Manitou Work Platforms 80ELX 100ELX 120ELX Repair Manual 547326 - PDF DOWNLOAD

R

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

YOUR DEALER

REF : 547 326 EN (12 / 01)

PLATFORMS

80/100/120 ELX REPAIR MANUAL

1st ISSUE DATE INFORMATION CATALOGUE

10 / 12 / 2001 DATE OF ISSUE

OBSERVATIONS

SUMMARY Units 0 0-1-M.61 EN

Chapters General Technical characteristics

35

Steering

35-7-M.61 EN

Steering

40 40-7-M.61 EN

65 65-7-M.61 EN

70

Brake Brake - Motor

Chassis Anti overturning system

Hydraulic

70-6-M.61 EN

Hydraulic diagram

70-7-M.61 EN

Hydraulic system components

80

Electricity

80-6-M.61 EN

Electrical diagram

80-7-M.61 EN

Electrical components

80-8-M.61 EN

SEVCON Variator

80-8-81-M.61 EN

Position of sensors

100 10-M.61 EN

Troubleshooting Troubleshooting

UNIT 0

GENERAL

TECHNICAL CHARACTERISTICS 80 ELX - 100 ELX - 120 ELX 0-1-M.61 EN

12.01

MAIN PARTS OF THE MACHINE

Platform control box

Extendable Platform

Platform

Upper lifting cylinder

Base control panel

Lower lifting cylinder

Chassis

1

Platform access ladder

SPECIFICATIONS

80 ELX SPECIFICATIONS - Working height

7,92 m

- Height of platform

6,10 m

- Height of the secured machine : Rails retracted

2,17 m 1,42 m

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

568 kg 136 kg

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

1,17 x 2,69 m 1,10 m 18 cm 1,07 m

- Total length

2,84 m

- Total width

1,19 m

- Base

2,06 m

- Track width

1,07 m

- Turning radius Interior Exterior

0m 2,43 m

- Ground clearance

91,4 cm

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

2272 kg

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

0-1,2 km/h 0-4,0 km/h

- Raising/lowering speed (approx.)

25 seconds / 25 seconds

- Maximum gradeability

25% / 14 degrees

- Ground wheel pressure (max.)

8,27 bar

- Wind speed (max.)

0 km/h

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

406,4 x 127 mm

- Pressure of tyres (except foam tyres)

Not applicable

- Wheel T-nut torque

102-115 Nm

- Hydraulic pressure : Main circuit Lifting circuit Steering

207 bar 172,4 bar 68,9 bar

- Capacity of hydraulic fluid tank

22,7 litres

- Fuel tank capacity

Not applicable

- Electrical supply - voltage

36 volts DC

- Battery charger -

120 volts AC, 60 Hz, 10,8 Amps 36 volts DC, 20 Amps progressive, programmed stoppage

Input Output

- Batteries

Six (6) volts; 218 Amps/hours for 20 hours

- Electric motor

6,9 hp : 4000 rev/min

- Cant

2°

2

100 ELX SPECIFICATIONS - Working height

9,75 m

- Height of platform

7,92 m

- Height of the secured machine : Rails retracted

2,33 m 1,57 m

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

454 kg 136 kg

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

1,17 x 2,69 m 1,10 m 18 cm 1,07 m

- Total length

2,84 m

- Total width

1,19 m

- Base

2,06 m

- Track width

1,07 m

- Turning radius Interior Exterior

0m 2,43 m

- Ground clearance

91,4 cm

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

2455 kg

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

0-1,2 km/h 0-4,0 km/h

- Raising/lowering speed (approx.)

30 seconds / 30 seconds

- Maximum gradeability

25% / 14 degrees

- Ground wheel pressure (max.)

8,62 bar

- Wind speed (max.)

0 km/h

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

406,4 x 127 mm

- Pressure of tyres (except foam tyres)

Not applicable

- Wheel T-nut torque

102-115 Nm

- Hydraulic pressure : Main circuit Lifting circuit Steering

207 bar 172,4 bar 68,9 bar

- Capacity of hydraulic fluid tank

22,7 litres

- Fuel tank capacity

Not applicable

- Electrical supply - voltage

36 volts DC

- Battery charger -

120 volts AC, 60 Hz, 10,8 Amps 36 volts DC, 20 Amps progressive, programmed stoppage

Input Output

- Batteries

Six (6) volts; 218 Amps/hours for 20 hours

- Electric motor

6,9 hp : 4000 rev/min

- Cant

2°

3

120 ELX SPECIFICATIONS - Working height

11,58 m

- Height of platform

9,75 m

- Height of the secured machine : Rails retracted

2,48 m 1,72 m

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

318 kg 136 kg

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

1,17 x 2,69 m 1,10 m 18 cm 1,07 m

- Total length

2,84 m

- Total width

1,19 m

- Base

2,06 m

- Track width

1,07 m

- Turning radius Interior Exterior

0m 2,43 m

- Ground clearance

91,4 cm

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

3045 kg

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

0-1,2 km/h 0-4,0 km/h

- Raising/lowering speed (approx.)

40 seconds / 40 seconds

- Maximum gradeability

25% / 14 degrees

- Ground wheel pressure (max.)

9,38 bar

- Wind speed (max.)

0 km/h

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

406,4 x 127 mm

- Pressure of tyres (except foam tyres)

Not applicable

- Wheel T-nut torque

102-115 Nm

- Hydraulic pressure : Main circuit Lifting circuit Steering

207 bar 172,4 bar 68,9 bar

- Capacity of hydraulic fluid tank

22,7 litres

- Fuel tank capacity

Not applicable

- Electrical supply - voltage

36 volts DC

- Battery charger -

120 volts AC, 60 Hz, 10,8 Amps 36 volts DC, 20 Amps progressive, programmed stoppage

Input Output

- Batteries

Six (6) volts; 218 Amps/hours for 20 hours

- Electric motor

6,9 hp : 4000 rev/min

- Cant

2°

4

MOVING THE MACHINE

In the event of battery failure the machine can be moved over short distances using a winch at a speed which is not to exceed 8 km/h.

Towing/moving the machine using a hoist.

Your machine is supplied with a hand-unbraking system.

Release the brakes before moving the machine with the assistance of a winch.

• Loosen the thumb wheel (Rep 1)located on the main unit.

• Press in the freewheel valve located on the main unit (Rep 2).

• Using the emergency pump located on the chassis (Item 3) restore circuit pressure until the breaks are released.

3

2 1

CAUTION NOTHING CAN STOP THE MACHINE MOVING WHEN THE BRAKES ARE OFF. DO NOT DRIVE THE MACHINE IF THE BRAKES ARE LOOSENED. Rearming the brakes: • Pull the freewheel valve located on the main block (Rep 2).

• Tighten the star wheel located on the main block (Rep 1).

5

CIRCUITS AND EMERGENCY PROCEDURES

CAUTION In the event of control circuit failure whilst the platform is raised, ask the operator to use the emergency lowering procedure to safely lower the platform.

Do not attempt to climb down the scissors.

EMERGENCY

LOWERING

CAUTION Draw back the extension prior to lowering the platform.

DRAW BACK THE EXTENSION PRIOR TO LOWERING THE PLATFORM. The emergency lowering, and brake release, device is used to lower the platform in the event of battery, or valve, failure.

This device is to be found in a compartment of the battery charger and can be accessed via a porthole in the cover of the charger. To lower the platform, the following procedure is to be applied: 1. Pull, and maintain pulled, the red valve located on the emergency lowering and brake release manifold.

2. Pump using the black valve, also located at the same place as that of the red one, until the platform starts to descend.

Should the platform descent stop before reaching the transport position, restart pumping.

3. Release the red valve when the platform is in the transport position.

4. Call your technician, or qualified repair department.

EMERGENCY LOWERING STICKER

EMERGENCY LOWERING

1. PULL AND HOLD

2. PUMP

6

UNIT 35

STEERING

STEERING 80 ELX - 100 ELX - 120 ELX 35-7-M.61 EN

12.01

STEERING SYSTEM

1

UNIT 40

BRAKE

BRAKE - MOTOR 80 ELX - 100 ELX - 120 ELX 40-7-M.61 EN

12.01

BRAKE SYSTEM EXPLODED VIEW (for rear wheels)

1

WHEEL MOTOR EXPLODED VIEW

2

UNIT 65

CHASSIS

ANTI OVERTURNING SYSTEM 80 ELX - 100 ELX - 120 ELX 65-7-M.61 EN

12.01

ANTI OVERTURNING BARS

1

UNIT 70

HYDRAULIC

HYDRAULIC DIAGRAM 80 ELX - 100 ELX - 120 ELX 70-6-M.61 EN

12.01

HYDRAULIC DIAGRAM

SV5 FORWARD MOVEMENT SOLENOID SV4 REVERSE MOVEMENT SOLENOID PD1 PD2 ANTI TORQUE VALVES PD3 RVI

190 BAR MAIN PRESSURE LIMITER

RV2 110 BAR LIFTING PRESSURE LIMITER (80 ELX) RV2 150 BAR LIFTING PRESSURE LIMITER (100 ELX) RV2 130 BAR LIFTING PRESSURE LIMITER (120 ELX) RV3 60 BAR STEERING LIFTING PRESSURE SV6 RIGHT AND LEFT STEERING SOLENOID WM1 & WM2

TRANSLATION FOR HYDRAULIC MOTORS (FRONT WHEELS)

WB1 & WB2

NEGATIVE BRAKE BLOCKS (REAR WHEELS)

TP1

LIFTING CIRCUIT MAIN PRESSURE HEAD

NV1 CLOSED CIRCUIT THUMB WHEEL FOR WM1 & WM2 MOTORS

1

Lifting cylinder

Lifting unit

Emergency pump

Main pump

Main pressure limiter

Steering pressure limiter

Steering

Balancing valve

Brakes

Main unit

80/100 ELX

2

3

Lower cylinder

138 bars

Lifting unit

138 bars

Upper cylinder

Emergency pump

Main pump

Main pressure limiter

Steering pressure limiter

Steering

Balancing valve

Brakes

Main unit

120 ELX

HYDRAULIC SYSTEM COMPONENTS 80 ELX - 100 ELX - 120 ELX 70-7-M.61 EN

12.01

PRESSURE TAP CONNECTION

The two connections are to be joined together using a sealing solution.

MA-2 MANUAL SAFETY UNIT 1

UNIT ATTACHED TO 80-100 ELX - MA-3 LIFTING CYLINDER

120 ELX - MA-4 ELEVATION CYLINDER VALVE UNIT 2

120 ELX MA-5 ELEVATION JUNCTION BLOCK

3

TP2 TP1 E

MV1

1.

2.

3-4.

5.

6-7.

8.

9.

10-7.

11.

12-7.

15-4.

17.

18-7.

Flow divider (FD1) Anti torque valve (PD1) Speed torque (SV7) Orifice 2 jet nozzle Brake hydraulic decompression unit solenoid (SV3) Steering limiter (RV3) Plug Descent solenoid (SV2) Main pressure limiter (RV1) Elevation/translation solenoid (SV1) Right steering (F) (SV6) Balance valve (CB1) Forward (B) (SV5) Reverse (D) (SV4)

MV1 Free wheel thumb wheel E Left steering (SV6) 22. Lifting limiter (RV2) 23. Free wheel activation valve (MP1) 24-25 Pressure tap (TP1 – TP2) 29. Regulator (FR1) 30. Hydraulic unit 41. Anti torque valve PD2-PD3 42. Orifice 1 nozzle 43. Motor brake solenoid (SV8)

MAIN UNIT MA-1

4

UNIT 80

ELECTRICITY

ELECTRICAL DIAGRAM 80 ELX - 100 ELX - 120 ELX 80-6-M.61 EN

12.01

2

80 / 100 / 120 ELX 3

ELECTRICAL COMPONENTS 80 ELX - 100 ELX - 120 ELX 80-7-M.61 EN

12.01

SUMMARY

PAGE - 6V BATTERY WIRING .............................................................................................

3

- ELECTRICAL POWER WIRING .............................................................................

4

- BASE CONTROL CONSOLE .................................................................................

5

- PROPORTIONAL MANIPULATOR .........................................................................

6

1

BATTERY COMPARTMENT

3

HYDRAULIC UNIT

4

2

Lifting/descent selector

4 11 5

16 5

20 3 Reset fuse

12

3

7 8

Emergency stop

4 50 Front

4 50 50

6 5 10 Back

Base / basket key control selector

5

50

4

50 4 Battery charge indicator

Hour meter

3

1

4

2

WIRE 8 A

5

Front Descent Contact

WIRE 12 B WIRE 11

6

Rear Lifting Contact

WIRE 8

8 7 9

24

10 11 12 13 14 15

29

16 17

28

18

A 27

19 20

B 26 25 24

23

22 21 20 k ohms variable resistor

CONTROL BOX COVER

6

1

2

A

B

C

13 15

A - «Anti torque» selector B - «Cant» indicator C - Horn

1 - Lifting-descent/translation selector 2 - Emergency stop 13 - «Torque mode» selector 15 - «Cant» indicator

CONTROL BOX

7

SEVCON VARIATOR 80 ELX - 100 ELX - 120 ELX 80-8-M.61 EN

12.01

DIAGNOSIS

The PowerPack variator is fitted with a flashing LED which indicates an error code.

List of error codes : LED on

Variator.

LED off

Variator turned off, or faulty.

1 flash

Non-volatile memory fault.

Check all parameters, turn off power then turn power on.

If the problem continues change the logical section of the variator.

2 flashes

Procedural fault (example : steering demand before closing the dead man’s brake contact). To solve this problem reposition the manipulator in the neutral position then restart the procedure.

3 flashes

Continually low motor power (MOSFET short circuit).

4 flashes

Continually high motor power (motor supply circuit open).

5 flashes

Variator insulation faulty (replace the variator).

6 flashes

Accelerator faulty. The manipulator potentiometer shows a value which exceeds 15 percent, or cut wire, at power input.

7 flashes

Faulty battery voltage (voltage either too low or too high).

8 flashes

Thermal cut off at 75°C (variator temperature).

9 flashes

Fault on the line contact supply line (short circuit or open circuit).

10 flashes

Anti overturning bars contact faulty.

11 flashes

Working position cant sensor intervention.

1

POWER PACK variator wiring

2

LINE CIRCUIT BREAKER REVERSE MOVEMENT DESCENT ASCENT SPEED TORQUE MODE LEFT STEERING BRAKE REALISING FORWARD MOVEMENT CANT RIGHT STEERING

Translation

Lifting

Cant

Potentiometer

Left steering

Cant

Right steering

Reverse/ascent

Ascent/descent

Fuse

Base basket

UPPER CONSOLE REF CONNECTION PIN << REF CONNECTION CONSOLE

Basket emergency stop

= closed contact

Dead Man’s pedal

Base emergency stop

Forward/descent

MOTEUR

NOTES 1. CAPTION :

CONNECTOR A - INPUTS 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160

Supply + 36 Volts Front translation + Descent Rear translation + Lifting Translation mode Speed troque (fast or slow) 2 meter switch transport mode/work mode Pothole switch/arm low Right steering Left steering Not connected Potentiometer acceleration Not connected Cant = closed contact Lifting mode Not connected Not connected CONNECTOR B - OUTPUTS 10 20 30 40 50 60 70 80 90 100 110 120

POWER PACK Variator

3

Supply + 36 Volts Line circuit breaker Reverse movement Descent Ascent Speed torque mode Left steering Brake releasing Forward movement Cant Right steering Supply + 36 Volts

POWER PACK Variator Connector A control inputs

Connector B control inputs

CONN B

CONN A

Parametering terminal connector

LED Variator under power

P

A

B+

R

Logic box

Power box

S

B-

The PowerPack variator assures the logical functions of the machine along with electric motor speed variation.

Note : This is an ivnerse logic variator.

Battery negative activates inputs and outputs.

OUTPUTS

INPUTS Power Pack Variator

POWER PACK variator menus TRACTION 0 OK

CALIBRATOR 0 OK

4-1

CHOICE OF LANGUAGE

1-1

PARAMETERING

1-2

MEASURE

1-3

TEST

1-4

IDB

1-5

FAULT

1-6

SETUP

4

Use of calibrator for POWER PACK ELX platform

Traction Ø -------------------------------------------------------------------------------> OK

Calibrator

1.1 Traction Ø ---> 1.2 Traction Ø ---> 1.3 Traction Ø ---> 1.4 Traction Ø ---> 1.5 Traction Ø ---> 1.6 Traction Ø Parametering measure test IDB fault setup

1.1.1 Trac. Para ---> 1.1.2 Trac. Para ---> 1.1.3 Trac. Para ---> 1.1.4 Trac. Para ---> 1.1.5 Trac. Para ---> 1.1.6 Trac. Para I max 300A trac accel 1.55 trac decel 0.1 s lift accel 0.2 s lift decel 0.1 s accel ass ster 0.1 s

> 1.1.7 Trac. Para

---> 1.1.8 Trac. Para ---> 1.1.9 Trac. Para ---> 1.1.10 Trac. Para ---> 1.1.11 Trac. Para ---> 1.1.12 Trac. Para decel ass steer 0.1 s Zero speed steer add 5% Trac speed 100% cut speed 1 15% Cut accel 1 1.5 s

> 1.1.15 Trac. Para accel mini 3.90 v

> 1.1.21 Trac. Para prot. batt 14.5 v

1.1 Traction Ø Parametering

---> 1.1.16 Trac. Para ---> 1.1.17 Trac. Para ---> 1.1.18 Trac. Para ---> 1.1.19 Trac. Para ---> 1.1.20 Trac. Para accel mini 0.20 v

Slow speed Ini 14.5 v

Slow speed cut out 14.5 v

high speed Ini 70.0 v

high speed cut out 70.0 v

---> 1.1.22 Trac. Para ---> 1.1.23 Trac. Para ---> 1.1.25 Trac. Para ---> 1.1.26 Trac. Para Prot. relay 2.5 s descent time 5.0 func timer 15.0 lift speed 100%

1.2 Traction Ø measure

1.3 Traction Ø test

1.4 Traction Ø IDB

1.5 Traction Ø fault

1.6 Traction Ø setup

1.2.1 Trac. Mes ---> 1.2.2 Trac. Mes ---> 1.2.3 Trac. Mes ---> 1.2.4 Trac. Mes ---> 1.2.5 Trac. Mes ---> 1.2.6 Trac. Mes battery 36.8 v Motor 0.0 v Motor 0 A temp 22°C Mos Fet 8.0 v Condens. 37.0 v

>1.2.7 Trac. Mes -----------> 1.2.8 Trac. Mes ---> Service Hour meter G 71.Ohrs Hora M 1.9 v Press + RAZ

5

1.1 Traction Ø Parametering

1.2 Traction Ø measure

1.3 Traction Ø test

1.4 Traction Ø IDB

1.5 Traction Ø fault

1.6 Traction Ø setup

1.3.1 Trac. test ---> 1.3.2 Trac. test --------> 1.3.3 Trac. test ----------> 1.3.4 Trac. test -------------> 1.3.6 Trac. test Accel 4% Accel 3.78 v fwd init open revers init open Trac Sel Sw open (manip reverse contact) (manip reverse contact) (remote cotnrol translation selection switch)

> 1.3.7 Trac. test -----------> 1.3.8 Trac. test -------------> 1.3.9 Trac test ---------> 1.3.10 Trac test ------------------> 1.3.13 Trac test Pwr mode ouvert Steer R ouvert Steer L ouvert speed 1 closed when < 2m lift closed (dead man pedal) (right steering) (left steering) lifting selector

> 1.3.14 Trac. test -----------> 1.3.15 Trac. test -------------> 1.3.16 Trac test pothole lim open Software v206HT Ser No 0020743

1.1 Traction Ø Parametering

1.2 Traction Ø measure

1.3 Traction Ø test

1.4 Traction Ø IDB

1.5 Traction Ø fault

1.6 Traction Ø setup

> 1.4.1 IDB

---------> 1.4.2 IDB ------------> 1.4.3 IDB -----------> 1.4.4 IDB ----------> 1.4.5 IDB ----------> 1.4.6 IDB 49% batt charge Batt voltage 36v regl 2.10v/lift Dech. 1.5v/lift avertiss. 0% cut out 1%

1.1 Traction Ø Parametering

1.2 Traction Ø measure

1.3 Traction Ø test

1.4 Traction Ø IDB

> 4*04 F

9.6hr ----------------------------------------------------------> Fault contactor c/o press + Reset (record a fault and give an error code)

6

1.5 Traction Ø fault

1.6 Traction Ø setup

1.1 Traction Ø Parametering

1.2 Traction Ø measure

1.3 Traction Ø test

1.4 Traction Ø IDB

1.5 Traction Ø fault

1.6 Traction Ø setup

1.6.1 Trc. Setup ------> 1.6.2 Trc. Setup --------> 1.6.3 Trc. Setup --------> 1.6.4 Trc. Setup ---------> 1.6.5 Trc. Setup convert select OFF accel linear IDB on Dead man Off power mode on

> 1.6.6 Trc. Setup Pin 8 steer

-------> 1.6.7 Trc. Setup --------> 1.6.8 Trc. Setup --------> 1.6.9 Trc. Setup ---------> 1.6.10 Trc. Setup Pin 9 Future use Pin 7 potehlim Pin 11 accel cont 6 decel conv

> 1.6.11 Trc. Setup -------> 1.6.12 Trc. Setup --------> 1.6.13 Trc. Setup --------> 1.6.14 Trc. Setup ---------> 1.6.15 Trc. Setup con 8 alarm EN Fault ON service param. On Mode number 0 DM SCIS SAFE ON

> 1.6.16 Trc. Setup Trac selec ON

-------> 1.6.17 Trc. Setup --------> 1.6.18 Trc. Setup steer decal OFF Tilt OFF

7

POSITION OF SENSORS 80 ELX - 100 ELX - 120 ELX 80-8-81-M.61 EN

12.01

Position of anti overturning bars

Cant sensors

COWLING

1

WORK/TRANSPORT MODE 2 METER SENSORS

2

UNIT100

TROUBLE SHOOTING

TROUBLESHOOTING 80 ELX - 100 ELX - 120 ELX 100-M.61 EN

12.01

TROUBLESHOOTING TABLE : ELECTRICAL SYSTEM

PROBLEM The basket does not raise when activated from the base or basket control consoles.

The platform does not raise when activated from the base control console.

The platform does not raise when activated from the basket control console.

CAUSE

REMEDY

Error 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.

Elevation valve faulty.

Replace the elevation valve.

Descent valve faulty.

Replace the descent valve.

Safety valve faulty, 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.

Motor control logic card faulty.

Replace the motor control logic card.

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.

1

PROBLEM The platform ascends slowly and in an iregular manner.

The platform does not descend when activated from the base or basket control consoles.

The platform does not descend when activated from the base control console.

The platform does not descend when activated from the basket control console.

CAUSE

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.

Emergency lowering valve faulty.

Replace the emergency lowering valve.

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.

Motor control logic card faulty.

Replace the motor control logic card.

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.

2

TROUBLESHOOTING TABLE

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

Two way steering problem.

CAUSE

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.

Steering valve faulty.

Replace the steering valve.

Right steering coil or wiring faulty.

Replace the coil and/or repair the wiring.

Battery voltage below 30 volts

Change the batteries.

The steering rocker switch is faulty.

Replace the handle two way rocker switch.

Faulty wiring.

Examine and repair the wiring.

Motor control logic card faulty.

Replace the motor control logic card.

3

PROBLEM Steering to the left does not operate.

No movement either forward or in reverse

CAUSE

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.

Faulty wiring.

Examine, and repair the wiring.

Motor control logic card faulty.

Replace the motor control logic card.

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.

Discharge valve coil faulty.

Replace the discharge valve coil.

Discharge valve faulty.

Replace the discharge valve.

Elevation valve faulty.

Replace the upper valve.

Mode selection switch faulty.

Replace the mode selection switch.

Wiring or wire faulty.

Examine and repair the faulty wiring or wire.

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TROUBLESHOOTING TABLE

PROBLEM No forward or reverse movement during elevation

Slow forward and reverse movement

No forward movement.

No movement when only in reverse.

Slow movement when only in forward.

CAUSE

REMEDY

Anti overturning system faulty.

Examine and repair the anti overturning system.

Anti overturning end of travel contact badly adjusted.

Readjust the anti spillage end of travel contact.

Anti overturning end of travel contact and/or wiring faulty.

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

Traction valve partially open.

Completely close the traction valve.

Discharge 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.

Wiring faulty.

Examine and repair the wiring.

Motor control logic card faulty.

Replace the motor control logic card.

Reverse movement valve faulty.

Replace the reverse movement valve.

Reverse/elevation selection switch faulty.

Replace the reverse/elevation selection switch.

Wiring faulty.

Examine and repair the wiring.

Motor control logic card faulty.

Replace the motor control logic card.

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.

5

PROBLEM

CAUSE

REMEDY

Slow movement when only in reverse

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 movement alarm, or repair the wiring.

Motor control logic card faulty.

The movement alarm indicator does not function.

Replace the motor control logic card.

Alarm indicator and/or wiring faulty.

Replace the warning indicator, or repair the wiring.

Motor control logic card faulty.

Replace the motor control logic card.

Horn or wiring faulty.

Replace the horn and/or repair the wiring.

Horn switch faulty.

Replace the horn 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.

Note : if the reduced speed limiter switch is not adjusted correctly, reduced speed may not function correctly, and it is possible that the overturning warning will not activate.

The horn does not function.

Torque mode not operational.

Reduced speed monitor switch and/or wiring faulty.

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

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).

Motor control logic card faulty.

Replace the motor control logic card.

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