Manitou Work Platforms A 110ELX Repair Manual 547 333 - PDF DOWNLOAD

R

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

YOUR DEALER

REF : 547 333 EN (03 / 02)

PLATFORMS

110ELX REPAIR MANUAL

1st DATE OF ISSUE INFORMATION CATALOGUE

DATE OF ISSUE

29 / 03 / 2002 OBSERVATIONS

SUMMARY Units 0 0-1-M.63 EN

Chapters General Technical characteristics

35

Steering

35-7-M.63 EN

Front axle

40 40-7-M.63 EN

65 65-7-M.63 EN

70

Brake Brake - Motor

Chassis Anti overturning system

Hydraulik

70-6-M.63 EN

Hydraulik diagram

70-7-M.63 EN

Hydraulik system components

80

Electricity

80-6-M.63 EN

Electrical diagram

80-7-M.63 EN

Electrical components

80-8-M.63 EN

SEVCON Variator

80-8-81-M.63 EN

Position of sensors

100 100-M.63 EN

Troubleshooting Troubleshooting

UNIT 0

GENERAL

TECHNICAL CHARACTERISTICS 110 ELX 0-1-M.63 EN

03.02

MAIN PARTS OF THE MACHINE

Platform control box Extendable apron

Platform main apron

Upper lifting cylinder

Compensating beams

Lower lifting cylinder Frame control panel

Frame

1

Ladder

SPECIFICATIONS

110 ELX SPECIFICATIONS - Working height

11 m

- Height of platform

9,14 m

- Height of the secured machine : Rails retracted

2,71 m 1,95 m

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

454 kg 181 kg

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

1,52 x 2,79 m 1,10 m 15 cm 1,22 m

- Total length

3,05 m

- Total width

1,73 m

- Base

2,18 m

- Track width

1,54 m

- Turning radius Interior Exterior

2,06 cm 4,45 m

- Ground clearance

11,11 cm

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

3078 kg

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

0-0,8 km/h 0-5,0 km/h

- Raising/lowering speed (approx.)

36 seconds / 26 seconds

- Maximum gradeability

25% / 14 degrees

- Ground wheel pressure (max.)

8,89 bar

- Wind speed (max.)

0 km/h

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

647,7 x 200,6 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 55,0 bar

- Capacity of hydraulic fluid tank

53,0 litres

- Fuel tank capacity

Non applicable

- Electrical supply - voltage

48 volts DC

- Battery charger -

230 volts AC, 50 Hz, 48 volts DC, 20 Amps progressive, programmed stoppage

Input Output

- Batteries

Eight (6) volts; 245 Amps/hours for 20 hours

- Electric motor

8 hp (6 kW) : 3400 rev/min

2

MOVING THE MACHINE In the event of power failure the machine can be moved, over short distances, using a winch at a speed which is not to exceed 8.05 km/h.

Releasing of the brakes / towing of the machine.

Your machine is fitted with valves for releasing the brakes, and the free wheel.

Release the brakes prior to moving the machine by means of a winch.

• Press on the manual valve for brake release which is located on the main manifold.

• Using the emergency lowering system manual pump (located in front of the left rear wheel inside the compartment) pump the valve until pressure rises and the brakes are released.

• Open the free wheel valve by turning it anti clockwise and enable the motors to let the wheels turn freely.

.

Pump

Pull and hold in this position

Free wheel valve

Brake release manual valve

CAUTION NOTHING CAN STOP THE MACHINE MOVING WHEN THE BRAKES ARE RELEASED. THE MACHINE MOVES FREELY ON SLOPES. TAKE CARE WHEN A MACHINE IS ADRIFT. DO NOT DRIVE A MACHINE WITH SLACKENED BRAKES.

Resetting the brakes: • The brakes are reset when the driving function is activated, or rearmed by pulling on the free wheel valve.

• Close the free wheel valve by turning it clockwise.

3

EMERGENCY PROCEDURES AND CIRCUITS

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

Do not attempt to descend by the compensating beams (scissors).

EMERGENCY LOWERING

CAUTION RETRACT THE EXTENSION BEFORE LOWERING THE PLATFORM.

The system for brake release and emergency lowering is used to lower the platform in the event of current or valve failure. To lower the platform proceed as follows: • Manually pull the valve plunger located at the bottom of the manifold and retain it in this position.

• While holding the plunger, manually pump the upper plunger until the platform starts to lower.

• Releasing the plunger from the bottom will stop descent.

(The manifold is located in front of the left rear’ wheel inside the compartment).

EMERGENCY LOWERING STICKER

2. PUMP 1. PULL & HOLD EMERGENCY LOWERING

4

UNIT 35

STEERING

FRONT AXLE 110 ELX 35-7-M.63 EN

03.02

FRONT AXLE

1

UNIT 40

BRAKE

BRAKE - MOTOR 110 ELX 40-7-M.63 EN

03.02

BRAKE SYSTEM EXPLODED VIEW (FOR REAR WHEELS)

1

1l 1m 1j 1j 1n

1j

1k

2q

2r 1i

2p 1h 1g

1c

1e

1f

1d 1b

1a

WHEEL MOTOR EXPLODED VIEW

2

UNIT 65

CHASSIS

ANTI OVERTURNING SYSTEM 110 ELX 65-7-M.63 EN

03.02

STABILISERS

1

UNIT 70

HYDRAULIC

HYDRAULIC DIAGRAM 110 ELX 70-6-M.63 EN

03.02

1

STEERING

HYDRAULIC DIAGRAM

DRIVING

UPPER LIFTING

LETTER MA-1 Q,V,W A B,H M F C D,Y I,U P,S E N,O K L B,H,M,N,O,P,S K K AA X R G AB MA-2 AC AD AE MA-3 AF AG CYL 1 G1 P1

DESCRIPTION OF PARTS

Connection unit assembly SAE 10 control valve Safety valve Two way valve Valve Valve Valve SAE 8 control valve Valve Valve Plug Valve Valve Valve Coil Coil Orifice plug Orifice plug Plug Valve Valve Connection unit Lifting cylinder connection unit Control valve Valve Orifice Emergency lowering connection unit Hydraulic manual pump Valve Steering cylinder Main and lifting pressure test point Pump

2

VALVE PRESSURE

N/A 3 Bar 190 Bar N/A N/A N/A N/A 3 Bar 105 Bar N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 150 Bar 55 Bar N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

HYDRAULIC SYSTEM COMPONENTS

110 ELX 70-7-M.63 EN

03.02

12

7

6

8 4 10 5

9

13 3 11 14

15

18

17

16

1 2

LIFTING UNIT 1

1 2 6 7

5

4

8 3 9

16 15 14 12

10

11 7 8

UNIT ATTACHED TO THE LIFTING CYLINDERS - MA-2 2

15

16

14 13 12 11 1

2

10 3

9 8 (under coil)

5-6 4

7

22

31

17

24

18

30 27-28 29

25-26 19

23 32

33

49

34

47 45

52

51

44

20-21

35

50

36

48 46

37 43 42

MAIN UNIT 3

41

40 39

38

UNIT 80

ELECTRICITY

ELECTRICAL DIAGRAM 110 ELX 80-6-M.63 EN

03.02

1

2

ELECTRICAL COMPONENTS 110 ELX 80-7-M.63 EN

03.02

SUMMARY

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

3

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

4

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

5

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

6

1

Battery

3

48 47 BATTERY

36 25 35 34 33 32

38

46 45 44 42-43 41 40

31

30

37 39

+

6 7 4

20

16

3

1

27

28

5

19 12 11

2

13 14 15

17 18

27

BATTERY

8

9

10

21

Electrical box

4

29 26 25 24 23 22

BASE/BASKET CONTROL

LIFTING/ DESCENT SELECTOR

FRONT

RESET FUSE

REAR

EMERGENCY STOP

BATTERY CUT OFF

RED WIRE 6

BATTERY LOAD INDICATOR

BLACK WIRE 14 BUZZER

5

HOUR METER

3

2

1

4

5 6 7 8

12

9

13 14 15

10 11

Control box

6

SEVCON VARIATOR 110 ELX 80-8-M.63 EN

03.02

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

Pothole bars contactor faulty.

11 flashes

Working position cant sensor intervention.

1

POWER PACK variator wiring N/C RED

ORN

ORN

BRN/BLU

N/C BRN/PNK

BRN/ORN

LT/ORN/WHT

BRN/RED

VIO/BLU

WHT/BLK/RED

WHT/BLK/VIO

WHT/BLK/BRN

WHT/BLK/BLU

RED

N/C

LINE CONT

TRANSLATION

LIFTING

CANT

POTENTIOM.

LEFT STEERING

RIGHT STEERING

CANT = CLOSED CONTACT

OPEN RETRACTEDPOTHOLE

POTHOLE SYSTEM CLOSED

CUTBACK CLOSED = SCISSORS SEATED

FORWARD/DESCENT REVERSE/ DEAD MAN PEDAL ASCENT

BASE EMERGENCY STOP

MOTEUR

HEIGHT LIMIT (OPTIONAL)

RED

N/C (8 +)

RED

BASKET EMERGENCY STOP

<<

RED

BLU/WHT

VIO/WHT

WHT/BLU

FUSE 15 AMP

1. CAPTION :

NOTES

ORN/RED

BLU/BLK

WHT/ORN

ASCENT/DESCENT

GRN/WHT

= REF CONSOLE CONNECTION

= REF PIN CONNECTION

= UPPER CONSOLE

BASKET/BASE

GRN/BLK

2

POWERPACK VARIATOR

CONNECTOR A CONTROL INPUTS CONNECTOR B OUTPUT TO SOLENOIDS CONN B

CONN A

PARAMETERING TERMINAL CONNECTOR

P

A

B+

R

LED

LOGIC BOX

S

B-

POWER BOX

VARIATOR UNDER POWER

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

3

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

4

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 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

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

---> 1.1.16 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

---> 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%

5

high speed cut out 70.0 v

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

1.2.1 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

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%

6

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

1.5 Traction Ø fault

1.6 Traction Ø setup

> 4*04 F

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

1.1 Traction Ø Parametering

1.2 Traction Ø measure

1.3 Traction Ø test

1.4 Traction Ø IDB

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 -------> 1.6.7 Trc. Setup --------> 1.6.8 Trc. Setup --------> 1.6.9 Trc. Setup ---------> 1.6.10 Trc. Setup Pin 8 steer 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 110 ELX 80-8-81-M.63 EN

03.02

Anti overturning bar’s sensor

Scissor’s end of travel sensor

1

UNIT100

TROUBLE SHOOTING

TROUBLESHOOTING 110 ELX 100-M.63 EN

03.02

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 thanks 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)

PROBLEM Steering

CAUSE

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 the adjustment of safety valve A. It should be set at 190 bars.

Check the adjustment of safety valve G. It should be set at 55 bars.

Check that valve F is not dirty. Check valve F voltage. For each steering turn, one of the coils must be under power.

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

Check the voltage of valves B and H. Coils should not be under power during turning.

Check that valves B, F, and H are not dirty.

Lifting

At test orifice level pressure is approwimately 69 bars.

Check that valve F is not dirty.

The platform does not ascent

Check test orifice (3) pressure whilst at the same time lifting. Under normal operation pressure should be approximately 152 bars – 110 ELX during lifting.

Test orifice pressure is much lower than 152 bars – 110 ELX.

Check safety valve A adjustment. It should be 190 bars.

Check safety valve R adjustment. It should be 152 bars.

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

Check the voltage of valve S. During lifting the coil should not be under power.

Check that valves B and S are not dirty.

Check that valve P is not dirty.

Check the voltage of valve P. During lifting the coil should not be under power.

Platform speed reduction

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

Check that valve S is not dirty.

The platform does not go back down manually

Check that the manual hand pump valve is operational.

Make sure that the hand pump is working.

2

PROBLEM Moving

CAUSE

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 safety valve A. It should be set at 190 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 the voltage of valves J and T. For each drive steering the opposite coils should be under power.

Check the voltage of valves M, N, and O. the coils in question should be under power in engaged torque mode, or without power in disengaged torque mode.

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

The torque mode does not engage.

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

Check that valves M, N, and O are not dirty.

The machine moves over flat ground but will not climb.

Check the voltage of valves M, N, and O. The coils in question should be under power so that the torque mode engages.

The machine does not stop smoothly.

Check the adjustment of safety valve A., it should be 190 bars.

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

OVER PRESSURE ADJUSTMENT PROCEDURE

STEERING Connect the pressure gauge (0-241 bars) using the female quick disconnect coupling to the main test orifice. Activate the steering, and turn it entirely to the left. Keep the selection switch pressed down for 20 seconds to obtain an exact reading on the pressure gauge.

Should an adjustment be necessary, set pressure to 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 pressure gauge (0-241 bars) using the female quick disconnect coupling to the main test orifice. Raise the platform to the maximum without load. Keep the selection switch pressed down for 20 seconds to obtain an exact reading on the pressure gauge.

Should an adjustment be necessary, set pressure to 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 pressure gauge (0-241 bars) gauge 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. Place the driving function under power by moving the handle (lever) in the direction of the already disconnected coil. Keep the selection switch pressed down for 20 seconds to obtain an exact reading on the pressure gauge.Page 80 Should an adjustment be necessary, set pressure to 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.

4

TROUBLESHOOTING TABLE : ELECTRICAL SYSTEM

PROBLEM

CAUSE

REMEDY

The platform does not Error of procedure : lifting ascend from the base or selected during power platform. 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.

Battery voltage below the previously set value: indicated by 7 flashes on the control LED.

Cut off contact, recharge the batteries and turn the current back on. Note: if batteries are recharged when current is turned on, the current must then be reset to activate lifting.

Ascent valve coil or wiring faulty.

Replace the coil and/or repair the wiring.

Ascent valve faulty.

Replace the ascent 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.

The platform does not ascend just from the base.

The platform does not ascend from just the platform.

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.

5

PROBLEM The platform does not ascend from just the platform.

CAUSE

Forward/lifting selection Replace the reverse/lifting selection switch. switch faulty.

Wiring, or wire faulty.

The platform ascends slowly and in an iregular manner.

REMEDY

Handle faulty.

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

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

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

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: Procedural error: lowering selected during power input.

Replace the emergency lowering valve.

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 accelerator error. For zero reset place the handle in the neutral position and/or repair the wiring, then reset the current.

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

Lowering valve coil or Replace the coil and/or repair the wiring. wiring faulty.

Lowering valve faulty.

Replace the lowering valve.

Motor control logic card Replace the motor control logic card. faulty.

The platform does not descend just from the base.

Mode selection switch Replace the mode selection switch. faulty.

Forward movement/ Replace the forward movement/lowering selection switch. lowering faulty.

Wiring or wire faulty.

Examine and repair the wiring and/or the wire.

6

PROBLEM The platform does not descend just from the platform.

CAUSE

REMEDY

Mode selection switch Replace the mode selection switch. faulty.

Forward movement/ Replace the forward movement/lowering selection switch. lowering faulty.

The platform descends slowly, or in an irregular manner.

Wiring or wire faulty.

Examine and repair the wiring and/or the wire.

Faulty lifting cylinder.

Repair or replace the lifting cylinder(s).

Faulty lowering valve.

Replace the lowering valve.

Lower orifice of the lower Remove the orifice and clean it. hydraulic chain blocked.

Two way steering problem

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

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

Steering valve faulty.

Replace the steering valve.

Lifting valve faulty.

Replace the lifting valve.

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

Steering to the right does not operate.

Steering valve faulty.

Replace the steering valve.

Right steering coil or wiring Replace the coil and/or repair the wiring. faulty.

Battery voltage less than 40 volts.

Recharge the batteries.

The steering rocker switch Replace the handle two way rocker switch. is faulty.

Faulty wiring.

Examine and repair the wiring.

Motor control logic card Replace the motor control logic card. faulty.

Steering to the left does not operate.

Steering valve faulty.

Replace the steering valve.

Left steering coil, or wiring Replace the coil, and/or the wiring. faulty.

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PROBLEM Steering to the left does not operate.

No movement either forward or in reverse

CAUSE

REMEDY

Battery voltage less than 40 volts

Recharge the batteries.

Faulty steering rocker switch.

Replace the control lever.

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.

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 brake valve coil.

Brake valve faulty.

Replace the brake valve.

Mode selection switch faulty.

Replace the mode selection switch.

Wiring or wire faulty.

Examine and repair the faulty wiring or wire.

No forward or reverse movement during elevation

Pothole system faulty.

Examine and repair the pothole system.

Pothole end of travel contact badly adjusted.

Re-adjust the pothole end of travel contact.

Slow forward and reverse movement

Pothole end of travel contact, and/or wiring faulty.

Replace the pothole end of travel contact, and/or repair wiring.

Traction valve partially open.

Completely close the traction valve.

Braking valve faulty

Replace the brake valve.

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PROBLEM

CAUSE

REMEDY

Elevation valve faulty.

Replace the elevation 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/ 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/elevation selection switch faulty.

Replace the reverse/elevation selection switch.

Wiring faulty.

Examine and repair the wiring.

Motor control logic card faulty.

Handle potentiometer fault

Replace the motor control logic card.

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.

Forward driving valve, or coil, faulty.

Replace the forward driving valve, or coil.

Torque valve faulty

Replace the torque valve.

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.

Reverse driving valve, or coil faulty

Replace the reverse driving valve, or coil.

Torque valve faulty

Replace the torque valve.

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.

Replace the motor control logic card.

Slow forward and reverse movement

No forward movement.

No movement when only in reverse.

Slow movement when only in forward.

Slow movement when only in reverse

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PROBLEM The movement alarm indicator does not function.

The horn does not function.

CAUSE

REMEDY

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.

Replace the horn switch.

Warning switch faulty.

The tilting alarm does not function during elevation.

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.

Torque mode not operational.

Reduced speed monitor switch poorly adjusted.

Adjust the new reduced speed monitor switch.

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.

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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LIGHT EMITTING DIODE DIAGNOSIS DEFINITIONS LED READING

DIAGNOSIS

LED on

Operational control device

Led off

Internal fault

1 flash

Redundancy cyclical parametering/control error. This error is, generally, an internal error of the permanent memory. To remove this error check all the personal parameters which can be adjusted and reset the current. Should the fault persist, or if this error reoccurs, replace the logic card.

2 flashes

Procedural error. This includes cases where driving, activation bar, steering, or lifting functions are selected at power input, and cases where driving, lifting, or steering functions are selected without the activation bar, and the dead point of the activation bar has remained inactive for 20 seconds.

Reset, by placing the handle in neutral which erases the error.

3 flashes

Motor permanently slow.

This includes MOSFET short circuits. This fault interrupts all modes. Reset by placing the handle in neutral. This erases the fault.

4 flashes

Motor permanently fast.

This includes the pump circuit breaker which is either stuck or open.

This fault interrupts all modes.

Reset the platform/base selection switch, which erases the error.

5 flashes

Supply chassis capacitor load error.

Check the wiring. Replace the power supply unit.

6 flashes

Faulty accelerator.

This includes the case where the accelerator is 15 % more powerful at power input, and where the wiring is disconnected. Should wiring become disconnected during an active function, motor speed will be invalid and the accelerator will be poorly adjusted.

7 flashes

Battery voltage error.

This includes the case where the battery voltage is either too high or too low (as defined by adjustable parameters) or the battery discharged indicator has reached the disconnection level. Reset the neutral to erase the error.

8 flashes

Thermal reduction.

This includes the case where the MOSFET temperature exceeds 75°C. Automatic erasure.

9 flashes

Short circuit of the pump circuit breaker coil, or poor wiring.

Reset the current to erase.

10 flashes

Faulty deployment of pothole system.

Lower the scissors to erase.

11 flashes

Interruption of tilting and elevation of the scissors.

In driving mode, lower the scissors to erase the error.

Lowering is still possible.

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