
(see • Put the motor pump set into place and secure with the collars.
6.3, • Reconnect the hydraulic hoses to the pump according to the marks
page made when dismantling.
22)
tion! • Reconnect the electric connections to the motor according to the marks
Ensure made when dismantling.
that oil • Close the inspection flap.
temper • Put the machine back into the operational configuration.
atureis • Perform several lifting cycles to purge the hydraulic circuit.
not too
high. • Check the oil level in the hydraulic oil tank.
t the
platform
using a
gantry
crane
or fork-
truckNB
3 2 1
4
3
Sheet 2/2
CORRECTIVE MAINTENANCE SHEETSHEET C020Sheet 1/2REPLACING A HYDRAULIC
BLOCK VALVE
2 - Removing a valve from the hydraulic block
is not too high.
• Remove the fixing lug (3) and take out the hydraulic block (4) if necessary
to make access easier.
• Open the valve concerned.
• Unscrew the base (2) of the valve (1) and remove from the hydraulic block.
• Fit a cap to the hydraulic block hole to protect it.
4 3 - Replacing a valve in the hydraulic block
• Screw a new valve onto the hydraulic block.
• Put the valve back into its initial state.
• Put back the fixing lug and the hydraulic block, if applicable.
• Make several travel movements to purge the hydraulic circuit.
3 2 1
Sheet 2/2
CORRECTIVE MAINTENANCE SHEETSHEET C021Sheet 1/2REPLACING A WHEEL
• Put the machine in the low configuration.
• Raise the machine using a jack or hoist.
2 - Removing a wheel
• Remove the pin (1) and fixing nut (2) from the wheel and remove the wheel
(3).
3 - Replacing a wheel
• Replace the key (4) if necessary.
• Put a new wheel into place and secure with the fixing nut and pin.
4
Sheet 2/2
CORRECTIVE MAINTENANCE SHEETSHEET C022Sheet 1/2REPLACING THE MANUAL
BRAKE RELEASE PULL
Ensure that oil temperature • Check that the brake release valve NV1 is open.
is not too high.
2 - Removing the manual brake release pull
• Unscrew the brake release pull (1) and take it out of the hydraulic block.
• Put a cap on the hydraulic block hole to protect it.
3 - Replacing the manual brake release pull

• Screw a new brake release pull into place.
• Put the machine back in the operational configuration.
• Apply and release the brakes manually several times to purge the
hydraulic circuit.
1
Sheet 2/2
CORRECTIVE MAINTENANCE SHEETSHEET C023Sheet 1/2REPLACING THE STEERING
CYLINDER
Caution! • Put the machine in the low configuration.
Ensure that oil temperature • Cut off the electric power supply (see § 6.3, page 22).
is not too high. • Raise the machine with a jack or hoist.
2 - Removing the steering cylinder

• Mark and disconnect the two steering cylinder hoses (1).
NB:Unscrew the hose slowly to allow residual hydraulic pressure todissipate.
• Fit caps to the hoses.

• Put the cylinder into slings.
• Remove the screws (3) and blocking yokes (4) then remove the
steering cylinder’s two axles (2).
• Remove the steering cylinder.
• 13 - Replacing the steering cylinder• Put a new steering cylinder into

place.• Replace the axles and blocking yokes and secure with screws
equipped withnew toothed washers.324• Reconnect the hydraulic hoses
according to the marks made when dismant-ling.Put the machine back into
the operational configuration.
• Make several steering movements to purge the hydraulic circuit.
Sheet 2/2
CORRECTIVE MAINTENANCE SHEETSHEET C024Sheet 1/2REPLACING A POTHOLE
CYLINDER
• Reconnect the hydraulic hoses according to the
marks made when dismant-ling.
1 - Preliminary • Put the machine back into the operational
operations configuration.
• Put the • Perform several up/down movements from the
Ca machine into
uti plaform above 1.5 meters (or 4ft92in) and travel
the movements with the platform lowered to purge the
on! maintenance
6 hydrau-lic circuit.
Ensur configuration
7 5 1 • Check that the pothole protective system extends and
e (see § 6.2, retracts correctly.
2
page 21).
t • Cut off the
h electric power
supply (see §
a
6.3, page 22).
t
2 - Removing a
o pothole cylinder
i • Mark and
l disconnect
the two
hoses (2) of
t
the pothole
e cylinder (1).
m Fit caps to
p the hoses.
e • Remove the
r special screw
(5), washer
a
(6) and nut (7)
t from the lower
u axle.
r • Remove the
e pin (3) and
washer (4)
i from the
s cylinder’s
upper joint
and remove
n
the pothole
o
cylinder.
t
3 - Replacing a
t pothole cylinder
o • Put a new
o pothole
cylinder into
place on the
h upper axle.
i • Put the
g washer into
h place and
. secure a new
pin.
• Fix the
pothole
cylinder rod
yoke with
3 4
the special
screw,
washer and
a new nut.
Sheet 2/2
CORRECTIVE MAINTENANCE SHEETSHEET C025Sheet 1/2REPLACING A PLATFORM
EXTENSION
• Put the machine in the low position.
2 1
2 - Removing the platform extension
• Remove the electric plug and its support, if any, from the platform.
• Remove the control panel (1) and the platform wiring harness (2).
• Put the platform extension (3) into slings.
• Remove the locking pedal (4) and support (5) assembly.
• Remove the two roller and roller axle assemblies at the back of the
extension by unscrewing the fixing screws (6).
• Remove the two safety brackets (7).
• Remove the platform extension.
3 - Replacing the platform extension

• Put the platform extension into place.
• Secure the two safety brackets.
7 3 • Put the locking pedal and support assembly, the two rollers and their axles back
into place and secure with screws equipped with new toothed washers.
• Install the electric plug support.
• Put the platform control panel back into place and reconnect the
platform wiring harness.
4 • Grease the friction parts of the slides.
NB: Only use the grease recommended by the manufacturer.

• Check that the platform extension can be extended and retracted easily.
5 6
Sheet 2/2
CORRECTIVE MAINTENANCE SHEETSHEET C026Sheet 1/2REPLACING THE PLATFORM
2 - Removing the platform

• Disconnect the wiring harness (1) from the platform control panel.
• Remove the control panel and remove the wiring harnesses from the
plat-form.
• Remove the electric plug and its support, if any, from the platform.
• Put the platform into slings.
• Remove the axle stop bolts from the four platform axles (two fixed axles
(2) and two moving axles (3)) and remove the four axles.
• Remove the platform.
• Remove the four pads and check their condition, remove the
adjustment wedges if necessary.
3 - Replacing the platform

• Put the four pads into place (fixed and moving) on the platform.
1 • Put the plaform on the scissors.
• Put the four fixed and moving platform axles into place and secure with
the axle stop bolts.
2
NB:Fit the bolts so that the screw is on the outside of the platform and thenut on
the inside (see diagram).
• Remount the electric plug, if applicable, on the platform.

• Put back the platform control panel.
• Grease the slides using a spatula
NB: Only use the grease recommended by the manufacturer.
• Put the
• machine
back into the
3 operational
configuration.
Perform
Scr several lifting
ew cycles to
Nu check that
t the machine
Nu works
t properly.
Nu
t ScrewScrewNutN
utNutScrewNutS
Nu
crewScrewNutS
t
crewNutScrewS
Nu crewScrewScrew
t ScrewNutScrew
NutScrewNutNut
NutScrewScrew
NutScrewNutScr
ewScrewScrew
NutNutScrew
Sheet 2/2
CORRECTIVE MAINTENANCE SHEETSHEET C027Sheet 1/2REPLACING THE SCISSORS
• 122 - Remove the scissors• Remove the platform (see SHEET C025
).Remove the lifting cylinder(s) (see SHEET C001 ).
• Mark and remove the hydraulic hoses and electric wiring harness routed
along the scissors.
• Fit caps on the hoses and hydraulic equipment.
• Put the scissors into slings.
• Remove the two axle stop bolts (8) on the two fixed chassis axles.
• Remove the two fixed chassis axles using the threaded holes.
• Remove the scissors and pads.
• 5343 - Dismantling the scissorsCarefully mark the equipment’s assembly.

• Remove the cable passage ducts (1):
• counterbore the eight rivets (2) at both ends of the duct and remove the
straps,
• remove the duct,
• remove the upper duct stop bracket.
• Put each element into slings and remove, one after the other, removing
the elastic rings (3) and washers (4) from the articulation axles (5).
NB:Remove the scissor elements starting from the top.84 - Reassembling

the scissors•Reassemble according to the dismantling procedure in reverse
order, respec-ting the marks made when dismantling.
5 - Replacing the scissors

• Check the condition of the pads and replace if necessary.
• Put the scissors into slings and into place on the chassis.
• Check that the axial clearance between the chassis and the lower arm (6)
does not exceed 1mm; otherwise, adjust the clearance using the
adjustment wedges (7) provided (see figure 2).
• Put the two fixed chassis axles into place and secure using the two axle
stop bolts.
NB:Fit the bolts so that the screw is on the top of the axle and the nut is un-derneath (see figure 1).
• Replace the hydraulic hoses and electric wiring harness routed along
the scissors, according to the marks made when dismantling.
• Replace the lifting cylinder(s) (see SHEET C001 ).
• Replace the platform (see SHEET C025 ).
• Grease the slides using lead-free grease.
CORRECTIVE MAINTENANCE SHEETSheet C027Sheet 2/2REPLACING THE
SCISSORSNB:Only use the grease recommended by the manufacturer.
• Perform several lifting cycles to check that the machine works properly.
ScrewScrewScrewNutNutNutScrewNutNutScrewScrewNutScrewNutScrewNutScrewScrewScrewScrewNutNutScrewNutScrewNutNutNutScrewNut
ScrewNutScrewNutScrewScrewNutScrewNutNutScrew
Fig. 1
7 6
Fig. 2
CORRECTIVE MAINTENANCE SHEETSHEET C028Sheet 1/2REPLACING A SCISSOR RING
OR AXLE
• 122 - Removing a scissor axle (1) or ring (2)• Remove the platform (see
SHEET C026 ).Remove the elastic ring and washer from the scissor axle in
question.
• Remove the axle stop bolt.
• Take out the scissor axle.
• Take out the two scissor rings.
3 - Replacing a scissor axle or ring

• Put new scissor rings into place.
• Put the scissor axle into place and secure using the axle stop bolt.
NB:Fit the axle stop bolts so that the screw is above the axle and the nutunderneath when the platform is in the
high position (see figure below)
• Put the washer and elastic ring back into place.
• Put the platform back (see SHEET C026 ).
• Make several lifting movements and check that the scissors work properly.
ScrewScrewScrewNutNutNutScrewNutNutScrewScrewNutScrewNutScrewNutScrewScrewScrewScrewNutNutScrewNutScrewNutNutNutScrewNu
tNutScrewScrewNutScrewScrewNutScrewNutNutScrew
Fig. 1
Sheet 2/2
Sheet 1/1
SHEET
C029REPL
ACING THE
BALANCIN
G VALVES 1 - Preliminary operations
2 - Removing the balancing valves

Caution!
• Disconnect the hydraulic brake hose (2) and close the holes on
Ensure that oil temperature the pipework and hydraulic block.
is not too high. • Unscrew the two screws (1) of the fixing lug and take out the
hydraulic block.
• Remove the balancing valves (3) by unscrewing them.
3 - Replacing the balancing valves

• Screw the new balancing valves (whose characteristics correspond to
the machine in question) into the hydraulic block.
• Put the hydraulic block back into place and secure using the screws
(1) equipped with new flat and toothed washers.
• Reconnect the hydraulic brake hose onto the block.
• Make several travel movements to purge the circuit.
• Position the machine on a 40% slope and check that the machine does
not go into runaway during a travel movement.
1 2
Caution!
The balancing valves
are safety elements.
They are calibrated in
the plant and must not
be re-adjusted.
Sheet 1/1
S • Put the
H machine back
E into the
E
T 1 - Preliminary operational
operations configuration.
C • Put the • Perform
0 machine in several
3 the movements
0
R maintenance using the
E configuration replaced
P (see § 6.2, electrovalve
L page 21). to check that
A • Cut off the
C it works
electric power
I supply (see §
properly.
N
G 6.3, page 22).
A 2 - Removing a
cartridge
C electrovalve
A
R • Remove the
T coil(s) (2) of
R the
I electrovalve
D (see SHEET
G C007 ).
E • Unscrew
E the
L electrov
E alve (1)
C with the
T
R Allen
O key and
V remove
A from the
L
V hydrauli
E c block.
3 - Replacing a
cartridge
electrovalve
• Screw a new
electrovalve,
equipped with
Cautio its seal, into
n! the hydraulic
Ensure that oil block.
tempe • Put the
rature coil(s)
back into
is not
place on
too the
high. electrovalv
e and put
the
hydraulic
block back
into place
(see
1 SHEET
2 C007 ).
Sheet 1/1
SHEET C031
REPLACING THE CHASSIS EMERGENCY STOP BUTTON
Caution!
• Disconnect the + and - terminals of the batteries to isolate the electric cir-
Do not use the
cuit.
machine during
maintenance 2 - Remove the emergency stop button
operations. • Mark and disconnect the emergency stop button’s electric connections
(1).
• Remove the emergency stop button (2).
3 - Replacing the emergency stop button

• Put a new emergency stop button into place.
when dismantling.
4 - Test
• Check that the emergency stop button works properly.
1 2
CORRECTIVE MAINTENANCE SHEETSHEET C032Sheet 1/2REPLACING THE HYDRAULIC
PUMP
SHEET
C019 ).
1 - Preliminary • Put the
operations machine
• Put the back into
machine the
Ca in the operation
uti maintena al
on nce configurati
! configurat on.
Ensure ion (see § • Perform
tha 6.2, page several
21). lifting
t
• Cut off cycles to
oil the purge the
te electric hydraulic
mp power circuit.
supply • Check the
era (see § oil level in
tur 6.3, page the
e is 22). hydraulic
not oil tank.
2 - Removing
too the hydraulic
hig pump
h. • Remove
the
motorpu
mp set
(see
SHEET
C019 ).
• Remove
the
screws
securing
the pump
to the
motor
and
remove
the
pump.
3 - Replacing
the hydraulic
pump
• Put a
new
pump
equipped
with seal
onto the
electric
motor
and
secure
with the
fixing
screws.
• Remount
the motor
pump set
(see
Sheet 2/2
CORRECTIVE MAINTENANCE SHEETSHEET C033Sheet 1/1REPLACING AND ADJUSTING
A PRESSURE SWITCH
• Reconnect the pressure switch’s hydraulic hose.
• Reconnect the pressure switch’s electric
2 1 - Preliminary
C connector.
3 operations
a • Put the machine back into the operational
u • Put the configuration.
ti machine in
o the 4 - Adjusting the pressure switch
n maintenanc
• Place a load corresponding to «movement
! e
disabling load» in the platform (see table below),
Ensure configuratio
n (see § raise the platform until the small rod of the lifting
t cylin-der is disengaged and adjust the pressure
6.2, page
h 23). switch screw (3) located on the lifting cylinder so
a • Cut off the that the movements are disabled for this given
t electric load.
o power • Check that the machine works properly in all
i supply (see positions with a load slightly less than nominal
l § 6.3, page load on the platform.
t 24).
e • Check low
m pressure
with the MachineNominal loadLoad setting for
p disablingmovementsH8SNoutdoor use: 120kgoutdoor
emergency
e control. use: 120kgindoor use: 350kgindoor use:
r 350kgH8SWoutdoor use: 120kgoutdoor use:
a 2 - Removing the 120kgindoor use: 450kgindoor use: 450kgH10Soutdoor
use: 120kgoutdoor use: 120kgindoor use: 450kgindoor
t pressure switch
use: 450kgH12SNoutdoor use: 120kgoutdoor use:
u • Disconnect 120kgindoor use: 300kgindoor use: 300kg
r the lifting (tolerance: + or - 10%)
e electric
connector
i (1) from the
lifting
s
cylinder’s
pres-sure
n switch.
o • Disconnect
t the
t pressure
o switch’s
o hydraulic
hose (2).
h • Fit a cap to
the hose.
i
• Unscrew
g
and remove
h the
. pressure
switch
fixing
screws.
3 - Replacing the
1 pressure switch
• Screw a
new
pressure
switch,
equipped
with its
seal, into
place.

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1

1 - GENERAL RECOMMENDATIONS - SAFETY

1.2 - GENERAL SAFETY RECOMMENDATIONS

1.3.1 - Risks of jolting - tipping over

1.3.3 - Electric risks

1.4.1 - Regular checks

1.4.2 - Examination of device suitability

2.1 - TECHNICAL CHARACTERISTICS

2.2 - Compact 8, Compact 8W technical data

DescriptionCompact 8Compact 8WLoad (indoor use)350 kg, including 2 people450 kg,

2.1.2 - Compact 10, Compact 12 technical data

DescriptionCompact 10Compact 12Load (indoor use)450 kg, including 3

2.2.3 - Compact 10 size

2.2.4 - Compact 12 size

2.38 m1.86 m1.20 m2.42 m

2.3 - TIGHTENING TORQUE

2.4 - Tightening torque for large thread

Nominal diameterTightening torque in N.M8.810.912.9 M 6*19 to 1113 to 1415 to 17M 7*115 to

ReferenceDescriptionFU1Motor-pump fuseFU2Speed variator output protective

3.2 - SAFETY CONTACT FUNCTIONS

ReferenceDescriptionSB1Line contactor / Chassis emergency stop buttonSB2Platform

3 U1JDeversMontÈeContacteurDescenteMontÈePF/CHSurchargeBasMARHautmËtres8Potholeindicateur 39B+4Version1KM1SA4H12SDescente9AU13SQ1>DescenteDescente4VMNPKlaxonLibreMAVGaucheDroiteGV-PVL60GVGVB-1 24042 1651 098761 62 01 91 831

74461181920212250232425262742 rchM YV1YV2aYV2bYV3YV4YV9YV5aYV5bYV6YV7YV8 HL2HA1SB1HL3

5.2 - HYDRAULIC DIAGRAM FOR COMPACT 12 (B16188) MODEL

These operations are to be carried out on both sides of the platform.

Putting the maintenance stand into place:

• Position the platform on a firm, horizontal floor.

Removing the maintenance stand:

6.3 - ELECTRICITY SUPPLY

Cutting off the electricity supply:

Starting the electricity supply:

6.4 - MAINTENANCE PLAN

6.4.2 - Maintenance diagram

6.5.1 - Summary table

FREQUENCYOPERATIONSREF•Check the levels:-hydraulic oil (see paragraph 7 -, sheet P001 ),1-electric

6.6.2 - Common "orange" labels

6.6.3 - Common "red" labels

•Put the machine in the maintenance configuration (see § 6.2, page

2 - Greasing the slides

•Grease the slides using a spatula.

NOTA : Only use the grease recommended by the manufacturer.

•Put the machine back into the operational configuration.

Before anything else, check that:

ANOMALYCHECKPROBABLE CAUSESOLUTION•Defective batteries•Oil level low• Defective fusesNo

ANOMALYCHECKPROBABLE CAUSESOLUTION•Oil viscosity too high•Empty the circuit

8.1.3 - Travel system

ANOMALYCHECKPROBABLE CAUSESOLUTION• No movement availableNo travel movement

8.1.5 - List of MDI codesNumericFlashDescriptionindicator00 on M.D.I + red led:Battery below 5% or

8.2 - FAILURE DETECTION FLOW CHARTS

Place the movement selector

Place the key switch in the

24VNOReplace wire no. 10present

24V atNOReplace switch SA2See SHEETterminals 37 or 38 ofC003the speed variatorYESENDReplace speedSee

No up movement from the chassis or

Check that there are no hydraulic leaks

Check the allowed load on

Load correctNO Reduce load

Disconnect the wiring harness from

Check for 24V on one of the two

Replace wiring harness

Adjust or replace pressureSee SHEET

Check supply to electrovalve YV7:

24VNOcoil supply Check electric continuity of the

Compact 12,NOCompact 3747E

Nominal diameterTightening torque in N.M8.810.912.9 M 619 to 1113 to 1415 to 17M 7115 to