Manitou Work Platforms 65ELX 75ELX Repair Manual 547322 - PDF DOWNLOAD

R

BP 249 Z.I. 44158 ANCENIS CEDEX FRANCE TEL : 02 40 09 10 11

YOUR DEALER

REF : 547 322 EN (10 / 01)

PLATFORMS

65 EX 75 EX REPAIR MANUAL

1st ISSUE DATE INFORMATION CATALOGUE

10 / 10 / 2001 DATE OF ISSUE

OBSERVATIONS

SUMMARY Units

0 0-1-M.60 EN

70

Chapters

General Technical characteristics

Hydraulics

70-5-M.60 EN

Hydraulic pressure

70-6-M.60 EN

Hydraulics’ diagram

70-7-M.60 EN

Hydraulic system components

80

Electricity

80-6-M.60 EN

Electrical diagram

80-8-M.60 EN

SEVCON variator

80-8-81-M.60 EN

Position of sensors

100 100-M.60 EN

Troubleshooting Troubleshooting

UNIT 0

GENERAL

TECHNICAL CHARACTERISTICS 65 EX - 75 EX 0-1-M.60 EN

10.01

MAIN PARTS OF THE MACHINE

Platform control box

Extensible platform

Platform

Arm Base control panel

Lifting cylinder Chassis Scissor struts

1

Platform access ladder

SPECIFICATIONS

65 EX SPECIFICATIONS - Working height

6,40 m

- Height of platform

4,57 m

- Height of the secured machine : Rails retracted

1,97 m Not applicable

- Lifting capacity (evenly distributed) Capacity of the unwinding extension apron

272 kg 113 kg

- Platform dimensions With the apron extension Rails Height of the foot board Length of the extended apron

0,76 x 1,68 m 1,10 m 19,05 cm 0,91 m

- Total length

1,88 m

- Total width

0,81 m

- Base

1,27 m

- Track width

0,70 m

- Turning radius Interior Exterior

3,81 cm 1,55 m

- Ground clearance

72,90 cm

- Weight of the machine (unloaded) (approx.)

1236 kg

- Total propulsion (proportional) Traction speed (platform raised) Traction speed (platform lowered)

0-0,74 km/h 0-3,38 km/h

- Raising/lowering speed (approx.)

17 seconds / 20 seconds

- Maximum gradeability

25% / 14 degrees

- Ground wheel pressure (max.)

6,13 bar

- Wind speed (max.)

0 km/h

- Tyres dimensions - standard (Super Terra Grip -Pneumatic)

355,6 x 114,3 mm

- Pressure of tyres (except foam tyres)

Not applicable

- Wheel T-nut torque

102-115 Nm

- Hydraulic pressure : Main circuit Lifting circuit Steering

190 bar 131 bar 62 bar

- Capacity of hydraulic fluid tank

11,36 litres

- Fuel tank capacity

Not applicable

- Electrical supply - voltage

24 volts DC

- Battery charger -

240 volts ca, 50 Hz, 5,6 Amps 24 volts DC, 15 Amps progressive, programmed stoppage

Input Output

- Batteries

Four at 6 volts; 218 Amps/hours for 20 hours

- Electric motor

2,0 hp (1,49 kW) : 3000 rev/min

2

75 EX SPECIFICATIONS - Working height

7,62 m

- Height of platform

5,79 m

- Height of the secured machine : Rails retracted

2,02 m Not applicable

- Lifting capacity (evenly distributed) Capacity of the unwinding extension apron

226 kg 113 kg

- Platform dimensions With the apron extension Rails Height of the foot board Length of the extended apron

0,76 x 1,68 m 1,10 m 19,05 cm 0,91 m

- Total length

1,88 m

- Total width

0,81 m

- Base

1,27 m

- Track width

0,70 m

- Turning radius Interior Exterior

3,81 cm 1,55 m

- Ground clearance

72,90 cm

- Weight of the machine (unloaded) (approx.)

1388 kg

- Total propulsion (proportional) Traction speed (platform raised) Traction speed (platform lowered)

0-0,74 km/h 0-3,38 km/h

- Raising/lowering speed (approx.)

17 seconds / 20 seconds

- Maximum gradeability

25% / 14 degrees

- Ground wheel pressure (max.)

6,72 bar

- Wind speed (max.)

0 km/h

- Tyres dimensions - standard (Super Terra Grip -Pneumatic)

355,6 x 114,3 mm

- Pressure of tyres (except foam tyres)

Not applicable

- Wheel T-nut torque

102-115 Nm

- Hydraulic pressure : Main circuit Lifting circuit Steering

190 bar 152 bar 62 bar

- Capacity of hydraulic fluid tank

11,36 litres

- Fuel tank capacity

Not applicable

- Electrical supply - voltage

24 volts DC

- Battery charger -

240 volts ca, 50 Hz, 2,74 Amps 24 volts DC, 15 Amps progressive, programmed stoppage

Input Output

- Batteries

Four at 6 volts; 218 Amps/hours for 20 hours

- Electric motor

2,0 hp (1,49 kW) : 3000 rev/min

3

UNIT 70

HYDRAULIC

HYDRAULIC PRESSURE 65 EX - 75 EX 70-5-M.60 EN

10.01

EXCESS PRESSURE ADJUSTMENT PROCEDURE

STEERING Connect the manometer (0-241 bars), using the female quick disconnect coupling to the main test orifice.

Turn on the steering, and turn totally to the left. Keep the switch pressed down for 20 seconds in order to obtain an exact reading on the manometer.

Should an adjustment be necessary, set pressure on the correct parameter. Refer to the technical characteristics or hydraulic diagram.

Remove the tamper proof cover, turn the adjustment screw to « IN » to increase pressure and to « OUT » to reduce it. When adequate pressure has been obtained, replace the tamper proof cover by a new cover.

LIFTING Connect the manometer (0-241 bars), using the female quick disconnect coupling to the main test orifice.

Raise the platform to maximum extension with no load on the platform. Keep the switch pressed down for 20 seconds in order to obtain an exact reading on the manometer.

Should an adjustment be necessary, set pressure on the correct parameter. Refer to the technical characteristics or hydraulic diagram.

Remove the tamper proof cover, turn the adjustment screw to « IN » to increase pressure and to « OUT » to reduce it. When adequate pressure has been obtained, replace the tamper proof cover by a new cover.

MAIN

ORIFICE/SYSTEM

Connect the manometer (0-241 bars), using the female quick disconnect coupling to the main test orifice.

Disconnect the coil in front of or to the rear of the driving valve. Turn on the driving function by moving the handle (lever) in the direction of the already disconnected coil. Keep the switch pressed down for 20 seconds in order to obtain an exact reading on the manometer.

Should an adjustment be necessary, set pressure on the correct parameter. Refer to the technical characteristics or hydraulic diagram.

Remove the tamper proof cover, turn the adjustment screw to « IN » to increase pressure and to « OUT » to reduce it. When adequate pressure has been obtained, replace the tamper proof cover by a new cover.

1

HYDRAULIC DIAGRAM 65 EX - 75 EX 70-6-M.60 EN

10.01

STEERING DIRECTION FREINS BRAKES MA-2

7

6 MA -1 POMPE A MAIN HANDBRAKE PUMP

F

DEFREINAGE

M

G

J

59 Bars

8

E 1.0 GPM

0 L K

9

MOTEUR DE RIGHT WHEEL ROUE DROITE

MOTOR

N

H I 103 Bars 5 P 10

D 4 MA-3

0,34 Bars

B C

R 165 Bars 75 EX 131 Bars 65 EX

3

11

12 190 Bars

1

2

LIFTING LEVAGE

A : Pressure limiter B : Elevation translation selector C : Manual repair D : Non-return valve E : Flow divider F : Steering system solenoid valve G : Steering system pressure limiter H : Brake solenoid valve I : Balancing valve J : Forward/reverse gear K : Retardation solenoid valve L : Flow regulator M : Anti-torque valve N : Flow divider O : Anti-torque valve P : Load holding valve

1

MOTEUR DE LEFT WHEEL ROUE GAUCHE MOTOR

HYDRAULIC SYSTEM COMPONENTS 70-7-M.60 EN

10.01

HYDRAULIC SYSTEM COMPONENTS HYDRAULIC OIL TANK This consists of a tank, a filler cap with breather, a drain plug, a sight gauge, and a by-pass with a 10 micron filtering element.

Weekly maintenance : • Check taht there are no leaks in the tank.

• Check that the safety bolts of the tank have been tightened.

Hydraulic filter (Fig. 1) 1 - Filler cap with filter 2 - Sight gauge 3 - Return filter, and filtering element (cartridge)

1 2 3

Fig. 1 All machines are equipped with a filter. This is a 10 micron removable bypass filter. When the filter is blocked the hydraulic fluid by-passes the filtering element. This last needs to be changed every six months, or every 500 hours. Given particularly dirty conditions the filter would have to be changed more frequently.

Hydraulic tank assembly

Care should be taken with hot oil since this can cause serious burns.

HYDRAULIC

PUMP

The 24 volts, 2.0 HP, hydraulic motor drives the constant volumetric displacement gear pump. The pump supplies the flow of hydraulic fluid necessary to operate the machine at a rate of 13.6 litres per minute.There are no adjustment devices on the pump. It supplies the energy necessary for lifting, moving, braking, and steering.

WHEEL

Hydraulic pump (left side)

DRIVING CIRCUIT

There are two (2) constant swept volume hydraulic geared motors supplying the energy necessary for the two (2) front wheels.

Wheel motor

1

DYNAMIC

BRAKING CIRCUIT

The brakes at the rear are engaged each time that the machine is instructed to move.

The lifting cylinder has a two position bi-directional integrated holding valve. This last has a manual device for lowering the platform in the event of emergency. The holding valve avoids withdrawal of the cylinder rod in the event of either failure in the hydraulic line or leakage between the cylinder and the relevant valve. Refer to the mechanical section of this manual for cylinder disassembly and replacement.

Brake

Lifting cylinder

Lifting cylinder

STEERING

CYLINDER

Steering cylinder

The steering system uses a single cylinder. The cylinder in question is of the “double acting” type and requires a flow of oil to activate the rod in both directions. The steering oil forces the piston to move in the direction of the end of the cylinder barrel, thus drawing out the cylinder rod.

By directing the oil to the side of the cylinder rod the piston is forced to move in the opposite direction, and the cylinder rod retracts.

Refer to the mechanical section of this manual for cylinder disassembly, and replacement.

Steering cylinder

2

Unit

24 V Coil

LIFTING UNIT

3

MANUAL PUMP CONTROL 4

E

D C

P A F

K

R

N

B O

G I H

J

M

L

A : Main pressure limiter B : Elevation./Trans. Selector C : Manual repair valve D : Non-return valve E : Steering/translation flow divider F : Left/right steering G : Steering pressure limiter H : Electronic brake I : Balancing valve

J : Front and rear operation solenoid K : Electro deceleration L : Flow rate regulator M : Anti-torque valve N : Wheel motor flow divider O : Anti-torque valve P : Load holding valve R : Elevation pressure limiter

MAIN UNIT 5

UNIT 80

ELECTRICITY

ELECTRICAL DIAGRAM 65 EX - 75 EX 80-6-M.60 EN

10.01

1

BASKET CONTROL

MANIPULATOR

ARM POSITION SWITCH BASIC CONTROLS

SEVCON MICROMOS VARIATOR

SPEED SELECTION

MANIPULATOR INPUT

CANT INDICATOR

GENERAL PRINCIPLE OF ELECTRICAL PLATFORMS

ELECTRIC MOTOR AND HYDRAULIC PUMP

MODE SELECTION SWITCH CONDUITE DRIVING

GAUCHE LEFT

DROIT RIGHT

LEVAGE LEVAGE

REVERSE REVERSE LIFTING DESCENT AR/LEVAGE AV/DESCENTE

TILTING TEMOIN D’INCLINAISON INDICATOR

ROTATION KLAXON HORN

DEADMAN’S HOMME-MORT BRAKE

ARRET EMERGENCY D’URGENCE STOP

DISCONNECT. RAPIDE RAPID DISCONNECTION TERMINAL SUPERIEUR

UPPER TERMINAL

KLAXON HORN TERMINAL INFERIEUR LOWER TERMINAL

TABLEAU CIRCUIT CIRCUIT BOARD

MOVEMENT ALARME ALARM MOUVEMENT ASCENT LEVEE ASCENT/DESCENT LEVEE/DESCENTE SWITCH DESCENTE DESCENT

FORWARD SIGNAL MOVEMENT MOUVEMENT SIGNAL AVANT REAR CLIGNOTANT FLASHING ARRIERE INDICATOR

PLATEFORME PLATFORM INTER. KEY CLE

LEVEL CAPTEUR SENSOR NIVEAU ARRET EMERGENCY D’URGENCE STOP

HORAMETRE HOUR METER

BATTERY NIVEAU LEVEL BATTERIE COUPE CIRCUIT CIRCUIT BREAKER

LIFTING LEVAGE

RIGHT DROIT

LEFT GAUCHE

BRAKE FREIN

MAIN UNIT BLOC PRINCIPAL

REVERSE ARRIERE FORWARD AVANT

ROTATION BLOC UNIT ROTATION

LIFTING BLOC UNIT LEVAGE

LIFTING VERIN CYLINDER LEVAGE

The LS1, LS2, LS3, and LS4 switches are shown with the platform in the transport position (lowered scissors).

2

Hour meter

(17)

Load indicator

(5)

EMPTY

(101)

(14)

(4)

(NEG)

(102) ( - )

(102) ( - )

(101)

(103)

(103)

(22)

(1)

(9)

(103)

(104B)

ASCENT / DESCENT

PLATFORM / BASE

EMERGENCY STOP

(104A) BATTERY CUT OUT (20) 12 12 12 12 12 12

(15)

(105)

MOVEMENTS’ ALARM OPTION

ELECTRICAL DIAGRAM

65 - 75 - 80 EX Electronic card

Note : TB1 is a lug connected to the 0 Volt battery

3

CABLED LOGIC CARD 65-75-80 EX Input signals :

Output signals : (Towards SEVCON Micromos)

Reverse movement solenoid

High speed

Brake solenoid

Forward movement solenoid Movement alarm option

Descent

Steering solenoid Left

Steering

0V BAT

Right steering solenoid

Lifting

Dead man’s brake

(24 V) Transport mode (0V) working LS 2

0V : slow speed 24 V : high speed

4

5

7

+

9

-

4

1 3

6 DESCENT TIMER CARD

SEVCON VARIATOR 65 EX - 75 EX 80-8-M.60 EN

10.01

24 V 10A FUSE

SUPPLY

1

Variator supply

2

Speed selection

3

Maximum speed

4

Dead man’s brake

5

+ 24V : High speed 0V : Low speed

6

Motor contactor coil

7

Lifting solenoid valve coil

TRANSLATION

STEERING

«DEAD MAN’S BRAKE» SAFETY HANDLE, SWITCH

TRANSPORT/WORK SWITCH (at 2 metres)

MOTOR CONTACT COIL

COIL LIFTING LIFTING COIL

8 9 2.7 k

10 20 K ohms 11

12

CONTROL BASE LIFTING POSITION N°2 PIN for SPEED SELECTION

N°4 PIN for DEAD MAN’S BRAKE

N°9 PIN (ACCELERATOR) control voltage input manipulator

5. 2m contact info 7. Negative when the battery voltage > 18V (lifting cutout) 9. 3.7/3.8V at neutral at manipulator output. Target is 0 volt in both directions.

MICROMOS VARIATOR WIRING DETAILS 1

Manipulator control voltage input

Turn on In neutral

Wire N°9

Wire N°16

Dead man’s brake pedal pressed down Transport mode

Wire N°9

Wire N°3

Wire N°21 Wire N°16

Wire N°9 Wire N°17

Wire N°3

Wire N°21

Lifting from the base or platform

Steering Left/right

Wire N°9 Wire N°17 Wire N°18 Wire N°3 Wire N°21

Forward / Reverse Transport mode

Wire N°9 Wire N°17

Wire N°3

Wire N°9 Wire N°17

Wire N°3

Wire N°21

Forward / Reverse Working mode

VERIFICATION OF CONTROL VOLTAGES ON THE MICRO-MOS VARIATOR

2

MICROMOS VARIATOR LED STATUS

PROBLEM

1

Variator OK

0

Variator out of use

2 flashes

Error in starting procedure. One control (steering, translation, lifting, manipulator trigger ...) is active at voltage input.

Check these elements.

3 flashes

Motor short circuit or variator internal fault.

Reset the variator after corrective action.

4 flashes

The motor circuit is open. The problem may originate from the variator or the line contactor. Check these two elements.

Reset the variator after problem correction.

5 flashes

The line contactor is not supplying the unit, check this component.

The problem may also originate from the variator.

6 flashes

Fault in the manipulator. The variator is receiving a set point from the potentiometer in excess of 15 percent.

Check this component and along with its associated wiring harness.

7 flashes

Battery voltage less than 12 Volts, or more than 45Volts.

8 flashes

Thermal cut out problem at 80°c. Check that the variator is correctly installed in the chassis which acts as heat sink.

9 flashes

Battery voltage less than or equal to 18 Volts. Lifting not authorised.

3

POSITION OF SENSORS 65 EX - 75 EX 80-8-81-M.60 EN

10.01

LS1 and LS2 basket detection switches at 2 meters from the ground

LS3 and LS4 pothole protection bar position switches

POSITION OF SENSORS

1

UNIT 100

TROUBLE SHOOTING

TROUBLESHOOTING 65 EX - 75 EX 100-M.60 EN

10.01

TROUBLESHOOTING MAIN RECOMMENDATIONS FOR FAULT ISOLATION.

Prior to seeking a cause for malfunction, check that : • battery connections are correct and that the battery is charged, • the emergency stop button is released (BASE/PLATFORM position), • the level of hydraulic fluid is correct, • the brake release valve is open, • the battery cut-out is in the « ON » position.

Usual causes of hydraulic system malfunctions : • incompatible hydraulic fluid mixtures which destroy additives, and result in the formation of a varnish which causes valve seizure.

• the presence of water in hydraulic fluid due to climatic humidity.

• the use of inappropriate hydraulic fluid. Viscosity too great in cold climates. Viscosity too low in hot climates.

NOTE : 150SSU (ISO 32) is an oil of multiple viscosity, sufficiently light for cold climates and resistant to fluidification in hot climates.

Please find hereafter a step by step guide to fault isolation : NOTE : Dirt always results in breakdown in a hydraulic system. It is very important to take care that no dirt penetrates into your hydraulic system during assembly. Please check that all orifices and manifold cavities, and all cylinders, are correctly covered whilst other work is being carried out during assembly of the machine.

Troubleshooting in an integrated hydraulic system (manifold) is easy to perform thaks to the use of a series of cavity covers designed for manifold fault isolation. MANITOU has already designed the covers in question.

1

TROUBLESHOOTING GUIDE : HYDRAULIC SYSTEM (refer to hydraulic diagram)

FUNCTION

Steering

PROBLEM

REMEDY

Does not turn in either one or both directions.

Check the level of pressure of the test orifice (3) whilst trying to turn. During normal operation pressure should attain approximately 69 bars at the end of turning travel.

At test orifice level pressure is lower than 69 bars.

Check adjustment of the safety valve (A). It should be at 189 bars.

Check adjustment of the safety valve (G). It should be at 59 bars.

Check that the valves (E & F) are not dirty.

Check voltages at the level of valve (F). For each turn of steering one of the coils should be under power.

At test orifice level pressure is much higher than 69 bars.

Check voltage at the level of valve (H). The coil should not be under power during turning.

Chech that vlaves B, E, F, and H are not dirty.

Lifting

At test orifice level pressure is approximately 69 bars

Check that the valves B & F are not dirty.

the platform does not ascend.

Check the pressure at the level of test orifice (3) whilst attempting lifting. During normal operation pressure should reach approximately 124 bars during lifting.

At test orifice level pressure is much lower than 124 bars.

Check safety valve A adjustment. It should be at 189 bars.

Check the adjustment of safety valve R. It should be at 162 bars.

Check valve B voltage. During lifting the coil should be under power.

Check that valve B is not dirty.

At the level of the test orifice, pressure is much higher than 124 bars.

Check that valves B and P are not dirty.

Platform speed reduction.

Check that the one way orifice, located at the end of the platform cylinder base, is not dirty.

Check that valves B and P are not dirty.

The platform does not go back down manually.

Check that the manual hand pump valve is operational.

Make sure taht the hand pump is working.

2

FUNCTION Moving

PROBLEM

REMEDY

No moving or reduced speed forward or reverse moving.

Check orifice test (3) pressure whilst moving. During normal operation moving pressure should reach approwimately 48 bars on flat ground.

At test orifice level pressure is a lot lower than 48 bars

Check the voltage at valve H level. During moving the coil should be under power.

Check the adjustment of the safety valve A. It should be 189 bars.

Check voltage at level of valve K. During moving the coil should be under power.

Check that valves H and K are not dirty. Ensure that valve L is completely closed (clockwise).

At test orifice level pressure is a lot higher than 48 bars.

Check voltages at the level of valve F. For each drive steering, one of the coils should be under power.

Check the voltages of valves M and O. The two coils should be under power when torque mode is engaged, and without power then torque mode is disengaged.

Check that valves B, E, F, I, J, M, N, and O are not dirty.

Check orifice 5 pressure. It should be similar to that of the test orifice.

The torque mode does not engage.

Check taht valves M and O are not dirty.

Check M and O valve voltage. The two coils must be under power so that torque mode is engaged.

The machine moves over flat ground but will not climb.

Check that the safety valve A is set correctly. It should be at 189 bars.

The machine does not stop smoothly.

Check the voltage of valve K. The coil should be without voltage when the machine stops moving.

Check that the orifice located under the K valve is not full of dirt.

Brakes

It is impossible to establish pressure manually.

Check that the manual push valve C retains pressure. Once the valve has been pushed in the closed position (by pumping oil using the hand pump), the pressure should rise to activate the brakes. Check that valve D is not dirty.

3

TROUBLESHOOTING TABLE : ELECTRICAL SYSTEM

FUNCTION The platform does not ascend from the base or platform.

The platform does not ascend just from the base.

The platform does not ascend from just the platform.

PROBLEM

REMEDY

EError of procedure : lifting selected during power input.

Two flashes of the LED located on the motor control panel indicate an error of procedure. To reset place the handle in the neutral position.

Accelerator error : the handle is not in the neutral position or the cable is disconnected from the handle during power input.

Six flashes of the LED located on the motor control panel indicate a fault with the accelerator. To reset place the handle in the neutral position and/or repair the wiring, then recycle the energy.

Upper valve coil or wiring faulty.

Replace the coil, and/or the wiring.

Ascent valve faulty.

Replace the ascent valve.

Descent valve faulty.

Replace the descent valve.

Safety valve fualty, or badly adjusted.

Should safety pressure be lower than that indicated in the technical instructions, replace the safety valve. Consult the hydraulic diagram to carry out adequate adjustment.

LED panel faulty/motor control faulty.

Replace the panel or the control depending upon the case.

Lifting selection switch faulty.

Replace the lifting selection switch.

Platform/base selection switch faulty.

Replace the platform/base selection switch.

Defective wiring.

Examine, and replace the wiring.

Activation selection switch and/or wiring faulty.

Replace the activation selection switch and/or repair the wiring.

Note : If the activation selection switch and/or the wiring are faulty, functions of moving, steering, and torque will not be operational.

Mode selection switch faulty.

Replace the mode selection switch.

Forward/lifting selection switch faulty.

Replace the reverse/lifting selection switch.

Wiring, or wire faulty.

Examine and repair the wiring, and/or the wire.

4

FUNCTION The platform ascends slowly and in an iregular manner.

The platform does not descend from the base or the platform.

The platform does not descend just from the base.

The platform does not descend just from the platform.

PROBLEM

REMEDY

Handle potentiometer faulty.

If voltage passing through the handle potentiometer is more than 0.2 V DC when completely raised, the potentiometer must be adjusted or replaced.

Safety valve faulty, or badly adjusted.

Il safety pressure is lower than shown in the technical characteristics, replace the safety valve. See the hydraulic diagram for correct adjustment.

Lifting cylinder(s) faulty.

Repair or replace the lifting cylinder(s).

Ascent valve faulty.

Replace the ascent valve.

Lowering valve faulty.

Replace the lowering valve.

Motor control faulty.

Replace the control.

Procedural error : lowering on voltage input.

2 flashes of the LED located on the motor control indicate a procedural error. To reset place the handle in the neutral position.

Accelerator error : the handle is not in the neutral position or the wiring was disconnected from the handle during voltage input.

6 flashes of the LED located on the motor control indicate an error with the accelerator. To reset, place the handle in the neutral position and/or repair the wiring, then recycle energy.

Lowering valve coil or wiring faulty.

Replace the coil and/or repair the wiring.

Lowering valve faulty.

Replace the lowering valve.

Ascent valve faulty.

Replace the ascent valve.

Lifting selection switch faulty.

Replace the lifting selection switch.

Platform/Base selection switch faulty.

Replace the platform/base selection switch.

Wiring faulty.

Examine and repair the wiring.

Mode selection switch faulty.

Replace the mode selection switch.

Forward movement/ lowering faulty.

Replace the forward movement/lowering selection switch.

Wiring or wire faulty.

Examine and repair the wiring and/or the wire.

5

TROUBLESHOOTING TABLE : ELECTRICAL SYSTEM

FUNCTION The platform descends slowly, or in an irregular manner.

Two way steering problem.

PROBLEM

REMEDY

Faulty lifting cylinder.

Repair or replace the lifting cylinder(s).

Faulty lowering valve.

Replace the lowering valve.

Faulty elevation valve.

Replace the elevation valve.

Lower orifice of the lower hydraulic chain blocked.

Remove the orifice and clean it.

Activation selection switch and/or wiring faulty.

Replace the activation selection switch and/or repair the wiring.

Note : If the activation selection switch and/or the wiring are faulty, moving and lifting functions will not be operational.

Steering to the right does not operate.

Steering valve faulty.

Replace the steering valve.

Lifting valve faulty.

Replace the lifting valve.

Safety valve faulty, or badly adjusted.

If safety pressure is lower than that indicated in the technical instructions, replace the safety valve. See the hydraulic diagram for correct adjustment.

LED panel faulty/control motor faulty.

Depending upon the case, replace the panel or the control.

Steering valve faulty.

Replace the steering valve.

Right steering coil or wiring faulty.

Replace the coil and/or repair the wiring.

The steering rocker switch is faulty.

Replace the handle two way rocker switch.

Faulty wiring.

Examine and repair the wiring.

LED panel faulty.

Replace the panel.

6

FUNCTION Steering to the left does not operate.

No movement either forward or in reverse

PROBLEM

REMEDY

Steering valve faulty.

Replace the steering valve.

Left steering coil, or wiring faulty.

Replace the coil, and/or the wiring.

Faulty steering rocker switch.

Replace the handle rocker switch.

LED panel faulty.

Replace the panel.

Faulty wiring.

Examine, and repair the wiring.

Error of procedure : Forward/reverse operation selected at power input.

Two flashes of the LED located on the motor panel indicate error of procedure. To reset, place the handle in the neutral position.

Accelerator error : the handle is not in the neutral positioon, or the cable was disconnected from the handle during power input.

Six flashes of the LED located on the motor panel indicate error at the level of the accelerator. To reset place the handle in the neutral position and/or repair the cable, then recycle the energy.

Activation selection switch, and/or wiring faulty.

Replace the activation section switch and/or repair the wiring.

Note : if the activation selection switch and/or the wiring are faulty, lifting, steering, and torsion functions will not be operational.

Open traction valve.

Close the traction valve.

Braking valve coil faulty.

Replace the braking valve coil.

Brake valve faulty.

Replace the braking valve coil.

Elevation valve faulty.

Replace the upper valve.

Mode selection switch faulty.

Replace the mode selection switch.

LED panel faulty/motor control faulty.

Replace the panel/control.

Wiring or wire faulty.

Examine and repair the faulty wiring or wire.

7

TROUBLESHOOTING TABLE : ELECTRICAL SYSTEM

FUNCTION No forward or reverse movement during elevation

Slow forward and reverse movement

No forward movement.

No movement when only in reverse.

PROBLEM

REMEDY

Anti overturning system faulty.

Examine and repair the anti overturning system.

Anti overturning bars end of travel switch poorly adjusted.

Readjust the end of travel switch of the anti overturning.

Anti overturning bars end of travel switch and/or wiring faulty.

Replace the anti overturning bars end of travel switch and/ or repair the wiring.

Traction valve par tially open.

Completely close the traction valve.

Brake valve faulty.

Replace the discharge valve.

Deceleration valve or deceleration valve coil faulty.

Replace the deceleration valve or deceleration valve coil.

Steering valve faulty.

Replace the steering valve.

Forward movement valve faulty.

Replace the forward movement valve.

Torque valve faulty.

Replace the torque valve.

Forward movement/ lowering selection switch faulty.

Replace the forward movement/lowering selection switch.

LED panel faulty.

Replace the panel.

Wiring faulty.

Examine and repair the wiring.

Reverse movement valve faulty.

Replace the reverse movement valve.

Reverse/elevation selection switch faulty.

Replace the reverse/elevation selection switch.

LED panel faulty.

Replace the panel.

Wiring faulty.

Examine and repair the wiring.

8

FUNCTION

PROBLEM

REMEDY

Slow movement when only in forward.

Handle potentiometer faulty.

If voltage passing through the handle potentiometer is greater than 0.2 V DC for complete forward movement, the potentiometer must be adjusted or replaced.

Slow movement when only in

Handle potentiometer faulty.

If voltage passing through the handle potentiometer is greater than 0.2 V DC for complete reverse movement, the potentiometer must be adjusted or replaced.

Acceleration during movement on an incline.

Balance valve faulty.

Replace the balance valve.

The movement alarm does not function.

Movement alarm or wiring faulty.

Replace the mvement alarm, or repair the wiring.

LED panel faulty.

Replace the panel.

Alarm indicator and/or wiring faulty.

Replace the warning indicator, or repair the wiring.

LED panel faulty.

Replace the panel.

Horn or wiring faulty.

Replace the horn and/or repair the wiring.

Alarm switch faulty.

Replace the warning switch.

The tilting alarm does not function during elevation.

Reduced speed monitor switch poorly adjusted.

Adjust the new reduced speed monitor switch.

Note : The tilting alarm and horn are the same device. Test the horn by pressing on the alarm switch. If the horn does not work refer to “the horn does not function” section. Otherwise continue.

Reduced speed monitor switch and/or wiring faulty.

Replace the reduced speed monitor switch and/or repair the wiring.

Torque mode not operational.

Torque selection switch and/or wiring faulty.

Replace the torque selection switch and/or repair the wiring.

Torque valve coil and/or wiring faulty.

Replace the torque valve and/or repair the wiring.

Torque valve faulty.

Replace the torque valve(s).

The movement alarm indicator does not function.

The horn does not function.

Note : If the reduced speed monitor switch is poorly adjusted, reduced speed may function but it could happen that the tilting alarm does not trigger.

9