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1. ER 61 re te ees cose e un e du sU ciara un M edo 62 IDENTIFICATION PLATES amp OPTIONAL 64 sme Ne mess get 67 hid pem En 68 io mad ce C ra ery 68 DIV IN Se CONTROLS nu DER 68 BintimP BESSER 69 NIIS d E 71 PLATFORMIROTATOR Em 74 T MATERIAL SAFETY tu a eee ee 75 SAN LEE 85 INSPECTION FORM FOR HAULOTTE GROUP AERIAL WORK PLATFORMS sss 93 HAULOTTE GROUP LIST OF ILLUSTRATIONS Foure 2 1 EE 13 Figure 3 1 Ground Lower Control Pane 20 Figure 3 2 Platform Upper Control E 22 FIqure 3 9 E OT cu 24 Figure 3 4 Platform Travel 25 Figure 3 5 Platlorm 25 Figure 3 6 eine eee 26 Figure 3 7 Hand Pump Controls for Manual
2. 18 S OPERATION T 19 GROUND LOWER CONTROL PANEL Lupa e emer Cus 20 PLATFORNMAUPPER GONTROL 22 e fedus uu Rea RR RAN e e eed ental 24 MANUAL BOOM OPERATION 2d usd esu eR tt tiet ten coms 28 TOWING THE AERIAL WORK PLATFORM 30 LIFTING THEAERIAL WORK Hr ulus umi S uo 32 TRANSPORTING THE AERIAL WORK PLATFORM ON A TRUCK uses 33 E QUIPMENT MAINTENANGE s nta itt 35 BATTERY RECHARGE idu ai e Ls Mum cde ac au 36 BATTERY FAULT CODES T 37 BY eroi ze Que M 38 WEEKLY SERVICE OGHEOK o 41 SERVICE GIHEGISS su denda auum E 42 OVERLOAD PROTECTION CALIBRATION PROCEDURE eene 43 ADDITIONAL SERVICE INFORMATION ziens nnne nnne enhn nennen nnn nnne 45 TROUBLE SHOGO THN Cp 46 ERROR CODE DEFINITIONS CONTROLS enhn nnns 47 ERROR CODE DEFINITIONS MOTOR CONTROLLER 58 MOE CALREPRLACEME NT
3. 28 Figure 3 8 Manual Boom Lowering Valve cccceeccceseeceseeceeeecceeeeceseeceuseceeeesueeseeessueeseueesseneensags 29 Figure 59 Taner ING pio MERE TS 31 Figure 3 10 Lifting the Aerial Work Platform eese nennen 32 Figure 3 11 Transporting the Aerial Work 33 Figure 4 1 Battery Charger 36 Figure 4 2 OUutlgger POSITION ioo alert a a a e e 39 Figure 4 5 Fiydraulic eset Vol ride Ea REDE 40 Figure 4 4 Wheel Nut Tightening Sequence essessssssssseeeee nennen nennen nnne nnn nnn nnns na rrr nnns 42 Figure 4 5 Platformi POSUN 43 Figure 4 6 Ground Lower Control Panel for Overload Protection 43 Figures M deo E T 59 Figure 6st Drive Ser COMMONS ep lcm ute 68 Figure 6 2 Disconnect Plug from Load Sense 71 Figure 6 3 Remove Platform Upper Control BOX 71 Figure 6 4 LOO DDACK DIG Eo o o o o TTE 71 PIGUIE 5 5 Fall ORM REMOVA idis ioi Tid P
4. 27 HAULOTTE GROUP 3 OPERATION MANUAL BOOM OPERATION Manual retraction rotation and lowering functions allow the telescoping boom lift to be moved and lowered during hydraulic power interruption or failure The following procedures for manual retraction rotation and lowering require a person on the ground to operate the manual controls and hand pump The hydraulic hand pump is located in the pump compartment In case of a power failure the hand pump and selected hydraulic valve can be used to manually retract the telescoping booms or rotate the boom turntable Manual Retraction Begin manual retraction or rotation by turning the proportional valve counterclockwise until it stops insert the pump handle into the pump handle fitting Pushing and holding the RETRACT button while simultaneously actuating the HAND PUMP will retract the extension boom Refer to Figure 3 7 Manual Rotation To rotate the Turntable counterclockwise Push and hold the ROTATION button IN and simultaneously actuate the hand pump To rotate the Turntable clockwise Pull the ROTATION button OUT and simultaneously actuate HAND PUMP NOTE Turn the PROPORTIONAL VALVE clockwise to return it to its original position before lowering the boom or resuming normal operation ROTATION BUTTON HAND PUMP RETRACT BUTTON PROPORTIONAL VALVE Figure 3 7 Hand Pump Controls for Manual Operation 28 HAULOTTE GROUP 3 OPERATION MANUAL BOOM OPERATION
5. Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE O O TABLE 4 3 ERROR CODE DEFINITIONS CONTROLS 158 SHORTED CIRCUIT FWS SPARE 2 159 OPEN CIRCUIT FWS SPARE 3 160 SHORTED CIRCUIT FWS SPARE 3 161 OPEN CIRCUIT FWS PROP A1 162 SHORTED CIRCUIT FWS PROP A1 OPEN CIRCUIT FWS PROP A2 SHORTED CIRCUIT FWS PROP A2 OPEN CIRCUIT FWS PROP B1 SHORTED CIRCUIT FWS PROP B1 OPEN CIRCUIT FWS PROP B2 SHORTED CIRCUIT FWS PROP B2 Excessive load was detected when FWS Spare 2 circuit was energized A load of less than 70 was detected when FWS Spare 3 circuit was energized Excessive load was detected when FWS Spare 3 circuit was energized A load of less than 70 was detected when FWS Prop A1 circuit was energized Excessive load was detected when FWS Prop A1 circuit was energized A load of less than 70mA was detected when FWS Prop A2 circuit was energized Excessive load was detected when FWS
6. Use a piece of wire to short the RS Ret FWS C22 coil Disconnect a wire from RS Ext FWS C23 coil Use a piece of wire to short the RS Ext FWS C23 coil Disconnect a wire from FS Ret FWS C24 coil This is a self clearing error When error condition is corrected error is cleared This is a self clearing error When error condition is corrected error is cleared This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a self clearing error When error condition is corrected error is cleared This is a self clearing error When error condition is corrected error is cleared This is a latched error Power or engine must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error Machines with Moment Sense option only Machines with Moment Sense option only Machines with Moment Sense option only Machines with Moment Sense option only Machines with 4WS option only Machines with 4WS option only Machines wit
7. 10 6 10 7 10 8 10 8 1 8 ANSI REPRINT Lower Controls The lower controls of aerial devices shall not be used for continuous operation with personnel in the platform Manufacturer s Safety Bulletins The user shall comply with the applicable safety related bulletins as received from the manufacturer installer dealer or owner Responsibilities of Operators General Responsibilities Each operator shall comply with the requirements of this section Personnel Only trained and authorized personnel shall be permitted to operate the aerial device Operation During operation of the aerial device all platform occupants shall use appropriate fall protection connected to the aerial device anchorage s Work Platform The operator shall not use railings planks ladders or any other device in or on the work platform for achieving additional working height or reach Brakes The vehicle parking brake s shall be set at all times that the boom is elevated except when the aerial device is being used in accordance with 10 11 Loading Any loading which includes a horizontal load shall be avoided unless the mobile unit is designed for that application Alterations Altering or disabling the function of safety devices guards or interlocks if so equipped is prohibited Observations Observations during operation for any defects shall be conducted on an ongoing basis Pre start Inspection Items determined by the owner in
8. 41 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE MONTHLY SERVICE CHECKS Perform the following service checks at least once each month Clean all battery terminals Check battery for loose connections or damaged wires Verify proper operation of manual lowering valves and hand pump e For manual boom operating procedures refer to the Operation section of this manual Lubricate slew ring and mating gear Use NLGI Grade 2 multi purpose grease Check wheel nut torque For correct wheel nut tightening sequence refer to Figure 4 4 Q e Evenly tighten wheel nuts to 25 84 N m in the tightening sequence shown e Repeat tightening sequence tighten wheel nuts to 60 Ib ft 81 N m and then to 100 136 N m Figure 4 4 Wheel Nut Tightening Sequence When wheels are newly installed or replaced verify wheel nut torque monthly Follow this procedure each time the wheel is removed and reinstalled Improperly torqued wheel nuts could result in wheel separation pre mature tire wear or damage to the equipment Check parking brakes Refer to the Set up and Adjustment located in the Axle and Related Components section of the Parts and Service Manual for more detailed information Verify that Level Sensor is operating correctly e Fully deploy outriggers until all outrigger LEDs and AUTO LEVEL 5 are lit and the buzzer the ground lower control panel sounds e Verify that the aerial work pla
9. Auto Zero Out of Internal pump current Replace motor controller Range measurement circuit could not be calibrated System Monitor Illegal system condition sensed Replace motor controller due to internal hardware fault Single flash 19 MOSFETs Off MOSFETs did not pulse when the Check for reversed cables among B B then off internal failsafe circuit was and A terminals If no miswire is found enabled replace motor controller Single flash MOSFETs On MOSFETs pulsed while the Check for reversed cables among B B then off internal failsafe circuit was and A terminals If no miswire is found disabled replace motor controller Single flash Contactor Drive Off Contactor output did not pulse Replace motor controller then off with the internal failsafe circuit enabled Single flash Contactor Drive On Contactor output pulsed while the Replace motor controller then off internal failsafe circuit was disabled INDICATOR LIGHT Figure 4 7 Motor Controller 99 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE 60 HAULOTTE GROUP 5 DECAL REPLACEMENT 5 DECAL REPLACEMENT Decals contain information that is required for the safe and proper use of the aerial work platform Decals should be considered necessary components of the machine and should be checked before each use to verify that they are correctly attached and legible Promptly replace all decals that are no longer legible 61 HAULOTTE GROUP 5 DECAL REP
10. HAULOTTE GROUP 3 OPERATION 34 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE 4 EQUIPMENT MAINTENANCE Performing the appropriate maintenance procedures will extend the life of the aerial work platform and will help ensure the safety of personnel operating the equipment Repair replacement or adjustment of any hydraulic or electrical control device should be performed only by fully trained and authorized personnel These include but are not limited to hydraulic load valves hydraulic flow control valves solenoid valves and limit switches These are safety related controls Improper adjustment or tampering with these devices may impair aerial work platform function and result in safety or damage hazards Persons performing maintenance or repairs on the aerial work platform should be trained in accordance with the manufacturer s recommendations Contact Haulotte Group Customer Service Department at 1 800 537 0540 or visit Haulotte Group online at www haulotte usa com if additional information is needed Critical or suspect areas identified during any scheduled inspection of the aerial work platform shall be examined by qualified personnel in accordance with all Federal State and Local codes and regulations that govern the safe operation of this equipment NEVER operate the aerial work platform if a defect or malfunction is identified or suspected All defects and malfunctions must be repaired and all maintenance performed before returning a
11. HOLD DOWN A SPEED a BUTTON WHILE SELECTING A BOOM CONTROL FUNCTION F OUTRIGGER CONTROLS HOLD DOWN ENABLE BUTTON WHILE SELECTING a RETRACT M MACHINE LEVEL w ie zo ctu 0 a z 000 u RM INTO THE STOWE POSITION FOR OUTRIGGER OR DRIVE _ OPERATION WHEN FLASHING Figure 6 1 Drive and Set Controls 1 Drive and Set Joystick The multi axis JOYSTICK 1 drives the aerial work platform in the direction of movement The JOYSTICK 1 only functions when the DRIVE ENABLE 2 button is pressed pushed in and held The aerial work platform stops when either the DRIVE ENABLE 2 button or JOYSTICK 1 is released 68 HAULOTTE GROUP 6 OPTIONAL EQUIPMENT DRIVE amp SET CONTROLS CONTINUED 2 Drive Enable Button Press push in and hold the DRIVE ENABLE 2 button to activate the JOYSTICK 1 To stop release either the DRIVE ENABLE 2 button or the JOYSTICK 1 3 Diagnostic Indicators DIAGNOSTIC INDICATOR LEDs 3 will light up to indicate that an error in boom lift or drive function has occurred When lit check the DISPLAY PANEL 5 on the ground lower control panel for an error code Refer to Table 4 3 Error Code Definitions located in the Equipment Maintenance section of this manual 4 Outrigger Controls The outriggers can be deployed and or retracted from either the ground lower or platform upper control panel on aerial work platforms with the Drive and Set Optio
12. device in accordance with one of the applicable 8 2 5 10 16 86 8 ANSI REPRINT methods and procedures as outlined in section 5 4 3 of this standard a Ifthe aerial device is used for ac bare hand work the in the field tests outlined in 5 4 3 1 10 c may be relied upon when performed frequently however the unit shall undergo an ac voltage test at least every three years in accordance with Table 2 criteria b Ifthe aerial device is used for dc bare hand work the in the field tests outlined in 5 4 3 1 10 c may be relied upon when performed frequently however the unit shall undergo an appropriate dc over voltage test at least every three years c After repair or replacement of any component that crosses the insulating system s or the repair or replacement of an insulating component s e g hoses leveling rods boom coating etc the unit shall be dielectrically tested in accordance with section 5 4 3 d An insulating replacement boom shall be tested to ensure conformance to 5 3 3 by the supplier e Bare hand work units shall be tested for the applicable unit rating in accordance with Table or appropriate dc test for units used on direct current lines see Appendix B after any major repair to the insulating boom or any insulating boom replacement Major repair to the insulating boom shall include resurfacing or repainting of the exterior or interior boom
13. A load of less than 70mA was detected when DC D Rev FWS C27 circuit was energized Excessive load was detected when DC D Rev FWS C27 circuit was energized A load of less than 70mA was detected when DC D FWS C28 circuit was energized Excessive load was detected when DC D FWS C28 circuit was energized A load of less than 70mA was detected when DC D FWS C29 circuit was energized Excessive load was detected when DC D FWS C29 circuit was energized A load of less than 70mA was detected when DC D FWS C30 circuit was energized Excessive load was detected when DC D FWS C30 circuit was energized A load of less than 70mA was detected when DC D FWS C31 circuit was energized Excessive load was detected when DC D FWS C31 circuit was energized Use a piece of wire to short the FS Ret FWS C24 coil Disconnect a wire from FS Ext FWS C25 coil Use a piece of wire to short the FS Ext FWS C25 coil Disconnect a wire from DC D Fwd FWS C26 Coil Use a piece of wire to short the DC D Fwd FWS C26 coil Disconnect a wire from DC D Rev FWS C27 coil Use a piece of wire to short the DC D Rev FWS C27 coil Disconnect a wire from DC D FWS C28 coil Use a piece of wire to short the DC D FWS C28 coil Disconnect a wire from DC D FWS C29 coil Use a piece of wire to short the DC D FWS C29 coil Disconnect a wire from DC D FWS C30 coil Use a piece of wire to sh
14. C29 coil Use a piece of wire to short the Torque H L C29 coil Disconnect a wire from Torque H L C30 coil Use a piece of wire to short the Torque H L C30 coil Disconnect a wire from Torque H L C31 coil Use a piece of wire to short the Torque H L C31 coil This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error Checked only at power up Machines with 4WD option only Checked only at power up Machines with 4WD option only Checked only at power up Machines with 4WD option only Checked only at power up Mac
15. Do not wear contaminated clothing or shoes Empty containers retain residue and may be dangerous Do not pressurize cut weld braze solder drill grind or expose such containers to heat flame sparks or other sources of ignition They may explode and cause injury or death Empty drums should be completely drained properly bunged and promptly shipped to the supplier or a drum reconditioner All containers should be disposed of in an environmentally safe manner and in accordance with governmental regulations Before working on or in tanks which contain or have contained this material refer to OSHA regulations ANSI Z49 1 and other references pertaining to cleaning repairing welding or other contemplated operations Conditions for safe storage Use and store this material in cool dry well ventilated area away from heat and all sources of ignition Keep container s tightly closed Store only in approved containers Keep away from any incompatible material see Section 10 Protect container s against physical damage 8 Exposure Controls Personal Protection Component US ACGIH Other ubricant Base Oil Petroleum TWA 5mg m TWA 5 mg m STEL 10 mg m as Oil Mist if generated as Oil Mist if generated Note State local or other agencies or advisory groups may have established more stringent limits Consult an industrial hygienist or similar professional or your local agencies for further information Engineering c
16. Feet Meters to 300V Avoid Contact Over 50KV to 200KV Over 500KV to 750KV 35 10 67 Over 750KV to 1000KV 13 72 DO NOT allow aerial work platform personnel or conductive materials inside prohibited zone Maintain M S A D from all energized lines and parts as well as those shown Assume all electrical parts and wires are energized unless known otherwise Failure to avoid energized power sources will result in death or serious injury Diagrams shown are only for purposes of illustration M S A D work positions not all work positions 8 ANSI REPRINT 91 HAULOTTE GROUP 8 ANSI REPRINT 92 INSPECTION FORM FOR HAULOTTE GROUP AERIAL WORK PLATFORMS Pe aMec A Machine Model No Serial No Date of Manufacture Inspection Performed by _ Inspection Location i O Inspection and Maintenance of the above listed machine shall be performed only by fully trained authorized and where applicable certified personnel All service checks shall be performed in accordance with manufacturer s recommendations Refer to the Parts and Service Manual Copy this form as needed Direct any questions to the Haulotte Group Customer Service Department 1 800 537 0540 or visit Haulotte Group online at www haulotte usa com Inspector Initial in the space provided beside each service check as it is completed Sign and date form after Inspection Owner Keep this form for your records Frequency Key D Daily or before each use
17. If contact occurs flush with water and consult a physician immediately ALWAYS disconnect ground cable first when removing battery ALWAYS connect ground cable last when installing battery ALWAYS charge batteries in open well ventilated areas ALWAYS replace batteries using only parts recommended by manufacturer factory ALWAYS use only batteries with sealed caps over cells NEVER smoke while servicing batteries NEVER charge batteries near flammable materials NEVER allow batteries to overcharge and boil NEVER short across battery posts to check for current NEVER break a live circuit at the battery NEVER disconnect battery from charger while charger is connected to a live power source NEVER jump start other vehicles using the aerial work platform batteries 12 HAULOTTE GROUP 2 SPECIFICATIONS 2 SPECIFICATIONS The following information is based on ideal working conditions Machine performance may vary based on work environment and on machine options Only one telescoping boom motion is permitted at a time and only as long as the telescoping boom is within the safe operating zone When a selected telescoping boom motion exceeds a safe operating limit the telescoping boom motion ceases and another telescoping boom motion must be selected within the safe operating zone Refer to Figure 2 1 RANGE OF MOTION 15 5 0 5 15 25 35 45 4 6m 1 5m 1 5m 4 6m 7 6m 10 7m 13 7m s lt a 50 12 2m Figure 2 1 Range of Motio
18. ON SOLID it indicates that the boom is in the stowed position and the outriggers are functional 21 HAULOTTE GROUP 3 OPERATION PLATFORM UPPER CONTROL PANEL The platform upper control panel is used to control all boom functions The platform upper control panel is activated by turning the KEY SWITCH 1 on the ground lower control panel clockwise to the PLATFORM 1b icon Enter the work platform using a three 3 point contact both hands and one foot The platform upper control panel includes the following controls and indicators Refer to Figure 3 2 CONDITION INDICATOR BUTTON WHILE SELECTING BOOM CONTROL FUNCTION S P D B U T T O N S Figure 3 2 Platform Upper Control Panel 1 2 Engine Start and Choke Glow Plug Models with Engines Only otart a cold engine by pressing pushing and holding the CHOKE 2 button and pressing pushing the ENGINE START 1 button to start the Engine To start restart a warm Engine press push the START 1 button only GLOW PLUG OPERATION Press push and hold the GLOW PLUG 2 button for 30 60 seconds then press push the ENGINE START 1 button 3 Horn Button Pressing pushing the HORN 3 button will sound the HORN Use the HORN 3 button to warn personnel in the area of a falling object hazard impending boom motions or the need for assistance 22 HAULOTTE GROUP 3 OPERATION PLATFORM CONTROL STATION
19. Prop A2 circuit was energized A load of less than 70mA was detected when FWS Prop B1 circuit was energized Excessive load was detected when FWS Prop B1 circuit was energized A load of less than 70mA was detected when FWS Prop B2 circuit was energized Excessive load was detected when FWS Prop B2 circuit was energized Use a piece of wire to short the FWS Spare 2 coil Disconnect a wire from FWS Spare 3 coil Use a piece of wire to short the FWS Spare 3 Coil Disconnect a wire from FWS Prop A1 coil Use a piece of wire to short the FWS Prop A1 coil Disconnect a wire from FWS Prop A2 coil Use a piece of wire to short the FWS Prop A2 coil Disconnect a wire from FWS Prop B1 coil Use a piece of wire to short the FWS Prop B1 coil Disconnect a wire from FWS Prop B2 coil Use a piece of wire to short the FWS Prop B2 coil This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cyc
20. W Weekly M Monthly SA Semi Annually A Annually Service Check Description Verify that all decals are legible correctly applied and in plain view Verify that all controls and indicators at ground and platform control stations operate properly Verify operation of running and brake lights Verify proper tire inflation See the side wall of the tire for proper inflation Inspect tires for damage or loose or missing lug nuts nspect structural components for obvious damage or debris Inspect machine for loose damaged or missing fasteners including pins and bolts Verify that boom down limit switches operate correctly Verify that outrigger safety interlocks operate correctly Inspect hydraulic system and fluid levels Check battery electrolyte level Inspect electrical wiring for damaged broken or frayed wires Inspect transport hitch for damage Inspect boom for missing loose or damaged hardware Inspect all hydraulic system components including power unit hoses and cylinders for damage leaks loss of pressure or speed and unusual noise or vibration Check engine oil Applicable for machines equipped with Engines Clean all battery terminals Check battery connections Verify proper operation of manual lowering valves and hand pump Lubricate all compartment hinges and latches slew ring and mating gear using NLGI Grade 2 multi purpose grease Check wheel nut torque Check coolant level Applicable for machines
21. energized Excessive load was detected when Proportional circuit was energized A load of less than 70 was detected when Motor Control Enable circuit was energized Excessive load was detected when Motor Control Enable circuit was energized Use a piece of wire to short the LR Outrigger coil Disconnect a wire from RR Outrigger coil Use a piece of wire to short the RR Outrigger coil Disconnect a wire from Engine Throttle coil Use a piece of wire to short the Engine Throttle coil Disconnect a wire from Engine Starter coil Use a piece of wire to short the Engine Starter coil Disconnect a wire from Engine Choke coil Use a piece of wire to short the Engine Choke coil Disconnect a wire from Engine Stop coil Use a piece of wire to short the Engine Stop coil Disconnect a wire from Proportional coil Use a piece of wire to short the Proportional coil Disconnect a wire from Motor Control Enable coil Use a piece of wire to short the Motor Control Enable coil This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to c
22. provided Haulotte is notified of such defect or defects within the applicable warranty period and given a reasonable time to correct the defect In no case shall any warranty extend to defects in materials components or services furnished by third parties Defects caused by chemical action or the presence of abrasive materials and defects arising following the operation beyond rated capacity or the improper use or application of any products shall not be considered defects within the scope of this warranty If any repairs or alterations are made or any parts are replaced during the applicable warranty periods by anyone other than Haulotte or an entity authorized by Haulotte for use in its products customer shall pay for such repairs or parts without recourse against Haulotte and Haulotte should be relieved of responsibility for fulfillment of this warranty with respect to such repairs alterations or replacement so made Haulotte obligations under this warranty shall at all times be subject to its current warranty policies and procedures The above mentioned warranty shall not apply to replacement or service parts made and sold by Haulotte Periodic maintenance periodic maintenance items including paint and decals and minor adjustments are excluded from this warranty Certain components including but not limited to engines tires and batteries which may be part of the product are not manufactured or warranted by Haulotte Any applicable warranty
23. 2 The purpose and function of all controls 3 Safety devices and operating characteristics specific to the aerial device 4 Under the direction of a qualified person the trainee shall operate the aerial device for a sufficient period of time to demonstrate proficiency in the actual operation of the aerial device Owner a Lessor When owners function as lessors they shall have the same responsibilities as specified under Section 11 of this standard Responsibilities of Users General Responsibilities Each User shall comply with the requirements of this section Personnel Only trained and authorized personnel shall be permitted to operate the aerial device Training Retraining and Familiarization of Operators General Training Only personnel who have received general instructions regarding the inspection application and operation of aerial devices including recognition and avoidance of hazards associated with their operation shall operate an aerial device Such items covered shall include but not necessarily be limited to the following issues and requirements 1 The purpose and use of manuals 87 HAULOTTE GROUP 9 3 2 9 3 3 9 3 4 9 4 Note 9 5 9 6 88 2 That operating manuals are an integral part of the aerial device and must be properly stored on the vehicle when not in use 3 A pre start inspection 4 Responsibilities associated with problems or malfunctions aff
24. Caution Component Damage Gas Engine Option Decal Notice Unleaded Fuel Only Gas Engine Option o1 52 51 B06 00 0486 Decal Notice Engine Specific Gas Engine Option EA 52 B06 00 0547 Decal Warning Eng Operate Hot Gas Engine Option 65 HAULOTTE GROUP 5 DECAL REPLACEMENT 66 HAULOTTE GROUP 6 OPTIONAL EQUIPMENT 6 OPTIONAL EQUIPMENT The Haulotte Model 4642T may be equipped with one or more optional components designed for the convenience and safety of operators when using the equipment to accomplish specific tasks Always use only those components manufactured and or authorized by Haulotte Group Never make any adjustments or modifications or otherwise alter the equipment in any way that is not expressly recommended by the manufacturer When operating an aerial work platform equipped with optional components observe all safety precautions set forth by the manufacturer as well as all Federal State and Local codes and regulations regarding this equipment and its components Consult rental agency or manufacturer regarding which optional components may be installed on the aerial work platform For questions regarding safe use contact Haulotte Group Customer Service Department at 1 800 537 0540 or visit Haulotte Group online at www haulotte usa com 67 HAULOTTE GROUP 6 OPTIONAL EQUIPMENT DRIVE AND SET The Drive and Set Option allows the operator to drive the aerial work platform deploy ret
25. Factors affecting stability 6 The purpose of placards and decals 7 Workplace inspection 8 Applicable safety rules and regulations such as Part 4 ANSI C2 2007 National Electrical Safety Code applies to utility workers as defined in ANSI C2 The above standard is an example other industries using aerial devices have safety rules pertinent to that industry 9 Authorization to operate 10 Operator warnings and instructions 11 Proper use of personal fall protection equipment Fall protection systems criteria and practices are covered in 29 CFR 1926 502 12 Electrical hazards and Minimum Approach Distance to energized conductors and apparatus See Appendix F Familiarization When operators are directed to operate an aerial device with which they are not familiar they BUS BARS SM 07 BUS BARS 11 5 11 6 12 12 1 12 2 8 ANSI REPRINT shall be instructed prior to operating the aerial device regarding the following items 1 The location of the manuals 2 The purpose and function of all controls 3 Safety devices and operating characteristics specific to the aerial device 4 Under the direction of a qualified person the trainee shall operate the aerial device for a sufficient period of time to demonstrate proficiency in the actual operation of the aerial device Communications In the event the manufacturer or installer provides the lessor m
26. Ib 400 N HAULOTTE GROUP 1 SAFETY WIND LOADING e Never operate the aerial work platform in strong or winds that exceed 28 mph 12 5 m s or 45 km h Never increase the surface area of the platform or the load Increasing the area exposed to the wind will decrease the aerial work platform stability The Beaufort scale of wind force is accepted internationally and is used when communicating weather conditions It consists of a number 0 10 each representing a certain strength or velocity of wind at 10m 33ft above ground level in the open Refer to Table 1 2 TABLE 1 2 BEAUFORT SCALE Description of wind Specifications for use on land m h m s Calm Calm smoke rises vertically 0 1 0 0 3 1 Light Air Direction of wind shown by smoke 1 5 0 3 1 5 Light Breeze Wind felt on face leaves rustle ordinary 4 7 6 11 1 6 3 3 vanes moved by wind Gentle Breeze Leaves and small twigs in constant motion 8 12 12 19 3 4 5 4 wind exceeds light flag Moderate Breeze Raises dust and loose paper small 13 17 20 28 5 5 7 9 branches are moved 5 Fresh Breeze omall trees in leaf begin to sway crested 18 24 29 38 8 0 10 7 wavelets form on inland waterways otrong Breeze Large branches in motion whistling heard 25 30 39 49 10 8 13 8 in telephone wires umbrellas used with difficulty Near Gale Whole trees in motion inconvenience felt 31 38 50 61 13 9 17 1 when walking against wind Gale Breaks twigs off trees generally impede
27. LATCH by lifting up on the handle and pivoting the platform upright Refer to Figure 3 4 Lift up on PLATFORM TRAVEL LATCH to release Platform Figure 3 4 Platform Travel Latch e PLATFORM LOCKING PINS will engage protrude through in the pivot locking holes on the PLATFORM MOUNT when the PLATFORM is in a full upright position Verify that the PLATFORM is locked into place To release the LOCKING PINS squeeze the LATCH KNOBS together e Verify that the PLATFORM is properly attached to the PLATFORM MOUNT on the boom end The RETAINING PIN should be fully inserted through the PLATFORM and the PLATFORM MOUNT on the boom end Refer to Figure 3 5 PLATFORM MOUNTING BRACKET Beveled LOCKING PIN must protrude through this mount LATCH KNOBS RETAINING PIN Figure 3 5 Platform Locking Pins Failure to verify proper attachment of the platform to the boom end could cause the platform to separate from the boom this could result in death or serious injury 25 HAULOTTE GROUP 3 OPERATION NORMAL OPERATING PROCEDURE CONTINUED At the ground lower control panel turn the KEY SWITCH 1 counter clockwise to the GROUND CONTROLS 1a icon If power does not come on make sure that both of the EMERGENCY STOP buttons GROUND 6 and PLATFORM 5 are pulled out and the main power disconnect plug is plugged in The control microprocessor will perform self diagnostics to test the operating system After seve
28. MAINTENANCE TROUBLESHOOTING Refer to the following Table for basic Troubleshooting Operations Contact Haulotte Group Customer Service Department at 1 800 537 0540 or visit Haulotte Group online at www haulotte usa com with any questions or before attempting any advanced troubleshooting operations TABLE 4 2 TROUBLE SHOOTING PROBLEM CAUSE SOLUTION a EMERGENCY STOP engaged a Disengage EMERGENCY STOP buttons Battery charge is low b Recharge as needed No lights on panel when key switch is turned to the on position Battery ground or in series cable is c Inspect and repair battery loose connections Battery main disconnect unplugged d Plug in main disconnect Blown Fuse e Replace Fuse as necessary Error code displayed on a Error detected by Control Box a Heferto Error Code Definitions Ground Control Panel Table 3 3 Green light flashing on a Error detected by Motor a Heferto Motor Controller Error Motor Controller Controller Code Definitions Table 3 4 Hydraulic function does a Error detected by safety interlock a Refer to error code definitions not work and display microprocessor Table 3 3 window shows an error b Aerial work platform electric or b Refer to error code definitions message electronic failure Table 3 3 Outrigger indicator LED a Key switch turned to the OFF or a Turn key switch to ground controls lights do not function platform controls position position b EMERGENCY
29. MUST ON BEFORE PLATFORM SED CAN BE RAIS e RETRACT E 1 if n Jl a p E d E if p ji fW B 1 ri 1 hh rd BN M J 1h i s A A a E Aa re 1 a a gt p IRA 7 if ff A Jh 1 jon AU i yo M s 7 i JS a he Figure 4 6 Ground Lower Control Panel for Overload Protection 3 Scroll through the maintenance menu using the TURTLE 15 BOTTOM button to scroll down use the RABBIT 15 TOP button to scroll back up until Load Sense Zero Calibration Utility is found 4 Press push both MID SPEED buttons MID HIGH MID LOW 15 CENTER on the ground lower control panel simultaneously Three consecutive beeps will sound and the display will read Load Sense Has Been Zero Calibrated confirming the operation The maintenance mode will then go to Load Sense Scaling Utility 43 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE OVERLOAD PROTECTION CALIBRATION PROCEDURE CONTINUED 5 In Load Sense Scaling Utility the display should read a ratio of 3 68 120 If the ratio is not 3 68 1 proceed to Step 6 If the ratio is correct but load is not 0 skip Step 6 and proceed to otep 7 If both the ratio and the load are correct proceed to Step 8 6 I
30. STOP button should only be pressed pushed in to immediately stop all aerial work platform motion To resume control pull the EMERGENCY STOP 6 button out 7 8 Boom Extend Retract Buttons Pressing pushing in and holding a desired SPEED 15 button and the BOOM EXTEND 7 button at the same time extends the boom Pressing pushing in and holding a desired SPEED 15 button and the BOOM RETRACT 8 button at the same time retracts the boom Boom motion continues until the buttons are released or until the boom reaches a hard stop or a safe travel limit 9 10 Boom Raise Down Buttons Pressing pushing in and holding a desired SPEED 15 button and the BOOM RAISE 9 button at the same time will raise the boom Pressing pushing a desired SPEED 15 button and the BOOM DOWN 10 button at the same time will lower the boom The selected boom motion continues until the buttons are released or until the selected boom reaches a hard stop or a safe travel limit 11 12 Boom Rotation Buttons Pressing pushing and holding a desired SPEED 15 button and the BOOM ROTATION 11 button at the same time enables the boom to rotate in the CLOCKWISE direction Pressing and holding a desired SPEED 15 button and the BOOM ROTATION 12 button at the same time enables the boom to rotate in the COUNTER CLOCKWISE direction The boom will rotate through 700 Non Continuous rotation until the buttons are released or the stop is reached 13 14 Platfo
31. TRAILER HITCH and lower the hitch onto the ball using the TONGUE JACK DOLLY WHEEL Push down on the RELEASE LEVER to secure the ball Use the TONGUE JACK DOLLY WHEEL to verify that the coupling is secure NOTE If using the jack raises the bumper of the tow vehicle 2 3 inches the ball hitch coupling is Secure e Release the PARKING BRAKE by rotating the handle down until it is parallel with tongue tube e On the TONGUE JACK DOLLY WHEEL pull the CLEVIS PIN and swivel the TONGUE JACK DOLLY WHEEL 90 to the travel position Re engage the CLEVIS PIN e Attach the safety chains to the tow vehicle Verify that the chains cross under the trailer tongue Failure to attach safety chains properly before towing will allow trailer tongue to drop in case of ball hitch failure resulting in damage to tow vehicle and aerial work platform e For models with the breakaway cable connect it to the tow vehicle Leave adequate slack to prevent brakes from dragging e Connect the trailer lights to the tow vehicle power plug 31 HAULOTTE GROUP 3 OPERATION LIFTING THE AERIAL WORK PLATFORM Refer to Figure 3 10 Completely lower and retract the boom Secure the boom travel latch A Remove all loose materials from machine Retract all outriggers to their fully stowed upright position When using a crane use only the designated crane fork lift pockets B Follow all crane operating instructions as indicated by the cr
32. The above standard is an example 10 12 2 10 12 3 10 13 11 11 1 11 1 1 11 1 2 11 1 3 11 1 4 11 3 1 8 ANSI REPRINT other industries using aerial devices have safety rules pertinent to that industry 9 Authorization to operate 10 Operator warnings and instructions 11 Proper use of personal fall protection equipment Fall protection systems criteria and practices are covered in 29 CFR 1926 502 Retraining The operator shall be retrained when so directed by the user based on the user s observation and evaluation of the operator Familiarization When operators are directed to operate an aerial device with which they are not familiar they shall be instructed prior to operating the aerial device regarding the following items 1 The location of the manuals 2 The purpose and function of all controls 3 Safety devices and operating characteristics specific to the aerial device 4 Under the direction of a qualified person the trainee shall operate the aerial device for a sufficient period of time to demonstrate proficiency in the actual operation of the aerial device Electrical Hazard All applicable safety related work practices intended to protect personnel from electrical hazards shall be defined and explained to the operator by a qualified person The operator shall maintain the appropriate Minimum Approach Distance MAD from energized conductors and apparatus commensurate with
33. and Installers 7 8 1 General Responsibilities Each dealer or installer as applicable shall comply with the requirements of this section Vehicle Specifications Each dealer or installer or both who sells an aerial device shall inform the owner or user or both of the manufacturer s minimum vehicle specifications 7 9 Vehicle Weight Distribution The installer shall be responsible for the weight distribution of the completed mobile unit in accordance with the requirements of the aerial device and the applicable regulations Allowance 8 shall be made for the weight of readily removable tools and material specified by the user Manuals Upon delivery of the equipment to the owner or user the dealer or installer shall provide the manuals as required by Paragraph 6 4 of this standard and manuals for auxiliary equipment added by the installer Installations The installer shall comply with Sections 5 8 2 and 6 of this standard relating to proper installation and shall follow the instructions of the manufacturer In the 8 2 1 event the original manufacturer no longer exists an equivalent entity may provide these instructions The installer shall maintain access to the lower controls as described in section 4 3 3 The installer of an aerial device shall before the mobile unit is placed in operation perform stability tests in accordance with the requirements of 4 5 1 and 4 5 2 the operational and visual tests in accordance with the
34. and pneumatic fittings hoses and tubing for evidence of leakage abnormal deformation or excessive abrasion 6 Compressors pumps motors and generators for loose fasteners leaks unusual noises or vibrations loss of operating speed and excessive heating 7 Hydraulic and pneumatic valves for malfunction and visible cracks in the external valve housing leaks and sticking spools 8 Visually inspect any vacuum prevention systems and verify function of such systems 9 Hydraulic and pneumatic cylinders and holding valves for malfunction and visible damage Hydraulic and pneumatic filters for cleanliness and the presence of foreign material in the system indicating other component deterioration 11 Electrical systems and components for deterioration or wear including those not readily visible on a frequent inspection 12 Performance test of all boom movements 13 Condition and tightness of bolts and other fasteners in accordance with the manufacturer s recommendation 14 Welds as specified by the manufacturer 15 Legible and proper identification operational and instructional markings If the aerial device is rated as an insulating device 8 3 the electrical insulating components and system s 8 3 1 shall be thoroughly inspected for lack of cleanliness and other conditions compromise insulation Then these components and system s shall be tested for compliance with the rating of the aerial
35. assess the extent of injury Early surgical treatment within the first few hours may significantly reduce the ultimate extent of injury Acute aspirations of large amounts of oil laden material may produce a serious aspiration pneumonia Patients who aspirate these oils should be followed for the development of long term sequelae Inhalation exposure to oil mists below current workplace exposure limits is unlikely to cause pulmonary abnormalities NFPA 704 Hazard Class Health 0 Flammability 1 Instability 0 D Minimal 1 Slight 2 Moderate 3 Serious 4 Severe Unusual Fire amp Explosion Hazards This material may burn but will not ignite readily If container is not properly cooled it can rupture in the heat of a fire Extinguishing Media Dry chemical carbon dioxide foam or water spray is recommended VVater or foam may cause frothing of materials heated above 212 F Carbon dioxide can displace oxygen Use caution when applying carbon dioxide in confined spaces Fire Fighting Instructions For fires beyond the initial stage emergency responders in the immediate hazard area should wear protective clothing When the potential chemical hazard is unknown in enclosed or confined spaces a self contained breathing apparatus should be worn In addition wear other appropriate protective equipment as conditions warrant see Section 8 Isolate immediate hazard area and keep unauthorized personnel out Stop spill release if it can be done
36. be cycled to clear error Machines with Moment Sense option only X Boom Machines with Kawasaki or Kubota engines Machines with Load Sense option only Machines with Load Sense option only Machines with Load Sense option only Checked only at power up Checked only at power up Checked only at power up Articulating Boom Models Checked only at power up Articulating Boom Models Checked only at power up Articulating Boom Models Checked only at power up Articulating Boom Models HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE ee O TABLE 4 3 ERROR CODE DEFINITIONS CONTROLS 027 OPEN CIRCUIT SECONDARY DOWN SHORTED CIRCUIT SECONDARY DOWN OPEN CIRCUIT JIB UP SHORTED CIRCUIT JIB UP OPEN CIRCUIT JIB DOWN 032 SHORTED CIRCUIT JIB DOWN 033 OPEN CIRCUIT EXTEND SHORTED CIRCUIT EXTEND OPEN CIRCUIT RETRACT SHORTED CIRCUIT RETRACT OPEN CIRCUIT PLATFORM LEVEL UP SHORTED CIRCUIT PLATFORM LEVEL UP OPEN CIRCUIT PLATFORM LEVEL DOWN SHORTED CIRCUIT PLATFORM LEVEL DOWN OPEN CIRCUIT PLATFORM CW SHORTED CIRCUIT PLATFORM CW A load of less than 70mA was detected when Secondary Down circuit was energized Excessive load was detected when Secondary Down circuit was energized A load of less than 70mA was detected when Jib Up circuit was energized Excessive load was detected when Jib Up circuit was energized A load of less than 70mA was detected when Jib Down circuit wa
37. equipped with Engines Inspect the air filter Applicable for machines equipped with Engines Verify proper level sensor operation use outriggers to tilt machine try to operate boom functions Check Belt tension Verify engine rpm Applicable for machines equipped with Engines Add or replace Hydraulic Oil and Hydraulic Filter annually replace more frequently in dirty conditions Inspect pivot pins and cylinders including rod ends for wear or damage Visually inspect all welds for wear damage or corrosion Inspect outriggers for wear or damage Inspect axle and parking brake adjust as necessary Inspect and adjust axle and parking brake Load test all boom functions with a 5006 227kg load 44015 200 load if machine is equipped with jib platform rotate Check slew ring for wear or damage A Frequency Refer to Engine Operators Manual for recommended Engine Maintenance Inspector Signature Date Haulotte 9 gt Distributed by GROUP 125 Taylor Parkway Archbold Ohio 43502 Phone 800 537 0540 419 445 8915 Fax 419 445 0367 www haulotte usa com B33 01 0107 Rev A 4642T Operation Manual September 201 1
38. hydraulic reservoir is originally filled with HVI AW32 Hydraulic Oil e Aminimum Viscosity Index of 175 is recommended for this aerial lift platform DO NOT mix hydraulic oils DO NOT add any fluid to the hydraulic system that is not expressly recommended by the manufacturer Adding unauthorized fluids to the hydraulic system could cause damage to the aerial work platform FILTER ELEMENT Waele FILL PORT SIGHT GAUGE Figure 4 3 Hydraulic Reservoir 40 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE WEEKLY SERVICE CHECKS Perform the following service checks at least once each week in addition to all recommended Daily service Checks Check Battery Electrolyte level e f battery charge is low add enough water to bring the electrolyte level to the top of the plates e f batteries are fully charged raise electrolyte level to full mark in each cell Inspect all electrical wiring e Check for cuts loose terminals broken wires chaffing and corrosion e Repair all damage remove corrosion and seal with proper materials Inspect transport hitch components for damage Applicable to trailer mounted aerial lift platforms only Inspect the aerial work platform for missing loose or damaged hardware e Repair or replace as necessary Inspect all hydraulic system components including pump and motor and cylinders for damage leaks loss of pressure or speed and unusual noise or vibration e Repair or replace as necessary
39. is engaged it is parallel with the tongue tube when disengaged it is perpendicular to the tongue e The trailer tires are adequately and evenly inflated See the side wall of the tire for proper inflation Periodically check the Wheel Nut torque according to manufacturer s recommendations Refer to the Monthly Service check section in the Equipment Maintenance section of this manual NEVER tow an aerial work platform with worn or damaged wheel components Prior to towing while the trailer wheels are elevated for aerial work platform operation inspect for loose wheels and for wheel lug wear If a loose wheel mounting is suspected remove and inspect wheel lugs for damage Obtain read and obey all recommendations set forth by the tow vehicle manufacturer before attempting to transport aerial work platform Verify that aerial work platform weight does not exceed the vehicle s towing capacity Exceeding the tow vehicle s rated capacity may result in damage to tow vehicle or aerial work platform 30 HAULOTTE GROUP 3 OPERATION TOWING THE AERIAL WORK PLATFORM CONTINUED Procedure to hitch and tow the aerial work platform Back the tow vehicle to the trailer Verify that the ball and trailer hitch are aligned and that the trailer hitch has proper clearance above the ball Refer to Figure 3 9 TRAILER HITCH N PARKING SAFETY t BRAKE CHAIN POWER PLUG Figure 3 9 Trailer Hitching e Lift the RELEASE LEVER on the
40. less than 19 5 percent oxygen situations or under conditions that are immediately dangerous to life and health IDLH suggestions provided in this section for exposure control and specific types of protective equipment are based on readily available information Users should consult with the specific manufacturer to confirm the performance of their protective equipment Specific situations may require consultation with industrial hygiene safety or engineering professionals Note Unless otherwise stated values are determined at 20 C 68 F and 760 mm Hg 1 atm Data represent typical values and are not intended to be specifications Appearance Physical Form Odor Odor Threshold pH Vapor Pressure Vapor Density air 1 Boiling Point Range Melting Freezing Point Pour Point Solubility in Water Partition Coefficient n octanol water Kow Specific Gravity Bulk Density Viscosity Evaporation Rate nBuAc21 Flash Point Test Method LEL vol in air UEL vol in air Autoignition Temperature Clear and bright Liquid Petroleum data Mot applicable 1 mm gt 1 No data lt 29 2 F lt 34 C 28 2 F lt 34 C Insoluble No data 0 87 60 F 15 6 C 7 3 lbs gal 7 12 cSt 100 C 32 68 cSt 40 C No data gt 320 F gt 160 C Pensky Martens Closed Cup PMCC ASTM 093 EPA 1010 No data No data No data 10 Stability and Reactivit Stability S
41. safely Move undamaged containers from immediate hazard area if it can be done safely Water spray may be useful in minimizing or dispersing vapors and to protect personnel Cool equipment exposed to fire with water if it can be done safely Avoid spreading burning liquid with water used for cooling purposes Hazardous Combustion Products Combustion may yield smoke carbon monoxide and other products of incomplete combustion Oxides of sulfur nitrogen or phosphorus may also be formed See Section 9 for Flammable Properties including Flash Point and Flammable Explosive Limits 6 Accidental Release Measures 78 HAULOTTE GROUP 7 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW AW HVI HYDRAULIC OIL CONTINUED 814636 Powerflow AW HVI Hydraulic Oil All Grades Page 3 7 Date of Issue 14 Nov 2008 Status Final 5 Accidental Release Measures Personal Precautions This material may burn but will not ignite readily Keep all sources of ignition away from spill release The use of explosion proof electrical equipment is recommended Stay upwind and away from spill release Notify persons down wind of the spill release isolate immediate hazard area and keep unauthorized personnel out Wear appropriate protective equipment including respiratory protection as conditions warrant see Section 8 See Sections 2 and for additional information on hazards and precautionary measures Environmental Precautions Stop spill rele
42. short the FWS Spare 1 coil Disconnect a wire from FWS Spare 2 coil This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only
43. than 70mA was detected when FWS C34 circuit was energized Excessive load was detected when FWS C34 circuit was energized A load of less than 70mA was detected when FWS R2 circuit was energized Excessive load was detected when FWS R2 circuit was energized A load of less than 70mA was detected when FWS Gen G1 circuit was energized Excessive load was detected when FWS Gen G1 circuit was energized A load of less than 70mA was detected when FWS Con 24V circuit was energized Excessive load was detected when FWS Con 24V circuit was energized A load of less than 70mA was detected when FWS Spare 1 circuit was energized Excessive load was detected when FWS opare 1 circuit was energized A load of less than 70mA was detected when FWS Spare 2 circuit was energized Disconnect a wire from FWS C32 coil Use a piece of wire to short the FWS C32 coil Disconnect a wire from FWS coil Use a piece of wire to short the FWS C33 coil Disconnect a wire from FWS C34 coil Use a piece of wire to short the FWS C34 coil Disconnect a wire from FWS R2 coil Use a piece of wire to short the FWS R2 coil Disconnect a wire from FWS Gen G1 coil Use a piece of wire to short the FWS Gen G1 coil Disconnect a wire from FWS Con 24V coil Use a piece of wire to short the FWS Con 24V Coil Disconnect a wire from FWS Spare 1 coil Use a piece of wire to
44. the warranty claims procedure 1 Contact Haulotte Group BilJax Customer Service Department at 1 800 537 0540 or visit Haulotte Group online at www haulotte usa com to report the claim and verify warranty coverage Machine serial number and machine hours must be provided when call is placed call ID number will be created when the call is placed The service representative will issue the call ID number to you at the end of the call 2 ldentify the components to be claimed under warranty along with description of failure An RMA number will be issued from Haulotte Group BilJax to return warranty parts at the time the parts order is placed 3 Replacement parts will then be sent by Haulotte Group BilJax to the dealer or distributor All parts are invoiced at dealer distributor list price Credits will be issued when defective parts are returned to Haulotte Group BilJax under the proper RMA number and found to be defective under warranty 4 After completing repairs submit warranty application form and return the defective parts to Haulotte Group BilJax Warranty application form and parts must be received within 30 days of claim in order to be eligible for credit Returned parts are to be sent prepaid and will be credited when part is received and verified Warranty labor rate will be paid at current rate set by Haulotte Group BilJax The amount of labor hours reimbursed will be determined by Haulotte Group BilJax and will be limited to 4 hours
45. this manual and attached to the aerial work platform e Read understand and obey all Federal State and Local codes and regulations e Become familiar with the proper use of all controls nexperienced users should receive instruction by a qualified instructor before attempting to operate or maintain the aerial work platform The use of intelligence and common sense is the best practice when following any safety policy LEGEND SAFETY ADVISORIES The following safety advisories are used throughout this manual to indicate specific hazards when operating or maintaining the aerial work platform Read understand and obey all safety advisories to prevent improper service damage to equipment personal injury or death Indicates a hazardous situation which if not avoided will result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided may result in minor or moderate injury Contains information important in the prevention of errors that could damage the machine or its components NOTE Contains additional information important for performing a procedure HAULOTTE GROUP 1 SAFETY BEFORE OPERATION Ensure the following general safety precautions are followed before operating the aerial work platform ALWAYS inspect the usage area for potential hazards such as unstable or unlevel surfaces overhead ob
46. through the complete range of motion would create a hazard c Check functionality of emergency controls HAULOTTE GROUP Any suspected items shall be carefully examined or tested and a determination made by a qualified person as to whether they constitute a safety hazard All unsafe items shall be replaced or repaired before use 10 9 Worksite Before the aerial device is used the worksite shall be surveyed for hazards such as 1 Insufficient supporting surfaces such as soft ground or tamped earth fills 2 Ditches 3 Excessive slopes drop offs curbs and floor obstructions Debris Overhead obstructions and electrical conductors Weather conditions Presence of unauthorized persons Road or worksite traffic Subsurface chambers such as underground utility components or septic systems 7 4 5 6 f 8 9 10 10 Precautions Before and during each use the operator shall 1 Check for overhead obstructions and electrical conductors 2 Insure that the load on the platform and or load lifting device is in accordance with the manufacturer s rated capacity 3 Insure that outriggers and stabilizers are used if the manufacturer s instructions require their use 4 Insure that guardrails are properly installed and the gates are closed 5 Use outrigger pads when necessary to provide firm footing 10 11 Mobile Operation Before engaging in mobile operation the operator shall deter
47. to the purchaser It is the responsibility of the purchaser to notify the manufacturer of the unit model and serial number and the name and address of the new owner within 60 days If the owner uses other entities as agents e g Brokers for the sale or the arrangement of a sale of an aerial device s their responsibilities under this section continue Markings The markings on the aerial device shall not be removed defaced or altered All missing or illegible markings shall be promptly replaced Parts When parts or components are replaced they shall be identical in specification and function to the original aerial device parts or components or shall provide an equal or greater factor of safety Safety Bulletins Owners shall comply with safety related bulletins as received from the manufacturer dealer or installer Manuals The owner shall insure that the operating manual s is stored on the mobile unit 8 12 8 12 1 8 12 2 8 12 3 8 13 9 2 9 3 9 3 1 8 ANSI REPRINT Training Retraining and Familiarization of Operators General Training Only personnel who have received general instructions regarding the inspection application and operation of aerial devices including recognition and avoidance of hazards associated with their operation shall operate an aerial device Such items covered shall include but not necessarily be limited to the following issues and requirements 1 The purpose and use o
48. 006 or AWS D1 2 2003 Should the original manufacturer no longer exist an equivalent entity may determine the required procedure Modifications No modifications or additions which affect the stability mechanical hydraulic or electrical integrity or the safe operation of the aerial device shall be made without the written approval of the manufacturer If such modifications or changes are made the capacity operation and maintenance instruction markings shall be changed accordingly In no case shall the safety factors be reduced below those specified in this standard or below the manufacturer s design safety factors whichever are greater Should the original manufacturer no longer exist an equivalent entity may approve required modification Alterations Altering or disabling the function of safety devices guards or interlocks if so equipped is prohibited Weight Distribution Changes in loading or additions made to the mobile unit after the final acceptance that affect weight distribution shall meet applicable regulations by governmental agencies In no case shall axle loads of the fully loaded vehicle exceed the Gross Axle Weight Ratings GAWR assigned by the manufacturer Note Any change in weight distribution may adversely affect stability Transfer of Ownership When a change in ownership of an aerial device occurs it shall be the responsibility of the seller to provide the manufacturer s manual s for that aerial device
49. CONTINUED 4 Battery Condition Indicator Indicator LEDs light up to indicate the level of charge in the batteries e Alighted green LED indicates an adequate charge level e Alighted yellow LED indicates the need for charging soon e A lighted red LED warns that the battery charge level is low all functional operations become non functional until the batteries are recharged 5 Emergency Stop Button When pushed pushed in the EMERGENCY STOP 5 button disconnects electrical power to the ground lower and platform upper control panels The EMERGENCY STOP 5 button should only be pressed pushed in to immediately stop all boom functions To resume control pull the EMERGENCY STOP 5 button out 6 Speed Buttons The SPEED 6 buttons are located along the lower right side of the control panel one of the speed buttons must be pressed pushed in and held while selecting the various boom functions There are four speeds that range from fast RABBIT to slow TURTLE available to help control the positioning of the Boom and the Jib 7 8 Boom Rotation Buttons Pressing pushing in and holding a desired SPEED 6 button and the BOOM ROTATION 7 button at the same time enables the boom to rotate in the CLOCKWISE direction Pressing pushing and holding a desired SPEED 6 button and the BOOM ROTATION 8 button at the same time enables the boom to rotate in the counter CLOCKWISE direction The boom will rotate through 700 Non Cont
50. CONTINUED Manual Boom Lowering Procedure The lift cylinder is equipped with a manual lowering valve this valve is found at the base of the lift cylinder Use the valve handle to lower the platform in case of a complete electrical power failure a load shift or other emergency To lower the work platform pull the valve handle forward and continue pulling until the boom is completely lowered Refer to Figure 3 8 Pull this Valve Handle Figure 3 8 Manual Boom Lowering Valve 29 HAULOTTE GROUP 3 OPERATION TOWING THE AERIAL WORK PLATFORM The aerial work platform trailer includes a single axle two inch ball hitch hydraulic surge brakes mechanical parking brake safety chains brake lights and side marker lights Proper aerial work platform transport requires the proper attachment and inspection of these components before towing Verify the following before towing the aerial work platform Make adjustments as necessary e he TONGUE JACK DOLLY WHEEL and outriggers are in their travel positions The TONGUE JACK DOLLY WHEEL is rotated up so that the TONGUE JACK DOLLY WHEEL assembly is parallel with the tongue tube the outrigger cylinders are fully retracted e Both travel latches boom and platform are engaged securing the boom in its fully stowed position All on board equipment is secured e he key switch is in the OFF position Remove the key e he parking brake is disengaged When the parking brake
51. ConocoPhillips Lubricants 600 N Dairy Ashford 2VV900 Houston Texas 77079 1175 Emergency Health and Safety Number Chemtrec 800 424 9300 24 Hours Customer Service U S 800 822 6457 or Intemational 1 83 2486 3363 Technical Information 800 766 0050 MSDS Information Internet http Av3 conocophillips com NetMSDS 2 Hazards Identification Emergency Overview This matenal is not considered hazardous according to OSHA criteria Appearance Clear and bright Physical Form Liquid Odor Petroleum Potential Health Effects Eye Contact may cause mild eye irritation including stinging watering and redness Skin Contact may cause mild skin irntation including redness and a burning sensation Prolonged or repeated contact can defat the skin causing drying and cracking of the skin and possibly dermatitis inflammation No harmful effects from skin absorption are expected Inhalation Breathing No information available on acute toxicity Ingestion Swallowing Low degree of toxicity by ingestion Signs and Symptoms Effects of overexposure may include irritation of the digestive tract nausea and diarrhea Inhalation of oil mist or vapors at elevated temperatures may cause respiratory irritation Pre Existing Medical Conditions Conditions which may be aggravated by exposure include skin disorders See Section 11 for additional Toxicity Information 814636 Powerflow AW HYI Hydraulic Oil All Grades Page 1 7
52. Date of Issue Status Final 77 HAULOTTE GROUP 7 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW AW HVI HYDRAULIC OIL CONTINUED 814636 Powerflow AW HV Hydraulic Oil All Grades 2 7 Date of Issue 14 Nov 2008 Status Final 3 Comi CASRN Lubricant Base Oil Petroleum VARIOUS PROPRIETARY All concentrations are percent by weight unless ingredient is a gas Gas concentrations are in percent by volume 4 First Aid Measures Eye Contact If irritation or redness develops from exposure flush eyes with clean water If symptoms persist seek medical attention Skin Contact Remove contaminated shoes and clothing and cleanse affected area s thoroughly by washing with mild soap and water or a waterless hand cleaner If irritation or redness develops and persists seek medical attention Inhalation Breathing If respiratory symptoms develop move victim away from source of exposure and into fresh air in a position comfortable for breathing If symptoms persist seek medical attention Ingestion Swallowing First aid is not normally required however if swallowed and symptoms develop seek medical attention Notes to Physician High pressure hydrocarbon injection injuries may produce substantial necrosis of underlying tissue despite an innocuous appearing external wound These injuries often require extensive emergency surgical debridement and all injuries should be evaluated by a specialist in order to
53. ED 6 and desired function buttons at the same time Become familiar with the location and function of all controls Learn to smoothly START and STOP all boom functions e When all aerial work platform operations are complete fully retract the boom extension Center the boom over the boom rest and fully lower the boom until seated in the stowed position for transport NOTE Always fully retract rotate and lower the boom to the stowed position before exiting the platform e Turn the key switch to the GROUND CONTROLS 1 position e Unfasten the safety harness and exit the platform by using a three 3 point contact both hands and one foot e Disengage platform locking pins and return the platform to a stowed position e Engage the boom and platform travel latches NOTE Refer back to earlier in this section to Figures 3 3 to 3 5 for a visual of these latches Turn key switch to the ground controls position e Inspect the area beneath the aerial work platform and trailer for obstructions before retracting outriggers Press push and hold the outrigger RETRACT 22 button and the AUTO LEVEL 23 button until all outriggers are fully retracted to their stowed upright positions NOTE Safety switches prevent outrigger retraction until the boom is completely lowered and in the stowed position At the ground lower control panel turn the KEY SWITCH 1 to the vertical power OFF position and remove the key
54. Engine Mode Ground Engine Mode Platform Function Speeds Boom Raise Fast 30 35 sec Boom Raise Slow 50 55 sec Boom Lower Fast 45 50 sec Boom Lower Slow 120 150 sec Boom Extend Fast 30 35 sec Boom Extend Slow 75 90 sec Boom Retract Fast 40 45 sec Boom Retract Slow 100 110 sec Turntable Rotation Fast 82 90 sec Turntable Rotation Slow 240 270 sec Platform Level Fast 8 10 sec Platform Level Slow 12 16 sec Outrigger Extend 15 20 sec Outrigger Retract 25 30 sec Localized Pressure per Outrigger 25 psi 1 7 Bar 1 8 kg cm 176 5 kPa Operating Temperature Range 20 to 110 Fahrenheit 29 to 43 Celsius 15 GROUP 2 SPECIFICATIONS WARRANTY NEW PRODUCT HAULOTTE NORTH AMERICA Haulotte US Inc Haulotte warrants its new products made by it to be free from defects in material or workmanship for twelve 12 months under normal operational conditions from the warranty start date delivery date In addition Haulotte further warrants the structural elements of each new product made by it as defined in its then current warranty policies and procedures to be free from defects in material or workmanship for five 5 years from the warranty start date delivery date Haulotte agrees to repair or replace at its own expense at its facility in Frederick MD or at an authorized repair facility designated by Haulotte any part or parts of the product found to be defective in material or workmanship
55. F interrupts all electric and hydraulic power operations except emergency lowering Removal of the key protects against any unauthorized person attempting to operate the aerial work platform The key may be removed with the key switch in any selected position 2 Battery Condition Indicator Indicator LEDs light up to indicate the level of charge in the batteries e Alighted green LED indicates an adequate charge level e Alighted yellow LED indicates the need for charging soon e A lighted red LED warns that the battery charge level is low all functional operations become non functional until the batteries are recharged 3 4 Engine Choke and Start Glow Plug Models with Engines Only Start a cold engine by pressing pushing in and holding the CHOKE 4 button then press push the ENGINE START 3 button To start restart a warm engine press push the ENGINE START 3 button only GLOW PLUG OPERATION Press push and hold for 30 60 seconds then press push the ENGINE START 3 button 20 HAULOTTE GROUP 3 OPERATION GROUND LOWER CONTROL PANEL CONTINUED 5 Display Panel The DISPLAY PANEL is a lighted text window that displays the current operating status or an existing error condition when the key switch is positioned at either 1a or 1b 6 Emergency Stop Button When pushed in the EMERGENCY STOP 6 button disconnects electrical power to the ground lower and platform upper control panels The EMERGENCY
56. IAL SAFETY 7 MATERIAL SAFETY The following Material Safety Data Sheets describe the correct procedures for the safe handling of chemical components within the Model 4642T Telescoping Boom Lift as well as any potential health and safety hazards related to these chemicals Material Safety Data Sheets are included here in accordance with all Federal State and Local codes and regulations Read and observe all safety precautions Maintain awareness of potential health and safety hazards MATERIAL SAFETY DATA SHEET FOR LEAD ACID BATTERIES WET FILLED WITH ACID SECTION GENERAL INFORMATION Manufacturer s Name Crown Battery Mfg Company EMERGENCY NO 800 487 2879 Street Address 1445 Majestic Drive OR 800 OIL TANK City State Zip Fremont Ohio 43420 Phone Number 419 334 7181 REVISION DATE 35 18 2000 SECTION II MATERIAL IDENTIFICATION AND INFORMATION COMPONENTS PERCENT ACGIH OTHER LIMITS CAS NUMBER Hazardous Components TLV 196 or greater Carcinogens 0 0196 or greater METALLIC LEAD METAL 0 05 mg m3 0 05 mg m3 7439 92 1 LEAD SULFATES 0 05 mg m3 0 05 mg m3 7439 92 1 LEAD OXIDES 0 05 mg m3 0 05 mg m3 7439 92 1 POLYPROPYLENE CASE MTL SEPARATORS SULFURIC ACID 2504 1 0 mg m3 1 0 mg m3 7664 93 9 WATER REGULATORY INFORMATION Those ingredients listed above are not subject to the reporting requirements of 313 of Title 1 of the Superfund Amendments and Reauthorization Act The items are covered in an exemption as a Manufactu
57. KIN RESPIRATORY SYSTEM amp DIGESTIVE SYSTEM Chronic EYES SKIN RESPIRATORY SYSTEM amp DIGESTIVE SYSTEM Signs and Symptoms of Exposure IRRITATION OF EXPOSED AREA BURNS AND RESPIRATORY PROBLEMS NO POSSIBILITY OF EXPOSURE OF LEAD WILL OCCUR UNLESS BATTERY IS DESTROYED Medical Conditions Generally Aggravated By Exposure EXPOSURE TO MIST MAY CAUSE LUNG DAMAGE amp AGGRAVATE PULMONARY CONDITION Emergency First Aid Procedures SEEK MEDICAL ASSISTANCE FOR FURTHER TREATMENT OBSERVATION AND SUPPORT IF NECESSARY Eye Contact WASH WITH COPIOUS QUANTITIES OF COOL WATER FOR AT LEAST 15 MINUTES Skin Contact FLUSH AREA WITH LARGE AMOUNTS OF COOL WATER FOR AT LEAST 15 MINUTES Inhalation REMOVE TO FRESH AIR IF BREATHING IS DIFFICULT GIVE OXYGEN Ingestion GIVE MILK TO DRINK DO NOT INDUCE VOMITING CALL PHYSICIAN SECTION VI REACTIVITY DATA Stability STABLE Conditions to Avoid N A Incompatibility AVOID COMBUSTIBLES ORGANIC MATERIALS AND STRONG REDUCING AGENTS Hazardous Decomposition Products SULFUR TRIOXIDE CARBON MONOXIDE SULFURIC ACID FUMES amp SULFUR DIOXIDE Hazardous Polymerization MAY OCCUR Conditions to Avoid N A SECTION VII SPILL OR LEAK PROCEDURES 76 Steps to be taken in case material is released or spilled CONTAIN SPILL USING NON COMBUSTIBLE MATERIALS VERMICULITE DRY SAND amp EARTH NEUTRALIZE WITH LIME SODA ASH SODIUM BICARBONATE ETC Waste disposal method CONSULT STATE ENVIRONMENTAL AGE
58. LACEMENT DECAL KIT 62 HAULOTTE GROUP 5 DECAL REPLACEMENT DECAL KIT 06 01 4018 DECAL KIT Includes following Decal D Main Instruction Hazard Platform ee ee ee 8 0202 0528 Decal Flag Made In USA 9 06 00 0586 Decal NOTICE Range of Motion 4642T Decal Danger Tip Over Hazard 6 16 B06 00 0400 Decal Warning Outrigger Crush Foot 8 Decal Danger Electrocution Decal Lubricate Semi Annually Decal Danger Battery Charger Safety Decal Danger Main Instruction Hazard Base Decal Danger Battery Charger Instruction Decal Caution Manual Rotate Retract 36 B06 00 0544 Decal Warning Tow Hazard 65 mph EN NN B06 00 0161B Decal Haulotte BilJax 5in Black Red on Clear 06 00 0587 Decal 6 Model 4642 2 HAULOTTE GROUP 5 DECAL REPLACEMENT IDENTIFICATION PLATES amp OPTIONAL EQUIPMENT 64 HAULOTTE GROUP 5 DECAL REPLACEMENT IDENTIFICATION PLATES amp OPTIONAL EQUIPMENT IDENTIFICATION PLATES B06 00 0499 REPLACEMENT DECALS FOR OPTIONAL EQUIPMENT ITEM NO PART NUMBER DESCRIPTION B06 00 0485 Decal Notice Material Lift Set up Material Lift Option 1 B06 00 0497 Decal Notice Material Lift Max 500 Ib Material Lift Option T Decal Notice Drive and Set Drive and Set Option Decal Warning Jockey Wheel Drive and Set Option Decal
59. NCY INDIVIDUAL STATE REGULATIONS VARY Precautions to be taken in Handling amp Storage SEPARATE FROM INCOMPATIBLE MATERIALS KEEP AWAY FROM FIRE SPARKS AND HEAT Other Precautions and or Special Hazards CONTACT WITH METALS MAY PRODUCE TOXIC SULFUR DIOXIDE FUMES amp MAY ALSO RELEASE FLAMMABLE HYDROGEN GAS THIS REACTION IS INTENSIFIED WHEN DILUTED NFPA Rating HEALTH 3 FLAMMABILITY 0 REACTIVITY 2 SPECIAL 0 HMIS Rating HEALTH 3 FLAMMABILITY 0 REACTIVITY 2 PERSONAL PROTECTION X SECTION VIII CONTROL AND PROTECTIVE MEASURES Respiratory Protection ABOVE P E L NIOSH APPROVED FITTED FULL FACE RESPIRATOR Protective Gloves ACID RESISTANT Eye Protection FULL FACE PROTECTION Ventilation LOCAL EXHAUST VENTILATED AREA PREFERRED MECHANICAL IF BELOW P E L SPECIAL MUST BE ACID amp EXPLOSIVE RESISTANT OTHER MUST BE ACID amp EXPLOSIVE RESISTANT Other Protective Equipment ACID RESISTANT CLOTHING AND BOOTS Hygienic Work Practices N A HAULOTTE GROUP 7 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW AW HVI HYDRAULIC OIL G c 06 Powerflow AW HVI Hydraulic Oil All Grades Material Safety Data Sheet 1 Product and Company Identification Product Name Powerflow AW HYI Hydraulic Oil All Grades MSDS Number 814636 Synonyms Powerflow AW Hydraulic 32 Powerflow AW Hydraulic Oil 46 Powerflow AW Hydraulic Oil 68 Intended Use Hydraulic Fluid Manufacturer Supplier
60. NE E EM 72 Figure 6 6 Material Lift Hook Installation 72 Figure 6 7 Material Lift in its Stowed Position seessseesssssseeseeeeeennn nennen 73 Figure 6 8 Material Lift In Use nennen 7 Fig re 6 9 Manual Platform eaa 74 Figure 8 1 Minimum Safe Approach DisStances c ccccccccsseeceeseeeeeeeceeeeeeesaeeeeeeseeaeeeesseaseeesseeeeeseas 90 LIST OF TABLES TABLE 1 1 MINIMUM SAFE APPROACH DISTANCES eene TABLE 1 2 c CBEAUFORT SQAEE suci ntl eu dH Fe nanan cu ducis eee es eee 10 TABLE 421 BATTERY GHARGER FAULT CODES oor Eo e teens 3 TABLE 4 2 TROUBLE SHOOTIN can tont ba der cas rape Ded etas 46 TABLE 4 3 ERROR CODE DEFINITIONS CONTROLS 47 TABLE 4 4 ERROR CODE DEFINITIONS MOTOR CONTROLLER 58 TABLE 8 1 MINIMUM SAFE APPROACH DISTANCES esee 91 HAULOTTE GROUP 1 SAFETY 1 SAFETY Proper training is required for the safe operation of any mechanical device Failure to follow all instructions and safety precautions in this manual and attached to the aerial work platform will result in death or personal injury Prior to Operation e Head understand and obey all instructions and safety precautions in
61. O TABLE 4 3 ERROR CODE DEFINITIONS CONTROLS 058 SHORTED CIRCUIT LR OUTRIGGER OPEN CIRCUIT RR OUTRIGGER SHORTED CIRCUIT RR OUTRIGGER OPEN CIRCUIT ENGINE THROTTLE SHORTED CIRCUIT ENGINE THROTTLE OPEN CIRCUIT ENGINE STARTER SHORTED CIRCUIT ENGINE STARTER OPEN CIRCUIT ENGINE CHOKE SHORTED CIRCUIT ENGINE CHOKE OPEN CIRCUIT ENGINE STOP SHORTED CIRCUIT ENGINE STOP OPEN CIRCUIT PROPORTION AL SHORTED CIRCUIT PROPORTIONAL OPEN CIRCUIT MOTOR CONTROL ENABLE SHORTED CIRCUIT MOTOR CONTROL ENABLE Excessive load was detected when LR Outrigger circuit was energized A load of less than 70mA was detected when RR Outrigger circuit was energized Excessive load was detected when RR Outrigger circuit was energized A load of less than 70mA was detected when Engine Throttle circuit was energized Excessive load was detected when Engine Throttle circuit was energized A load of less than 70mA was detected when Engine Starter circuit was energized Excessive load was detected when Engine Starter circuit was energized A load of less than 70mA was detected when Engine Choke circuit was energized Excessive load was detected when Engine Choke circuit was energized A load of less than 70 was detected when Engine Stop circuit was energized Excessive load was detected when Engine Stop circuit was energized A load of less than 70mA was detected when Proportional circuit was
62. ODULE located on the PLATFORM MOUNT NOTE If the loopback plug is not inserted into the Load Sense the Emergency Stop circuit will not be complete and the aerial work platform will not function e Firmly secure the platform to prevent equipment damage e Remove the clevis pin holding the platform to the boom lift Refer to Figure 6 5 e Remove the platform from the boom by lifting the cage up and away from the mounting bracket on the boom nose PLATFORM MOUNTING BRACKET Figure 6 5 Platform Removal e Attach the material lifting hook to the mounting bracket on the boom nose re insert the clevis pin Refer to Figure 6 6 Retaining Pin Figure 6 6 Material Lift Hook Installation 72 HAULOTTE GROUP 6 OPTIONAL EQUIPMENT MATERIAL LIFT HOOK CONTINUED ground lower control panel turn the key switch 1 clockwise to the platform control 1b icon This provides for optimal control of the lift by using the platform upper control panel and also allows for remote access e Reverse this procedure to reattach the Work Platform Figure 6 7 Material Lift in its Stowed Position Figure 6 8 Material Lift In Use Position NOTE To recalibrate the load sense refer to the Overload Protection Calibration Procedure located in the Equipment Maintenance section of this manual ALWAYS observe the manufacturers weight lifting limitations when using the material lifting hook ALWAYS use lifting s
63. ON BOOM FUNCTION DISABLED LOSS OF LOAD CELL CONNECTION OPEN CIRCUIT PRIMARY UP SHORTED CIRCUIT PRIMARY UP OPEN CIRCUIT PRIMARY DOWN SHORTED CIRCUIT PRIMARY DOWN OPEN CIRCUIT SECONDARY UP SHORTED CIRCUIT SECONDARY UP Pressure sensor output is out of range Engine had low oil pressure while running Machine has gone out of level with use A Boom Rotate Extend or Retract function has been requested while boom is down An Outrigger function has been requested while boom is up Lower Control has lost RS485 communication with Load Sense Module Load Sense Module has detected an overloaded boom and disabled boom functions Load Sense Module has lost connection with Load Cell A load of less than 70 was detected when Primary Up circuit was energized Excessive load was detected when Primary Up circuit was energized A load of less than 70mA was detected when Primary Down circuit was energized Excessive load was detected when Primary Down circuit was energized A load of less than 70 was detected when Secondary Up circuit was energized Excessive load was detected when Secondary Up circuit was energized Disconnect Pressure Sensor Kawasaki Engine While engine is running disconnect engine oil pressure sense wire Kubota Engine While engine is running disconnect engine oil pressure sense wire and connect wire to ground Tilt level sensor Try to Rotate Extend or
64. OPERATOR S MANUAL Haulotte 5 GROUP 1621241 g A Ww i SERIES TRAILER MOUNTED BOOMS B33 01 0107 HAULOTTE GROUP AERIAL WORK PLATFORM This equipment is designed and manufactured in compliance with the duties responsibilities and standards set forth for manufacturers in the ANSI standards in effect at the time of manufacture This equipment meets or exceeds applicable ANSI codes and standards when operated in accordance with manufacturer s recommendations It is the responsibility of the user to follow all Federal State and Local codes and regulations that govern the safe operation of this equipment Obtain read and obey all safety precautions before performing maintenance or repairs or attempting to operate this equipment This includes all manufacturer recommendations as well as all Federal State and Local codes and regulations To ensure proper and safe use of this equipment it is strongly recommended that only trained and authorized personnel attempt to operate and maintain the aerial work platform This manual shall be considered a permanent and necessary component of the aerial work platform and shall be kept with the machine at all times Owners and Lessors should complete a full inspection of all components and perform a test of all functions including brake functions before commissioning or reselling the aerial work platform Repair or replace all damaged or
65. RIVE ENABLE OPEN CIRCUIT DRIVE DUMP C21 SHORTED CIRCUIT DRIVE DUMP C21 OPEN CIRCUIT TURN LEFT C22 SHORTED CIRCUIT TURN LEFT C22 OPEN CIRCUIT TURN RIGHT C23 A load of less than 70mA was detected when Spare Output circuit was energized Excessive load was detected when Spare Output circuit was energized A load of less than 70mA was detected when AC Switch circuit was energized Excessive load was detected when AC Switch circuit was energized A load of less than 70mA was detected when Strobe circuit was energized Excessive load was detected when Strobe circuit was energized A load of less than 70mA was detected when Drive PWM circuit was energized Excessive load was detected when Drive PWM circuit was energized A load of less than 70mA was detected when Drive Enable circuit was energized Excessive load was detected when Drive Enable circuit was energized A load of less than 70mA was detected when Drive Dump C21 circuit was energized Excessive load was detected when Drive Dump C21 circuit was energized A load of less than 70mA was detected when Turn Left C22 circuit was energized Excessive load was detected when Turn Left C22 circuit was energized A load of less than 70mA was detected when Turn Right C23 circuit was energized Disconnect a wire from Spare Output coil Use a piece of wire to short the Spare Output coil Disconnect a wire from AC
66. Retract the boom while boom is down Try to move an outrigger while boom is up Remove Load Sense Module from machine Overload Boom Disconnect Load Cell from Load Sense Module Disconnect a wire from Primary Up coil Use a piece of wire to short the Primary Up coil Disconnect a wire from Primary Down coil Use a piece of wire to short the Primary Down coil Disconnect a wire from Secondary Up coil Use a piece of wire to short the Secondary Up coil This is a self clearing error When error condition is corrected error is cleared This is a latched error Power must be cycled to clear error This is a self clearing error When error condition is corrected error is cleared This is a self clearing error When error condition is corrected error is cleared This is a self clearing error When error condition is corrected error is cleared This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a self clearing error When error condition is corrected error is cleared This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must
67. STOP engaged Disengage EMERGENCY STOP buttons Outriggers not deployed Deploy all outriggers One or more telescoping a Key switch is turned to the OFF or Turn key switch to ground or boom controls do not incorrect control position platform controls position function b Battery charge is low Recharge battery OR EMERGENCY STOP engaged Disengage EMERGENCY STOP buttons Battery ground or in series cable Inspect and repair battery loose connections improperly All outriggers not properly deployed Deploy all outriggers and level aerial work platform OR Hydraulic pump inoperative Inspect pump replace or repair as One or more Telescoping needed Boom Controls function Loose wiring connector Check wiring terminals in control intermittently box and at valve manifold replace or repair as needed Valve solenoid not operating Clean valve solenoid and recheck properly function s replace or repair as needed One or more Telescoping Boom Controls function i Check display for system status See Table 3 3 for error code definitions and correction i Error detected by system interlock j Broken or loose wire j Inspect wiring in control box and at valve manifold and valve coil repair or replace as needed 46 HAULOTTE GROUP ERROR CODE DEFINITIONS CONTROLS The DISPLAY PANEL located on the ground lower control panel indicates the present operating status of the aerial work platform displ
68. Switch coil Use a piece of wire to short the AC Switch coil Disconnect a wire from Strobe Use a piece of wire to short the Strobe coil Disconnect a wire from Drive PWM coil Use a piece of wire to short the Drive PWM coil Disconnect a wire from Drive Enable coil Use a piece of wire to short the Drive Enable coil Disconnect a wire from Drive Dump C21 coil Use a piece of wire to short the Drive Engage coil Disconnect a wire from Turn Left C22 coil Use a piece of wire to short the Turn Left C22 coil Disconnect a wire from Turn Right C23 coil This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error Not Used Not Used Error Suppressed due to low current draw Error Suppressed due to low current draw Error Suppressed due to low current draw Error Sup
69. TICK 1 in the desired direction he aerial work platform will continue to move in the desired direction until the JOYSTICK 1 or DRIVE ENABLE 2 button is released e Once you have reached the work location lower the outriggers and level the aerial work platform using either the ground lower or platform upper control panel NOTE Boom functions are not available until outriggers are fully deployed and the aerial work platform is level 69 HAULOTTE GROUP 6 OPTIONAL EQUIPMENT DRIVE amp SET CONTROLS CONTINUED During Operation Utilize the Drive and Set option to advance to the next work location Use the following procedure to operate the Drive and Set option e Completely lower the platform into its stowed position e Fully retract outriggers into the stowed upright position NOTE The aerial work platform MUST be in its fully lowered stowed position before moving e Press push and hold the DRIVE ENABLE button on the Platform lower Control Panel move the JOYSTICK in the desired direction e he aerial work platform will continue in the desired direction until the JOYSTICK or DRIVE ENABLE button is released e locontinue platform operations lower outriggers and level the aerial work platform using either the ground lower or platform upper control panel NOTE Boom functions are not available until outriggers are fully deployed and the aerial work platform is level 70 HAULOTTE GRO
70. UP 6 OPTIONAL EQUIPMENT MATERIAL LIFT HOOK If an aerial work platform is equipped with the Material Lift Hook option several steps need to be performed to change from the Platform to the Lift Hook Use the follow procedure to make this change e Unwind the platform upper control box s six foot 6 cord from the cord wrap on the platform e Disconnect the platform upper control box s PLUG from the LOAD SENSE MODULE located on the PLATFORM MOUNT Refer to Figure 6 2 PLATFORM PLUG RECEPTACLE MOUNT LOAD SENSE MODULE To Boom Cable DO NOT REMOVE Figure 6 2 Disconnect Plug from Load Sense Module e Remove the platform upper control box from the platform by releasing the LATCH on the back of the control box take the platform upper control box to the ground lower control station Refer to Figure 6 3 PLATFORM PLATFORM UPPER CONTROL BOX Figure 6 3 Remove Platform Upper Control Box e Disconnect the electric LOOPBACK PLUG from the receptacle on the bottom right of the ground lower control box Refer to Figure 6 4 Loopback Plug Figure 6 4 Loopback plug 71 HAULOTTE GROUP 6 OPTIONAL EQUIPMENT MATERIAL LIFT HOOK CONTINUED e Insert the PLUG from the platform upper control panel into the receptacle on the bottom right of the ground lower control box replacing the LOOPBACK PLUG from the previous step e Take the LOOPBACK PLUG and insert it into the open receptacle on the LOAD SENSE M
71. WAYS keep away from an aerial work platform that is exposed to electrically charged power lines If the aerial work platform comes in contact with electrically charged power lines NEVER touch or operate the aerial work platform until power lines are shut off ALWAYS operate only on a firm and level surface NEVER operate on surfaces that do not support the aerial work platform with its rated load capacity or on surfaces that do not support force exerted by the outriggers during aerial work platform operation Operate only on surfaces that can support a pressure of 25 psi 1 8 kg cm to ensure safe operation ALWAYS keep personnel away from potential pinch and shear points and from potential crush hazards as indicated by decals attached to the aerial work platform ALWAYS keep the safety bar lowered closed unless personnel are entering or exiting the work platform HAULOTTE GROUP 1 SAFETY DURING OPERATION CONTINUED ALWAYS use a three 3 point contact both hands and one foot when entering or exiting the work platform ALWAYS wear proper footgear ALWAYS keep the platform free of debris ALWAYS keep personnel and obstructions clear of the aerial work platform when repositioning the boom or platform ALWAYS cordon the area surrounding the outriggers to keep personnel vehicles and moving equipment away from the aerial work platform while in use ALWAYS stay clear of overhead obstructions including wires and cables ALWAYS unhi
72. accordance with the manufacturer s recommendations for each specific aerial device shall be inspected for defects prior to each day s operation The following tests and inspections shall be performed by the operator once daily prior to first use 1 Conduct walk around visual inspection looking for damaged components cracks or corrosion excessive wear and any loose deformed or missing bolts pins fasteners locking devices and covers 2 Check all controls and associated mechanisms for proper operation to include but not limited to the following a Proper operation of interlocks b Controls return to neutral when released and not sticking Control functions and operation clearly marked 3 Check visual and audible safety devices for proper operation 4 Visually inspect fiberglass and insulating components for visible damage and contamination b Check for missing or illegible operational and instructional markings 6 Check hydraulic and pneumatic systems for observable deterioration and excessive leakage 7 Check electrical systems related to the aerial device for malfunction signs of excessive deterioration dirt and moisture accumulation 8 Perform functional test to include but not limited to the following a Set up aerial device for operation including outriggers b Cycle each aerial device boom function through its complete range of motion from the lower controls except where operation
73. ane manufacturer When using a forklift use only the designated forklift pockets B Follow all forklift operating instructions as indicated by the forklift manufacturer Adjust rigging to keep the machine level and to minimize the risk of damage to machine NOTE Only trained and authorized personnel should attempt to lift the aerial work platform using a crane or forklift 32 Figure 3 10 Lifting the Aerial Work Platform HAULOTTE GROUP 3 OPERATION TRANSPORTING THE AERIAL WORK PLATFORM ON A TRUCK BED Refer to Figure 3 11 Transporting the Aerial Work Platform Verify that the truck or trailer is parked on a firm and level surface Completely retract and lower the boom Secure both BOOM TRAVEL LATCHES Retract all OUTRIGGERS CYLINDERS to their fully stowed upright position Load boom onto the truck or trailer Chock A the wheels and apply PARKING BRAKE Place a wooden block B under the TONGUE near the TRAILER HITCH Lower the TONGUE JACK DOLLY WHEEL C until the TRAILER TONGUE rests on the wooden block owing up and lock the TONGUE JACK DOLLY WHEEL C so that the weight of the TONGUE now rests on the wooden block Secure the aerial work platform to the trailer bed using straps or chains Use only the four attachment points D beneath the machine adjacent to the outriggers Adjust as necessary to prevent damage to rigging equipment or machine Figure 3 11 Transporting the Aerial Work Platform 33
74. anuals bulletins or other materials for the information of the user of an aerial device the lessor shall pass them on to the user without delay Use of Brokers If Brokers are employed in leasing the responsibility of lessors and lessees as specified in this Section continue even though a Broker may be involved in the transaction Responsibilities of Brokers Broker Involved In a Sale A broker involved in a sale shall 1 Assure that the entity actually transferring ownership knows the proper location and identification of proper personnel of the purchasing entity 2 Confirm that operations and maintenance manuals are provided to the new owner 3 Confirm that all parties are aware of their responsibilities under Section 8 7 of this standard Broker Involved In a Lease A broker involved in a lease shall 1 Assure that the entity actually transferring possession knows the proper location and identification of the proper personnel of the lessee or user of the aerial device 2 Confirm that the operators manual maintenance manual and a Manual of Responsibilities are provided to the lessee 3 Confirm that all parties are aware of their responsibilities under Section 11 4 of this standard DENOTES PROHIBITED ZONE Figure 8 1 Minimum Safe Approach Distances HAULOTTE GROUP Over 200KV to 350KV TABLE 8 1 MINIMUM SAFE APPROACH DISTANCES Voltage Range Minimum Safe Approach Distance Phase to Phase
75. ase if it can be done safely Prevent spilled material from entering sewers storm drains other unauthorized drainage systems and natural waterways Use water sparingly to minimize environmental contamination and reduce disposal requirements Spills into or upon navigable waters the contiquous zone or adjoining shorelines that cause a sheen or discoloration on the surface of the water may require notification of the National Response Center phone number 800 424 8802 Methods for Containment and Clean Up Notify relevant authorities in accordance with all applicable regulations Immediate cleanup of any spill is recommended Dike far ahead of spill for later recovery or disposal Absorb spill with inert material such as sand or vermiculite and place in suitable container for disposal Handling and Storage Precautions for safe handling Wash thoroughly after handling Use good personal hygiene practices and wear appropriate personal protective equipment High pressure injection of hydrocarbon fuels hydraulic oils or greases under the skin may have serious consequences even though no symptoms or injury may be apparent This can happen accidentally when using high pressure equipment such as high pressure grease guns fuel injection apparatus or from pinhole leaks in tubing of high pressure hydraulic oil equipment Do not enter confined spaces such as tanks or pits without following proper entry procedures such as ASTM D 4276 and 29CFR 1910 146
76. ayed on this panel 4 EQUIPMENT MAINTENANCE lf an error condition is detected the appropriate error code will be Refer to Table 4 3 to resolve the error or contact Haulotte Group Customer Service Department at 1 800 537 0540 or visit Haulotte Group online at www haulotte usa com with any additional questions TABLE 4 3 ERROR CODE DEFINITIONS CONTROLS 001 MACHINE IS IN DOWN ONLY MODE LOSS OF PLATFORM COMMUNICATION LOSS OF DRIVE COMMUNICATION LOSS OF PC COMMUNICATION PLATFORM CONTROL HAS STUCK KEY DRIVE CONTROL HAS STUCK KEY DRIVE CONTROL HAS STUCK JOYSTICK GROUND CONTROL HAS STUCK KEY BOOM UP WITHOUT OUTRIGGERS ON GROUND LEVEL SENSOR HAS ERRATIC OUTPUT TRYING TO DRIVE W TRAILER BRAKE OFF ANGLE SENSOR IS DISCONNECTED OR BAD Machine went out of level with use moment sense or load sense circuits have detected an overload Lower Control has lost RS485 communication with Platform Control Lower Control has lost RS485 communication with Drive Control Lower Control has lost RS232 communication with PC Platform Control has detected a stuck or pressed key on power up Drive Control has detected a stuck or pressed key on power up Drive Control has detected a stuck or pressed joystick on power up Lower Control has detected a stuck or pressed key on power up Lower Control has detected the boom is up and all four outriggers are not on the ground The Lower Contr
77. ces These manuals shall be stored on the mobile unit Inspection and Test Prior to delivery the lessor of an aerial device shall perform a frequent inspection as specified in Section 8 2 3 of this standard 89 HAULOTTE GROUP 11 3 2 11 4 1 11 4 2 90 Responsibilities Upon delivery each lessor of an aerial device shall inform the lessee of their responsibilities in accordance with Section 8 as to inspection testing and maintenance requirements Section 9 as to user s responsibilities and Section 10 as to operator s responsibilities Training The lessor shall offer training or training materials that aid the lessee in the operation inspection testing and maintenance of the aerial device This training shall be offered initially and subsequently on request General training Only personnel who have received general instructions regarding the inspection application and operation of aerial devices including recognition and avoidance of hazards associated with their operation shall operate an aerial device Such items covered shall include but not necessarily be limited to the following issues and requirements 1 The purpose and use of manuals 2 That operating manuals are an integral part of the aerial device and must be properly stored on the vehicle when not in use 3 A pre start inspection 4 Responsibilities associated with problems or malfunctions affecting the operation of the aerial device 5
78. cted maximum pressure setting Excessive engine temperature was detected Engine alternator is not charging When driving engine high RPM was too low A load of less than 70mA was detected when Brake FWS C21 circuit was energized Excessive load was detected when Brake FWS C21 circuit was energized A load of less than 70 was detected when RS Ret FWS C22 circuit was energized Excessive load was detected when RS Ret FWS C22 circuit was energized A load of less than 70 was detected when RS Ext FWS C23 circuit was energized Excessive load was detected when RS Ext FWS C23 circuit was energized A load of less than 70 was detected when FS Ret FWS C24 circuit was energized Put 500lbs in boom level boom and extend until alarm sounds and error is displayed Put 500lbs in boom level boom and extend until alarm sounds and error is displayed Put 500lbs in boom lower cylinder pressure setting using configuration program and extend boom until alarm sounds and error is displayed Disconnect safety pressure switch wires Remove wire from engine temperature sensor and connect wire to ground Remove P wire from alternator and connect wire to ground Misadjust engine high RPM to a value less than 3000 RPM and attempt to drive Disconnect a wire from Brake FWS C21 coil Use a piece of wire to short the Brake FWS C21 coil Disconnect a wire from RS Ret FWS C22 coil
79. d to any express warranties except for the exclusive warranty provided herein or implied warranties as to merchantability or fitness for any particular purpose This warranty shall be void if upon the occurrence of any incident involving any product made by Haulotte and resulting in any personal injury or property damage customer shall fail to notify Haulotte within 48 hours of such occurrence or permit Haulotte and its representatives to have immediate access to such product and all records of or within the control of the customer relating to the product and occurrence For the procedure to apply for warranty please refer to the warranty procedure document QC 00001 North America Warranty 2010 4 QC 00002 16 HAULOTTE GROUP 2 SPECIFICATIONS WARRANTY CLAIMS PROCEDURE In order to qualify for warranty coverage the following conditions must be met 1 Return of completed Warranty Registration form to Haulotte Group BilJax within 15 days of receipt of product 2 Notification to Haulotte Group BilJax Service within 48 hours of any claimed defect or damage resulting from the claimed defect 3 Warranty is limited to parts that are determined to be defective by an authorized service dealership in conjunction with Haulotte Group BilJax Service This does not include parts worn out due to normal wear and tear Haulotte Group BilJax authorized dealers or distributors are responsible for filing claims under warranty Listed below is
80. e a piece of wire to short the Platform Level Down coil Disconnect a wire from Platform CW coil Use a piece of wire to short the Platform CW coil This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error Checked only at power up Articulating Boom Models Checked only at power up Articulating Boom Models Checked only at power up Articulating Boom Models Checked only at power up Articulating Boom Models Checked only at power up Articulating Boom Models Checked o
81. e aerial device for a sufficient period of time to demonstrate proficiency in the actual operation of the aerial device Proof of Training Users providing training should provide successful trainees a means to evidence their training and should provide such proof if requested by the trainee The document evidencing training shall include the following information 1 Name of trainee 2 of entity providing training or retraining 3 Name of trainer s 4 Clear identification of the make s and model s of the mobile unit s on which the operator has been trained Application The employer and authorized operator s shall insure that the aerial device is used only for intended applications as defined in the operating manual and that all recognized safety practices are observed The User is directed to Appendix C for guidance as to appropriate applications Electrical Hazard All applicable safety related work practices intended to protect from electrical hazards shall be defined and explained to the operator by a qualified person The operator shall maintain the appropriate Minimum Approach Distance MAD from energized conductors and apparatus commensurate with the operator s qualifications See Appendix F for the information on the Minimum Approach Distances and other precautions Bare Hand Work For bare hand work a Category A aerial device shall be used 9 7 9 8 10 10 1 10 2 10 3 10 4 10 5
82. ecommended daily service checks Refer to Equipment Maintenance section of this manual HAULOTTE GROUP DURING OPERATION Ensure the following general safety precautions are followed while operating the aerial work platform 1 SAFETY ALWAYS position away from power lines this ensure that no part of the aerial work platform can accidentally reaches into an unsafe area This includes full extension of the telescoping boom through 700 Non Continuous rotation Over 500KV to 750KV Over 750KV to 1000KV 13 72 This aerial work platform is NOT insulated for use near electrical power lines and DOES NOT provide protection from contact with or close proximity to any electrically charged conductor Operator must maintain safe clearances at all times 10 ft 3 05m minimum and must always allow for Platform movement due to gusty winds Always contact power company before working near power lines Assume every power line is live Power lines can be blown by the wind Refer to Table 1 1 for minimum safe approach distances between the machine and electrical power lines TABLE 1 1 MINIMUM SAFE APPROACH DISTANCES Minimum Safe Approach Voltage Range Distance Phase to Phase Feet Meters to 300V Avoid Contact Over 300V to 50KV 20 Over 200KV to 350KV 6 10 Over 350KV to 500KV 25 7 62 10 67 ALWAYS check with local electrical authorities regarding any local requirements which may differ from those shown in Table 1 1 AL
83. ecting the operation of the aerial device b Factors affecting stability 6 The purpose of placards and decals 7 Workplace inspection 8 Applicable safety rules and regulations such as Part 4 ANSI C2 2007 National Electrical Safety Code applies to utility workers as defined in ANSI C2 The above standard is an example other industries using aerial devices have safety rules pertinent to that industry Authorization to operate Operator warnings and instructions Actual operation of the aerial device Under the direction of a qualified person the trainee shall operate the aerial device for a sufficient period of time to demonstrate proficiency in the actual operation of the aerial device Proper use of personal fall protection equipment Fall protection systems criteria and practices are covered in 29 CFR 1926 502 Retraining The operator shall be retrained when so directed by the user based on the user s observation and evaluation of the operator O O lt x 12 Familiarization When operators are directed to operate an aerial device with which they are not familiar they shall receive prior instruction regarding the following items 1 The location of the manuals 2 The purpose and function of all controls 3 Safety devices and operating characteristics specific to the aerial device 4 Under the direction of a qualified person the trainee shall operate th
84. ections and tests shall be performed Intervals shall be set by the owner in accordance with the manufacturer s recommendations Such intervals are dependent upon component function and exposure to wear deterioration and other agents which adversely affect component life Two classifications are designated 1 Frequent Inspection and Test Daily to monthly intervals 2 Periodic Inspection and Test One to twelve month intervals Frequent Inspection and Test Items determined by the owner in accordance with the manufacturer s recommendations for each specific aerial device shall be inspected for defects The following inspections and tests shall be performed by the operator immediately prior to first use at the beginning of each shift 1 Conduct walk around visual inspection looking for damaged components cracks or corrosion excessive wear and any loose deformed or missing bolts pins fasteners locking devices and covers 2 Check all controls and associated mechanisms for proper operation to include but not limited to the following a Proper operation of interlocks b Controls return to neutral when released and not sticking c Control functions and operation clearly marked 85 HAULOTTE GROUP 3 Check visual and audible safety devices for proper operation 4 Visually inspect fiberglass and insulating components for visible damage and contamination 5 Check for missing or illegible operational and instruc
85. ed This is a self clearing error When error condition is corrected error is cleared This is a self clearing error When error condition is corrected error is cleared This is a self clearing error When error condition is corrected error is cleared Error will be displayed only if boom is raised The Platform Control Engine On LED will also blink a 2 blink error code Machines with Drive option only The Drive Control Engine On LED Will also blink a 2 blink error code Error message will only be display if connected to a PC that is not communicating The Platform Control Engine On LED will also blink a 1 blink error code Machines with Drive option only The Drive Control Engine On LED will also blink a 1 blink error code Machines with Drive option only The Drive Control Engine On LED will also blink a 3 blink error code The Lower Control Power LED will also blink a 1 blink error code This error is suppressed during extending and retracting outriggers Machines with Drive and Set option only Machines with Moment Sense option only 47 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE r O TABLE 4 3 ERROR CODE DEFINITIONS CONTROLS ERROR MESSAGE ERROR DEFINITION TO SIMULATE ERROR TO CLEAR ERROR COMMENTS 013 48 PRESSURE SENSOR IS DISCONNECTED OR BAD CHECK ENGINE LOW OIL PRESSURE MACHINE IS NOT LEVEL LIFT BOOM STOW BOOM LOSS OF LOAD SENSE COMMUNICATI
86. erial Safety Data Sheet was prepared HOWEVER NO WARRANTY OF MERCHANTABILITY FITNESS FOR ANY PARTICULAR PURPOSE OR ANY OTHER WARRANTY IS EXPRESSED OR IS TO BE IMPLIED REGARDING THE ACCURACY OR COMPLETENESS OF THE INFORMATION PROVIDED ABOVE THE RESULTS TO BE OBTAINED FROM THE USE OF THIS INFORMATION OR THE PRODUCT THE SAFETY OF THIS PRODUCT OR THE HAZARDS RELATED TO ITS USE No responsibility is assumed for any damage or injury resulting from abnormal use or from any failure to adhere to recommended practices The information provided above and the product are furnished on the condition that the person receiving them shall make their own determination as to the suitability of the product for their particular purpose and on the condition that they assume the risk of their use In addition no authorization is given nor implied to practice any patented invention without a license 83 HAULOTTE GROUP 7 MATERIAL SAFETY 84 HAULOTTE GROUP 8 ANSI REPRINT The following sections are reprinted from the ANSI A92 2 2009 code in effect at the time of manufacture and govern the safe use of the Haulotte Group It is the responsibility of all owners and operators of this machine to read understand and obey the recommendations set forth by the ANSI code 8 ANSI REPRINT Permission to reprint this material has been granted by the Scaffold Industry Association f 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 8 Responsibilities of Dealers
87. f manuals 2 That operating manuals are an integral part of the aerial device and must be properly stored on the vehicle when not in use pre start inspection Responsibilities associated with problems or malfunctions affecting the operation of the aerial device b Factors affecting stability 6 The purpose of placards and decals 7 Workplace inspection 8 Applicable safety rules and regulations such as Part 4 ANSI C2 2007 National Electrical Safety Code applies to utility workers as defined in ANSI C2 The above standard is an example other industries using aerial devices have safety rules pertinent to that industry Authorization to operate 10 Operator warnings and instructions 11 Actual operation of the aerial device Under the direction of a qualified person the trainee shall operate the aerial device for a sufficient period of time to demonstrate proficiency in the actual operation of the aerial device 12 Proper use of personal fall protection equipment Fall protection systems criteria and practices are covered in 29 CFR 1926 502 Retraining The operator shall be retrained when so directed by the user based on the user s observation and evaluation of the operator Familiarization When an operator is directed to operate an aerial device they are not familiar with the operator prior to operating shall be instructed regarding the following items 1 The location of the manuals
88. for such component is provided through the original manufacturer of the component or its distributor organization Haulotte warranty does not apply to defects caused by negligence misuse accidental damage inadequate or improper use or maintenance acts of nature and normal wear and tear of the products Under no circumstances shall Haulotte be liable for any consequential or special damages which any person or entity may incur or claim to incur as a result of any defect in the product or in any correction or alteration thereof made or furnished by Haulotte or others Consequential or special damage includes but not limited to cost of transportation lost sales lost orders lost profits lost income increased over head labor and material costs and cost of manufacturing variances and operational inefficiencies Haulotte maximum liability under this warranty shall be the purchase price paid to Haulotte with respect to the product to which such warranty is claimed This warranty constitutes Haulotte entire and exclusive warranty as to the product and is the sole and exclusive remedy for the product defects in material and workmanship Haulotte does not assume and has not authorized any other person to assume on its behalf any other warranty or liability in connection with any product covered by this warranty Haulotte expressly disclaims any and all other warranties of any kind whatsoever as to the product furnished hereunder including but not limite
89. fore the unit is returned to service Return to service shall be approved by a qualified person Inspection and Test Records Frequent Items to be inspected shall be designated to the operator or other authorized person making frequent inspections Records of frequent inspections need not be made However where a safety hazard is found it shall be reported in writing to a person responsible for the corrective action and that report and a record of the HAULOTTE GROUP 8 3 2 8 4 8 4 1 8 4 2 8 5 8 5 1 8 6 8 7 8 8 8 9 8 10 8 11 correction shall be maintained for five years or as required by applicable regulations Periodic Written or appropriately archived electronic dated and signed reports and records shall be made of periodic inspections and tests and retained for a period of five years or as required by applicable regulations Maintenance Maintenance and frequency of maintenance shall be determined by the owner in accordance with the manufacturer s recommendations Maintenance Training The owner shall train their maintenance personnel in inspection and maintenance of the aerial device in accordance with the manufacturer s recommendations and Section 8 of this standard Weldings Welding repairs of components or welds designated as critical in the manufacturer s manual shall be made in accordance with the manufacturer s recommendations and shall meet the Structural Welding Code AWS D1 1 2
90. fthe ratio is not 3 68 1 press push the MID HIGH MID LOW 15 CENTER SPEED button until the ratio is correct Proceed to Step 7 7 Press push the RABBIT 15 TOP button to return to Load Sense Zero Calibration Utility and repeat Steps 4 and 5 The Display should now read 3 68 1 0 If so proceed to Step 8 8 Exit the maintenance mode by scrolling through the menu using the TURTLE 15 BOTTOM button 9 Press push the PLATFORM TILT UP 13 button and PLATFORM TILT DOWN 14 button simultaneously until the display reads Load 0000 Ibs kg 10 N Return the platform to the upright position and re install the clevis pin Press push the PLATFORM TILT UP 13 button and the PLATFORM TILT DOWN 14 button simultaneously to visualize the display it should now read 65lbs 30kg 10 NOTE For lifts with the Platform Rotate option the display should read 125lbs 57kg 11 Add between 350 400lbs 159 182kg to platform NOTE Keep accurate track of how much weight within 5lbs 2 3kg is added to the platform 12 The Boom Load on the display should read the added weight plus the initially displayed weight against the load cell this weight needs to be within 10 To determine the percentage use the formulas below where W1 is the platform only weight and W2 is the weight that was added to the platform Minimum Load 0 9 W1 W2 Maximum Load 1 1 W1 W2 13 If the displayed load is within
91. functions may be accomplished manually To manually operate boom retraction and turntable rotation functions use the hand pump and selected valves on the hydraulic pump unit that can be accessed inside the pump compartment Manual lowering of the boom and platform may also be performed by actuating the valve plunger found on the base of each boom lift cylinder Pulling and holding the valve plunger retracts the boom lift cylinder The boom may need to be rotated to a clear area before lowering HAULOTTE GROUP 3 OPERATION GROUND LOWER CONTROL PANEL The ground lower control panel is used to operate outriggers and control all boom functions To access the ground lower control panel open the control panel access cover found on the turntable The ground lower control panel includes the following controls and indicators DISPLAY PANEL BATTERY CONDITION INDICATOR HOLD DOWN EXTEND OR RETRACT BUTTON WHILE SELECTING INDIVIDUAL OUTRIGGER BUTTONS OR THE AUTO LEVEL BUTTON i ALL OUTRIGGER LIGHTS MUST BE ON BEFORE PLATFORM CAN BE RAISED RETRACT zo cm Figure 3 1 Ground Lower Control Panel 1 Key Switch Turning the key switch counter clockwise to the GROUND 1a icon selects operation from the ground lower control panel Turning the key switch clockwise to the PLATFORM 1b icon selects operation from the platform upper control panel Turning the key to the vertical position power OF
92. h 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE ee O TABLE 4 3 ERROR CODE DEFINITIONS CONTROLS 128 SHORTED CIRCUIT FS RET FWS C24 OPEN CIRCUIT FS EXT FWS C25 SHORTED CIRCUIT FS RET FWS C25 OPEN CIRCUIT DC D FWD FWS C26 SHORTED CIRCUIT DC D FWD FWS C26 OPEN CIRCUIT DC D REV FWS C27 SHORTED CIRCUIT DC D REV FWS C27 OPEN CIRCUIT DC D FWS C28 SHORTED CIRCUIT DC D FWS C28 OPEN CIRCUIT DC D FWS C29 SHORTED CIRCUIT DC D FWS C29 OPEN CIRCUIT DC D FWS C30 SHORTED CIRCUIT DC D FWS C30 OPEN CIRCUIT DC D FWS C31 SHORTED CIRCUIT DC D FWS C31 Excessive load was detected when FS Ret FWS C24 circuit was energized A load of less than 70mA was detected when FS Ext FWS C25 circuit was energized Excessive load was detected when FS Ext FWS C25 circuit was energized A load of less than 70mA was detected when DC D Fwd FWS C26 circuit was energized Excessive load was detected when DC D Fwd FWS C26 circuit was energized
93. h the ground Verify that all outrigger status LEDs on the ground control panel are unlit Lower one outrigger until the footpad makes contact with the ground and the outrigger begins lifting the trailer If the LED is lit before the footpad makes contact with the ground or if the LED remains unlit after the weight is transferred to the outrigger the position switch or wiring is faulty Repeat this procedure for each outrigger Repair or replace as necessary Refer to Figure 4 2 POSITION SWITCH Figure 4 2 Outrigger Position Switch 39 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE DAILY SERVICE CHECKS CONTINUED Inspect hydraulic System and fluid levels e Check all hydraulic hoses and fittings for leaks and or damage Tighten or replace as necessary to prevent hydraulic oil or pressure loss The hydraulic oil level should be checked with the boom is down all outriggers are raised and the trailer wheels are on a level surface e Hydraulic oil level should be visible in but not above the sight gauge hydraulic oil level is not visible to at least half way up the sight gauge add clean Hydraulic Fluid while the boom and outriggers are fully retracted and stowed Pour slowly to avoid creating air pockets in the reservoir DO NOT fill above the sight gauge Overfilling the hydraulic reservoir may cause damage to hydraulic lines and may result in aerial work platform malfunction Refer to Figure 4 3 e he
94. hecked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only 55 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE r O TABLE 4 3 ERROR CODE DEFINITIONS CONTROLS 143 OPEN CIRCUIT FWS C32 144 SHORTED CIRCUIT FWS C32 145 OPEN CIRCUIT FWS C33 146 SHORTED CIRCUIT FWS C33 147 OPEN CIRCUIT FWS C34 148 SHORTED CIRCUIT FWS C34 149 OPEN CIRCUIT FWS R2 150 SHORTED CIRCUIT FWS R2 151 OPEN CIRCUIT FWS GEN G1 152 SHORTED CIRCUIT FWS GEN G1 153 OPEN CIRCUIT FWS CON 24V 154 SHORTED CIRCUIT FWS CON 24V 155 OPEN CIRCUIT FWS SPARE 1 156 SHORTED CIRCUIT FWS SPARE 1 157 OPEN CIRCUIT FWS SPARE 2 56 A load of less than 70 was detected when FWS C32 circuit was energized Excessive load was detected when FWS C32 circuit was energized A load of less than 70 was detected when FWS C33 circuit was energized Excessive load was detected when FWS C33 circuit was energized A load of less
95. hines with 4WD option only Checked only at power up Machines with 4WD option only Checked only at power up Machines with 4WD option only Checked only at power up Machines with 4WD option only Checked only at power up Machines with 4WD option only Checked only at power up Machines with 4WD option only Checked only at power up Machines with 4WD option only Checked only at power up Machines with 4WD option only Checked only at power up Machines with 4WD option only Checked only at power up Machines with 4WD option only Checked only at power up Machines with 4WD option only Checked only at power up Machines with 4WD option only 53 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE r O TABLE 4 3 ERROR CODE DEFINITIONS CONTROLS 103 54 OUTREACH NEAR MAXIMUM OUTREACH AT MAXIMUM OVER MAXIMUM CYLINDER PRESSURE OUTREACH SENSING FAULT ENGINE TEMP HIGH CHECK WATER LEVEL CHECK ALTERNATOR NOT CHARGING ENGINE RPM FAULT HIGH RPM IS TOO LOW OPEN CIRCUIT BRAKE FWS C21 SHORTED CIRCUIT BRAKE FWS C21 OPEN CIRCUIT RS RET FWS C22 SHORTED CIRCUIT RS RET FWS C22 OPEN CIRCUIT RS EXT FWS C23 SHORTED CIRCUIT RS RET FWS C23 OPEN CIRCUIT FS RET FWS C24 Boom has exceeded 95 of maximum outreach Boom has reached maximum outreach setting Cylinder pressure has exceeded maximum pressure setting Cylinder safety pressure switch has dete
96. ial work platform be returned to our facility for a complete inspection and recertification For any questions concerning whether your aerial work platform may have sustained structural damage or the Damaged Equipment Policy please direct any questions to the Haulotte Group Customer Service Department at 1 800 537 0540 or visit Haulotte Group online at www haulotte usa com Damage Repair Notice There may be occasions when a Haulotte Group aerial work platform is involved in an accident resulting in damage to non structural components When such damage occurs and repairs are made by the owner or area distributor please notify Haulotte Group of these non maintenance repairs and request a repair form to be filled out and returned to Haulotte Group 18 HAULOTTE GROUP 3 OPERATION 3 OPERATION The 4642T Telescoping Boom Lift is a Summit Series trailer mounted aerial work platform designed and manufactured to position personnel with their tools and equipment at overhead work locations The platform load capacity is rated at 500 pounds 227 kilograms for a restricted range of motion or 350 pounds kilograms for a non restricted range of motion During all aerial work platform operations four extended outriggers support the unit The aerial work platform is battery powered and operated with electronic pushbutton controls a hydraulic power unit a hydraulic gear motor and hydraulic cylinders The hydraulic power unit includes a reservoir pu
97. inuous rotation until the buttons are released or the stop is reached 9 10 Boom Raise Down Buttons Pressing pushing and holding a desired SPEED 6 button and the BOOM RAISE 9 button at the same time will raise the boom Pressing a desired SPEED 6 button and the BOOM DOWN 10 button at the same time will lower the boom The selected boom motion continues until the buttons are released or until the boom reaches a hard stop or a safe travel limit 11 12 Boom Extend Retract Buttons Pressing pushing and holding a desired SPEED 6 button and the BOOM EXTEND 11 button at the same time extends the boom Pressing pushing and holding a desired SPEED 6 button and the BOOM RETRACT 12 button at the same time retracts the boom Boom motion continues until the buttons are released or until the boom reaches a hard stop or a safe travel limit 13 14 Platform Tilt Buttons Press push and hold any SPEED 6 button and the desired PLATFORM TILT UP 13 or PLATFORM TILT DOWN 14 button at the same time to level the work platform This levels the platform only NOT the aerial work platform Outlet An outlet has been provided as a power source for running electrical power tools while in the work platform The power plug is located on the trailer frame in front of the accessory equipment stowage plate A connecting power cord must be plugged into a suitable power source The outlet is rated for a 15 ampere load DO NOT overload the acces
98. kaging Instruction EE Max Qty Per Package 15 Regulatory Information CERCLA SARA Section 302 Extremely Hazardous Substances and TPQs in pounds This material does not contain any chemicals subject to the reporting requirements of SARA 302 and 40 CFR 372 CERCLA SARA Section 311 312 Title Ill Hazard Categories Acute Health No Chronic Health No Fire Hazard Mo Pressure Hazard No Reactive Hazard CERCLA SARA Section 313 and 40 CFR 372 This material contains the following chemicals subject to the reporting requirements of Section 313 of SARA Title Ill and 40 CFR 372 Component Concentration de minimis EPA CERCLA Reportable Quantity in pounds This material does not contain any chemicals with CERCLA Reportable Quantities California Proposition 65 This material does not contain any chemicals which are known to the State of California to cause cancer birth defects or other reproductive harm at concentrations that trigger the warning requirements of California Proposition 65 Canadian Regulations This product has been classified in accordance with the hazard criteria of the Controlled Products Regulations CPR and the MSDS contains all the information required by the Regulations WHMIS Hazard Class None National Chemical Inventories All components are either listed on the US TSCA Inventory or are not regulated under TSCA All components are either on the DSL or are exem
99. l work platform to a well ventilated area with direct access to an AC electrical outlet Keep the aerial work platform and batteries away from open flame or other potential ignition sources Attach a 12 AWG multi strand grounded EXTENSION CORD with a maximum length of 50 feet 15 meters to the receptacle located on the GENERATOR INTERFACE PLATE in front of the turntable NOTE Using an underrated or long power cord will reduce the output of the battery charger 36 and may extend charge time Plug the EXTENSION CORD into outlet Verify that the GREEN CHARGING indicator LED is lit on the BATTERY CHARGER FACEPLATE Refer to Figure 4 1 The charging indicator LED remains lit continuously during the first stage of the charge cycle The charge current will be displayed on the BATTERY CHARGER FACEPLATE To display the Battery Voltage press push in and hold the BATTERY VOLTAGE button Refer to Figure 4 1 Linear Battery Charger x Q Charging Charge Current o 80 Charged T S Battery Voltage Check Battery Press to Reset Figure 4 1 Battery Charger Faceplate HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE BATTERY RECHARGE CONTINUED e Battery fault is detected the appropriate fault code will appear on the charge current display The red check battery indicator LED will become lit Refer to Table 4 1 for battery charger fault codes DO NOT disconnect any output leads or connectors between the batteries a
100. lear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error Checked only at power up Checked only at power up Checked only at power up Error Suppressed due to low current draw Error Suppressed due to low current draw Not Tested Do not want to crank engine on power up Not Tested Do not want to crank engine on power up Error Suppressed due to low current draw Error Suppressed due to low current draw Error Suppressed due to low current draw Error Suppressed due to low current draw Checked only at power up Checked only at power up Error Suppressed due to low current draw Error Suppressed due to low current draw 51 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE TABLE 4 3 ERROR CODE DEFINITIONS CONTROLS ERROR MESSAGE ERROR DEFINITION TO SIMULATE ERROR TO CLEAR ERROR COMMENTS 073 52 OPEN CIRCUIT SPARE OUTPUT SHORTED CIRCUIT SPARE OUTPUT OPEN CIRCUIT AC SWITCH SHORTED CIRCUIT AC SWITCH OPEN CIRCUIT STROBE SHORTED CIRCUIT STROBE OPEN CIRCUIT DRIVE PWM SHORTED CIRCUIT DRIVE PWM OPEN CIRCUIT DRIVE ENABLE SHORTED CIRCUIT D
101. led to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE ERROR CODE DEFINITIONS MOTOR CONTROLLER The Motor Controller indicates the operational status of the controller it is located under the power compartment cover left driver side and behind the ground lower control panel If an error condition is detected the appropriate error code will be displayed by a flashing indicator light Refer to Figure 4 7 at the end of the error codes for a visual of the controller Refer to Table 4 3 to resolve the Fault or contact Haulotte Group Customer Service Department at 1 800 537 0540 or visit Haulotte Group online at www haulotte usa com with any questi
102. malfunctioning components Haulotte Group is dedicated to the continuous improvement of this and all Haulotte Group products Therefore equipment information is subject to change without notice Direct any questions or concerns regarding errors and or discrepancies in this manual to the Haulotte Group Customer Service Department at 1 800 537 0540 or visit Haulotte Group online at www haulotte usa com CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm HAULOTTE GROUP TABLE OF CONTENTS pes ubere eec c 5 LEGEND SAFETY ADVISORIES il ruentem Medo uc Ret 5 BEFORE Or cpm EET 6 DURING OP ar qug astra 7 FALE PROTECTION orm 9 VISAS IE SUM Car c E ME 9 CMT 10 EXP LO e RI A ID 10 VIS S Em NANG o 11 2 EE GIP I GANONG T 13 RANGE OF MOTION E 13 GIFRIOA TIONS PR E 14 WARRANTY NEW PRODUCT HAULOTTE NORTH 16 WARRANTY GEAIMS PROGEDUFME stu bita 17 DAMAGED EQUIPMENT POLICY unu Facta Dusche
103. mine that the aerial device is specifically designed for mobile operation 10 11 1 Driver Precautions Before and during driving the driver shall 1 Avoid traveling on any surface that adversely affects vehicle stability 2 Maintain a safe distance from obstacles and overhead lines 3 Maintain communications between driver and operator 4 Responsibilities associated with problems or malfunctions affecting the operation of the aerial device 10 12 Training Retraining and Familiarization of Operators 10 12 1 General Training Only personnel who have received general instructions regarding the inspection application and operation of aerial devices including recognition and avoidance of hazards associated with their operation shall operate an aerial device Such items covered shall include but not necessarily be limited to the following issues and requirements 1 The purpose and use of manuals 2 That operating manuals are an integral part of the aerial device and must be properly stored on the vehicle when not in use 3 A pre start inspection 4 Responsibilities associated with problems or malfunctions affecting the operation of the aerial device b Factors affecting stability 6 The purpose of placards and decals 7 Workplace inspection 8 Applicable safety rules and regulations such as Part 4 ANSI C2 2007 National Electrical Safety Code applies to utility workers as defined in ANSI C2
104. mp and control valves Hydraulic cylinders elevate and extend the telescoping boom and maintain the platform at level during operation The hydraulic motor and mating worm gear allow the telescoping boom to rotate 700 Non Continuous around a vertical axis The hydraulic power unit uses a 24 Volt DC motor to drive the hydraulic pump The DC motor is powered by four 6 Volt DC 245 Amp hour deep charge batteries connected in series An automatic onboard battery charger is provided for recharging the batteries at the end of each work period The ground lower control panel controls the power outriggers boom lift elevation and rotation functions The platform upper control panel only controls boom lift elevation and rotation NOTE The elevation and rotation controls are operational only when the outriggers are correctly extended and the extension boom is within a programmed safe operating zone The ground lower control panel includes a lighted text window that displays the current operating status or an existing error condition Safety devices prevent the boom from retracting suddenly in the event of a hydraulic hose or system failure It is strongly recommended that no one adjust or tamper with these safety devices If service is required contact the Customer Service Department at 1 800 537 0540 or visit Haulotte Group online at www haulotte usa com In the event of power loss control system failure or other malfunction boom lowering
105. n 5 Outrigger Enable Button The outrigger ENABLE 5 button works in tandem with both the outrigger RETRACT button and the outrigger EXTEND button Pressing pushing in and holding the ENABLE 5 button while pressing pushing in on the RETRACT button fully retracts all four 4 outriggers simultaneously Pressing pushing in and holding the ENABLE 5 button while pressing pushing in on the EXTEND button fully deploys all four 4 outriggers simultaneously 6 Machine Level Indicator The machine LEVEL INDICATOR LED 6 will light up to indicate that the aerial work platform is level and boom functions can be performed 7 Platform Position LED When the PLATFORM POSITION LED 7 is flashing the boom must be fully retracted and in the stowed position before resuming outrigger control or drive and set operations DRIVE AND SET USE Initial Operation Use the following procedure to operate the Drive and Set option upon arriving on site Set the parking brake Drive functions will not operate unless the parking brake is set e Lower the TONGUE JACK DOLLY WHEEL and unhitch the aerial work platform from tow vehicle e Enter the work platform using a three 3 point contact both hands and one foot put on a safety harness and attach the lanyard to the ANCHORAGE attachment point on the side of the platform support beam e Press push in and hold the DRIVE ENABLE 2 button on the platform upper control panel move the JOYS
106. n HAULOTTE GROUP 2 SPECIFICATIONS SPECIFICATIONS Serial Number O O Y Maximum Working Height 52 ft 4 in 16 1 m Maximum Platform Height 46 ft 4 in 14 1 m Maximum Horizontal Outreach From Centerline 41 ft 6 in 12 6 m From Outrigger Footpad Edge 35 ft 1 in 10 7 m Rated Platform Capacity Without Platform Rotation 500 Ib 227 kg With Platform Rotation 440 Ib 200 kg Maximum Occupants Total Weight Without Options 5 700 Ib 2 585 kg With All Options 6 100 Ib 2 767 kg Turntable Rotation 700 Non Continuous Leveling Capability 12 5 Platform Dimensions Height 3 ft 7 in 1 1 m Length 2 ft 6 in 0 8 m Width 4 ft 1 2 m Stowed Dimensions Height 6 ft 5 in 2 0 m Length 19 ft 2 in 5 8 m Width 5 ft 5 in 1 7 m Outrigger Footprint To Center of Pad Length 12 ft 11 in 4 0 m Width 12 ft 9 in 4 1 m Footpad Diameter 12 5 in 0 3 m Parking Brake Mechanical Towing Brake Hydraulic Surge Rated Towing Speed 65 mph 105 km h Tire Size ST 235 75 R15D Control System 24V DC Battery 4 x 6V 245 amp hr Charger 110 Volt 60 Hz 14 HAULOTTE GROUP 2 SPECIFICATIONS SPECIFICATIONS CONTINUED Hydraulic Pressure 3 000 psi 207 bar 20 684 kPa Reservoir Capacity 5 6 Gallons 21 2 L Hydraulic System Capacity 8 5 Gallons 32 2 L Hydraulic Oil Standard HVI AW32 Platform Rotation Option 75 Manual Maximum Decibel Level DC Mode Ground DC Mode Platform
107. n aerial work platform to service This manual contains a list of recommended maintenance procedures to be performed daily weekly and monthly refer to it when inspecting this aerial work platform For annual maintenance refer to the Parts and Service Manual It is the practice of Haulotte Group to issue Service and or Safety Bulletins which may include updates to the information contained in this manual In such instances procedures contained in Haulotte Group Service Bulletins or Safety Bulletins supersede the information contained in manual Always follow the maintenance schedule regardless of use 35 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE BATTERY RECHARGE Recharge aerial work platform batteries after each 8 hour work shift or as needed When the aerial work platform is not in use batteries should be recharged at least once per week Under normal circumstances battery recharge should take approximately 10 12 hours However a full recharge may take up to 24 hours if the battery charge is extremely low Recharge batteries in a well ventilated area only DO NOT charge batteries near fire spark or other potential ignition sources Batteries may emit highly explosive Hydrogen gas while charging Failure to properly ventilate the charge gasses could result in death or serious injury Always charge aerial work platform batteries away from flammable materials To recharge the aerial work platform batteries Move the aeria
108. nauthorized fluids to the hydraulic system or battery NEVER mix hydraulic oils Consult manufacturer specifications Refer to the Equipment Maintenance Section of this manual for hydraulic system maintenance procedures Refer to the next page for Battery maintenance NEVER exceed the manufacturer s recommended relief valve settings NEVER touch or allow metal tools to contact any components that are sensitive to static discharge ALWAYS use static discharge prevention mats and grounding devices when handling electronic components NEVER adjust repair replace or bypass any hydraulic or electrical control or safety device These include but are not limited to hydraulic load control and flow control valves solenoid valves and limit switches ALWAYS consult an authorized Haulotte Group technician if repairs are necessary NEVER modify alter or change the aerial work platform without first consulting an authorized Haulotte Group technician and NEVER in any way that would affect its original design or operation HAULOTTE GROUP 1 SAFETY MAINTENANCE SAFETY CONTINUED Battery Maintenance Ensure the following general safety precautions are followed when performing battery maintenance on the aerial work platform ALWAYS check the battery fluid level daily ALWAYS wear safety glasses when working with or near batteries ALWAYS avoid contact with battery acid Battery acid causes serious burns and should be kept away from skin or eyes
109. nd the charger when the charger is on To stop a charge in progress always unplug the extension cord from the AC Power source When the battery charge reaches 80 of capacity the yellow 80 CHARGED indicator LED will become lit and the GREEN CHARGING indicator LED will begin to flash When the batteries have reached a full charge the green and yellow indicator LEDs will turn themselves off CC Charge Complete will appear on the CHARGE CURRENT display After two hours this display will fade and the CHARGE CURRENT will read OO Unplug the extension cord from the outlet and the charger receptacle on the aerial work platform Store the extension cord for next use BATTERY FAULT CODES TABLE 4 1 BATTERY CHARGER FAULT CODES Limits gt 112 charge voltage gt 60 amperes Operating machine while charging lt 80 charge at 16 hrs Battery fault gt 80 and lt full charge Battery fault after 6 hrs Max Board fault or charger exposed to Error Standby Cause Loose connection or battery missing Connected to wrong battery voltage extreme cold Triac Error Board shorted Full Power to Transformer No Current Output Charger Off Battery shorted or low AC line voltage or charge fault Charger resting between pulses AGM batteries only Batteries charged Charge Mode Complete Always unplug the battery charger power cord before moving the aerial work platform Failure to disconnect power cord could cause damage t
110. nly at power up Articulating Boom Models Checked only at power up Checked only at power up Checked only at power up Checked only at power up Checked only at power up Checked only at power up Checked only at power up Checked only at power up Checked only at power up Articulating Boom Models Checked only at power up Articulating Boom Models 49 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE r O TABLE 4 3 ERROR CODE DEFINITIONS CONTROLS 043 OPEN CIRCUIT PLATFORM CCW SHORTED CIRCUIT PLATFORM CCW OPEN CIRCUIT TURNTABLE CW SHORTED CIRCUIT TURNTABLE CW OPEN CIRCUIT TURNTABLE CCW SHORTED CIRCUIT TURNTABLE CCW OPEN CIRCUIT OUTRIGGER RETRACT SHORTED CIRCUIT OUTRIGGER RETRACT OPEN CIRCUIT OUTRIGGER EXTEND SHORTED CIRCUIT OUTRIGGER EXTEND OPEN CIRCUIT LF OUTRIGGER SHORTED CIRCUIT LF OUTRIGGER OPEN CIRCUIT RF OUTRIGGER SHORTED CIRCUIT RF OUTRIGGER OPEN CIRCUIT LR OUTRIGGER 50 A load of less than 70 was detected when Platform CCW circuit was energized Excessive load was detected when Platform COW circuit was energized A load of less than 70mA was detected when Turntable CW circuit was energized Excessive load was detected when Turntable CW circuit was energized A load of less than 70mA was detected when Turntable CCW circuit was energized Excessive load was detected when Turntable CCW circuit was energized A load of less than 70mA wa
111. o the equipment HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE DAILY SERVICE CHECKS The following Maintenance Procedures should be performed daily or before each operation Verify that all decals are legible correctly applied and in plain view Refer to the Decal Replacement Section of this Manual for decal locations Verify that all controls and indicators at the ground and platform control stations operate properly Lower outriggers to level the aerial work platform e Operate all booms functions e Press push the EMERGENCY STOP button Verify that all functions are deactivated e Verify that the cylinders are functional and there is no internal leakage an indication of this is that the booms would not remain elevated and or they may drift e Pull out the EMERGENCY STOP button all functions will now be activated Lower the boom e f either control station is unresponsive refer to the Trouble Shooting procedures TABLE 4 2 TROUBLE SHOOTING is located later in this section e Ifthe DISPLAY PANEL on the GROUND LOWER CONTROL PANEL displays an error code refer to the Control Panel Error Code definitions TABLE 4 3 ERROR CODE DEFINITIONS is located later in this section e lf the Motor Controller s Green light is flashing there is an error refer to the Motor Controller Error Code Definitions TABLE 4 4 ERROR CODE DEFINITIONS MOTOR CONTROLLER is located later in this section e the aerial work platform has the Dri
112. ol has detected an erratic output from the level sensor An attempt was made to drive machine without engaging the trailer brake Angle sensor output is out of range Level machine raise boom and tilt level sensor Open Platform Control and remove green wire from J1 Open Drive Control and remove green wire from J1 Connect a PC without running the configuration program On Platform Control hold down a key at power up On Drive Control hold down a key at power up On Drive Control hold joystick to side at power up On Lower Control hold down a key at power up Disconnect a wire from either the boom down or any outrigger switch and turn on machine Shaking the level sensor after machine has been leveled Trying to drive machine with trailer brake off Disconnect Angle Sensor This is a self clearing error When error condition is corrected error is cleared This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a self clearing error When error condition is corrected error is cleared This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a self clearing error When error condition is corrected error is clear
113. ons TABLE 4 4 ERROR CODE DEFINITIONS MOTOR CONTROLLER FLASH PRIORITY ID FAULT DESCRIPTION SOLUTION FAULT Steady ON 1 System is operating normally None required no flashing 1 11 Configuration Range One or more controller Use Sevcon calibrator to enter correct Error personality settings are out of settings from latest Personality Sheet range 1 12 Error The controller personality Use Sevcon calibrator to enter correct checksum is incorrect settings from latest Personality Sheet Otherwise replace motor controller 2 5 Sequence Fault Enable line is active at power up Check enable line B wiring and Molex connector 2 Accelerator Fault Invalid accelerator personality Check speed input line B wiring Molex setting connector and 1000 ohm resistor 3 17 MOSFET Short MOSFET short circuit or Check for miswired B B or pump cables Circuit controller miswire detected Make sure pump terminals are not shorted to frame If cables and pump are OK then replace motor controller 4 14 Line Contactor The line contactor is welded or Check line contactor wiring If wiring is OK Welded otherwise shorted then replace line contactor 4 15 Line Contactor did Line contactor did not close or is Check line contactor wiring and Molex not Close otherwise open circuit connector Measure the contactor coil resistance it should be around 50 ohms If contactor and wiring are OK then replace motor cont
114. ontrols If current ventilation practices are not adequate to maintain airborne concentrations below the established exposure limits additional engineering controls may be required Eye Face Protection The use of eye protection that meets or exceeds ANSI Z 87 1 is recommended to protect against potential eye contact irritation or injury Depending on conditions of use a face shield may be necessary Skin Hand Protection The use of gloves impervious to the specific material handled is advised to prevent skin contact Users should check with manufacturers to confirm the breakthrough performance of their products Suggested protective materials Nitrile 79 HAULOTTE GROUP 80 7 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW AW HVI HYDRAULIC OIL CONTINUED 5146356 Powerflow M AW HVI Hydraulic Oil All Grades Date of Issue 14 Nov 2008 Page 4 7 status Final Respiratory Protection VVhere there is potential for airborne exposure above the exposure limit NIOSH certified air purifying respirator equipped with R or P95 filters may be used A respiratory protection program that meets or is equivalent to OSHA 29 CFR 1910 134 and ANSI 288 2 should be followed whenever workplace conditions warrant a respirators use Air purifying respirators provide limited protection and cannot be used in atmospheres that exceed the maximum use concentration as directed by regulation or the manufacturer s instructions in oxygen deficient
115. or if the aerial work platform was stored without use during a seasonal climate change Air trapped in the hydraulic system will affect aerial work platform performance Follow procedures for bleeding air from the hydraulic system found in the Cylinder Replacement section of the Haulotte Parts and Service Manual Owners and lessors should complete a full inspection of all components and perform a test of all functions including brake functions before commissioning or reselling the aerial work platform Always repair or replace all damaged or malfunctioning components before commissioning or reselling an aerial work platform When a change in ownership occurs it is the responsibility of the seller to provide the new owner with all manuals for the aerial work platform It is the responsibility of the buyer to notify the manufacturer of the unit model and serial number and the name and address of the new owner within sixty 60 days of the purchase Use the service checklists found at the back of this manual to record all service checks as well as any maintenance repairs or alterations performed on the aerial work platform Records of frequent safety checks need not be made However where a safety hazard is found it shall be reported in writing to the owner of the aerial work platform and a record of any corrective action shall be maintained for five years or as required by the authority having jurisdiction 45 HAULOTTE GROUP 4 EQUIPMENT
116. ort the DC D FWS C30 coil Disconnect a wire from DC D FWS C31 coil Use a piece of wire to short the DC D FWS C31 coil This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only C
117. performing maintenance on hydraulic cylinders ALWAYS disconnect power to the hydraulic pump drive motor before making electrical checks to the hydraulic valves ALWAYS keep all mechanical parts properly adjusted and lubricated according to maintenance schedule and manufacturer factory specifications Refer to the Equipment Maintenance section of this manual ALWAYS perform a function check of operating controls before each use and after any repairs have been made ALWAYS locate and protect against possible pinch points before performing any maintenance or repairs ALWAYS use only manufacturer approved parts to repair or maintain aerial work platform If any portion of this aerial work platform is rebuilt or repaired retesting is required in accordance with manufacturer factory instructions ALWAYS maintain a safe distance while testing the hydraulic components ALWAYS relieve hydraulic pressure before loosening or removing hydraulic components NEVER test or operate the hydraulic components while personnel are near the aerial work platform NEVER allow water or foreign particles into the DC electric motor housing Inclusion of water or foreign particles may cause serious damage to the motor If the motor becomes wet refer to the Motor Drying Instructions located in the Maintenance section of the Parts and Service Manual or consult an authorized Haulotte Group service technician for proper drying instructions NEVER add u
118. pressed due to low current draw Checked only at power up Machines with Drive option only Checked only at power up Machines with Drive option only Checked only at power up Machines with Drive option only Checked only at power up Machines with Drive option only Checked only at power up Machines with 4WD option only Checked only at power up Machines with 4WD option only Checked only at power up Machines with 4WD option only Checked only at power up Machines with 4WD option only Checked only at power up Machines with 4WD option only HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE ee O TABLE 4 3 ERROR CODE DEFINITIONS CONTROLS 088 SHORTED CIRCUIT TURN RIGHT C23 OPEN CIRCUIT FORWARD 1 C24 SHORTED CIRCUIT FORWARD 1 C24 OPEN CIRCUIT REVERSE 1 C25 SHORTED CIRCUIT REVERSE 1 C25 OPEN CIRCUIT FORWARD 2 C27 SHORTED CIRCUIT FORWARD 2 C27 OPEN CIRCUIT REVERSE 2 C28 SHORTED CIRCUIT REVERSE 2 C28 OPEN CIRCUIT TORQUE H L C29 SHORTED CIRCUIT TORQUE H L C29 OPEN CIRCUIT TORQUE H L C30 SHORTED CIRCUIT TORQUE H L C30 OPEN CIRCUIT TORQUE H L C31 SHORTED CIRCUIT TORQUE H L C31 Excessive load was detected when Turn Right C23 circuit was energized A load of less than 70mA was detected when Forward 1 C24 circuit was energized Excessive load was detected when Forward 1 C24 circuit was energized A load of le
119. pt from DSL listing requirements U S Export Control Classification Number 16 Other Information Date of Issue 14 Nov 2008 Status Final Revised Sections or Basis for Revision New MSDS MSDS Number 814636 Guide to Abbreviations ACGIH American Conference of Governmental Industrial Hygienists CASRN Chemical Abstracts Service Registry Number CEILING Ceiling Limit 15 minutes CERCLA The Comprehensive Environmental Response Compensation and Liability Act EPA Environmental Protection Agency IARC International Agency for Research on Cancer LEL Lower Explosive Limit NE Not Established NFPA National Fire Protection Association NTP National Toxicology Program OSHA Occupational Safety and Health Administration PEL Permissible Exposure Limit OSHA SARA esupertund Amendments and Reauthorization Act STEL Short Term Exposure Limit 15 minutes TLV Threshold Limit Value ACGIH TWA Time Weighted Average 8 hours UEL Upper Explosive Limit WHMIS Worker Hazardous Materials Information System Canada 82 HAULOTTE GROUP 7 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW AW HVI HYDRAULIC OIL CONTINUED 814636 Powerflow AW HVI Hydraulic Oil All Grades Page 7 7 Date of Issue 14 Nov 2008 Status Final Disclaimer of Expressed and implied Warranties The information presented in this Material Safety Data Sheet is based on data believed to be accurate as of the date this Mat
120. r Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error This is a latched error Power must be cycled to clear error Checked only at power up Articulating Boom Models Checked only at power up Articulating Boom Models Checked only at power up Checked only at power up Checked only at power up Checked only at power up Checked only at power up Checked only at power up Checked only at power up Checked only at power up Checked only at power up Checked only at power up Checked only at power up Checked only at power up Checked only at power up HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE O
121. ract and level the outriggers from the platform upper control panel The platform upper control panel which has additional controls added is used to control all boom motions as well as all Drive and Set functions The platform upper control panel is activated by turning the KEY SWITCH 1 at the ground lower control panel clockwise to the PLATFORM 1b icon and entering the platform using a three 3 point contact both hands and one foot DRIVE AND SET SAFETY NEVER drive the aerial work platform unless the parking brake is set NEVER drive the aerial work platform without the platform either fully lowered and the outriggers fully retracted in the stowed upright position NEVER drive the aerial work platform without the operator fully secured inside the platform NEVER operate the Drive function on grades exceeding 4 5 NEVER operate the aerial work platform with more than one 1 person in the platform ALWAYS watch for personnel and obstructions in the path of the machine Be aware of limited visibility and blind spots DRIVE AND SET CONTROLS The platform upper control panel of a Drive and Set equipped aerial work platform includes the following controls and indicators Refer to Figure 6 1 p B DIAGNOSTIC 7 BATTERY CONDITION L GENERAL FAULT INDICATOR DOWN ONLY m ams te NE OVERLOADED SEE DISPLAY AT GROUND CONTROL STATION a 1 DRIVE WE NABLE
122. ral seconds the DISPLAY PANEL window will read HAULOTTE GROUP ACCESS SOLUTIONS Monitor the battery condition indicator during operation and charge the batteries as necessary Extend the four outriggers individually or for simultaneous extension use the AUTO LEVEL 23 button on the ground lower control panel When the aerial work platform is leveled properly a buzzer will sound the two LEDs at each OUTRIGGER 25 and 26 button and the LED at the AUTO LEVEL 23 button will be lit See Figure 3 6 OUTRIGGER CONTROLS HOLD DOWN EXTEND OR RETRACT BUTTON WHILE SELECTING INDIVIDUAL OUTRIGGER BUTTONS OR THE AUTO LEVEL BUTTON ALL OUTRIGGER LIGHTS MUST ON BEFORE PLATFORM CAN BE RAISED RETRACT Figure 3 6 Outrigger Controls o Auto Level Press push and hold the EXTEND 21 and AUTO LEVEL 23 buttons at the same time o Manual Level Extend the two outriggers closest to the trailer coupler first Lower the front pair of outriggers by pressing pushing the EXTEND 21 button and the two front OUTRIGGER buttons at the same time Lower the back pair of outriggers by pressing pushing the EXTEND 21 button and the two back OUTRIGGER buttons at the same time Verify that the AUTO LEVEL 23 indicator LED is lit If the AUTO LEVEL 23 indicator is not lit the aerial work platform may not be level and the weight of the machine may not be on the outrigger foot pad NOTE the boom is not level or if one or more ou
123. red Article 372 30 b SECTION III PHYSICAL CHEMICAL CHARACTERISTICS Boiling Point Approximately 203F Vapor Density Greater Than 1 Vapor Pressure 14 37 80 F Melting Point 36 F to 10 6 Solubility in Water 100 Water Reactive Yes Produces Heat Specific Gravity 1 245 1 295 Battery Electrolyte Appearance amp Odor Clear Liquid with Sharp Pungent Odor SECTION IV FIRE AND EXPLOSION HAZARD DATA Flash Point Not Combustible Auto Ignition Temperature N A Flammability Limits in Air by Volume N A Extinguishing Media Dry Chemical Carbon Dioxide Water Fog Water Special Fire Fighting Procedures Sulfuric Acid Fumes Sulfur Dioxide Gas or Carbon Monoxide may be released when acid decomposes Wear NIOSH approved self contained breathing apparatus Unusual Hazards Water applied to sulfuric acid generates heat and causes acid to splatter Wear full cover acid resistant clothing Sulfuric acid reacts violently with metals nitrates chlorates carbides fulminates picrates and other organic materials Reacts with most metals to yield explosive flammable hydrogen gas This reaction is intensified when sulfuric acid is diluted with water to form battery electrolyte 19 HAULOTTE GROUP 7 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET FOR LEAD ACID BATTERIES WET FILLED WITH ACID CONTINUED SECTION V HEALTH HAZARD DATA Primary Routes of Entry Inhalation YES Skin YES Ingestion YES Health Hazards Acute EYES S
124. requirements of 6 6 1 and 6 6 2 and the appropriate electrical tests required in 5 4 of this standard For insulating aerial devices the installer shall assure conformance to the Qualification test requirements of 5 3 2 by either obtaining a certification of the test and performing a periodic test after installation or by performing the Qualification test The installer shall when installing an aerial device on a chassis which is a highway vehicle comply with all requirements of the applicable Federal Motor Vehicle Safety Standards in effect at the time of installation Certification as a manufacturer alteration intermediate or final of a motor vehicle under the Federal Motor Vehicle Safety Standards is required The travel height of the mobile unit shall be posted in a location that is readily visible to the vehicle operator 8 2 2 8 2 3 Quality Assurance The installer shall have a documented quality assurance program which will ensure compliance with this standard Weldings All welds made by the installer whose failure could result in motion of the platform s shall meet the Structural Welding Code AWS D1 1 2006 or AWS 01 2 2003 The installer shall establish applicable welding quality assurance procedures for all weldments Training The dealer or installer shall offer training or training materials that aid owners users operators lessors and lessees in the operation inspection testing and maintenance of the aerial de
125. rm Tilt Buttons Press push and hold any SPEED 15 button and the desired PLATFORM TILT UP 13 or PLATFORM TILT DOWN 14 button at the same time to level the work platform This levels the platform only NOT the aerial work platform 15 Speed Buttons The SPEED 15 buttons are located along the lower right side of the control panel one of the speed buttons must be pressed pushed in and held while selecting the various boom functions There are four speeds that range from fast RABBIT to slow TURTLE available to help control the positioning of the Boom 16 19 Outrigger Controls For simultaneous outrigger extension retraction of all four 4 outriggers Select the EXTEND 16 button or RETRACT 17 button and the AUTO LEVEL 18 button at the same time To individually extend or retract the outriggers Select the EXTEND 16 button or RETRACT 17 button and one of the four OUTRIGGER 19 buttons at the same time The outrigger indicator LED lights up when the outriggers are properly deployed and the aerial work platform weight is on the outrigger foot pads Each of the outer outrigger LEDs 19 indicates load is on the outrigger footpad Each of the inner outrigger LEDs when flashing indicate that side is low and needs to be further raised for leveling 20 Auto Level LED When this LED is FLASHING it indicates that the boom is not in the stowed position and the outriggers are not functional When this LED is
126. roller 5 16 Motor Open Circuit Pump motor cable disconnected Check pump motor and controller cables Measure pump motor resistance it should be near zero ohms N A Not used in this N A N A application 7 7 Low Battery Battery voltage is too low Recharge the batteries Look for shorted battery cells Make sure one or more batteries are not reversed 7 High Battery Battery voltage is too high Make sure battery charger is off Check for poor or corroded battery connections 7 10 High Battery with High battery voltage was Make sure battery charger is off or that the Line Contactor Open detected at power up before line battery is not overcharged contactor closed 1 Thermal Cutback Maximum power available to Remove power and allow controller to cool If motor has been reduced due to fault repeatedly occurs look for binding on excessive heat sink temperature the hydraulic cylinders or sticking valves Otherwise the pump motor may be failing 3 Pump Current Maximum power available to Recycle power If fault repeatedly occurs Limit Cutback pump motor has been reduced by look for binding on the hydraulic cylinders or the Current Limit Cutback sticking valves Otherwise the pump motor function may be failing N A Not used in this N A N A application 58 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE TABLE 4 4 ERROR CODE DEFINITIONS MOTOR CONTROLLER FLASH PRIORITY ID FAULT DESCRIPTION SOLUTION ELEN Not used in this
127. roperties It is possible that the material as produced contains constituents which are not required to be listed in the MSDS but could affect the hazardous waste determination Additionally use which results in chemical or physical change of this material could subject it to regulation as a hazardous waste This material under most intended uses would become Used Oil due to contamination by physical or chemical impurities Whenever possible Recycle Used Oil in accordance with applicable federal and state or local regulations Container contents should be completely used and containers should be emptied prior to discard 14 Transportation Information U S Department of Transportation DOT Shipping Description Not regulated Note If shipped by land in a packaging having a capacity of 3 500 gallons or more the provisions of 49 CFR Part 130 apply Contains oil International Maritime Dangerous Goods IMDG shipping Description Not regulated Note U S DOT compliance requirements may apply See 49 CFR 171 22 23 amp 25 International Civil Aviation Org International Air Transport Assoc ICAO IATA Not regulated 81 HAULOTTE GROUP 7 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW AW HVI HYDRAULIC OIL CONTINUED 814636 Powerflow AW HVI Hydraulic Oil All Grades Page 6 7 Date of Issue 14 Nov 2008 Status Final ortation Information LTD QTY Passenger Aircraft Cargo Aircraft Only Pac
128. s energized Excessive load was detected when Jib Down circuit was energized A load of less than 70mA was detected when Extend circuit was energized Excessive load was detected when Extend circuit was energized A load of less than 70mA was detected when Retract circuit was energized Excessive load was detected when Retract circuit was energized A load of less than 70mA was detected when Platform Level Up circuit was energized Excessive load was detected when Platform Level Up circuit was energized A load of less than 70mA was detected when Platform Level Down circuit was energized Excessive load was detected when Platform Level Down circuit was energized A load of less than 70mA was detected when Platform CW circuit was energized Excessive load was detected when Platform CW circuit was energized Disconnect a wire from Secondary Down coil Use a piece of wire to short the Secondary Down coil Disconnect a wire from Jib Up coil Use a piece of wire to short the Jib Up coil Disconnect a wire from Jib Down coil Use a piece of wire to short the Jib Down coil Disconnect a wire from Extend coil Use a piece of wire to short the Extend coil Disconnect a wire from Retract coil Use a piece of wire to short the Retract coil Disconnect a wire from Platform Level Up coil Use a piece of wire to short the Platform Level Up coil Disconnect a wire from Platform Level Down coil Us
129. s 39 46 62 74 17 2 20 7 progress Strong Gale Slight structural damage occurs chimney 47 54 75 88 20 8 24 4 pots and slates removed 10 Storm Violent Trees uprooted widespread damage to 55 89 gt 24 5 Storm Hurricane structures widespread devastation EXPLOSION HAZARD e NEVER operate aerial work platform if you smell or detect Liquid Petroleum Gas LPG gasoline diesel fuel or other explosive substances Q3 ALWAYS charge Batteries only in an open well ventilated area away from sparks flames and lighted tobacco If this aerial work platform is equipped with a generator e NEVER refuel with the engine running e NEVER operate engine unless in a well ventilated area to avoid carbon monoxide poisoning 10 HAULOTTE GROUP 1 SAFETY MAINTENANCE Ensure the following general safety precautions are followed while performing maintenance on the aerial work platform General Maintenance ALWAYS perform maintenance procedures according to manufacturers guidelines NEVER disregard or bypass proper maintenance procedures ALWAYS inspect hydraulic system to ensure that all lines connectors and fittings are properly fastened and are in good condition ALWAYS turn the key switch to the OFF position and remove key before performing maintenance Whenever possible ALWAYS perform maintenance with the boom and platform in a fully lowered stowed position ALWAYS secure the boom before
130. s detected when Outrigger Retract circuit was energized Excessive load was detected when Outrigger Retract circuit was energized A load of less than 70mA was detected when Outrigger Extend circuit was energized Excessive load was detected when Outrigger Extend circuit was energized A load of less than 70mA was detected when LF Outrigger circuit was energized Excessive load was detected when LF Outrigger circuit was energized A load of less than 70mA was detected when RF Outrigger circuit was energized Excessive load was detected when RF Outrigger circuit was energized A load of less than 70mA was detected when LR Outrigger circuit was energized Disconnect a wire from Platform CCW coil Use a piece of wire to short the Platform CCW coil Disconnect a wire from Turntable CW coil Use a piece of wire to short the Turntable CW coil Disconnect a wire from Turntable CCW coil Use a piece of wire to short the Turntable CCW Coil Disconnect a wire from Outrigger Retract coil Use a piece of wire to short the Outrigger Retract coil Disconnect a wire from Outrigger Extend coil Use a piece of wire to short the Outrigger Extend coil Disconnect a wire from LF Outrigger coil Use a piece of wire to short the LF Outrigger Coil Disconnect a wire from HF Outrigger coil Use a piece of wire to short the RF Outrigger Coil Disconnect a wire from LR Outrigger coil This is a latched erro
131. sory power circuit 23 HAULOTTE GROUP 3 OPERATION NORMAL OPERATING PROCEDURE Become familiar with the location and function of all controls Learn to smoothly START and STOP all boom functions Perform the following procedures to operate the Haulotte Telescoping Boom Lift 24 Read and obey all safety precautions and operating instructions as well as all Federal State and Local codes and regulations Conduct a Pre Operation Inspection by performing all recommended Daily Service Checks Refer to the Equipment Maintenance Section of this manual Position the aerial work platform at the work area Make sure the aerial work platform is on a firm and level surface and there are no potential hazards such as overhead obstructions or electrically charged conductors Do Not operate the aerial work platform if such hazards exist Apply the aerial work platform parking brake or chock the wheels Lower the TONGUE JACK DOLLY WHEEL and unhitch the aerial work platform from the tow vehicle Failing to unhitch the aerial work platform before operation may lead to damage to equipment or tow vehicle and makes the aerial work platform unstable this could result in death or serious injury Release the boom travel latch by raising the latch handle and swinging the clasp down Refer to Figure 3 3 Figure 3 3 Boom Travel Latch HAULOTTE GROUP 3 OPERATION NORMAL OPERATING PROCEDURE CONTINUED e Release the PLATFORM TRAVEL
132. ss than 70mA was detected when Reverse 1 C25 circuit was energized Excessive load was detected when Reverse 1 C25 circuit was energized A load of less than 70mA was detected when Forward 2 C27 circuit was energized Excessive load was detected when Forward 2 C27 circuit was energized A load of less than 70mA was detected when Reverse 2 C28 circuit was energized Excessive load was detected when Reverse 2 C28 circuit was energized A load of less than 70mA was detected when Torque H L C29 circuit was energized Excessive load was detected when Torque H L C29 circuit was energized A load of less than 70mA was detected when Torque H L C30 circuit was energized Excessive load was detected when Torque H L C30 circuit was energized A load of less than 70mA was detected when Torque H L C31 circuit was energized Excessive load was detected when Torque H L C31 circuit was energized Use a piece of wire to short the Turn Right C23 coil Disconnect a wire from Forward 1 C24 coil Use a piece of wire to short the Forward 1 C24 coil Disconnect a wire from Reverse 1 C25 coil Use a piece of wire to short the Reverse 1 C25 coil Disconnect a wire from Forward 2 C27 coil Use a piece of wire to short the Forward 2 C27 coil Disconnect a wire from Reverse 2 C28 coil Use a piece of wire to short the Reverse 2 C28 coil Disconnect a wire from Torque H L
133. ss the manufacturer s safety devices NEVER attach a safety harness to an adjacent structure pole or to nearby equipment while working from the platform NEVER raise the outriggers or move the trailer with materials or personnel on board or while boom is raised or extended NEVER sit stand or climb on platform railing ALWAYS keep both feet firmly on the platform floor NEVER attempt to increase the working height with boxes ladders stools or any other materials NEVER operate this aerial work platform when exposed to high winds thunderstorms ice or any weather conditions that would compromise operator safety HAULOTTE GROUP 1 SAFETY DURING OPERATION CONTINUED NEVER operate aerial work platform in conditions where wind speeds exceed 28 mph 12 5 m sec or 45 km h Steady or gusty winds that exceed the recommended wind speed may affect stability and aerial work platform operation NEVER allow ropes electric cords hoses or other equipment to become entangled in the aerial work platform NEVER exceed the load limits set by the manufacturer factory Use only the material lifting hook supplied as an option and manufactured by Haulotte Group when lifting materials Safely stow all tools and equipment NEVER exceed load ratings by transferring loads to the aerial work platform at elevated heights NEVER use the platform to lift a load that exceeds the platform dimensions NEVER lift a load in such a way that the center of gra
134. structions and electrically charged wires or conductors ALWAYS watch for moving vehicles in the operating area ALWAYS conduct a thorough visual inspection of the aerial work platform before operation Check for damaged or worn parts hydraulic leaks damaged wiring loose wiring conductors damaged outriggers low tire pressure uneven tire wear or tire damage Check for any improperly operating components NEVER operate the aerial work platform if any damage is observed or suspected Repair damaged or malfunctioning equipment before operation ALWAYS wear proper clothing Wear protective equipment as required by all Federal State and Local codes and regulations Keep loose clothing jewelry gloves and hair away from moving parts ALWAYS wear a Safety Harness and energy absorbing Lanyard such as the Safety Harness and Lanyard available through the Haulotte Group ALWAYS inspect platform floor and outrigger footpads for mud grease debris or other foreign material ALWAYS remove any such material from the aerial work platform before operation ALWAYS RED tag any part of this machine known or suspected to be damaged or malfunctioning ALWAYS remove a malfunctioning damaged or defective aerial work platform from service NEVER operate an aerial work platform that has any known or suspected defect ALWAYS comply with the instructions found in Safety and or Service Bulletins distributed by the manufacturer factory Bulletins may contain cri
135. surfaces The removal and subsequent reinstallation of a gradient control device is not considered a major repair provided proper reinstallation of the gradient control device is performed by a qualified person in accordance with the manufacturer s instructions If the aerial device has upper controls equipped with high electrical resistance components and the manufacturer so indicates they shall be maintained as high electrical resistance components and should be electrically tested per 5 4 3 6 Any suspected items shall be carefully examined or tested and a determination made by a qualified person as to whether they constitute a safety hazard All unsafe items shall be replaced or repaired before use 17 Post Event Inspection or Test After any reported event during which structural members of an aerial device or mobile unit are suspected of being subjected to loading or stresses in excess of design stress such as after an accident involving overturning of the mobile unit or application of unintended external mechanical or electrical forces to the aerial device the aerial device shall be removed from service and subjected to the applicable periodic inspection requirements in 8 2 4 In addition to the periodic inspection supplemental non destructive examination procedures or other tests to assist in detecting possible structural damage to the aerial device may be required All damaged items shall be replaced or repaired be
136. table under normal ambient and anticipated conditions of use Conditions to Avoid Extended exposure to high temperatures can cause decomposition Materials to Avoid Incompatible Materials Avoid contact with strong oxidizing agents and strong reducing agents Hazardous Decomposition Products Not anticipated under normal conditions of use Hazardous Polymerization Not known to occur HAULOTTE GROUP 7 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW AW HVI HYDRAULIC OIL CONTINUED 814636 Powerflow AW HVI Hydraulic Oil All Grades Page 5 7 Date of Issue 14 Nov 2008 Status Final 11 Toxicological Information Chronic Data Lubricant Base Oil Petroleum Carcinogenicity The petroleum base oils contained in this product have been highly refined by a variety of processes including severe hydrocracking hydroprocessing to reduce aromatics and improve performance characteristics All of the oils meet the IP 346 criteria of less than 3 percent PAH s and are not considered carcinogens by NTP IARC or OSHA Acute Data Component Oral LD50 Dermal LD50 Inhalation LC50 lubricant Base Oil Petroleum gt 59 hk 12 Ecological Information Ecotoxicity Experimental studies show that acute aquatic toxicity values are greater than 1000 mg l These values are consistent with the predicted aquatic toxicity of these substances based on their hydrocarbon compositions Mobility Volatiliza
137. tch trailer from tow vehicle before operating outriggers Failure to unhitch trailer from tow vehicle prior to outrigger deployment could cause damage to trailer tongue and or tow vehicle ALWAYS disengage aerial work platform travel latches before raising aerial work platform sections and reengage aerial work platform travel latches before towing trailer ALWAYS exercise caution when rotating the boom from the ground control station ALWAYS watch for personnel inside the radius of the turntable and boom arm when rotating from the ground or platform controls ALWAYS remove personnel from the aerial work platform before attempting to free an elevated platform that has become caught or snagged on an adjacent structure or obstacle NEVER operate the aerial work platform from a position on a truck bed trailer floating vessel or scaffolding without written approval from the manufacturer factory NEVER operate the Drive function if equipped on grades exceeding 4 5 or with more than one person in the platform ALWAYS maintain drive enable button during drive operation NEVER allow electrode contact with any part of the aerial work platform while welding from the platform NEVER use the aerial work platform as a ground for welding NEVER operate without the outriggers fully extended or when the aerial work platform is not level NEVER position an elevated platform against another object to steady the platform NEVER override or bypa
138. tform is level and that the level sensor located on the control side of the turntable is giving an accurate reading e Repair or replace as necessary For aerial work platforms with material hook option Verify the weight reading displayed at the ground lower control panel is within 10 of actual weight tested Recalibrate load cell if needed See the Load Cell Calibration procedure located on the next page 42 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE OVERLOAD PROTECTION CALIBRATION PROCEDURE 1 Remove the CLEVIS PIN securing the PLATFORM to the PLATFORM MOUNTING BRACKET allowing the PLATFORM to pivot about the PLATFORM PIN This removes the load from the LOAD CELL Refer to Figure 4 5 CLEVIS PIN PLATFORM MOUNTING BRACKET PLATFORM PIN Figure 4 5 Platform Position Use the ground lower control panel to access the control box maintenance menu Refer to Figure 4 6 2 Enter the maintenance mode by pressing pushing both ROTATE 11 amp 12 buttons and the OUTRIGGER EXTEND 16 button on the ground lower control panel simultaneously and holding for 5 seconds ff E Y DISPLAY PANEL as E Jj bu BATTERY i CONDITION n INDICATOR v HOLD DOWN EXTEND OR RETRACT BUTTON WHILE SELECTING INDIVIDUAL OUTRIGGER BUTTONS OR THE AUTO LEVEL BUTTON DL EF OWN SPEED ON WHILE SELECTING CONTROL FUNCTION hl amp ALL OUTRIGGER LIGHTS
139. the operator s qualifications See Appendix F for information on the Minimum Approach Distance and other precautions Responsibilities of Lessors or Lessees General Responsibilities Each lessor or lessee shall comply with the requirements of the applicable section or sections below Lessor or Lessee as Dealer or Installer When a lessor or lessee uses the aerial device as a dealer or installer they shall have the same responsibilities as specified under Section 7 of this standard Lessor or Lessee as Owner When a lessor or lessee uses the aerial device as an owner they shall have the same responsibilities as specified under Section 8 of this standard Lessor or Lessee as User When a lessor or lessee uses the aerial device as a user they shall have the same responsibilities as specified under Section 9 of this standard Lessor or Lessee as Operator When a lessor or lessee uses the aerial device as an operator they shall have the same responsibilities as specified under Section 10 of this standard Ownership Responsibilities The lessor shall carry out the responsibilities of ownership specified in this standard which are not assigned to the lessee as the user Obligations Upon delivery each lessor of an aerial device shall provide the operators manual and the ANSI SIA A92 2 2009 Manual of Responsibilities for dealers owners users operators lessors lessees and brokers of Vehicle Mounted Elevating and Rotating Aerial Devi
140. tical procedures that supersede the information contained in this manual NEVER operate this aerial work platform while under the influence of drugs or alcohol while taking prescription medications that may leave the operator drowsy or prone to dizziness or while feeling ill NEVER modify alter or change the aerial work platform in any way that would affect its original design or operation NEVER deface modify or obscure any decals or markings on the aerial work platform NEVER operate this aerial work platform in any way for which it is not intended NEVER operate this aerial work platform in explosive or flammable environments Before attempting aerial work platform operations operator s should e Attend a training program as required by all Federal State and Local codes and regulations e Obtain read and obey all safety precautions as indicated by manufacturers recommendations and all Federal State and Local codes and regulations e Become familiar with the location and use of all controls e Verify that there are no overhead obstructions or live power sources in the work area that could interfere with the safe operation of the aerial work platform e Cordon off the area surrounding the aerial work platform to keep personnel vehicles and moving equipment away from the aerial work platform while in use e Position the aerial work platform on a firm and level surface Conduct a pre operation inspection by performing all r
141. tion to air is not expected to be a significant fate process due to the low vapor pressure of this material In water base oils will float and spread over the surface at a rate dependent upon viscosity There will be significant removal of hydrocarbons from the water by sediment adsorption In soil and sediment hydrocarbon components will show low mobility with adsorption to sediments being the predominant physical process The main fate process is expected to be slow biodegradation of base oil components in soil and sediment Persistence and degradability The hydrocarbons in this material are not readily biodegradable but since they can be degraded by microorganisms they are regarded as inherently biodegradable Bioaccumulation Potential Log Kow values measured for the hydrocarbon components of this material range from 4 to over 6 and therefore regarded as having the potential to bioaccumulate In practice metabolic processes may reduce bioconcentration osal Considerations The generator of a waste is always responsible for making proper hazardous waste determinations and needs to consider state and local requirements in addition to federal regulations This material if discarded as produced would not be a federally regulated RCRA listed hazardous waste and is not believed to exhibit characteristics of hazardous waste See Sections and 8 for information on handling storage and personal protection and Section 9 for physical chemical p
142. tional markings 6 Check hydraulic and pneumatic systems for observable deterioration and excessive leakage 7 Check electrical systems related to the aerial device for malfunctions signs of excessive deterioration dirt and moisture accumulation 8 Perform functional test to include but not limited to the following a Set up the aerial device for operation including outriggers b Cycle the aerial device functions through the complete range of motion from the lower controls except where operation through the complete range of motion would create a hazard c Check functionality of emergency controls Any suspected items shall be carefully examined or tested and a determination made by a qualified person as to whether they constitute a safety hazard All unsafe items shall be replaced or repaired before use 8 2 4 Periodic Inspection or Test An inspection of the mobile unit shall be performed at the intervals defined in 8 2 2 depending upon its activity severity of service and environment or as specifically indicated below These inspections shall include the requirements of 8 2 3 1 Structural members for deformation cracks or corrosion 2 Parts such as pins bearings shafts gears rollers locking devices chains chain sprockets wire and synthetic ropes and sheaves for wear cracks or distortion Hydraulic and pneumatic relief valve settings Hydraulic system for proper oil level Hydraulic
143. tolerances proceed to Step 14 If not return to the maintenance mode scroll PAST Load Sense Zero Calibration Utility and proceed directly to Load Sense Scaling Utility 14 Adjust displayed weight by pressing pushing the MID HIGH MID LOW 15 CENTER SPEED buttons until the weight is within tolerances Exit the maintenance mode The Ratio should be within 3 50 1 to 4 00 1 If so continue on to Step 15 If the ratio is not within the above values contact Haulotte Group Customer Service Department at 1 800 537 0540 or visit Haulotte Group online at www haulotte usa com 15 Remove the weight from the platform The Boom Load should now return to the initially displayed weight from Step 9 16 Operate all functions in all speeds from both the ground lower and platform upper control panels to verify proper operation 17 Recalibration is complete 44 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE ADDITIONAL SERVICE INFORMATION Refer to the Haulotte Group 4642T Parts and Service Manual for a comprehensive list of Annual Service checks Seals on hydraulic cylinders should be replaced every five years or as indicated by aerial work platform performance All service checks should be performed on an aerial work platform that has been stored without use for a period exceeding thirty 30 days Check for air in the hydraulic system if the aerial work platform has been stored without use for a period exceeding thirty 30 days
144. traps or wire rope slings that are rated at a minimum 500 Ibs lifting capacity NEVER stand beneath an elevated load or position an elevated load above personnel Falling objects could cause death or serious injury This aerial work platform is not insulated for use near electrical power lines and DOES NOT provide protection from contact with or close proximity to any electrically charged conductor Operator must maintain safe clearances at all times and always allow for platform movement such as wind induced sway Refer to Table 1 1 for minimum safe approach distances between the aerial work platform and electrical power lines 7 HAULOTTE GROUP 6 OPTIONAL EQUIPMENT PLATFORM ROTATOR The optional platform rotator allows the operator to rotate the elevated work platform 90 around a vertical axis by actuating a rotator handle found below the platform control panel Refer to Figure 6 9 To operate manual platform rotator turn the rotator handle in the direction of desired rotation clockwise or counterclockwise Motion continues in the desired direction until rotator handle is released or the platform reaches a safe travel limit Installation of a Manual Platform Rotator may reduce the rated load limit of the work platform Follow all manufacturer s recommendations and safety precautions when operating an aerial work platform equipped for platform rotation Figure 6 9 Manual Platform Rotator 74 HAULOTTE GROUP 7 MATER
145. triggers not supporting the machines load the safety interlock system prevents all telescoping boom operations NOTE The Range of Motion Diagram at the ground lower and platform upper control 26 stations displays the range of platform motion safe operating zone facing away from the trailer tonque Verify that the operating zone is clear of obstructions through 700 of Non Continuous rotation HAULOTTE GROUP 3 OPERATION NORMAL OPERATING PROCEDURE CONTINUED e Use the ground lower control panel to operate the boom lift functions Raise lower extend and rotate the boom by pressing pushing and holding the desired SPEED and function buttons at the same time e Fully lower the boom onto the boom rest to enter the platform using a three 3 point contact both hands and one foot e Raise the safety bar and enter the work platform by using a three 3 point contact both hands and one foot Put on a safety harness and attach the lanyard to the ANCHORAGE attachment point on the side of the platform support beam e Should the platform become tilted out of the normal vertical axis press push and hold the desired SPEED 6 button and one of the PLATFORM TILT 16 or 17 buttons at the same time to level the platform back into the normal vertical axis e Use the platform upper control panel to operate the boom lift functions Raise lower extend and rotate the boom by pressing pushing and holding the desired SPE
146. unless approved by Haulotte Group BilJax Service 5 The warranty application must include the issued RMA number the invoice number for the associated parts the machine serial number the machine hours on the date of failure the issued call ID number failure and repair description and requested customer information Failure to follow the warranty claims procedure may result in delay in processing claim or denial of the claim Haulotte Group BilJax reserves the right to limit or adjust warranty claims with regard to parts labor and travel time Replacement components purchased from suppliers other than Haulotte Group BilJax are not covered under the terms of this warranty QC 00001 HAULOTTE GROUP 2 SPECIFICATIONS DAMAGED EQUIPMENT POLICY Safety Statement At Haulotte Group we are dedicated to the safety of all users of our products All Haulotte Group aerial work platforms are designed manufactured and tested to comply with current applicable ANSI Standards and regulations Damage Policy There may be occasions when a Haulotte Group aerial work platform is involved in an incident that results in structural damage to the aerial work platform Such damage can seriously compromise the ability of the aerial work platform to perform in a safe manner Therefore whenever a Haulotte Group aerial work platform has sustained visual structural damage or when there is suspected internal structural damage Haulotte Group may require that the aer
147. ve and Set option operate the drive function from the platform upper control panel Verify correct operation of turn signals brakes and running lights Verify proper tire inflation See side wall of tire for proper inflation Inspect tires for damage or loose or missing lug nuts e Repair or replace as necessary Inspect structural components and platform for obvious damage or debris e Repair or replace as necessary Inspect the aerial work platform for missing loose or damaged fasteners including pins and bolts Verify that the boom limit switches operate correctly e Limit switches are actuated when the boom is in a fully lowered stowed position Limit switches must be activated to raise or lower outriggers e f outrigger controls are unresponsive when the booms are fully lowered and stowed inspect the limit switches for loose mounting or visible damage e Repair or replace as necessary e Verify that the booms remain elevated and do not drift 38 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE DAILY SERVICE CHECKS CONTINUED Verify that outrigger safety interlocks operate correctly Begin with the outriggers fully extended and the aerial work platform level Raise one outrigger until the footpad is not in contact with the ground Verify that boom functions are unresponsive when one outrigger is raised Repeat this procedure for each outrigger Raise all outriggers until the footpads are not in contact wit
148. vice This training shall be offered initially and subsequently on request Dealer or Installer as User Whenever a dealer or installer directs personnel to operate an aerial device inspecting sales demonstrations or any form of use the dealer or installer shall assume the responsibilities of users as specified in Section 9 of this standard All personnel authorized to operate the aerial device shall have been trained in a program that meets the requirements of this standard Maintenance Training Dealer maintenance personnel shall be trained in inspection testing and maintenance of the aerial device in accordance with the manufacturer s recommendations Responsibilities of Owners General Responsibilities Each owner shall comply with the requirements of this section The following responsibilities pertain to the owner s inspection testing maintenance modification training and transfer of ownership These activities shall be performed by qualified person s Inspection and Testing Classifications Initial Inspection and Test Prior to initial use all new or modified mobile units shall be inspected and tested to ensure compliance with the provisions of this standard Certification by the manufacturer dealer final installer or an equivalent entity s meets this requirement Regular Inspection and Tests The inspection procedure for mobile units is divided into two classifications based upon the intervals at which insp
149. vity is higher than the top guardrail of the platform NEVER modify the platform or carry materials that would increase the surface area of the platform Increasing the area exposed to the wind may affect the aerial work platform stability NEVER attach overhanging loads when raising or lowering the platform NEVER use the boom or platform to push or pull or to lift any part of the trailer NEVER use the boom or platform to place a load against any structure materials or equipment NEVER climb on the boom NEVER leave an elevated platform unattended NEVER leave the keys in the aerial work platform while unattended or not in use FALL PROTECTION e Occupants must wear safety belt or harness in accordance with all Federal State Local codes and regulations Attach to HI ma the anchor provided on the work platform n e Never sit stand or climb on the platform guard rails Maintain a firm footing on the platform floor at all times e Never climb down from the platform when raised If a power failure should occur ground personnel should use the manual controls to lower the platform Refer to the Operation section of this manual for manual operation e Keep platform floor clear of debris e Lower the platform entry mid rail or close the entry gate before operating MANUAL FORCE e Never push off or pull toward any object outside the platform e Maximum allowable manual force is 90

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