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PARTS AND SERVICE MANUAL

1.
2. e e e e e Sal 56 12 MEE amp omm j 10 195 828 aud Wud 803 vo3 aons 106 01 E 908 S 99 MM bai e e e im 1590007 e 5092 DNS 06 exuns 019i f aS SZ97L i GLI i Si i aog og S 400 aog I opulo i M PO S ae nel 140 HAULOTTE GROUP 7 SCHEMATICS HYDRAULIC SCHEMATIC DESCRIPTION Pump Gear 2 0cc Rev Motor 24 Volt DC 3KW 3300 rpm Pump Hand 5cc Pump 6 1802 15 0501 j Filer amp Housing _ Valve Prop 9 1802 14 0095 Coil Prop P 4 21 22 Slew Drive 80CC 39 A 00257 Hydraulic Swivel Only on Machines with 360 Continueous Rotation 141 7 SCHEMATICS HYDRAULIC SCHEMATIC FOR DRIVE amp SET OPTION HAULOTTE GROUP 1590008 9229 US b 19S VEN dc 1
3. 130 700718 POWER WIRE HARNESS asasi 131 00719 OUTRIGGER SWITCH CONTINUOUS ROTATION WIRE HARNESS 131 A 00720 OUTRIGGER COIL CONTINUOUS ROTATION WIRE HARNESS 132 A 00746 OUTRIGGER COIL AND SWITCH 700 ROTATION WIRE HARNESS 133 A 00715 ANALOG WIRE HARNESS PRIOR 2008 134 A 00721 ANALOG WIRE HARNESS EFFECTIVE 2008 0 134 A 00948 ANALOG WIRE HARNESS FOR DRIVE 8 SET OPTION 135 00726 110 VOLTS AC TRAILER TO TOWER WIRE HARNESS 135 00722 110 VOLTS AC TOWER TO PLATFORM WIRE HARNESS 136 01 01 0194 BOX TO TRAILER WIRE 55 136 01 01 0195 GFI BOX TO PLATFORM WIRE 136 A200272 BATTERY LAYOUT tu a Mutua tactu aun 137 A 00943 BATTERY LAYOUT FOR DRIVE SET OPTION 138 AIR LINE TO PEATFORMu u eek 139 00701 WATER HINE TO PLATFORM uu 139 ercer mu Ug 140 HYDRAULIC SCHEMATIC FOR DRIVE SET OPTION eee 142 A 00182 HYDR
4. 2 450 1 poy 190 J9pul AQ S S poy SL i pog SL 9408 9Jog JSpul io 142 HAULOTTE GROUP 7 SCHEMATICS HYDRAULIC SCHEMATIC FOR DRIVE amp SET OPTION ITEMNO PARTNUMBER DESCRIPTION 51 54 02 15 0520 Pump Gear 2 0 Rev 143 HAULOTTE GROUP 7 SCHEMATICS A 00182 HYDRAULIC HOSE LAYOUT TRAILER 360 CONTINUOUS ROTATION al AX wo 5 O Os 71 Outrigger 22 Hydraulic Swivel ITEM PART NUMBER DESCRIPTION B02 01 0213 4 x 28 Hydraulic Hose B02 01 0214 4 x 28 Hydraulic Hose B02 01 0215 6 x 56 Hydraulic Hose B02 01 0216 6 x 56 Hydraulic Hose B02 01 0217 6 x 16 Hydraulic Hose 6 B02 01 0218 6 x 16 Hydraulic Hose B02 01 0219 6 x 28 Hydraulic Hose 8 B02 01 0220 6 x 28 Hydraulic Hose 9 B02 01 0273 6 x 18 Hydraulic Hose B02 01 0272 6 x 18 Hydraulic Hose 02 01 0258 6 MORFS TEE 02 01 0259 6 MORFS 6 MORB STRAIGHT 02 01 0264 6 MORFS 6 MORB 45 144 HAULOTTE GROUP 7 SCHEMATICS A 03182 HYDRAULIC HOSE LAYOUT TRAILER 700 ROTATION 6 B02010220 6 28 1_ 8 02 01 0986 6 46 SSS 9 802 0058 6MORFSTEE O 145 7 SCHEMATICS HAULOTTE GROUP
5. 8 18ga BL Put in split loom Female Spade Ins 01 09 0091 FM Term 01 09 0093 Green Seal 801 09 0109 2 Pin Male Housing 01 09 0110 Male Term 01 09 0093 Green Seal Split Loom Sleeve Strobe Light 133 HAULOTTE GROUP 7 SCHEMATICS A 00715 ANALOG WIRE HARNESS PRIOR 2008 Amp Pin Pump Speed Signal y4 FM Spade 770680 1 lt 3 36 18 ga Green gt Insulated Label Pin Motor Enab FM Spade 16 lt 3 36 18 ga Yellow gt Insulated ji Pin Ground rj B01 09 0109 2 Pin Housing ean EIS 01 09 0110 Male Terminal 10 12 18 ga Red B01 09 0093 Wire Seal 15 Loom Ya FM Spade Ya FM Spade Insulated Insulated 01 09 0152 m Relay NO Contactor 7 23 Pin Plug Fr 18 18ga Black Relay 8 18ga Black Contactor ine Ya FM Spade Insulated 18 18ga Red Relay Splice 8 Heat Shrink Seal Level Sensor 24 10 18 Rd gt Level Sensor GND A A Label 2 lt All wires TXL or Equivalent 01 09 0127 4 Pin housing poe s 22 lt 18 18 ga Orange gt B01 09 009
6. Housing 4Pin Flat Wires Need to be molded together Plug iLabel A 00198 MARKER AND TAIL LIGHT 700 ROTATION WIRE HARNESS Spli 4 gt 01 09 0093 gt 5 O o Cable Seal Green 4Pin Flat B01 09 0110 50 Braided Loom amp Heat Seal Male Term Plug lt gt O O Ground pes w lt lt Marker Lights Br D E 01 09 0125 E 22 4 Pos Male Housing E 10 O Wires Need to be molded together Label Driver Side Signal Part Number Rev Passanger Side Signal 284 A 00782 ELECTRIC BRAKE TAIL LIGHT CONTINUOUS ROTATION WIRE HARNESS MEER 01 09 0109 W White 2 Pin Male Housing Yellow BI Blue 01 09 0110 White Lot Brown a Y Yellow Male Terminal l G Green Ai ES R Red 48 go BARCA e y Tu Turn 42 __ 52 Braided Loom 8 Heat Seal Loom amp Heat Seal Loam YA 01 09 0093 Green Seal mE 01 09 0093 Cable Seal Green 01 09 0091 zn Female Terminal 7 Pin RV EREEEEEREREEERERER FS A MEE remar 5 Housing ee ee ROS QR lt C o Wires Need to be molded together ioe Label _ lt 228 Part Number 276 Rev 128 HAULOTTE GROUP 7 SCHEMATICS A 00193 ELECTRIC BRAKE TAIL LIGHT 700 ROTATION WIRE HARNESS 01 09 0109 E 2 Pin M
7. CO MM aes Nee EH A 19 Black A Level Sensor 01 09 0127 4 Pin Housing Ges Pin rA 01 09 0110 Male Terminal 18 Orange Level Sensor X A1 A1 s B0 1 09 0093 Wire Seal be o 18 Brown gt Level Sensor Y gt 5 00726 110 VOLTS AC TRAILER TO TOWER WIRE HARNESS B01 09 0120 Male Terminal 01 09 0121 Cable Seal 80 SJO B01 09 0032 Female Spade Blue Or Equivalent Black Label A 00726 A B01 09 0123 3 Pos Male Housing 135 HAULOTTE GROUP 7 SCHEMATICS A 00722 110 VOLTS AC TOWER TO PLATFORM WIRE HARNESS B01 09 0123 3 Pin Male Housing B01 09 0120Male Terminal B01 09 0121 Gray cable seal 466 2 TR 14 3 SJO CB or Equivalent Part SJO B01 01 0194 GFI BOX TO TRAILER WIRE HARNESS Label Part Rev B01 09 0123 3 Pin Housing 01 09 0120 Male Term 12 14ga Trailer 01 09 0121 Wire Seal 110VAC Label Part Rev 01 09 0114 3 Pin Housing 01 09 0119 Female Terminal Cage B01 09 0121 Wire Seal 110VAC 136 HAULOTTE GROUP 7 SCHEMATICS A 00272 BATTERY LAYOUT Controller Gauge Length Colo End 1 2gage 30 Red 5 M6Ring SBClug 1 3 2gauge 8 Black 5 16Ring 5 16 Ring 2 L 5 2 Fed SBC Lug 1 e gauge 49 Bak 7 2gage
8. a CD 1 Remove the emergency breakaway battery and store inside out of the weather Charge the battery at least every 90 days 2 Jack up the trailer and place jack stands under the trailer frame so that the weight will be off the tires Follow trailer manufacturer s guidelines to lift and support the unit Never jack up or place jack stands on the axle tube or on the equalizers Do not lift or support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury or death 3 Lubricate mechanical moving parts such as the hitch and suspension parts that are exposed to the weather 4 Boat trailer axles are subject to repeated immersion Before storing remove brake drums clean dry and re lubricate moving brake components inspect bearings clean and re lubricate 5 On oil lubricated hubs the upper part of the roller bearings are not immersed in oil and are subject to potential corrosion For maximum bearing life it is recommended that you revolve your wheels periodically every 2 3 weeks during periods of prolonged storage 210 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS STORAGE CONTINUED After Prolonged Storage Inspection Procedure Before removing trailer from jack stands 1 Remove all wheels an
9. anbioy wg 02 Wl ege gz 01 b 61 SNOIOL A EA anbioy 61 518 Ww 8 2 anbioy wal zo a er WAI g Id a MI 8 2 01 bete EET M 2 anboy t yq zo L T zL Bnid m 22 5 81 ol IL iu 5 5 2 91 3s k 14 anbioy Wal 6 6 01 dl 22 5 BL enbJo NOLLO3S OL T a aero Wal 22 9 8 0 N EAS Nid 910201 m 9p SNEASTDOL oy m enbJo 08 51 4918 109 anbaoy 61 ff Y ql 56 82 0 Ya sea o 8L cL GZ 01 anbjo amen anbloy LL Wal enbJo JON Wal EE 82 01 61 02 A e zol anbioy uonoes eas 96 HAULOTTE GROUP 6 REPLACEMENT PARTS POWER UNIT COMPONENTS 6 B02 14 0091 Valve Check 1 8 02 14 0094 __ Valve Proportional 1 9 B02140095 Sterling Proportional Valve 1 97 6 REPLACEMENT PARTS POWER UNIT COMPONENTS CONTINUED HAULOTTE GROUP eDexee SI eJnsu 4IL o uay IL uay iL OL LL 62 02 01 syog anb o 4 6 gt ya c Lc 01 enbJo iquasse Buunp Buu o
10. 01 09 0091 Female Terminal Pass Hear HR a D _ 01 09 0093 Green Seal G 801 09 0129 6 Pin Male Housing 338 Bo 01 09 0110 Female Terminal 383 ___ B01 09 0093 Green Seal 959 Spice grouper H B01 09 0128 6 Pin Female Housing ogo wires together B Cavity Plug 258 and u 1 O Lee A y 7 Insert all contacts into Drivers Rear LR Designated Locations of CA r AMP Housing Pind e 2S Pass Rear 008 v 6 107 Pin 24 4 12 18 BL gt Put all splices Strobe Pos gt yh CIC A Strobe Neg a in sleeve amp wire rg A 18ga x 12 25 S tie sleeve Female Spade Ins TAE Pr Egquyalen 3 18ga BL 18ga x 12 25 Label each wire Wire Color i Pin 6 TXL or Equivalent Both ends C20 AH Pin 7 8 022 E 36 Pin 9 emn 1 5 3 Pin 10 Nylon Sleeve Pin 12 ____ Pin 33 Pin 34 ____ Pin 17 Pin 18 Pin 19 20 Pin 21 Pin35 BlackAW 2 Outrigger Coil Switches d 152 HAULOTTE GROUP 7 SCHEMATICS A 00947 MANIFOLD HARNESS FOR DRIVE amp SET OPTION 01 09 0080 Socket Terminal trust B01 09 0136 2 Pin Plug LabelWires _______ Green C C22 Both Ends E Wire Color E Wires ze lt Bot o9 137 W2S Wedge ee REDET C
11. i Starter Engine Engine Stop 125 HAULOTTE GROUP 7 SCHEMATICS 3632T HTT 13 ELECTRICAL WIRE HARNESS P3 Loop Back Plug Replacement A 00082 36 23 16 35 24 OOOOOOOOOO00 1 1 i 90000000000 00000009 12 1 8 1 12 1 XZ Pin Location FILI Down NO Strobe Boom Down NC Outrigger Switches Boom Down Relay NC 126 HAULOTTE GROUP 3632T HTT 13 ELECTRICAL WIRE HARNESS Upper Control Box A 00465 Standard A 00931 Drive amp Set A 0099 Load Cell Module A 00988 Load Cell QOO m r3 2 White 3 Green Replacement 00082 23 16 35 00000009 00000000 OOOOOOOOOOOO 1 8 12 7 SCHEMATICS 24 OOO 1 127 HAULOTTE GROUP 7 SCHEMATICS A 00153 MARKER AND TAIL LIGHT CONTINUOUS ROTATION WIRE HARNESS 54 Splices 01 09 0093 01 09 0091 Cable Seal Green Female Terminal 38 PPM PAPAS Braided Loom amp Heat Seal o 2 4 bai gt as EEE 01 09 0124 rawan wawam 2 7 B t 0 0 250 4 D D D D EN E ut 4 z 4 22 4 Pos Female
12. 2 o 9 00960042 Hex Nut with Nylon Insert 2 B12 00 0068 2 5 16in Ball Coupler Option Not Shown 11 00900878 Screw HexHeadCap 5 8 11X434 2 12 0090 0425 Flat Washer SAE 5 8 _ 4 18 00900194 Hex Nut with Nylon Insert 58 14 A 00185 N a a lt lI HERE N 14 15 16 6 REPLACEMENT PARTS TONGUE ASSEMBLY FOR DRIVE amp SET OPTION HAULOTTE GROUP KSSS 4 60 HAULOTTE GROUP 6 REPLACEMENT PARTS TONGUE ASSEMBLY FOR DRIVE amp SET OPTION Replaces B12 00 0169 Effective 2008 B12 00 0068 2 5 16in Ball Coupler Option Not Shown 8 0090045 _ FlatWashen 58 9 0 21 14 9 0090 0194 Nylon Insert 5 611 0 Replaces A 00167 Effective 2006 Pin Cotter 3 32 x 3 4 Not Shown Replaced B36 00 0089 Effective 2006 0096 0042 Hex Nut with Nylon Insert M12 61 6 REPLACEMENT PARTS HAULOTTE GROUP TONGUE ASSEMBLY FOR ELECTRIC BRAKE OPTION 62 HAULOTTE GROUP 6 REPLACEMENT PARTS TONGUE ASSEMBLY FOR ELECTRIC BRAKE OPTION ITEM NO PART NUMBER DESCRIPTION _ 00170 Tongue Tube B12 00 0066 2in Ball Coupler B12 00 0068 2 5 16in Ball Coupler Option Not Shown 00196 Electric Brake Coupler EY A 00172 Hitch Step Revised for Compatibility Effective 2007 6 00900878 5 Hex Head 5 8 11 434 2 8 00900194 ____ Nut
13. HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS MAINTENANCE CONTINUED Bearing Lubrication Grease Do not mix Lithium calcium sodium or barium complex greases due to possible compatibility problems When changing from one type of grease to another it is necessary to insure all the old grease has been removed g sunig sqng Along with bearing adjustment proper lubrication is essential to the proper function and reliability of your trailer axle Bearings should be lubricated every 12 months or 12 000 miles The method to repack bearing cones is as follows suea 1 Place a quantity of grease into the palm of your hand 2 Press a section of the widest end of the bearing into the outer edge of the grease pile closest to the thumb forcing N grease into the interior of the bearing 3 Hepeat this while rotating the AA bearing from roller to roller lt Y 4 Ve Pu i a e 4 Continue this process until you have the entire bearing completely filled with grease 5 Before reinstalling apply a light coat of grease on the bearing cup Bearing Lubrication Oil If your axles are equipped with oil lubricated hubs periodically check and refill the hub as necessary with a high quality hypoid gear oil to the level indicated on the clear plastic oil cap The oil can be filled from either the oil fill hole if present in the hub or through the rubber plug hole in the
14. I 118 Use only parts manufactured and or authorized by Haulotte Group when replacing damaged components See the back pages for replacement part ordering information NOTE Unless otherwise noted High strength Grade 5 Class 8 8 fasteners are used in the assembly of this equipment 97 6 REPLACEMENT PARTS HAULOTTE GROUP TONGUE ASSEMBLY 58 HAULOTTE GROUP 6 REPLACEMENT PARTS TONGUE ASSEMBLY ITEM NO PART NUMBER DESCRIPTION 00172 Hitch Step Revised for Compatibility Effective 2007 B12 00 0211 Coupler Hydraulic Surge Assembly 1 Replaces B12 00 0169 Effective 2008 al 12 00 0220 Cap for Master Cylinder 3 A0070 3 j ToguwTube 1 4 B22 00 0074 Hand Brake Assembly 1 4A A 00192 Brake Lever Replaces A 00167 Effective 2006 4B A02177 BrakeBraket 4C 0096 0000 Head Cap M8x20 4 4D 0096 0000 Hex Nut with Nylon Insert 4 4E 04 06 0033 FlatWasher NotShown________________ 1 4F 36 00 088 Pin Clevis Not Shown 1 Pin Cotter 3 32 x 3 4 Not Shown Replaced B36 00 0089 Effective 2006 5 A0098 JjTalligtKt 5A 8 01 10 0239 GrommetMarerlight 2 5B 01 10 0297 Marker Light Red O 2 6 03 00 0017 Safety Chain Assembly 7 10096 0186 SerewHexHeadCap Mi2x160 1 8 400960076 Flat Washer M12
15. Repair and removal of the hydraulic cylinder requires the use of lifting straps and an overhead crane or lifting gear to support the aerial work platform and hydraulic cylinders Personnel should be thoroughly trained in the operation of these devices before attempting installation or removal Hydraulic cylinders are heavy and may have hydraulic oil on their surface Failure to use proper equipment or to securely support aerial work platform and cylinders could result in death or serious injury and damage to aerial work platform e Lower the boom until it is resting in a stowed position e Pull and hold the emergency lowering valve handle on the lift cylinder to relieve all hydraulic pressure to the cylinder Refer to Figure 4 1 e Turn key switch at the ground station to the OFF position and remove the key VALVE HANDLE Figure 4 1 Location of Emergency Lowering Valve Handle 47 HAULOTTE GROUP 4 CYLINDER REPLACEMENT LIFT CYLINDER REPLACEMENT CONTINUED 48 Locate the piston rod end of the cylinder to be removed Unbolt and remove the retainer plate from each side of the pivot pin Refer to Figure 4 2 Verify that the cylinder is supported by lifting straps and an overhead hoist Remove the pivot pin using a hammer and a brass or hardwood drift Use an overhead crane or lifting gear to raise the boom section Adequate clearance is necessary to reach the cylinder valve block and hydraulic hose ports Unplug t
16. Wheels and Tires 187 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS HOW TO USE YOUR BRAKES PROPERLY How to Use Your Electric Brakes Properly Your trailer brakes are designed to work in synchronization with your tow vehicle brakes Never use your tow vehicle or trailer brakes alone to stop the combined load Your brake controller must be set up according to the manufacturer s recommendations to ensure proper synchronization between the tow vehicle and the trailer Additionally you may have to make small adjustments occasionally to accommodate changing loads and driving conditions Proper synchronization of tow vehicle to trailer braking can only be accomplished by road testing Brake lockup grabbiness or harshness is quite often due to the lack of synchronization between the tow vehicle and the trailer being towed too high of a threshold voltage over 2 volts or under adjusted brakes 91119313 Before any synchronization adjustments are made your trailer brakes should be burnished in by applying the brakes 20 30 times with approximately a 20 m p h decrease in speed e g 40 m p h to 20 m p h Allow ample time for brakes to cool between application This allows the brake shoes and magnets to slightly wear in to the drum surfaces Trailer Wire Size Chart Recommended Number Hitch to Axle Minimum Hookup of Brakes Distance in Feet Wire Size Copper J em 4 ume
17. 2 6 A001200 Outrigger Weldment 7 00136 X FootPadKit j 1 7A 00135 FootPadBall 1 7B 0096 0010 Screw Head 8 20 1 4 7C 0096 0040 HexNutwihNyoninet M8 4 Foot Pad Lock PONE Replaces A 00769 Effective 2007 ES 7E 00960121 Screw FlatHeadCap M8x 30 4 7F 0096 0040 HexNuwihNyoniset M8 4 7G A00137 FootPadBottom 12Y 7H A00136 7 Foot Pad Alumnum 12 __ 1 71 A0039 FoopadCap __ 10 0 O 1 73 045 Oing 1140010 __ 1 7K 0096 0045 fHexNuwihNyoniset M20 1 B22 00 0053 Retrofit Kit Footpad __ 1 7B 0096 0010 Screw HexHeadCap M8x20 4 7C 0096 0040 Hex Nutwith Nylon Insert M8 8 ua Replaces 0096 0012 Effective 2007 BINAE OUTRE Replaces A 00769 Effective 2007 Replaces 00769 Effective 2007 8 __ 0096 0036 ScrewHexHeadCap Mt6x150 9 0096 0051 Screw Hex Head Cap M16 x 100 0096 0044 Hex Nut with Nylon Insert M16 5 im 75 HAULOTTE GROUP 6 REPLACEMENT PARTS BRAKE AND AXLE ASSEMBLY DETAIL B DETAIL B A Fi 76 HAULOTTE GROUP 6 REPLACEMENT PARTS BRAKE AND AXLE ASSEMBLY 2 A 05119 Axle 1 PO CUTE 2B B10 00 0047 Brake Assembly Left Driver Side 1 8 810000007 Replaces B10 00 0042
18. 5 0 C24 um 01 09 0129 6 Pin Plug 78 9 Cond 18 Wire EL B01 09 0110 Male Terminal SOOW or Equivalent CONO whites B01 09 0093Wire Seal amp ee ev Y range A Label ALO Stripe all wire to 12 ee eee 01 09 0110 Male Terminal B01 09 0093 Wire Seal Wire Color Label A 00946 BRAKE SWITCH HARNESS FOR DRIVE amp SET OPTION 01 09 0092 2 Pin FM Housing 01 09 0091 FM Terminal 01 09 0109 2 Pin Male Housing 01 09 0110 Male Terminal CIR Seal B01 09 0093 Green Seal 8 19 18 2 SJO or Equivalent Brake Switch jc m x Brake Switch E Label Both ends 153 HAULOTTE GROUP 7 SCHEMATICS 154 HAULOTTE GROUP 8 OPTIONAL EQUIPMENT 8 OPTIONAL EQUIPMENT IC ENGINE GENERATOR COVER AND TRAY 55 156 IC ENGINE GENERATOR MOTOR MOUNT ASSEMBLY seen 158 IC ENGINE GENERATOR AC POWER HOOK UP ASSEMBLY 114 MANUAL PLATFORM ROTATE ASSEMBLY in 160 MATERIAL LE ASSEMBLY ran 162 MATERIAL HOOR du em 164 LOAD CELL CALIBRATION 167 SWIVEL ROTATION dre ad vost oa 168 155 8 OPTIONAL EQUIPMENT IC ENGINE GENERATOR COVER AND TRAY ASSEMBLY HAULOTTE GROUP 156
19. OPEN CIRCUIT PROPORTION AL SHORTED CIRCUIT PROPORTIONAL OPEN CIRCUIT MOTOR CONTROL ENABLE SHORTED CIRCUIT MOTOR CONTROL ENABLE OPEN CIRCUIT SPARE OUTPUT 36 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 70mA 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 energized Excessive load was detected when Proportional circuit was energized A load of less than 70mA was detected when Motor Control Enable circuit was energized Excessive load was detected when Motor Control Enable circuit was energized A load of less than 70mA was detected when Spare Output circuit was energized Disconnect a wire from HR Outrigger coil Use a piece of wire to short the RR Outrigger coil
20. 12 gt 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 the 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 Name 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 th
21. 27 Red 516Ring 59689 1 8 2gage 44 Red 56Rn2 1 gauge 4 Bak st ing sem 1 10 2gage 19 Si6Rng 1 19 5 16Ring 1 Ca 807008 01 09 0131 SBC Plug Connector 01 09 0132 A Frame Handle 137 HAULOTTE GROUP 7 SCHEMATICS A 00943 BATTERY LAYOUT FOR DRIVE amp SET OPTION A 02272 Kit 200 AMP Fuse Contactor 24VDC 100AMP 200 AMP BO1 06 0058 Fuse Motor Controller Contactor 24VDC 100 01 06 0058 lenga Color dy Re Sieg 1 BN EM gage i9 Ba Si lug S 6lug pe 4 Bed Sieb 1 05 29 40 Black 5 1609 5 16lug 1 De 29 20 Red 516 ary 01 10 0330 Fuse200 mp 138 HAULOTTE GROUP 7 SCHEMATICS A 00700 AIR LINE TO PLATFORM FITTING FITTING HOSE LABEL HOSELABEL TAPE A 00700 AIR LINE 3632T A 00700 AIR LINE 3632T AIR LINE FITTING KIT DESCRIPTION 6MJIC BULK ZAMNPT With Jam Nut 4 INDUSTRIAL INTERCHANGE 20 SERIES QD COUPLER Female W 4FMNPT 6MJIC 6MJIC STR Nip esss a i 71 mousma WrERCHANGE GD neemo armer ow IC Low IC Air Line Minimum PSI Rating 300 PSI Measurement from Fitting end to Fitting end Burst 4 1
22. Check engine Applicable for machines with engines aI W Clean battery terminas Check battery connections M T _ Verify proper operation of manual Towering valves and hand pump m Lubricate all compartment hinges and latches slew ring and mating gear using NLGI Grade 2 multi purpose grease Check coolant level Applicable to 55XA aerial ift platforms M Inspect the Air Filter Applicable for aerial it platforms with engines M Check belt tension engine pump generator Applicable to X Booms ony SA engine Applicable for machines with engines SA _ FRepacehydrauicolandhydrulcfier Inspect pivot pins and cylinders including rod ends for wear or damage a Visually inspect all welds for wear damage or corrosi n A T _ Inspect outriggers for wear or damage Verify proper level sensor operation mspectandadustadeandparmgbrae o A Load test all boom functions with a 500 227kg load 440lb 200kg load if machine is equipped with jib platform rotate Check slew ring for wear or damage A 7 Refer to Engine Operator s Manual for recommended Engine Maintenance E lt lt gt 055 Inspector Signature Haulotte gt 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
23. HAULOTTE GROUP 8 OPTIONAL EQUIPMENT IC ENGINE GENERATOR COVER AND TRAY ASSEMBLY PART NUMBER DESCRIPTION A 01425 Cover 0096 0014 Screw Hex Head Cap M10 x 20 A 01428 Gas Tank Steel A 01434 Filler Cap Vented for Steel Tank 02 02 0291 Fitting 90 4 MNPT 4 FMNPT Brass 02 04 0116 Valve Ball 1 4 HB x 1 4 MBV 02 00 0063 Hose Clamp 4 B20 00 0021 Fuel Line 1 4 Inch A 01437 Pad Cover 0096 0068 Screw Flat Head Socket Cap 10 x 45 0096 0041 Hex Nut with Nylon Insert M10 A 01405 Air Filter Cover 0096 0010 Screw Hex Head Cap M8 x 20 0096 0067 Nut Clip M8 A 01407 Motor 9 HP Tapered Shaft A 00406 Generator 3600 rpm 60 Hz A 01406 Generator Cap A 01410 Tray A 01421 0096 0092 0096 0041 B02 02 0181 02 01 0001 02 02 0182 01420 0096 0016 0096 0041 01 06 0053 0096 0125 0096 0126 00419 0096 0017 0096 0041 0096 0047 01408 00410 00410 00 00 0170 01 09 0092 01 09 0091 01 09 0093 39 00 0020 0090 0144 0096 0074 0096 0073 N 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 5A 35B 35C 35D 34E SOF 36 3 38 39 Screw Flat Head Socket Cap M10 x 30 Hex Nut with Nylon Insert M10 Fitting Engine Oil Drain Not Shown Hose Hydraulic 4 x 15 0 inch 4NPTM Fitting Cap Hex 4 NPT Bracket Screw Hex Head Cap M10 x 25 Hex Nut wit
24. Temp Range 40F 212F Min Bend Radius Sr 4 4 00701 WATER LINE TO PLATFORM HOSE LABEL HOSE LABEL A 00701 WATER LINE 36321 1 09 00 0044 6PW4000 KW 6FJ 142 2 Bo o0 0081 1 epwaooo kw eFu 490 90701 WATER LINE 36327 VENDOR PARTA DESCRIPTION i6 ST SERIES QD 6 ST SERIES QD ST N3 B09 00 0055 4 6 MJIC 6 MJIC 37 STR HOSE TYPE F Water Hose 27777777 Measurement from Fitting end to Fitting end Water Line Minimum PSI Rating 4000 PSI Burst 4 1 Meet or Exceed ISO 11237 Type SAE 100R17 Temp Range 40F 212F Fluid Temp 250F Min Bend Radius 139 7 SCHEMATICS HYDRAULIC SCHEMATIC HAULOTTE GROUP rn h
25. 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 self clearing error When error condition is corrected error is cleared 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
26. B29 00 0166 1 Left Hand B29 00 0166 2 Right Hand 5C 00 00 0180 Bracket Cable Trak Driven End Effective 2010 Replaces B29 00 0165 1 Left Hand B29 00 0165 2 Right Hand ___6 0036 S O ___8 ___ 0096 0040 Hex Nut with Nylon Insert M8 _______ 9 __ 0058 Cable Support Tube 0 2 2 Replaces 0096 0049 Effective 2008 107 HAULOTTE GROUP 6 REPLACEMENT PARTS BOOM ASSEMBLY CONTINUED DETAIL B 108 HAULOTTE GROUP 6 REPLACEMENT PARTS BOOM ASSEMBLY CONTINUED 3 1 lt Replaces B00 00 0031 Effective 2010 6 40056 Cable Track Tray 8 A00532 __ Tube Slider O j 9 0096 008 ScrewHexHeadCap Mi0x40 sd Screw Hex Head Cap M10 x 16 Aluminum Replaces 0096 0013 Effective 2008 Tire Mount Kit Spare Tire Option Not Shown 109 6 REPLACEMENT PARTS HAULOTTE GROUP PLATFORM MOUNT ASSEMBLY lt LLI O lt DETAIL A 110 HAULOTTE GROUP 6 REPLACEMENT PARTS PLATFORM MOUNT ASSEMBLY 6 0096 00 Screw Head 12 30 710 8 ___ 00522 BoomEndWeldmnt 0 1 9 ___ 00031 Bearing Composite 1 00x125x100 2 24 0096 0003 lt lt Screw Head Socket Cap M x20 0 8 25 0096 0039 Hex Nut with Nylon Insert M 8 Replaces B01 10 0035 Effective 2009 0096 0055 Screw Hex Head Cap M12 x 190 ___ _ _ _ 111 6 REPLACEMENT PARTS PLATFORM
27. C24 A C23 Coil Coil JA Coil 8 7 6 C22N C21 C20 Coil N Coil JA Coil HAULOTTE GROUP 7 SCHEMATICS 3632T HTT 13 ELECTRICAL WIRE HARNESS P1 STANDARD Loop Back Plug Replacement A 00082 23 16 OOOOOOOO 8 1 Main Motor Controller Contactor NEA Main Pump Motor 123 HAULOTTE GROUP 7 SCHEMATICS 3632 13 ELECTRICAL WIRE HARNESS P1 DRIVE amp SET OPTION Loop Back Plug Replacement A 00082 36 23 16 lt i 55555550 1 1 12 8 1801 01 018 NEZ 01 E1 NEL D1 E1 Aux Pump Motor Main Pump Motor 124 HAULOTTE GROUP 7 SCHEMATICS 3632T HTT 13 ELECTRICAL WIRE HARNESS P2 Loop Back Plug Replacement A 00082 A 00721 Standard A 00948 Drive amp 36 23 16 35 24 000000090 00000000000 P3 0000000 0060600000000 000000000000 00000009 000000000000 1 12 1 8 12 e e e e 6 IC Engine Option Engine Stop m Engine Spark Starter Coil LO Te
28. 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 A load of less than 70mA was detected when FWS C32 circuit was energized 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 short 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 Disconnect a wire from FWS C32 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 erro
29. 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 limited 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 W
30. Jo jou oq A quiesse oud yue pue ueajo Ajddy M qI SL 017 SINN Buueeq JO OW 6094 914901 jo doup Ajddy H speaJu 911207 jo doup jddy 0 syog 8 2 91 enbJo ya 20 060 L nid nbio SL idde pue 489 Yl r 8 91 9 0 nid 61 lt hia nn 0 nid 08 17418 8 Jeugjse 4 enbJo S 98 HAULOTTE GROUP 6 REPLACEMENT PARTS POWER UNIT COMPONENTS CONTINUED amp Ring MEE 55 B02150533 O Ringonly 6 B02150476 SightGlass 1 8 B02020247 Fitting Plug M14 x 1 5x5 8 __ 1 9 B02150478 SedRing 11 4 _________ 802 02 0276 _ Fitting Plug 8 ORB UnderResevor I 1 99 HAULOTTE GROUP 6 REPLACEMENT PARTS COVER ASSEMBLY DETAIL C 100 HAULOTTE GROUP 6 REPLACEMENT PARTS COVER ASSEMBLY ITEM NO PART NUMBER DESCRIPTION 1 00200 Turntable Weldment 2 A 00228 3 A 00239 Cover Right Power Unit Replaces A03239 Effective 2007 4 A 00240 Cover Left Control 1 Replaces A 03240 Effective 2007 0090 1080 Pop Rivet A 00284 Controls Cover Weldment Replaces A 00258 Effective 2007 7 A 00292
31. Stowed Position sasajaane aaa aaa aaa a gana pana ag aa pan aaa eene 166 MatenlabEiit SE POSO a 166 Minimum Safe Approach 225 LIST OF TABLES MINIMUM SAFE APPROACH DISTANCES 7 BEAUFORT SCALE OF WIND FORGE cu ee 10 TROUBLESHOOTING 22 31 ERROR CODE E 32 MOTOR CONTROLLER ERROR CODE DEFINITIONS 44 MINIMUM SAFE APPROACH DISTANCES 225 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 Read understand and obey all instructions and safety precautions in this manual and attached to the aerial work platform e Read understand and obey all applicable government regulations e Become familiar with the proper use of all controls users should receive instruction by a qualified operator 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 manu
32. 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 Excessive load was detected when Turn Right C23 circuit was energized Use a piece of wire to short the Spare Output coil Disconnect a wire from AC 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 coll 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 Disco
33. essential to the longevity of the bearings service life This design is typically lubricated with grease packed into the bearings Oil lubrication is another method which is available in some of the larger axle capacities E Z Lube is another option chosen by some trailer manufacturers If your axle is equipped with the Dexter E Z Lube feature the bearings can be periodically lubricated without removing the hubs from the axle This feature consists of axle spindles that have been specially drilled and assembled with grease fittings in their ends When grease is pumped into the fitting it is channeled to the inner bearing and then flows back to the outer bearing and eventually back out the grease cap hole Nev R Lube option is the latest innovation from Dexter Nev R Lube bearings are comprised of opposed tapered roller bearing cones sealed inside of a precision ground one piece double cup arrangement These bearings are designed with a small amount of axial end play This end play is essential to the longevity of the bearings service life They are lubricated assembled and sealed at the factory No further lubrication is ever needed Before attempting any disassembly of your Dexter axle make sure you read and follow the instructions for the appropriate axle type Hub Removal Standard Bearings Whenever the hub equipment on your axle must be removed for inspection or maintenance the following procedure should be util
34. following a Proper operation of interlocks b Controls return to neutral when released and not sticking c Control functions and operation clearly marked 219 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 instructional 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 specificall
35. magnet arm magnet and brake shoes Make certain that all the parts removed are replaced in the same brake and drum assembly Inspect for any loose or worn parts stretched or deformed springs and replace as necessary POTENTIAL ASBESTOS DUST HAZARD Some older brake linings may contain asbestos dust which has been linked to serious or fatal illnesses Certain precautions need to be taken when servicing brakes 1 Avoid creating or breathing dust 2 Avoid machining filing or grinding the brake linings 3 Do not use compressed air or dry brushing for cleaning dust can be removed with a damp brush Brake Lubrication Before reassembling apply a light film of grease or anti seize compound on the brake anchor pin the actuating arm bushing and pin and the areas on the backing plate that are in contact with the brake shoes and magnet lever arm Apply a light film of grease on the actuating block mounted on the actuating arm Do not get grease or oil on the brake linings drums or magnets 10 AXLE AND RELATED COMPONENTS 191 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS MAINTENANCE CONTINUED 192 Braking Systems Electric Shoes and Linings A simple visual inspection of your brake linings will tell if they are usable Replacement is necessary if the lining is worn to or less Shoes contaminated with grease or oil or abnormally scored or gouged should also be replaced Hairline heat cracks
36. 00269 HYDRAULIC HOSE LAYOUT BOOM A 9A97 Jexyseg 91d09S3 9 UONEJON Joyseg 1 SE N 146 HAULOTTE GROUP 7 SCHEMATICS HYDRAULIC HOSE LAYOUT BOOM x 52 Hydraulic Hose 4 42 Hydraulic Hose 6 2040279 f4x4 amp HydadicHoss ra 8 44 36 1 9 B0201 0233 _ 4x 419 Hydraulic Hose 4 x 427 Hydraulic Hose 4 x 20 Hydraulic Hose PART NUMBER QTY 2 02 0064 Fe MORFS OMORBAS 8 8022029 6 MORFS 6 MORB STRAIGHT 6 D B02 02 0262 f8MORFS K10MORB4 02 02 0196 1 8 MNPT 1 8 FMNPT 90 02 00 0082 Hex Nut with Nylon Insert 2 02 00 0081 147 HAULOTTE GROUP 7 SCHEMATICS A 00928 MANIFOLD FOR DRIVE amp SET OPTION B1 IN AAA 3000psi 2402 2447 N HAULOTTE GROUP 7 SCHEMATICS A 00928 MANIFOLD FOR DRIVE amp SET OPTION T DESCRIPTION Valve Pressure Relief 3000 PSI Valve Cart NC Valve Check Valve Cart NO 149 7 SCHEMATICS SE LAYOUT FOR DRIVE amp SET OPTION HAULOTTE GRO
37. 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 ConocoPhillips Lubricants 600 Dairy Ashford 244900 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 irritation 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 Inhala
38. 10 AXLE AND RELATED COMPONENTS 10 AXLE AND RELATED COMPONENTS The following sections are reprinted from the Dexter Axle Operation and Maintenance Manual 2008 SET UP AND ADJUSTMENT Introduction Important Safety Notice Appropriate service methods and repair procedures are essential for the safe reliable operation of all running gear as well as the personal safety of the individual doing the work This manual provides general directions for performing service and repair work with tested effective techniques Following these guidelines will help assure reliability There are numerous variations in procedures techniques tools parts for servicing axles as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Anyone who departs from the instructions provided in this manual must first establish that they neither compromise their personal safety nor the vehicle integrity by their choice of methods tools or parts Hefer to your vehicle manufacturer s owners manual for additional procedures techniques and warnings prior to performing any maintenance or repairs This is the safety alert symbol It is used to alert you to potential injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Getting Started Setup and Adjustment For proper performance all new axles should hav
39. 219 INSPECTION FORM FOR HAULOTTE GROUP AERIAL WORK PLATFORMS 226 HAULOTTE GROUP Figure 2 1 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 8 1 Figure 8 2 Figure 8 3 Figure 8 4 Figure 8 5 Figure 8 6 Figure 11 1 TABLE 1 1 TABLE 1 2 TABLE 3 2 TABLE 3 3 TABLE 3 4 TABLE 11 1 LIST OF ILLUSTRATIONS Range l MOUGN kuy 13 Battery ShargerFaceplale uei 20 Outrigger Position 23 Reservo lucia dias 24 Wheel Nut Tightening 26 Slew Ring Position 28 Platform Rotation for Slew Ring Measuremernt 28 MOON to ls cR 45 Location of Emergency Lowering Valve Handle 47 50 aba a a aaa aaa dana 48 Outrigger Cylinder 49 Cylinder Valve a aas mara aia dl dag das 49 POAC Sense MBUN aa naa 164 Ground Control Panel Receptacle 164 o 165 Material Lifting Hook 165 Material Lift
40. 4WS option only Checked only at power up Machines with 4WS option only 39 HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE x O TABLE 3 3 ERROR CODE DEFINITIONS 129 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 OPEN CIRCUIT FWS C32 40 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 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
41. AUTO LEVEL LED s are lit and the buzzer at the ground station sounds e Verify that the aerial work platform is level and that the level sensor is giving an accurate reading e Repair or replace as necessary For aerial work platforms with material hook option e Verify the weight reading displayed at the ground control station is within 10 of actual weight tested Recalibrate load cell if needed See the Load Cell Calibration procedure located in the Optional Equipment section ANNUAL SERVICE CHECKS Perform the following service checks at least once each year Replace Hydraulic Oil and Oil Filter e Wipe away dirt and excess oil from the area around the power unit hoses and filter s using cleaning cloths and alcohol solvent e Drain reservoir by removing the hex plug located on the bottom side of the reservoir e After oil is drained remove oil filter s from top of tank Re Install the filter being careful not to introduce any debris into the system Do not over tighten e Replace oil with AW32 or equivalent AW32 Hydraulic oil e With the fill port cap on but not tightened completely raise and lower the telescoping boom to bleed trapped air from the lift cylinders Repeat as necessary e Repeat every 100 hours or annually which ever comes first Inspect pivot pins and cylinders including rod ends for wear or damage Replace as necessary Visually inspect welds and structural components for wear
42. Added Weight If displayed load is within tolerances proceed to Step 14 If not return to maintenance mode scroll PAST Load Sense Zero Calibration Utility and proceed directly to Load Sense Scaling Utility Adjust displayed weight by pressing mid high or mid low speed until weight is within tolerances exit maintenance mode The Ratio should be within 3 50 1 to 4 00 1 If so continue on to Step 14 If the ratio is not within the above values contact Haulotte Group Customer Service Department 1 888 440 9240 Remove weight from basket The Boom Load should now return to the initially displayed weight from otep 9 Return weight to the basket The Boom Load should read the same weight as the weight recorded in step 11 Repeat steps 14 and 15 Remove the weight and turn the machine off Turn the machine back on the display should return to the weight displayed in Step 9 Repeat steps 14 and 15 twice making sure that Boom Load is reading properly Operate all functions in all speeds from both upper and lower controls to verify proper operation Recalibration is complete 167 HAULOTTE GROUP 8 OPTIONAL EQUIPMENT SWIVEL WITH 360 ROTATION 6 SQ p ul lt 86 168 HAULOTTE GROUP 8 OPTIONAL EQUIPMENT SWIVEL WITH 360 ROTATION 4 0096001 CapScewMBx25 6 5 009040 Hex Nu
43. 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 On 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 i Check display for system status See Table 3 3 for error code definitions and correction j Broken or loose wire j Inspect wiring in control box and at valve manifold and valve coil repair or replace as needed One or more Telescoping Boom Controls function i Error detected by system interlock 31 HAULOTTE GROUP ERROR CODE DEFINITIONS CONTROLS 3 EQUIPMENT MAINTENANACE The DISPLAY PANEL located on the Ground Control Panel indicates the present operating status of the aerial work platform If an error condition is detected the appropriate error code will be displayed on this panel Refer to Table 3 3 to resolve the error TABLE 3 3 ERROR CODE DEFINITIONS 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 CON
44. 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 Spare 1 circuit was energized A load of less than 70mA was detected when FWS Spare 2 circuit was energized Excessive load was detected when FWS opare 2 circuit was energized 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 short the FWS Spare 1 Coil Disconnect a wire from FWS Spare 2 coil Use a piece of wire to short the 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 err
45. Cover Latch Assembly 2 Replaces A 00250 Effective 2007 8 A0074 24 9 00900920 Ball Stud MM 4 10 00900185 Hex Nut with Nylon Insert 5 1618 4 15 0096 0002 Screw Hex Head Cap M6 x 20 4 16 0096 0039 Hex Nut with Nylon Insert M6 N JJ N nN EE 2 101 6 REPLACEMENT PARTS HAULOTTE GROUP COUNTER WEIGHT ASSEMBLY 102 HAULOTTE GROUP 6 REPLACEMENT PARTS COUNTER WEIGHT ASSEMBLY 6 0096 0082 Screw Head 16 30 3 8 00960045 Hex Nut with Nylon 0 4 9 A0030 JTallightKt 11 3 9B BO0t 100235 Tailligt 2 9D 01 10 0238 Marker Light Red 2 103 HAULOTTE GROUP 6 REPLACEMENT PARTS BOOM ASSEMBLY E m lt C 104 HAULOTTE GROUP 6 REPLACEMENT PARTS BOOM ASSEMBLY 6 0096 004 Hex Nut with Nylon Insert MO s 00 1 8 00200 TumtebeWeldmet s 9 A002 JjPini25x85 2 28B 28D 0096 0000 Screw FlatHeadSocketCap M6x25 1 8 28F 12 Ref 105 HAULOTTE GROUP 106 BOOM ASSEMBLY CONTINUED 6 REPLACEMENT PARTS DETAIL B o gt 1 wee 1 p C DETAIL D HAULOTTE GROUP 6 REPLACEMENT PARTS BOOM ASSEMBLY CONTINUED 1 1 Replaces 00 00 0031 Cable Track 41 Links Effective 2010 Replaces 00 00 0074 Effective 2010 5B 00 00 0179 Bracket Cable Trak Fixed End Effective 2010 Replaces
46. Equivalent 4 92 gt gt 5 Pos Pin 1 5 16 Ring Terminal 12ga Black TXL Or Equivalent 4 92 gt gt 5 Neg Pin 2 l 5 16 Ring Terminal A 00718 Rev Fill Strain Relief with RTV then put on cable clamp and wipe off excess Bundle wires in 20 of loom Tape both ends if split loom is used A 00719 OUTRIGGER SWITCH CONTINUOUS ROTATION WIRE HARNESS All Cables SJO Or Equivalent 13 156 Strip to 8 2 01 09 0110 Male Terminal 3B01 09 0093 Cable Seal F 2 Splice group of wires together and seal Part Number Rev Label all wires Label 131 HAULOTTE GROUP 7 SCHEMATICS A 00720 OUTRIGGER COIL CONTINUOUS ROTATION WIRE HARNESS Cables SJO Or Equivalent Strip all wires 3 Oil Resistant Spli f wi ga ai 227 En 6 Dj C ES DD D B01 09 0093 Cable Seal A 00720 Rev Plug F with 12010300 Cavity Plug lt w g 8 r 3 18ga Black Oil Resistant Ya Female Spade 132 7 SCHEMATICS HAULOTTE GROUP HARNESS 000000000000 00000000000 000000000000 3 18ga BL A 00746 OUTRIGGER COIL AND SWITCH 700 ROTATION WIRE Splice group of Part Number wires together Rev and seal Splice group of wires together gt
47. Personal Protection Component US ACGIH 2 ubricant Base Oil Petroleum TWA 5ma 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 controls current ventilation practices are not adequate to maintain airborne concentrations below the established exposure limits additional engineering controls may be required Protection The use of eye protection that meets or exceeds ANSI 2 6 7 1 is recommended to protect against potential eye contact irritation or injury Depending on conditions of use a face shield may be necessary SkinfHand Protection 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 175 HAULOTTE GROUP MATERIAL SAFETY DATA SHEET 9 MATERIAL SAFETY DEXRON III MERCON AUTOMATIC TRANSMISSION FLUID HYDRAULIC OIL CONTINUED 614636 Powerflow AW Hydraulic Oil All Grades Date of Issue 14 Nov 2008 status Final Respiratory Protection Where there is potential for airborne exposure above the exposure limit a NIOSH certified air pu
48. REPLACEMENT PARTS I HAULOTTE GROUP 6 REPLACEMENT PARTS GROUND LOWER CONTROL BOX __ 00238 Ground Lower Control Box Complete 22 A00238B Ground Lower Control Box Only 1 Wiring Harness DB9 6 01 020119 Emergency Stop Button with Contact and Mount 1 7 01 02 0118 Key Switch 3 Position 1 8 01 01 15 Wiring Harness Key Switch and Emergency 1 9 01010111 Ribbon Cabe Decal Ground Lower Control Box Overlay 93 6 REPLACEMENT PARTS POWER UNIT COMPARTMENT ASSEMBLY HAULOTTE GROUP DETAIL A 94 HAULOTTE GROUP 6 REPLACEMENT PARTS POWER UNIT COMPARTMENT ASSEMBLY 6 024 GasSpig 1 4 ___8 0090 48 Hex Nut with Nylon Insert 51618 2 A A 4 11 0096 0039 Hex Nut with Nylon Insert M6 L ie Jack Handle 13 _ 4 07 003 OI Nut with Nylon Insert M6 95 6 REPLACEMENT PARTS HAULOTTE GROUP POWER UNIT COMPONENTS T yal 8 7 01 3791 5 2 0 anbioy snbuoL n e S00 DN3 Jed Enid Japuedx3 c WO 5 6 anbioL yal 6 2 Wal 6 2 oi 1 41 86 62 01 Wa 92 0 enbuo snbuoL anbioy AL m 22 ES va se INN enbuoL 4 22 5 8 0 5 1 41 9 WA 9 5 Ne J wal 8 01 INN anbioy ny anbuoL
49. 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 surfaces 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 bypass the manufacturer s safety devices NEVER attach a safety harness to an adjacent structure pole or to nearby equipment while working from the platform cage NEVER raise the outriggers or move the trailer with materials or personnel on board or while telescoping boom is raised or extended NEVER sit stand or climb on platform cage railing ALWAYS keep both feet firmly on the platform cage floor NEVER attempt to increase the working height with boxes ladders stools or any other materi
50. authorized Haulotte Group technician if repairs are necessary NEVER modify alter or change the aerial work platform without first consulting an authorized Haulotte Group service 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 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 pl
51. cap itself 197 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS MAINTENANCE CONTINUED Recommended Wheel Bearing Lubrication Specifications Grease Lithium Complex EP Corrosion amp Oxidation Inhibitors Approved Grease Sources ConocoPhillips Multiplex RED 2 L427 Super Blu Grease _ 76 Lubricants Kendall Lithoplex MP 2 Lithoplex CM 2 Mystik JT 6 Hi Temp Grease 2 Ronex MP Mobilith AW 2 Mobil Synthetic Grease Liquid O Ring No 167L Exxon Mobil Company Oil Center Research of Oklahoma Pennzoil Quaker State Company Rotella Heavy Duty Lithium Shell Complex 2 Royal Mfg Company Royal 98 Lithium Complex EP 2 Chevron Texaco Chevron Ulti Plex Grease EP 2 Texaco Starplex Moly MPGM 2 Valvoline Multi Purpose GM Synthetic Red Grease ALBIDA EP 2 ALBIDA Grease SLC 220 Valvoline Durablend Great Plains Lubricants Lithium Complex EP 2 Arrow 2282 Hubs Drums Bearings 198 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS MAINTENANCE CONTINUED pe Approved Oil Sources o Ashland Oil Valvoline Dura Blend Valvoline Power Lube CITGO Petroleum Co CITGO Premium Gear Oil MP Mystik JT 7 ep Mystik Power Lube gt Exxon Company USA Gear Oil GX 80W 90 Industrial Oils Unlimited Super MP Gear Oil 80W 90 Kendall Refining Co Kendall NS MP Hypoid Gear Lube Lubriplate Di
52. drum turning or armature refacing operations Make certain that the wheel bearing cavities are clean and free of contamination before reinstalling bearing and seals The presence of these contaminants will cause premature wheel bearing failure Bearing Inspection Wash all grease and oil from the bearing cone using a suitable solvent Dry the bearing with a clean lint free cloth and inspect each roller completely Never spin the bearing with compressed air THIS CAN DAMAGE THE BEARING 195 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS MAINTENANCE CONTINUED 196 Hubs Drums Bearings If any pitting spalling or corrosion is present then the bearing must be replaced The bearing cup inside the hub must be inspected IMPORTANT Bearings must always be replaced in sets of a cone and a cup Be sure to wear safety glasses when removing or installing force fitted parts Failure to comply may result in serious eye injury When replacing the bearing cup proceed as follows 1 Place the hub on a flat work surface with the cup to be replaced on the bottom side 2 Using a brass drift punch carefully tap around the small diameter end of the cup to drive out 3 After cleaning the hub bore area replace the cup by tapping in with the brass drift punch Be sure the cup is seated all the way up against the retaining shoulder in the hub Replace only with bearings as specified in the Bearing Replacement Chart
53. 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 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 oll 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 15 unlikely to cause pulmonary abnormalities 5 Fire Fighting Measures NFPA 704 Hazard Class Health 0 Flammability 1 Instability 0 0 Minimal 1 Slight 2 Moderate 3 Serious 4 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 Water 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 respo
54. less than 3 percent PAH s and are not considered carcinogens by NTP IARC or Acute Data Oral LD50 Dermal LD50 Inhalation LC50 Lubricant Base Oil Petroleum 112 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 Volatilization 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
55. light is flashing there is an error refer to the Motor Controller Error Code Definitions Table 3 4 is located later in this section 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 telescoping boom down limit switches operate correctly e Down limit switches are actuated when the telescoping boom is in a fully lowered stowed position Limit switches must be operational to raise or lower outriggers e f outrigger controls are unresponsive when the telescoping boom is fully lowered and stowed inspect down limit switches for loose mounting or visible damage e Repair or replace as necessary 22 HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE 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 footpa
56. not necessarily be limited to the following issues and requirements 1 The purpose and use of manuals 221 HAULOTTE GROUP 9 3 2 9 3 3 9 3 4 9 4 Note 9 5 9 6 222 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 Responsibilities associated with problems or malfunctions affecting the operation of the aerial device 5 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 Kan lt x
57. questions to the Haulotte Group Customer Service Department 1 888 440 9240 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 this form for your records Frequency Key D Daily or before each use W Weekly M Monthly SA Semi Annually A Annually Service Check Description Frequency Initials Verify that all decals are correctly applied and in plain view D d Verity that all controls and indicators at ground and platform control stations operate propery D _ Verify operation of running and brake in Verily proper tire inspect tires for damage or loose or missing lug O Inspect structural components for obvious damage or debris J Db inspect machine for loose damaged or missing fasteners including pins and bots D Verify that boom down limit switches operate corectly o Jo Verity that outrigger safety interlocks operate correcty spect hydraulic system and fluid levels OOOO Db T Check batteryelectoytelevel W mspeceeciialw ng _ T I W mspeciwansporh chfordamage OM Inspect boom for missing loose or damaged hardware W Inspect all hydraulic system components including power unit hoses and cylinders for damage leaks loss of pressure or speed and unusual noise or vibration
58. road free of sand and gravel If the trailer brakes lock and slide decrease the gain setting on the controller If they do not slide slightly increase the gain setting Adjust the controller just to the point of impending brake lockup and wheel skid Note Not all trailer brakes are capable of wheel lockup Loading conditions brake type wheel and tire size can all affect whether a brake can lock It is not generally considered desirable to lock up the brakes and slide the tires This can cause unwanted flat spotting of the tires and could also result in a loss of control If the controller is applying the trailer brakes before the tow vehicle brakes then the controller adjustments should be made so the trailer brakes come on in synchronization with the tow vehicle brakes For proper braking performance it is recommended that the controller be adjusted to allow the trailer brakes to come on just slightly ahead of the tow vehicle brakes When proper synchronization is achieved there will be no sensation of the trailer jerking or pushing the tow vehicle during braking HAULOTTE GROUP SET UP AND ADJUSTMENT CONTINUED Wheels and Tires Do not attempt to repair or modify a damaged wheel Even minor modifications can cause a dangerous failure of the wheel and result in personal injury or death Torque Requirements In June of 2004 Dexter Axle ceased production of trailer wheels If your vehicle is equipped with Dexter
59. 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 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 as 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
60. 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 manuals 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 operato
61. you may damage the bearing 2 Apply a PERMATEX sealant to the outside of the new seal Note Permatex sealant should not be used rubber encased seals IR BS 7 3 Tap the new seal into place using a clean wood block Bearing Adjustment and Hub Replacement If the hub has been removed or bearing adjustment is required the following adjustment procedure must be followed 1 After placing the hub bearings washers and spindle nut back on the axle spindle in reverse order as detailed in the previous section on hub removal rotate the hub assembly slowly while tightening the spindle nut to approximately 50 Ft Lbs 12 wrench or pliers with full hand force 2 Then loosen the spindle nut to remove the torque Do not rotate the hub HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS MAINTENANCE CONTINUED 3 Finger tighten the spindle nut until just snug 4 Back the spindle nut out slightly until the first castellation lines up with the cotter key hole and insert the cotter pin 5 Bend over the cotter pin legs to secure the nut 6 Nut should be free to move with only restraint being the cotter pin For E Z Lube axles using the new nut retainer 1 After placing the hub bearings washers and spindle nut back on the axle spindle in reverse order as detailed in the previous section on hub removal rotate the hub assembly slowly while tightening the spindle nut to approxi
62. 1 1 A00449 PlatormAssemby 1 2 A00345 Gearbox O C I Replaces A 00325 Round Shaft Effective 2010 Bolt Supplied with GearBox 1 __6_ 0030 Bearing 751Dx 75Longx 125Thick 2 8 0017 PinRetainer 75 __ 1 2 9 0096 0014 ScrewHexHeadCap Mi0x20 161 HAULOTTE GROUP 8 OPTIONAL EQUIPMENT MATERIAL LIFT ASSEMBLY SCREW 21 TORQUE TO 15 FT LBS SCREW 24 SHOULD SPIN BY HAND 162 HAULOTTE GROUP 8 OPTIONAL EQUIPMENT MATERIAL LIFT ASSEMBLY A0046 _____ Material Lit Package 6 0096 0041 Hex Nut with Nylon Insert gt 8 00960085 Screw Hex Head Cap M12X190 1 e 0096 0042 Hex Nut with Nylon Insert 1 11 0086 0003 ScrewFliHealSoelCap M8x20 8 12 0096 0077 Water 13 0096 0039 HexNutwithNyloninsert M6 Hex Nut with Nylon Insert M12 2 Pin 0 5 x 8 875 30 jCastleNu suppiedwth 1 31 gt 163 HAULOTTE GROUP 8 OPTIONAL EQUIPMENT MATERIAL LIFT HOOK If the aerial work platform is equipped with a Material Lifting Hook observe the following procedure for material lift operation e Remove the Platform Control Box from the work platform by releasing the latch on the back of the control box e Disconnect the Platform Control Box from the Load Sense Module located on the Boom Lift Bulkhead e Disconnect the electric loopback plu
63. 1 09 0091 FM Term 01 09 0091 FM Term 01 09 0093 Green Seal B01 09 0093 Green Seal 01 09 0093 Green Seal Label Pin 1 12 18ga 00716 Pin 11 B01 09 0080 Bev B Socket Terminal Outrigger Ret Pos Outrigger Ext Pos Prop Valve Pos Prop Valve Neg Extend Sol Pos Retract Sol Pos 13 60 Ape B01 09 0136 2 Pin Plug Pin 9 B01 09 0080 Socket Terminal E RIA B01 09 0137 Wedge A Pin 10 48 18ga 34 36 18ga Pin 17 01 09 0149 Plug White 35 Pin 01 09 0146 Female Terminal Rotate CW Pos Rotate CCW Pos Plat Level Up Pin 35 36 Plat Level DN Prim 208 Pin 18 Boom 090 18 2 O60 Pin 32 Prop Valve Pos gt W Vi Female Spade Ins 806 Pin 33 Prop Valve Neg gt Female Spade Ins 080 Pin 26 059 01 09 0123 3 Pos Housing 01 09 0114 3 Pos Housing 0509 Pin 25 B B01 09 0110 Male Term Cavity Seal 552 01 09 0093 Green Seal Pin 27 A B01 09 0114 3 Pos Housing B01 09 0123 3 Pos Housing 01 09 0092 2 Pin FM Housing B B B01 09 0091FM Term Cavity Seal B01 09 0091 FM Term B01 09 0093 Green Seal B01 09 0093 Green Seal A C Pin 20 01 09 0123 3 Pos Housing Pin 31 01 09 0110 Male Term e mousing B01 09 0093 Green Seal Pin 21 C 130 HAULOTTE GROUP 7 SCHEMATICS A 00718 POWER WIRE HARNESS 12ga Red TXL Or
64. 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 determine 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 Under all travel conditions the driver shall limit travel speed in accordance with conditions of the ground surface congestion and slope 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 int
65. 3 Wire Seal lt 5 Loom Pin Level Sensor Y gt NE 23 lt 18 18 Brown gt gt wem i Start Label A 00721 ANALOG WIRE HARNESS EFFECTIVE 2008 01 09 0109 2 Pin Housing B01 09 0110 Male Terminal 01 09 0092 2 pin Housing ss 0 s B oi _ Pin Redi Engine Tach 147 Loom 01 09 0152 23 Pin Black Plug Ohm AW SolderResistor connections 1 Y Ring t Resistor amp Heat shrink over wires 8 Resistor Terminal Pin A 1 Pin 10 Loom 16 Level Sensor Terminals 077 pose cle A B01 09 0146 Female Terminal g e e Y Y TT sate 01 09 0118 Female Terminal 0 74 Female Spade Terminal _ Splice amp Heat Shrink Seal Pin AL 2 Ck Contactor m 4 15 DE B01 09 0127 4 Pin Housing Pin un 01 09 0110 Male Terminal AO Ba E ZEIT B01 09 0093 Wire Seal 25 C 134 HAULOTTE GROUP 7 SCHEMATICS A 00948 ANALOG WIRE HARNESS FOR DRIVE amp SET OPTION E Green 0 B B01 09 0109 2 Pin Housing O 1 B01 09 0110 Male Terminal AO Rea Engine Tach A 04 09 0093 Wire seal i i 3 19 Black gt Brake Switch BO 1 09 0109 2 Pin Housing 01 09 0092 2 Pin Housing CK E 01 09 0110 Male Terminal Ca
66. 3C 802 14 0087 Orifice Disc 1 3D 02 14 0107 Check Valve Not Shown Lt B02 13 0129 Packing Kit Not Shown j 1 4 0096 0009 Head 8 10 j 2 5 00960010 ____ Screw Head 8 20 T 2 6 20 00 0019 Bumper Single Stud 125 Diameter 8 000 9 __ 00020 125 55 2 10 0019 12 4 j 2 11 0096 006 Screw HexHeadCap M10x25 2 12 0096 0041 Hex NutwithNylonisert MO 13 0032 7 Bearing 1 25 x 1 50 1 25 2 14 00 2 125545 11 4 15 0019 JPinRetanen125 1 16 0096 0016 Screw HexHeadCap M10x25 1 17 0096 0041 Nut with Nylon 1 18 00120 02 Outrigger Weldment U 1 19 0096 0036 Screw HexHeadCap M16x150 j 1 20 0096 0051 Screw Hex Head Cap M16x100 j 1 21 00960044 Hex Nut with Nylon Insert M16 2 al N N IN 73 6 REPLACEMENT PARTS HAULOTTE GROUP OUTRIGGER FOOT ASSEMBLY 2 lt O lt C QO 2 74 HAULOTTE GROUP 6 REPLACEMENT PARTS OUTRIGGER FOOT ASSEMBLY i Koi Pad Mount S oO W gt 80 08 0078 sss Replaces B01 03 0078 Effective 2007 4 0090 0692 Screw Round Head Machine 8 32X11 4 2 5 0090 0187 Hex Nut with NylonInset 8 32
67. 60 TONGUE ASSEMBLY FOR ELECTRIC BRAKE OPTION 62 DOLLY WHEEL ASSEMBLY eerte reete teneret tette teatro L opos 64 DOLLY WHEEL ASSEMBLY FOR DRIVE amp SET OPTION 66 DOLLY WHEEL WITH TAPERED SWIVEL 8 YOKE ASSEMBLY OPTION 68 BOOM REST SWITCH AS Boedo 70 OUTRIGGER LEG ASSEMBLY iiaii aai N ANAA iiia 72 OUTRIGGER FOOT ASSEMBLY 74 BRAKE AND AXLE 6 2 t ttt ttt 76 BRAKE AND AXLE ASSEMBLY FOR DRIVE amp SET OPTION I 78 DRIVE MOTOR ASSEMBLY FOR DRIVE amp SET OPTION 80 xi teres aceto ends datae aee presas 82 BATTERY COMPARTMENT ASSEMBLY 84 CONTROL COMPARTMENT ASSEMBLY nennen 86 CONTROL COMPARTMENT ASSEMBLY FOR DRIVE amp SET 90 GROUND LOWER CONTROL BOX l 92 POWER UNIT COMPARTMENT ASSEMBLY nennen 94 POWER UNIT COMPONENTS 96 COVER ASSEN BIY A 100 COUNTER WEIGHT ASSEMBLY I ankh k ankn knakk knakk ann n aan ann anna aana eannan 102 BOOM ASSEMBLY A 104 PLATFORM MOUNT ASSEMBLY eter ttt tte 110 AC POWER HOOK UP ASSEMBLY siaina neira iae terere reete tete rather tao 114 PLATFORM ASSEMBLY ccccscssecsesessessesecsecscsessecsesecsecsessssecsussssessusassecsecessucsecarsacsecsesasancassasancaseeven 116 PLATFORM UPPER CONTROL BOX
68. AULIC HOSE LAYOUT TRAILER 360 CONTINUOUS ROTATION 144 A 03182 HYDRAULIC HOSE LAYOUT TRAILER 700 145 00269 HYDRAULIG HOSE LAYOUT BOOM usa eg aaa 146 00928 MANIFOLD FOR DRIVE amp SET OPTION sanak gana bea aa a Gan anaa a a 148 A 00938 HYDRAULIC HOSE LAYOUT FOR DRIVE 4 SET 150 A 00939 OUTRIGGER COIL TO SWITCHES FOR DRIVE 8 SET 152 A 00947 MANIFOLD HARNESS FOR DRIVE 8 SET OPTION eene HH 153 A 00946 BRAKE SWITCH HARNESS FOR DRIVE 8 SET OPTION 153 121 HAULOTTE GROUP w B ML ML Tail Lights 122 3632T HTT 13 ELECTRICAL WIRE HARNESS ELECTRICAL Tailight Platform GFI 00722 Upper Control Box A 00465 Standard A 00931 Drive amp Set A 00992 Load Cell Module 1 26 Refers to thecoil number from the Hydraulic Schematic A 00988 1 Load Cell Red Aux Motor Controller 7 SCHEMATICS IC Engine Option Engine Stop Starter Coil Engine Spark e Engine Engine Stop Engine Start Throttle Fe Chok
69. D H2SO4 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 III of the Superfund Amendments and Reauthorization Act The items are covered an exemption as a Manufactured 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 F Solubility in Water 10096 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 elect
70. DRIVE MOTOR ASSEMBLY FOR DRIVE amp SET OPTION PART ITEM NO NUMBER DESCRIPTION an 1 A 00100 Base Weldment Tas Cymer 27 A00901L Mount Weldment Driver Side Hydraulic Surge Brake 1 SS Mount Weldment Diver Sida Surge ti 38 009018 Mount Weldment Passenger Side Hydraulic Surge Brake 1 _ 3C A 00950R Mount Weldment Passenger Side Electric Surge Brake A 00908L Fender Mount Rear DriverSide S A 00908R Fender Mount Rear Passenger Side A 5 00960016 Screw HexHeadCap M10x25 J6 6 0096 0041 Je 7 A027 PmwihHead 75X326 8 00047 PmReamerj S 2 BE 9 0996 0016 Hex Cap 2 00960041 Hex Nutwith Nylon Insert 2 _ A0007i ____ Fender Mount A 00907 2 FendrMomtRihi O 1 _ i2 00960016 Screw HexHeadCap MIOx28 6 00960041 HexNutwihNyoniset MiO 14 A007 PiwihHead 75X325 O 2 15 A0017 O 16 00960016 Screw 0 25 2 17 0096 0041 2 2 18 00960018 Screw Head 0 25 19 00960041 HexNutwihNyoninset MiQ 29 Pwo Wedmet __ 2 1 A091 Poan 2 22 A006 Pm x25 NR 23 00926 PinRetaimer 75 NR 24 00960066 S
71. 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 Disconnect a wire from Spare Output 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 m
72. EAK PROCEDURES 172 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 AGENCY 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 9 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET DEXRON III MERCON AUTOMATIC TRANSMISSION FLUID HYDRAULIC OIL cx 6 Powerflow AW HVI Hydraulic Oil All Grades Material Safety Data Sheet
73. EL vol in air Autoignition Temperature 10 Stability and Reactivity Clear and bright Liquid Petroleum No data Not applicable lt 1 mm Hg gt 1 data lt 29 2 F lt 34 lt 29 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 data No data No data Stability Stable 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 176 HAULOTTE GROUP 9 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET DEXRON III MERCON AUTOMATIC TRANSMISSION FLUID HYDRAULIC OIL CONTINUED 814636 Powerflow AW 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
74. ENT HERE GROUND LEVEL MEASUREMENT HERE a h Lo mmm GS GROUND LEVEL Figure 3 6 Platform Rotation for Slew Ring Measurement 28 HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE STRUCTURAL INSPECTION A comprehensive structural inspection of the unit shall be performed under any of the following conditions e years from the date of manufacture and every five years thereafter After any actual suspected or potential damage is sustained that could affect the structural integrity or stability of the aerial work platform e After a change in ownership Owners should provide a complete service history when reselling the unit The structural inspection shall include the following considerations o The service history of the unit including hours of service work performed and environmental conditions The inspection and maintenance record of the aerial work platform The effectiveness of all controls and components A visual inspection of the aerial work platform for wear or damage Manufacturer recommendations A visual weld inspection to be performed by qualified personnel in accordance with applicable Government regulations MOTOR DRYING INSTRUCTIONS Inclusion of water or foreign particles into the DC electric motor housing may cause serious damage to the motor If the motor becomes wet follow these instructions or contact an authorized Haulotte Group service techni
75. Effective 2008 BN 2C B10 00 0048 Brake Assembly Right Passenger Side Replaces B10 00 0043 Effective 2008 6 0096 050 lt lt Washer M16 o Z 2 8 8 A0043 Fender y d 2 9 __ 001511 Fender Mount Left S 11 0096 0014 Screw Hex Head Cap 10 20 B 12 009 041 Nut with Nylon Insert M10 8 18 0096 0016 _____ Screw Hex Head Cap 10 25 268 14 009 041 Nut with Nylon Insert M10 8 Cable Assembly Parking Brake B21 00 0026 Brake Line Kit Hydraulic Brakes Not Shown 77 6 REPLACEMENT PARTS HAULOTTE GROUP BRAKE AND AXLE ASSEMBLY FOR DRIVE amp SET OPTION DETAILA 78 HAULOTTE GROUP 6 REPLACEMENT PARTS BRAKE AND AXLE ASSEMBLY FOR DRIVE amp SET OPTION Ref 5 0096 0044 7 5 HexHeadCap Mi0x20 1 1 1 1 1 8 6 10096 00414 X HexNutwihNyoninseert MiO 8 7 A 05119 Axle 1 x UC B10 00 0047 Brake Assembly Left Driver Side 1 Brake Assembly Right Passenger Side Replaces B10 00 0043 Effective 2008 8 A00223 Cable Parking Brake Electric Surge Brake 2 Y 10096 00354 7 5 HexHeadCap Mi6x40 10 0096 0000 Washer 6 1 1 1 1 18 Replaces B08 02 0023 Effective 2008 12 12 19 HAULOTTE GROUP 6 REPLACEMENT PARTS DRIVE MOTOR ASSEMBLY FOR DRIVE amp SET OPTION DETAIL FENDER MOUNT ATTACHMENT HAULOTTE GROUP 6 REPLACEMENT PARTS
76. MOUNT ASSEMBLY CONTINUED HAULOTTE GROUP lt LLI O Pd lt DETAIL A 112 HAULOTTE GROUP 6 REPLACEMENT PARTS PLATFORM MOUNT ASSEMBLY CONTINUED 38 A00608 7 Compression Spring 1 5 39 0661 SnapPinleft 1 ___40 ___ 00606 8_____ Snap Pin Rigt 41 00609 Knob Platform Lateh 2 3 2 113 6 REPLACEMENT PARTS HAULOTTE GROUP AC POWER HOOK UP ASSEMBLY PLATFORM se 114 HAULOTTE GROUP 6 REPLACEMENT PARTS POWER HOOK UP ASSEMBLY 6 00944 8 079 Cord Assembly 11 9 __ 00186 Lock Connector 5 1 0090 1081 Screw Pan Head Sheet Metal 4 x 3 4 115 6 REPLACEMENT PARTS HAULOTTE GROUP PLATFORM ASSEMBLY MAS 4 IN SNC AN NN NEP 7 577 e SNA POSTERIOR VIEW A 7 4 oS 7 ab NG 20 DETAILA POSTERIOR VIEW B 116 HAULOTTE GROUP 6 REPLACEMENT PARTS PLATFORM ASSEMBLY A009 PlatformAssembly 1 2 A00465 1 2A _ 00931 _ Upper Control Drive 8 Set Option 1 3 0461 Upper Control Box Mount 1 4 046 ControlBoxLatch 1 5 0090 0679 PopRiveL5 2x250 __ 6 009 016 Screw HexHeadCap M10x25 2 7 0096 0041 Nylon Insert 2 ___8 045 Storage Box 1 3 9 046 ManualMount
77. Machines with 4WS option only Checked only at power up Machines with 4WS option only 41 HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE x O TABLE 3 3 ERROR CODE DEFINITIONS 159 OPEN CIRCUIT FWS SPARE 3 160 SHORTED CIRCUIT FWS SPARE 3 161 OPEN CIRCUIT FWS PROP 1 162 SHORTED CIRCUIT FWS PROP 1 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 42 A load of less than 70mA was detected when FWS Spare 3 circuit was energized Excessive load was detected when FWS opare 3 circuit was energized A load of less than 70mA 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 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 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
78. ON 68 HAULOTTE GROUP 6 REPLACEMENT PARTS DOLLY WHEEL WITH TAPERED SWIVEL amp YOKE ASSEMBLY OPTION 02337 Swivel and Yoke Assembly 1 6 0242 7 SeaL3 154LD x 270O D 2 058 tt 8 __ 023770 JackAxe 1 9 0090 0147 jPinCoter 1 x11 4 1 1 11 009600807 Washer M20 12 1 0096 0011 7 ScrewHexHeadCap M8x 25 8 18 0096 0040 Hex Nut with Nylon Insert M8 8 69 HAULOTTE GROUP 70 BOOM REST SWITCH ASSEMBLY DETAIL A BOOM SWITCH ASSEMBLY 6 REPLACEMENT PARTS HAULOTTE GROUP 6 REPLACEMENT PARTS BOOM REST SWITCH ASSEMBLY 03 00 0197 Replaces 00168 Effective 2007 Replaces 01 03 0079 Effective 2007 Replaces 01 03 0078 Effective 2007 5 015 FrontRestPad 6 4 6 ___ 0096 0017 Screw Head 10 30 7 12 8 019 __ 1 0090 1081 71 6 REPLACEMENT PARTS HAULOTTE GROUP OUTRIGGER LEG ASSEMBLY END VIEW OF CYLINDER 72 HAULOTTE GROUP 6 REPLACEMENT PARTS OUTRIGGER LEG ASSEMBLY 1 ____ 00141 Outrigger Cylinder Guard 1 22 2 GuardSlide 14 3 0018 Outrigger Cylinder 1 02 04 0118 Valve Replaces B02 04 0102 Effective 2007 3B 01 08 0022 Coil 1 Replaces 02 15 0493 Effective 2007 NOTE If the Coil is of Metal casing replace with 01 08 0022 Coil If the Coil is of Plastic casing replace with both 01 08 0022 Coil and 02 04 0118 Valve
79. PARTS AND SERVICE MANUAL Haulotte gt gt GROUP a Us RAILER MOUNTED cou T B33 01 0090 04 AERIAL WORK PLATFORM This equipment is designed and manufactured in compliance with the duties responsibilities and standards set forth for manufacturers in the ANSI CSA AS and or CE standards in effect at the time of manufacture This equipment meets or exceeds applicable ANSI CSA AS and CE codes and standards when operated in accordance with manufacturer s recommendations It is the responsibility of the user to follow all regional 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 those directives set forth by government and local authorities 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 malfunctioning
80. Plate T 10 044 71 Cord Wrap Bracket 1 11 0096 001 Screw Hex Head Cap M6x16 4 12 0096 0009 HexNutwith Nylon Insert M6 4 3 ta 0096017 Screw HexHeadCap M10x30 _____ 14 0096 000 HexNutwithNyloninsert M10 2 Pin 0 5 x 8 875 ha 16 00900147 Cotter Pin 8x14 2 17 0028 1 OClevsPinwthTensionLock 18 044 Mid RailTube 1 19 A0043 M dRalEnd 4 20 0096 000 Screw Head 6 40 2 21 0096 0115 Screw Head 25 22 0096 0039 fHexNuwihNyonInset M 1 4 23 A02600 Tool Box Assembly 1 A 02609 CupHolder 1 222 060 RearBrace 280 0096 0066 10 60 2 23E 0096041 Nylon 29 0096 0010 Screw Head 8 20 12 2938 0096 0000 Hex Nut with Nylon Insert M8 NotShown 2 a a maa 117 HAULOTTE GROUP 118 6 7 8 6 REPLACEMENT PARTS PLATFORM UPPER CONTROL BOX BATTERY CONDITION INDICATOR HOLD DOWN SPEED BUTTON WHILE SELECTING A BOOM CONTROL FUNCTION O 5 P E D B u T T 5 HAULOTTE GROUP 6 REPLACEMENT PARTS PLATFORM UPPER CONTROL BOX 2 00465 Platform Upper ConrolBox 1 12004658 Platform Upper Control Box Only 1 Wiring Harness Alarm 6 A 0042 Spool Now
81. SI CSA AS and or CE 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 aerial 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 contact an authorized Haulotte Group representative or your regional Haulotte Group dealer 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 EQUIPMENT MAINTENANACE 3 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 R
82. Shown 0 3 8 0096 0089 HexNutwthNylninset M 393 9 14 00466 D Decal Platform Upper Control Box Overlay 01 10 0400 Standoff Circuit Board Not Shown 119 HAULOTTE GROUP 6 REPLACEMENT PARTS 120 HAULOTTE GROUP 7 SCHEMATICS 7 SCHEMATICS 36321 HTT 13 ELECTRICAL WIRE HARNESS 122 3632T HTT 13 ELECTRICAL WIRE HARNESS P1 123 3632T HTT 13 ELECTRICAL WIRE HARNESS P1 DRIVE SET 124 3632T HTT 13 ELECTRICAL WIRE HARNESS P2 125 36321 Hb TS EEECTRIGAE WIRE FARNESS Dee 126 3632T 13 ELECTRICAL WIRE 55 4 1 1 1 1 4 2 4 1 nnne nnn 127 A 00153 MARKER AND TAIL LIGHT CONTINUOUS ROTATION WIRE HARNESS 128 A 00198 MARKER AND TAIL LIGHT 700 ROTATION WIRE HARNESS 128 A 00782 ELECTRIC BRAKE TAIL LIGHT CONTINUOUS ROTATION WIRE HARNESS 128 A 00193 ELECTRIC BRAKE TAIL LIGHT 700 ROTATION WIRE HARNESS 129 A 00210 TAIL LIGHT REAR WIRE 55 129 PLATFORM WIRE HARNESS as ek 129 A 00716 PUMP AND CYLINDER WIRE 59
83. Stay upwind 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 7 for additional information on hazards and precautionary measures Environmental Precautions Stop spill release 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 contiguous 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 600 424 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 7 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
84. TROL 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 PRESSURE SENSOR IS DISCONNECTED OR BAD 32 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 Control 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 Pressure 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 pow
85. UP O A 00938 HYDRAULIC H 150 HAULOTTE GROUP 7 SCHEMATICS A 00938 HYDRAULIC HOSE LAYOUT FOR DRIVE amp SET OPTION 6 x 69 Hydraulic Hose 6 02 01 036 4 6x69 HydauicHose Z 8 B02 01 0358 f6x26 HydauicHose 9B 02 01 417 4x73 HydraulicHose A B02020259 6MORFS 6MORBSTRAIGHT 8 B B020202686 amp 6MORFS f10MORB90 14 D 1802 02 0287 4MORFS f4MORBSTRAIGHT 02 02 0289 4 MORFS 4 MORFS 4 MORFS TEE 02 02 0301 M14 6 MORFS 90 02 02 0302 M18 8 MORFS 90 151 7 SCHEMATICS A 00939 OUTRIGGER COIL TO SWITCHES FOR DRIVE amp SET OPTION HAULOTTE GROUP 2 B01 09 0146 Female Terminal t B gt B01 09 014a Plug Black 35 Pin ya Female Spade B01 09 0092 2 Pin FM Housing in 27A 01 09 0091 FM Terminal AmpFMConn 0000 To 01 09 0093 Green Seal 7705201 g 8gaBL c E II Ed Sn 2 01 09 0109 2 Pin Male Housing Solus 180 gt 01 09 0110 Male Terminal wires together Pass Front RF 110 B01 09 0093 Green Seal A 00939 ano seal ALT 801 09 0128 6 Pin Female Housing real SO P ON B01 09 0091 Female Terminal Drivers Rear LR D B01 09 0093 Green Seal B01 09 0114 3 Pin Female Housing 1566
86. Upper Explosive Limit WHMIS Worker Hazardous Materials Information System Canada 178 HAULOTTE GROUP 9 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET DEXRON III MERCON AUTOMATIC TRANSMISSION FLUID HYDRAULIC OIL CONTINUED 814636 Powerflow AW 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 Material 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 179 HAULOTTE GROUP 9 MATERIAL SAFETY 180 HAULOTTE GROUP
87. a waste 15 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 7 and 8 for information on handling storage and personal protection and Section 9 for physical chemical properties 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 ap
88. al 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 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 alterati
89. al 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 obstructions 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 e
90. ale Housing BI Blue 01 09 0110 Br Brown Male Terminal 2 R EN B01 09 0093 2 G Green Green Seal ursi R Red Bus VR ic uc LS 48 Splices 01 09 0093 M a Gas Green Cable Seal Green 42 Braided Loom amp Heat Seal 01 09 0091 gt gt Female Terminal 7 Pin RV lt gt lt Style Plug T B01 09 0124 4 Pos Female Housing 9 Wires Need to be molded together see Label 228 Part Number 240 ETUR A 00210 TAIL LIGHT REAR WIRE HARNESS 12 Drop Label LP Light kw am 01 09 0124 4 Pin Female Housing Dp w CR Er BI Tail Lu R 20 Drop 52 Label Pass Tail Wires either Braided Loom or SJO No Split tube SO 6 72 00714 PLATFORM WIRE HARNESS 01 09 0142 B01 09 0089 Pins Part of Kit Female 41 6 Terminal 01 09 0088 B01 09 0086 Pin A Orange 18 6 Cable Orange Strain Relief Plug For Cable Track i E Pin Pin 9 Pin D Pin 8 E Pin E Pin 4 Pin F Y Pin 6 Number Jacket of cable must i Rev be in strain relief Sys Label 3 Jacket of cable must be in strain relief Fill Strain Relief with Black RTV and wipe off excess 129 7 SCHEMATICS A 00716 PUMP AND CYLINDER WIRE HARNESS HAULOTTE GROUP 01 09 0109 2 Pin Male Housing 01 09 0092 2 Pin FM Housing 01 09 0092 2 Pin FM Housing 01 09 0110 Male Term 0
91. als NEVER operate this aerial work platform when exposed to high winds thunderstorms ice or any weather conditions that would compromise operator safety 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 recommended wind speeds that may affect stability and aerial work platform operation HAULOTTE GROUP 1 SAFETY DURING OPERATION CONTINUED NEVER allow ropes electric cords hoses or other equipment to become entangled with 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 gravity is higher than the top guardrail of the platform NEVER modify the platform cage 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 structu
92. anufacture and govern the safe use of the Haulotte Group 11 ANSI REPRINT 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 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 and Installers General Responsibilities Each dealer or installer as applicable shall comply with the requirements of this section 7 8 1 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 Vehicle Weight Distribution The installer shall be a responsible for the weight distribution of the completed mobile unit in accordance with the requirements of the aerial device and the applicable regulations Allowance shall be made for the weight of readily removable tools 8 and material specified by the user 8 1 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 and 6 of this standard relating to proper installation and 8 2 shall follow the instructions of the manufacturer In the 8 2 1
93. are normal in bonded linings and should not be cause for concern When replacement is necessary it is important to replace both shoes on each brake and both brakes of the same axle This will help retain the balance of your brakes Acceptable Hairline Cracks POTENTIAL ASBESTOS DUST HAZARD Some older brake linings may contain asbestos dust which has been linked to serious or fatal illnesses Certain precautions need to be taken when servicing brakes 1 Avoid creating or breathing dust 2 Avoid machining filing or grinding the brake linings 3 Do not use compressed air or dry brushing for After replacement of brake shoes and linings the brakes must be re burnished to seat in the new components This should be done by applying the brakes 20 to 30 times from an initial speed of 40 m p h slowing the vehicle to 20 m p h Allow ample time for brakes to cool between applications This procedure allows the brake shoes to seat in to the drum surface HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS MAINTENANCE CONTINUED Hubs Drums Bearings Dexter Axle offers several types of bearing arrangements and lubrications methods e Dexter s standard wheel bearing configuration consists of opposed tapered roller bearing cones and cups fitted inside of a precision machined cast hub This method of using tapered roller bearings requires that a minimal amount of axial end play be provided at assembly This end play is
94. arranty 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 the warranty claims procedure 1 Contact Haulotte Group BilJax Service at 1 888 440 9240 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 Identify 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 complet
95. atform 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 50 45m 1 5m 1 5m 45m 5m 10 5m LIEN LLL Figure 2 1 Range of Motion HAULOTTE GROUP 2 SPECIFICATIONS SPECIFICATIONS SerialNumber _____ Maximum Working Height 43 ft 6 in 13 4 m Maximum Platform Height 37 ft 6 in 11 4 m Maximum Horizontal Outreach From Centerline 32 ft 9 8 m From Outrigger Footpad Edge 27 ft 8 2 m Rated Platform Capacity Without Platform Rotation 500 Ib 227 kg With Platform Rotation 440 Ib 200 kg Maximum Occupants Total Weight Without Options 4 400 Ib 1 996 kg With All Options 5 000 Ib 2 268 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 21 ft 11 in 6 7 m Width 5 ft 5
96. ce 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 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 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 11 4 2 12 12 1 12 2 11 ANSI REPRINT 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
97. ces A 00259 Effective 2007 9 0096 0113 Screw Hex Head Cap M4 x 16 10 0096 0073 Hex Nut with Nylon Insert M4 no PO 87 6 REPLACEMENT PARTS CONTROL COMPARTMENT ASSEMBLY CONTINUED HAULOTTE GROUP 88 HAULOTTE GROUP 6 REPLACEMENT PARTS CONTROL COMPARTMENT ASSEMBLY CONTINUED ITEM PART NUMBER DESCRIPTION QTY B01 06 0053 Relay 24V DC 20 Amp with Mounting Bracket 6 00960113 4 Screw HexHeadCap M4x16 2 8 ___ 00200 X TumtabeWeldmet 9 1400267 GFiMountPlae 1 Replaces A 00255 Effective 2008 89 6 REPLACEMENT PARTS HAULOTTE GROUP CONTROL COMPARTMENT ASSEMBLY FOR DRIVE amp SET OPTION HAULOTTE GROUP 6 REPLACEMENT PARTS CONTROL COMPARTMENT ASSEMBLY FOR DRIVE amp SET OPTION ITEM NO Replaces A 00255 Effective 2008 5 5B 7 D 10 11 12 13 14 19 0096 0061 Washer Flat M4 0096 0041 Hex Nut with Nylon Insert M10 91 HAULOTTE GROUP 92 GROUND LOWER CONTROL BOX BATTERY CONDITION INDICATOR 12 Power OUTRIGGER CONTROLS amp HOLD DOWN EXTEND OR RETRACT BUTTON WHILE SELECTING INDIVIDUAL OUTRIGGER BUTTONS OR THE AUTO LEVEL BUTTON ALL OUTRIGGER LIGHTS MUST BE ON BEFORE PLATFORM CAN BE RAISED RETRACT A FULLY LOWER PLATFORM INTO THE STOWED POSITION FOR OUTRIGGER OPERATION WHEN FLASHING DISPLAY PANEL 6
98. cian O O O O O e Remove brush cover band e Blow warm air into motor using a heat gun e Spray electrical contact cleaner solution into motor armature area e Replace brush cover band 29 HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE ADDITIONAL SERVICE INFORMATION 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 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 next section of this 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 th
99. cled 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 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 Ch
100. 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 Service Department 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 gt gt GROUP 125 Taylor Parkway Archbold Ohio 43502 Phone 1 888 440 9240 Fax 419 445 0367 www haulotte usa com HAULOTTE GROUP TABLE OF CONTENTS SAFE Pe HR 5 LEGEND SAFETY ABVISORIES A 5 BEFORE OPERATION u u u dis 6 Wii CIO II Te 7 uu u aeng 9 MANUAL FORGE uuu ere ene e ana eee eee 9 WIND LOADING terrae rere nse ida 9 EXPLOSION HAZARD in 10 MAINTENANCE tet 11 2 SPEGIFISATION5 Ss aa a E aa 13 OL NIOTIOS T 13 SPEGIRIERTIOND a a ae eee ee esr blas 14 WARRANTY NEW PRODUCT HAULOTTE NORTH AMERICA 16 WARRANTY CLAIMS PROCEDURE EL 17 DAMAGED EQUIPMENT S tac QNS ua Emu VR Be
101. cordance 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 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 c 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 5 Check for missing or illegible operational and instructional markings 6 Check hydraulic and pneumatic systems for observable deterioration an
102. crew Hex Head Cap M10x60 4 25 00960041 HexNutwihNyoninset MiQ 4 26 A005 _ 27 00960066 Screw Head Cap M10x60 4 28 00960041 HexNutwihNyoninset MiQ 4 29 A0090 F iconWhel 2 30 00960022 Screw HexHeadCap M12x75 31 00960042 HexNuwihNyoniset MiB 8 l I IN N I N NN N N 2 81 6 REPLACEMENT PARTS HAULOTTE GROUP SLEW RING ASSEMBLY TORQUE TO 200 FT LBS TORQUE TO 200 FT LBS SCREW 2 NUT 5 LLI E O 2 82 HAULOTTE GROUP 6 REPLACEMENT PARTS SLEW RING ASSEMBLY Ref NOTE Torque to 200 ft lb NOTE Torque to 200 ft Ib 6 00100 BaseWeldment Ref A 00351 8 A0052 9 0036 Ring Stop O j 1 6 REPLACEMENT PARTS HAULOTTE GROUP BATTERY COMPARTMENT ASSEMBLY DETAIL A HAULOTTE GROUP 6 REPLACEMENT PARTS BATTERY COMPARTMENT ASSEMBLY 6 0096 0041 Hex Nut with Nylon Inset MO 8 Cam 2 9 00960000 Screw Hex Head Cap 6 2 37 00960004 Screw Hex Head Cap MBx25 38 00960059 Hex Nut with Nylon Inse Me 85 6 REPLACEMENT PARTS CONTROL COMPARTMENT ASSEMBLY HAULOTTE GROUP 86 HAULOTTE GROUP 6 REPLACEMENT PARTS CONTROL COMPARTMENT ASSEMBLY Replaces A 00277L Effective 2007 6 0096 0002 Screw Hex Head Cap M6x20 j 2 A 00294 Level Sensor 1 Repla
103. d 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 through the complete range of motion would create a hazard 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 A o o 4 5 6 7 8 9 P ER 10 10 Precautions Before and during each use the operator shall 1 Check for overhead obstructions and electrical conductors
104. d hubs or brake drums Note which spindle and brake that the drum was removed from so that it can be reinstalled in the same location 2 Inspect suspension for wear Check tightness of hanger bolt shackle bolt and U bolt nuts per recommended torque values Check brake linings brake drums and armature faces for excessive wear or scoring Check brake magnets with an ohmmeter The magnets should check 3 2 ohms If shorted or worn excessively they must be replaced Lubricate all brake moving parts using a high temperature brake lubricant LUBRIPLATE or Equivalent Do not get grease or oil on brake linings or magnet face Remove any rust from braking surface and armature surface of drums with fine emery paper or crocus cloth Protect bearings from contamination while so doing Inspect oil or grease seals for wear or nicks Replace if necessary 9 Lubricate hub bearings Refer to procedure in manual Reinstall hubs and adjust bearings per instructions in manual Mount and tighten wheels per instructions in manual 211 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS STORAGE CONTINUED 212 Trip Preparation Checklist trailer axle assembly that can add to its life and in the case of Ba There are a number of simple rules to follow in caring for your UL CD some of these rules you may be protecting your own life as well Using the following checklist before starting a trip wit
105. d inspect spindle shaft Apply a light coating of anti seize lubricant to the spindle shaft prior to assembling drum 7 Install drum assembly onto spindle Do Nor Force 8 Install steel washer onto spindle end 9 Start self locking nut onto spindle thread by hand Complete installation using a 112 or 1746 socket and torque wrench 203 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS MAINTENANCE CONTINUED Nut should be torqued to 145 155 Ft Lbs this torque will un set the internal bearing adjustment no other adjustments are to be made 224 10 Install torque instruction washer onto end of spindle C 11 Install external snap ring onto end of spindle to retain washer 12 Inspect assembly for excessive end play noise and rotation restriction prior to mounting final wheel end hardware CD e 204 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS MAINTENANCE CONTINUED Tires Before mounting tires onto the wheels make certain that the rim size and contour is approved for the tire as shown in the Tire and Rim Association Yearbook or the tire manufacturers catalog Also make sure the tire will carry the rated load If the load is not equal on all tires due to trailer weight distribution use the tire rated for the heaviest wheel position Note The capacity rating molded into the sidewall of the tire is not always the proper rating for the tire if used in a tra
106. damage and corrosion e Follow all manufacturers recommendations when making repairs to critical components e Personnel making repairs to welds should be certified in accordance with applicable Government regulations Inspect outriggers for wear or damage Repair or replace as necessary Inspect and adjust axle and parking brakes e Refer to the Axle and Related Components section in the back of this manual for a partial reprint of the Dexter Operation Manual Load test telescoping boom lift operations with 500 Ib 227 kg load 27 HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE ANNUAL SERVICE CHECKS CONTINUED Check slew bearing for wear or damage Place a 175 lb 65 kg load the platform and raise the boom e Measure the distance between the slew ring gear and the horizontal plate above using a 2 inch 50 mm caliper or bore micrometer Refer to Figure 3 5 i e MEASURE SLEW HERE RING Ben m v JK oot Jk rr E maim j TOW END OF TRAILER Figure 3 5 Slew Ring Position Measurement e Record the measurement e Rotate the platform 180 and re record the measurement Refer to Figure 3 6 lf the difference in measurements is greater than 0 25 in 6 35 mm the slew ring bearing should be replaced Contact manufacturer for replacement instructions and assistance TAKE MEASUREM
107. ds are not in contact with 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 Refer to Figure 3 2 Repeat this procedure for each outrigger Repair or replace as necessary POSITION SWITCH Figure 3 2 Outrigger Position Switches 23 HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE DAILY SERVICE CHECKS CONTINUED Inspect hydraulic System and fluid levels 24 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 telescoping boom down all outriggers raised and the trailer wheels on a level surface Hydraulic oil level should be visible in but not above the sight gauge If the hydraulic oil level is not visible to at least half way up the sight gauge add clean Hydraulic Fluid as necessary while all telescoping boom and outriggers are fully retracted and stowed Pour slowly to avoid creating air pockets in the reservoir Do Not fill above sight gauge Overfilling the hydraulic reservoir may cause damage to hydraulic lines and may result in aerial work platform mal
108. e OO CA00114 e e Ni Loop Back Plug 4 P4 amp P5 34 i Replacement 00082 00721 Standard 00939 Drive amp Set t 00948 Drive amp Set 36 24 23 76 00000000 4 00000000009 0000000 i P1 00000000 12 1 8 1 12 q 1200946 TU 24 3 4 26 15 16 23 8 2 16 20 9 aa 8 23 1 10 Go 1 2 27 22 dei d X Y R B Br Strobe Level Sensor gy A R 30 86 85 87 Main Motor Controller RAN RAN 5 A B 5 A 12 12 1 1 8 E 8 H 5 Fuse A2 A1 Contactor 200 A Fuse A2 200 A Fuse A1 Contactor V V MUR LF NO G LF Coil LR Coil my RF NO Boom A Down NO 85 f LR NO me Die Die 30 Main Pump Aux Pump Down Motor Motor Recpticle Relay NC Down NC RR NO A Outrigger 85 87 Switches 30 87 86 B Es P 28 C 10 Rot CCW 53525965 A 00272 Battery Cable Kit A 00943 Battery Cable Kit Drive amp Set OO C8 Prop Coil C 6A Chk Valve C12 Boom EXT CI Boom RET Drive amp Set Manifold 9 C25N
109. e Dexter replacements Please consult the following troubleshooting charts to determine the causes and solutions for common problems found in trailer braking systems Best braking performance is achieved with a controller setting that is just short of wheel lock up or slide Overly aggressive braking which results in wheel lock up and sliding can cause a dangerous loss of control and result in personal injury or death 216 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS TROUBLE SHOOTING CONTINUED Troubleshooting SYMPTOM CAUSES REMEDIES Open Circuits Severe Faulty Controller Find amp Correct Adjust Brakes Test amp Correct Short Circuits Find amp Correct Grease or Oil on Magnets or Linings Clean or Replace Clean amp Correct Corroded Connections Cause of Corrosion Worn Linings or Magnets Replace Scored or Grooved Brake Drums Weak Brakes Improper Synchronization Machine or Replace Correct Underadjustment Adjust Brakes Glazed Linings Reburnish or Replace Overloaded Trailer Correct Underadjustment Improper Synchronization Test amp Correct 72 Faulty Controller Locking Brakes Loose Bent or Broken Brake Components Replace Components Out of Round Brake Drums Machine or Replace Adjust System Resistor Insufficient Wheel Load and Synchronize Faulty Controller Test amp Correct Intermittent Brakes Broken Wires Loose Conn
110. e 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 Testing Aerial Work Platform Stability The Summit Series aerial work platform has been tested for stability using a load equal to 150 of the rated capacity of the machine and placed at the center of the platform with the telescoping boom fully extended Stability tests should be conducted only by trained personnel and only when the machine is properly anchored to safeguard against tipping Failure to anchor the machine could result in death or serious injury and damage to the machine 30 HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE TROUBLESHOOTING Refer to the following Table for basic Troubleshooting Operations Contact the Haulotte Group Service Department with any questions or before attempting any advanced troubleshooting operations TABLE 3 2 TROUBLE SHOOTING CAUSE SOLUTION a EMERGENCY STOP engaged a Di
111. e 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 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 35 HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE x O TABLE 3 3 ERROR CODE DEFINITIONS 059 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
112. e 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 10 6 10 7 10 8 10 8 1 11 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 ac
113. e the following checked at the specified intervals Wheel Nut Torque at 10 25 and 50 miles e Brake Adjustment at 200 and 3 000 miles e Tire pressure to manufacturer s requirements Brake synchronization set brake controller per controller manufacturer s directions 181 HAULOTTE GROUP SET UP AND ADJUSTMENT CONTINUED 182 General Maintenance Electric Brakes Brake Adjustment Most Dexter 12 electric brakes have a self adjusting feature If manual adjusting is required use the following procedure Brakes should be adjusted 1 after the first 200 miles of operation when the brake shoes and drums have seated 2 at 3 000 mile intervals 3 or as use and performance requires The brakes should be adjusted in the following manner 1 Jack up trailer and secure on adequate capacity jack stands Follow trailer manufacturer s recommendations for lifting and supporting the unit Make sure the wheel and drum rotates freely Do not lift or support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury 2 Remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate 3 With a screwdriver or standard adjusting tool rotate the star wheel of the adjuster assembly to expand the bra
114. ecked only at power up Articulating Boom Models HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE x 222 TABLE 3 3 ERROR CODE DEFINITIONS 044 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 SHORTED CIRCUIT LR OUTRIGGER Excessive load was detected when Platform CCW 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 was 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 Out
115. ections Repair or Replace Find amp Repair Braking Systems Electric Faulty Ground Find amp Repair 217 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS TROUBLE SHOOTING CONTINUED Troubleshooting SYMPTOM CAUSES REMEDIES d Incorrect Adjustment Linings Magnets Brakes Pull to One Side Clean or Replace Find amp Repair Bad Connections Find amp Repair Underadjustment Adjust Improper Synchronization Harsh Brakes Improper Controller Change Faulty Controller Underadjustment Adjust Lack of Lubrication Lubricate Noisy Brake Broken a Brake Components Replace Component Incorrect Brake Grease or Oil on Linings or Magnet Out of Round or Cracked Brake Drums Faulty Controller Overadjustment Readjust Correct 9112913 Bune1g Test amp Correct Clean or Replace Machine or Replace Surging Brakes Test amp Correct Out of Round Machine or Replace Brake Drums Incorrect Brake Replace Components po _ Loose Bent or Broken Replace Dragging Brakes Brake Components Faulty Breakaway Repair or Replace Switch Loose Wheel Bearing Adjustment Bent Spindle Replace Axle 218 HAULOTTE GROUP 11 ANSI REPRINT The following sections are reprinted from the ANSI code in effect at the time of m
116. egral 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 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 11 3 1 11 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 direc
117. eme cold Full Power to Battery shorted of low AC line voltage Transformer No or charge fault Current Output Charger Off Charger resting between pulses AGM batteries only Charge Mode Complete Batteries charged Always unplug the battery charger power cord before moving the aerial work platform Failure to disconnect power cord could cause damage to the equipment 21 HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE DAILY SERVICE CHECKS The following Maintenance Procedures should be performed daily or before each operation Verify that all decals are 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 ground and platform control stations operate properly e Lower outriggers to level the aerial work platform e Raise and extend the telescoping boom e Press EMERGENCY STOP button This will deactivate all functions e Verify that the telescoping boom remains elevated and does not drift e Pull out STOP button and lower the telescoping boom e Operate drive functions from the platform control station to confirm proper operation for applicable machines lf either control station is unresponsive refer to the Trouble Shooting procedures fthe Display Panel displays an error code refer to the Control Panel Error Code definitions Table 3 3 is located later in this section lf the Motor Controller s Green
118. en off with the internal failsafe circuit enabled Single flash 23 Contactor Drive On Contactor output pulsed while the Replace motor controller internal failsafe circuit was disabled then off INDICATOR LIGHT Figure 3 7 Motor Controller 45 HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE 46 HAULOTTE GROUP 4 CYLINDER REPLACEMENT 4 CYLINDER REPLACEMENT If repair or replacement of an aerial work platform or outrigger hydraulic cylinder or its component parts becomes necessary observe the following procedures in accordance with the safety precautions established in Section 1 of this manual Removing the hydraulic cylinder from the aerial work platform may require the use of specialized tools and lifting equipment NEVER attempt to operate overhead hoists or cranes or related equipment without proper training authorization and supervision Perform all maintenance procedures only in an area that is well lit and well ventilated Haulotte Group is not responsible for personal injury or property damage resulting from the improper use of equipment or failure to follow all procedures and related safety precautions Direct all questions regarding cylinder removal and replacement to your regional Haulotte Group representative or to the Haulotte Group Service Department at 1 888 440 9240 LIFT CYLINDER REPLACEMENT Use the following procedure to remove and replace faulty or damaged hydraulic cylinders on the aerial work platform
119. epair 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 your regional Haulotte Group representative 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 applicable Government regulations 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 an aerial work platform to service 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 HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE BATTERY RECHARGE Recharge aerial work p
120. er which is the output to the brakes The BLUE wire must be disconnected and the ammeter put in series into the line System amperage draw should be as noted in the following table Make sure your ammeter has sufficient capacity and note polarity to prevent damaging your ammeter Braking Systems Electric 207 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS MAINTENANCE CONTINUED Magnet Amperes Chart Brake Amps Two Four Six Magnet Size Magnet Brakes Brakes Brakes Ohms 7 x 1 120 180 32 10 2 60 120 180 32 120 180 80 12 1214 x 2 12 3 lf a resistor is used in the brake system it must be set at zero or bypassed completely to obtain the maximum amperage reading Individual amperage draw gt can be measured by inserting the ammeter in the line at the magnet you want to check Disconnect one of the magnet lead wire connectors and attach the ammeter between the two wires Make sure that the wires are properly reconnected and sealed after testing is completed 91119913 AMMETER The most common electrical problem is low or no voltage and amperage at the brakes Common causes of this condition are Poor electrical connections Open circuits Insufficient wire size Broken wires Blown fuses fusing of brakes is not recommended Improperly functioning control
121. er 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 Disconnect Pressure 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 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 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 bli
122. event the original manufacturer no longer exists an En 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 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 failu
123. face where the brake shoes make contact during stopping and the armature surface where the magnet contacts only in electric brakes 10 AXLE AND RELATED COMPONENTS HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS MAINTENANCE CONTINUED The drum surface should be inspected for excessive wear or T heavy scoring If worn more than 020 oversized or the drum E has worn out of round by more than 015 then the drum surface 74 should be re machined If scoring or other wear is greater than 090 on the diameter the drum must be replaced When turning Q the drum surface the maximum rebore diameter is as follows e 7 Brake Drum 7 090 diameter o 10 Brake Drum 10 090 diameter e 12 Brake Drum 12 090 diameter 12 Brake Drum 12 340 diameter e 6K and 8K Rotor 1 03 minimum thickness 3 5K Rotor 85 minimum thickness e The machined inner surface of the brake drum that contacts the brake magnet is called the armature surface If the armature surface is scored or worn unevenly it should be refaced to a 120 micro inch finish by removing not more than 030 of material To insure proper contact between the armature face and the magnet face the magnets should be replaced whenever the armature surface is refaced and the armature surface should be refaced whenever the magnets are replaced Note It is important to protect the wheel bearing bores from metallic chips and contamination which result from
124. function Refer to Figure 5 2 The hydraulic reservoir is originally filled with AW32 Hydraulic Oil A minimum 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 Fill Port Sight Gauge Figure 3 3 Hydraulic Reservoir HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE 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 lf battery charge is low add enough distilled water to bring the electrolyte level to the top of the plates e batteries are fully charged raise electrolyte level to full mark in each cell Inspect all electrical wiring Check for cuts loose terminals broken wires chaffing and corrosion e Repair all damage remove corrosion and seal exposed connections 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 the power unit hoses and cylinders for damage leaks loss of pressure or speed and unusual noise or vib
125. g from the receptacle on the bottom right of the Ground Control Box and insert it into the Platform Control Box See Figures 8 1 amp 8 2 Remove Platform Control Insert Loopback Plug From Ground Controls To Boom Cable DO NOT REMOVE Figure 8 1 Load Sense Module Loopback Plug Remove and replace with Platform Controls Plug Figure 8 2 Ground Control Panel Receptacle e Insert the removed electric loopback plug into the open receptacle on the load sense module replacing the platform control cable 164 HAULOTTE GROUP 8 OPTIONAL EQUIPMENT MATERIAL LIFT HOOK CONTINUED Firmly secure the platform to prevent equipment damage Remove the clevis pin holding the platform to the boom lift See Figure 8 3 Remove the platform from the boom by lifting the cage up and away from the mounting bracket on the boom nose See Figure 8 3 MOUNTING BRACKET Figure 8 3 Platform Removal Attach the material lifting hook to the mounting bracket on the boom nose and re insert the clevis pin See Figure 8 4 Verify that the Key Switch is in the correct position for operation using the Platform Control Box For optimal control operate the material lifting hook remotely using the Platform control box Reverse this procedure to reattach the Work Platform Clevis Pin Retaining Pin Figure 8 4 Material Lifting Hook Installation 165 HAULOTTE GROUP 8 OPTIONAL EQUIPMENT MATERIAL LIFT HOOK CONTINUED Figure 8 5 Mate
126. h E Z Lube are not designed for immersion and bearings should be repacked after each immersion If hubs are removed from an axle with the E Z Lube feature it is imperative that the seals be replaced BEFORE bearing lubrication Otherwise the chance of grease getting on brake linings is greatly increased Inner Bearing Rubber Plug mmt S DN Grease Flow TER SR Grease Fitting 4 E etal NS Double Lip Seal SS HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS MAINTENANCE CONTINUED Using an arbor press and When replacing a Hubs Drums Bearings Bearing Replacement and Drum Installation 1 Once the drum and bearing assembly is removed from the axle remove internal snap ring from the bearing bore that retains bearing mandrel press the bearing out of the drum Bearing will exit on the wheel side of the drum Nev R Lube bearing pack the bore in the hub should be cleaned and inspected for visual damage replace as necessary Install the new bearing using an arbor press fitted with a hollow ey stepped punch face to press only on the outer housing of the bearing Bearing Failure to follow procedure will damage the bearing and or seals during installation Press bearing until it seats against the backup shoulder machined into the hub Install internal snap ring into hub Clean an
127. h Nylon Insert M10 Relay 24 VDC 20 Amp screw Hex Head Cap M5 x 16 Hex Nut with Nylon Insert M5 Mount Solenoid Screw Hex Head Cap M10 x 30 Hex Nut with Nylon Insert M10 Washer Nylon M10 Solenoid Bracket Solenoid Assembly 24Volt Solenoid 24Volt Continuous Duty Wire Casing Not Shown Connector Assembly 2 Female Not Shown Terminal Female 16 18 Gauge Not Shown Seal Wire 16 18 Gauge Green Not Shown Spring Tension Pin Cotter 3 32 x 3 4 Screw Hex Head Cap M4 x 20 Hex Nut with Nylon Insert M4 15 8 OPTIONAL EQUIPMENT HAULOTTE GROUP IC ENGINE GENERATOR MOTOR MOUNT ASSEMBLY 158 HAULOTTE GROUP 8 OPTIONAL EQUIPMENT IC ENGINE GENERATOR MOTOR MOUNT ASSEMBLY 5 20 00 06 X MomtRing j 4 6 B07 10 1263 ___ Tube 375 4_ 7 ___ 820 00 0007 Mount Bushing 4 8 B07065198 1 ae I 10 0096 0077 _ FletWashenM Lage 8 13 jCheeAm PatofEngn 14 __ 820 00 0018 Wire Chokelinkage 051gauge 15 899009000 Spring Tension 16 B2000 0017 Fuel Filter Inline t 4inobhEnds 1 19 GovmorAm PatofEngne 21 __ 801 09 0130 ___ Wire splice 18 14gauge NotShown 159 HAULOTTE GROUP 8 OPTIONAL EQUIPMENT MANUAL PLATFORM ROTATE ASSEMBLY 160 HAULOTTE GROUP 8 OPTIONAL EQUIPMENT MANUAL PLATFORM ROTATE ASSEMBLY A 00300 2 Manual Platform Rotator Assembly
128. h it is not intended HAULOTTE GROUP 1 SAFETY DURING OPERATION Ensure the following general safety precautions are followed while operating the aerial work platform ALWAYS position away from power lines to ensure that no part of the aerial work platform can accidentally reach into an unsafe area This includes full extension of the telescoping boom through 700 rotation 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 ALWAYS 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 capacit
129. h your trailer is highly recommended Some of these items should be checked 2 3 weeks prior to a planned trip to allow sufficient time to perform maintenance 1 Check your maintenance schedule and be sure you are up to date 2 Check hitch Is it showing wear Is it properly lubricated 3 Fasten safety chains and breakaway switch actuating chain securely Make certain the breakaway battery is fully charged Inspect towing hookup for secure attachment Load your trailer so that approximately 10 of the trailers total weight is on the hitch For light trailers this should be increased to 15 Do Not Overload Stay within your gross vehicle rated capacity consult your trailers identification plate Inflate tires according to manufacturer s specifications inspect tires for cuts excessive wear etc Check wheel mounting nuts bolts with a torque wrench Torque in proper sequence to the levels specified in this manual Make certain the brakes are synchronized and functioning properly Check tightness of hanger bolt shackle bolt and U bolt nuts per torque values specified in manual Check operation of all lights Check that your trailer is towing in a level position and adjust hitch height if required HAULOTTE GROUP TROUBLE SHOOTING Braking Systems Hydraulic Introduction to Troubleshooting Proper brake function is critical to the safe operation of any vehicle A properly installed vac
130. he appropriate emergency lowering valve solenoid Tag and number all hydraulic hoses that attach to the cylinder valve block Use a marker to label the valve block ports with the appropriate hose numbers Place absorbent cloths below the cylinder ports and detach hydraulic hoses from the cylinder Elevate hoses to prevent leakage Plug or cap exposed hose fittings and cylinder ports At the base of the cylinder unbolt and remove retainer plate from each side of the pivot pin Remove the pivot pin using a hammer and a brass or hardwood drift Lift and remove the cylinder using an overhead hoist and lifting straps Replace or reinstall the cylinder by following the above instructions in the reverse order of removal Actuate the hydraulic system and check for leakage Tighten hydraulic fittings as needed Bleed trapped air from the hydraulic system by raising and lowering the telescoping boom with the reservoir fill port cap on but not tightened Allow several cycles of operation for trapped air to escape Repeat as necessary PIN P CYLINDER PISTON CY END Ve d fe c 94 j 0 Figure 4 2 Lift Cylinder Replacement HAULOTTE GROUP 4 CYLINDER REPLACEMENT OUTRIGGER CYLINDER REPLACEMENT Use the following procedure to remove and replace faulty or damaged hydraulic cylinders on the outriggers Lower the outrigger until the footpad is touching the ground Do not transfer the weight
131. hen 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 Boom has exceeded 95 of maximum outreach 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 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 Put 500lbs in boom level boom and extend until alarm sounds and error is displayed This is a latched error Power must be cycled to clear error
132. icate Semi Annually Decal Danger Main Instruction Hazard Base Decal Danger Battery Charger Instruction Decal Danger Battery Charger Safety HAULOTTE GROUP 5 DECAL REPLACEMENT DECAL REPLACEMENT IDENTIFICATION PLATES amp OPTIONAL EQUIPMENT 54 HAULOTTE GROUP 5 DECAL REPLACEMENT DECAL REPLACEMENT IDENTIFICATION PLATES amp OPTIONAL EQUIPMENT IDENTIFICATION PLATES IDENTIFICATION PLATES Used on all standard equipment 41 42 41 00 0490 VIN Plate 42 06 00 0499 ANSI ID Plate a lt REPLACEMENT DECALS FOR OPTIONAL EQUIPMENT DECAL REPLACEMENT FOR OPTIONAL EQUIPMENT Decal Notice Material Lift Set up Material Lift Option Decal Notice Material Lift Max 500 Material Lift Option 1 Decal Notice Platform Rotate Manual Rotation Option Decal Warning Drive and Set Drive and Set Option Decal Notice Drive and Set Drive and Set Option Decal Warning Jockey Wheel Drive and Set Option Decal Caution Component Damage Gas Engine Option Decal Notice Unleaded Fuel Only Gas Engine Option Decal notice engine Specifics Gas Engine Option Decal Warning Eng Operate Hot Gas Engine Option 55 HAULOTTE GROUP 5 DECAL REPLACEMENT 56 HAULOTTE GROUP 6 REPLACEMENT PARTS 6 REPLACEMENT PARTS TONGUE ASSEMBLY 58 TONGUE ASSEMBLY FOR amp SET OPTION
133. iler application Use the following guidelines SI UN 1 LT and ST tires Use the capacity rating molded into the tire 2 Passenger Car Tires Use the capacity rating molded into the tire sidewall divided by 1 10 for trailer use Use tire mounting procedures as outlined by the Rubber Manufacturer s Association or the tire manufacturers Tire inflation pressure is the most important factor in tire life Inflation pressure should be as recommended by the manufacturer for the load Pressure should be checked cold before operation Do not bleed air from tires when they are hot Check inflation pressure weekly during use to insure the maximum tire life and tread wear The following tire wear diagnostic chart will help you pinpoint the causes and solutions of tire wear problems Tire wear should be checked frequently because once a wear pattern becomes firmly established in a tire it is difficult to stop even if the underlying cause is correcied 205 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS MAINTENANCE CONTINUED Tire Wear Diagnostic Chart Wear Pattern Cause Action Adjust pressure to Center Wear Over Inflation particular load per tire catalog Adjust pressure to H Edge Wear Under Inflation particular load per tire catalog Make sure load 4 Loss of camber doesn t exceed Side Wear or overloading axle rating Align at alignment
134. in 1 7 Outrigger Footprint To Center of Pad Length 12 ft 2 in 3 7 Width 11 ft 4 in 3 4 m Footpad Diameter 12 5 in 0 3 m Parking Brake Standard Mechanical Charger US 110 Volt 60 Hz 220 Volt 50 Hz HAULOTTE GROUP 2 SPECIFICATIONS SPECIFICATIONS CONTINUED Hydraulic Pressure 3 000 psi 207 bar 20 684 kPa Reservoir Capacity 4 8 Gallons 18 2 L Hydraulic System Capacity 7 Gallons 26 5 L Hydraulic Oil Standard AW32 Platform Rotation Option 90 Manual Maximum Decibel Level DC Mode Ground DC Mode Platform 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 8 kg cm 176 5 kPa Operating Temperature Range 20 to 110 Fahrenheit 29 to 43 Celsius 15 HAULOTTE 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 operation
135. ing 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 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 AN
136. istons Defective or Damaged Install New Shoe and Shoe and Lining Lining Complete Axle One Side Out of Adjustment Replace Rubber Parts Improper Fluid Fill with DOT4 Fluid Blocked Master Open with Compressed Cylinder Air or Replace Cylinder x Dragging ww Parking Brake Free Cable Cable Frozen and Lubricate ne Improper Lining Install New Shoes LI Thickness or Location and Linings Braking Systems Hydraulic 215 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS TROUBLE SHOOTING CONTINUED Introduction to Troubleshooting Proper brake function is critical to the safe operation of any vehicle If problems are encountered with your trailer braking system the following guide can be used to find the causes and remedies for some of the more common problems If you are unsure or unable to resolve the problem please contact your nearest repair facility for professional assistance Troubleshooting Most electric brake malfunctions that cannot be corrected by either brake adjustments or synchronization adjustments can generally be traced to electrical system failure Voltmeters and ammeters are essential tools for proper troubleshooting of electric brakes 31119913 HUME Mechanical causes are ordinarily obvious i e bent or broken parts worn out linings or magnets seized lever arms or shoes scored drums loose parts etc Replace defective parts with genuin
137. ized g suinig sqng shuuee HAULOTTE GROUP MAINTENANCE CONTINUED 194 Hubs Drums Bearings 1 Elevate and support the trailer unit per manufacturers instructions You must follow the maintenance procedures to prevent damage to important structural components Damage to certain structural components such as wheel bearings can cause the wheel end to come off of the axle Loss of a wheel end while the trailer is moving can cause you to lose control and lead to accident which can result in serious injury or death 2 Remove the wheel 3 Remove the grease cap by carefully prying progressively around the flange of the cap If the hub is an oil lube type then the cap can be removed by unscrewing it counterclockwise while holding the hub stationary 4 Remove the cotter pin from the spindle nut For E Z Lube axles produced after February of 2002 a new type of retainer is used Gently pry off retainer from the nut and set aside 5 Unscrew the spindle nut counterclockwise and remove the spindle washer 6 Remove the hub from the spindle being careful not to allow the outer bearing cone to fall out The inner bearing cone will be retained by the seal 7 For 7 200 Ib and 8 000 Ib axles a hub puller may be necessary to assist in drum removal Brake Drum Inspection There are two areas of the brake drum that are subject to wear and require periodic inspection These two areas are the drum sur
138. ke shoes Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn Note For drop spindle axles a modified adjusting tool may be necessary 4 Then rotate the star wheel in the opposite direction until the wheel turns freely with a slight lining drag 5 Replace the adjusting hole cover and lower the wheel to the ground 6 Repeat the above procedure on all brakes For best results the brakes should all be set at the same clearance 10 AXLE AND RELATED COMPONENTS 91119913 SUI9IS S Hulyelg HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS SET UP AND ADJUSTMENT CONTINUED General Maintenance Hydraulic Brakes Drum Brake Adjustment Manual Most Dexter 1274 hydraulic brakes have a self adjusting feature lf manual adjusting is required use the following procedure Brakes should be adjusted 1 after the first 200 miles of operation when the brake shoes and drums have seated 2 at 3 000 mile intervals 3 or as use and performance requires The brakes should be adjusted in the following manner 1 Jack up trailer and secure on adequate capacity jack stands Follow trailer manufacturer s recommendations for lifting and supporting the unit Make sure the wheel and drum rotates freely 9ijne1p H Do not lift or support the trailer any part of the axle or suspension system Never go under any trailer unless it is pro
139. latform 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 gases could result in death or serious injury Always charge aerial work platform batteries away from flammable materials To recharge the aerial work platform batteries e Move the aerial work platform to a well ventilated area with direct access to a 120 VAC 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 cargo plate in front of the turntable NOTE Using an underrated or long power cord will reduce the output of the battery charger and may extend charge time e Plug the extension cord into outlet Verify that the green CHARGING indicator LED is lit on the battery charger faceplate Refer to Figure 3 1 he CHARGING indicator LED remains lit continuously during the firs
140. le 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 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 11 ANSI REPRINT Training Retraini
141. lers or resistors Another common electrical problem is shorted or partially shorted circuits indicated by abnormally high system amperage Possible causes are 1 Shorted magnet coils 2 Defective controllers 3 Bare wires contacting a grounded object 208 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS MAINTENANCE CONTINUED Braking Systems Electric Finding the cause of a short circuit in the system is done by isolating one section at a time If the high amperage reading drops to zero by unplugging the trailer then the short is in the trailer If the amperage reading remains high with all the brake magnets disconnected the short is in the trailer wiring All electrical troubleshooting procedures should start at the controller Most complaints regarding brake harshness or malfunction are traceable to improperly adjusted or non functioning controllers See your controller manufacturer s data for proper adjustment and testing procedures For best results all the connection points in the brake wiring should be sealed to prevent corrosion Loose or corroded connectors will Cause an increase in resistance which reduces the voltage available for the brake magnets 209 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS STORAGE storage Storage Preparation lf your trailer is to be stored for an extended period of time or over the winter it is important that the trailer be prepared properly Y pua e
142. mately 50 Ft Lbs 12 wrench or pliers with full hand force 2 Then loosen the spindle nut to remove the torque Do not rotate the hub 3 Finger tighten the nut until just snug align the retainer to the machined flat on the spindle and press the retainer onto the nut The retainer should snap into place Once in place the retainer nut assembly should be free to move slightly 4 If the nut is too tight remove the retainer and back the nut off approximately one twelfth of a turn and reinstall the retainer The nut should now be free to move slightly 5 Reinstall grease cap Typical E Z Lube After Spring 2002 D Washer Nut Retainer q suinig sqny suea HAULOTTE GROUP MAINTENANCE CONTINUED 202 Hubs Drums Bearings 10 AXLE AND RELATED COMPONENTS E Z Lube Lubrication The 1 24 procedure is as follows Remove the rubber plug from the end of the grease cap Place a standard grease gun onto the grease fitting located in the end of the spindle Make sure the grease gun nozzle is fully engaged on the fitting Pump grease into the fitting The old displaced grease will begin to flow back out the cap around the grease gun nozzle When the new clean grease is observed remove the grease gun wipe off any excess and replace the rubber plug in the cap Rotate hub or drum while adding grease Note The E Z Lube feature is designed to allow immersion in water Axles not equipped wit
143. ming the operation The maintenance mode will then go to Load Sense Scaling Utility 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 Step 7 If both the ratio and the load are correct proceed to Step 8 If the ratio is not 3 68 1 press the mid high or mid low speed key until the ratio is correct Proceed to Step 7 Press the rabbit key 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 Exit the maintenance mode by scrolling through the menu using the turtle key Press the Basket Compensate Up and Down simultaneously until the display reads Boom Load 0000 Ibs kg Return the basket to the upright position and re install the clevis pin with tension lock The display should now read 65lbs 30kg 10 Note The display should read 125lbs 57kg for lifts with the Platform Rotate option 10 Add between 350 400lbs 159 182kg to basket Note Keep accurate track of how much weight within or 5lbs 2 3kg is going into the basket 11 12 13 The Boom Load on the display should read the added weight plus the initially displayed weight 10 Minimum Load 0 9 W1 W2 Maximum Load 1 1 W1 W2 Where W1 Initial displayed weight and W2
144. n only Checked only at power up Machines with 4WS option only Checked only at power up Machines with 4WS option only HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE THIS PAGE INTENTIONALY LEFT BLANK 43 HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE ERROR CODE DEFINITIONS MOTOR CONTROLLER The Motor Controller located under the left power driver side compartment cover behind the lower control box indicates the operational status of the controller If an error condition is detected the appropriate error code will be displayed by a flashing indicator light Refer to Figure 3 7 at the end of the error codes for a visual of the controller Refer to Table 3 4 to resolve the Error TABLE 3 4 MOTOR CONTROLLER ERROR CODE DEFINITIONS FLASH PRIORITY ID ERROR DESCRIPTION ERROR Steady ON None is operating normally MA NG required no flashing Configuration Range One or more controller Use Sevcon calibrator to enter correct Error personality settings are out of settings from latest Personality Sheet 1 12 CRC Error The controller personality Use Sevcon calibrator to enter correct checksum is incorrect settings from latest Personality Sheet Otherwise replace motor controller 2 Accelerator Error 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 c
145. nders 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 safely Move undamaged containers from immediate hazard area if it can be done safely VVater 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 174 HAULOTTE GROUP 9 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET DEXRON III MERCON AUTOMATIC TRANSMISSION FLUID HYDRAULIC OIL CONTINUED 814636 Powerflow AW Hydraulic Oil All Grades Page 3 7 Date of Issue 14 Nov 2008 Status Final 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
146. ng Actuating System Brake Adjustment Not Correct Harsh Brakes Grease or Fluid on Linings Grease or Oil __on Linings Out of Round Drums or Cracked Drums Surging Brakes 214 a 1 z E 10 AXLE AND RELATED COMPONENTS REMEDIES Repair or Replace Adjust Brakes Troubleshoot System Manual Adjust Brakes Automatic Make Several Reverse Stops Replace Shoe and Lining Install Correct Shoe and Lining 3i ne1p H SUIIS S Repair Grease Seal or Wheel Cylinder Install New Shoe and Lining Recondition or Replace All Cylinders Brake Fluid Reburnish or Replace Replace Bleed System Correct Troubleshoot System Manual Adjust Brakes Automatic Make Several Reverse Stops Replace Shoes and Linings Clean or Replace achine or Replace HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS TROUBLE SHOOTING CONTINUED Troubleshooting SYMPTOM CAUSES REMEDIES asma Lack of Lubrication Lubricate Noisy Brakes Broken Brake Components Replace Components Incorrect Brake x Loose Bent or Broken Brake Components Locking Brakes Underadjustment ES Out of Round Drums Machine or Replace Replace Components Incorrect Tire Inflate Evenly on Both Pressure Sides to Req Pressures Pulls to One Side Unmatcnec Tras Match Tires on Axle a en Check for Stuck Malunctoning cylinder or Sluggish P
147. ng 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 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 The above standard is an example other industries using aerial devices have safety rules pertinent to that industry Authorization to operate 0 Operator warnings and instructions 1 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
148. ng 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 OF WIND FORCE Description of wind Specifications for use on land f Calm Calm smoke rises vertically Light Air Direction of wind shown by smoke o Jan 0 3 1 5 Light Breeze Wind felt on face leaves rustle ordinary vanes 11 Jun 1 6 3 3 moved by wind Gentle Breeze Leaves and small twigs in constant motion wind 19 Dec 3 4 5 4 exceeds light flag Moderate Raises dust and loose paper small branches are 20 28 5 5 7 9 Breeze moved Fresh Breeze omall trees in leaf begin to sway crested wavelets 29 38 8 0 10 7 form on inland waterways otrong Breeze Large branches in motion whistling heard in 39 49 10 8 13 8 telephone wires umbrellas used with difficulty Near Gale Whole trees in motion inconvenience felt when 50 61 13 9 17 1 walking against wind Gale Breaks twigs off trees generally impedes progress 62 74 17 2 20 7 Strong Gale olight structural damage occurs chimney pots and 75 88 20 8 24 4 slates removed 2 5 N EXPLOSION HAZARD e NEVER operate aerial work platform if you smell or detect Liquid Petroleum Gas LPG gasoline diesel fuel or other explosive substances e 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 e
149. ng of the fasteners should be done in stages Following the recommended sequence tighten fasteners per wheel torque requirements diagram 4 Wheel nuts bolts should be torqued before first road use and after each wheel removal Check and re torque after the first 10 miles 25 miles and again at 50 miles Check periodically thereafter Wheel Torque Requirements For Dexter Steel Wheels Prior to June of 2004 Torque Sequence Wheel Size 1st Stage 2nd Stage 3rd Stage ____ 5075 15 2025 5060 90202 16 5 x 6 76 16 5 9 75 5560 120 125 175 225 14 5 Demount Tighten sequentially to 85 95 17 5 Hub Pilot 100 120 190 210 Clamp ring amp Cone Nuts 17 5 Hub Pilot 50 60 90 200 275 325 78 Flange Nuts x 1 1 1 1 4 4 y 9 5 4 3 4 5 2 5 2 2 4 BOLT 5 BOLT 6 BOLT 8 BOLT 10 AXLE AND RELATED COMPONENTS pue sjaauM HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS SET UP AND ADJUSTMENT CONTINUED Maximum Wheel Fastener Torque The wheel mounting studs used on Dexter axles conform to the SAE standards for grade 8 The maximum torque level that can be safely applied to these studs is listed in the following chart Stud Size Maximum Torque _ 20 UNF class 2A 120 Ft Lbs sas 9 18 UNF class 2A 170 Ft Lbs 325Ftlbs Exceeding the above listed torque limits can damage studs and or nuts and lead to eventual fractures and dangerous wheel separation
150. ng the above instructions in the reverse order of removal Actuate the hydraulic system and check for leakage Tighten hydraulic fittings as necessary Bleed trapped air from the hydraulic system by raising and lowering the boom with the reservoir fill port cap on but not tightened Allow several cycles of operation for trapped air to escape Repeat as necessary 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 no longer legible 91 HAULOTTE GROUP 5 DECAL REPLACEMENT DECAL REPLACEMENT DECAL KIT 52 HAULOTTE GROUP 5 DECAL REPLACEMENT DECAL REPLACEMENT DECAL KIT 06 01 4002 DECAL KIT Includes the following ITEM NO PART NUMBER DESCRIPTION Decal Danger Main Instruction Hazard Platform Decal Air 120 PSI 6 ___ 806 00 0531 ____ Decal Water 3000 PSI 8 10202 0523 Decal Flag Made In USA 9 B06 00 0476 Decal Notice Range of Motion 3632T HTT 13 2 10 B06 00 0474 Decal Notice Platform Maximum Load 1 Decal Danger Tip Over Hazard 6 16 ___ 806 00 0404 Warning Outrigger Crush Foot 8 Decal Danger Electrocution Decal Lubr
151. ngine 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 manufacturer s 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 OFF and remove key before performing maintenance Whenever possible ALWAYS perform maintenance with the telescoping boom and platform in a fully lowered stowed position ALWAYS secure the telescoping boom before 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 ae
152. nk 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 Machines with Moment Sense option only HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE 014 CHECK ENGINE LOW OIL PRESSURE MACHINE IS NOT LEVEL LIFT BOOM STOW BOOM LOSS OF LOAD SENSE COMMUNICATION 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 OPEN CIRCUIT SECONDARY DOWN TABLE 3 3 ERROR CODE DEFINITIONS ERROR MESSAGE ERROR DEFINITION TO SIMULATE ERROR TO CLEAR ERROR COMMENTS Engine had low oil pressure while running Machine has gone out of level with use A Boom Rotate Extend or Re
153. nly 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 3 HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE x EOM TABLE 3 3 ERROR CODE DEFINITIONS 089 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 C30 SHORTED CIRCUIT TORQUE H L C30 OPEN CIRCUIT TORQUE H L C31 SHORTED CIRCUIT TORQUE H L C31 OUTREACH NEAR MAXIMUM 38 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 less 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 w
154. nnect a wire from Turn Right C23 coil Use a piece of wire to short the 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 ERROR MESSAGE ERROR DEFINITION TO SIMULATE ERROR TO CLEAR ERROR COMMENTS 074 SHORTED CIRCUIT Not Used 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 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 o
155. of the aerial work platform onto the outrigger Leave the weight of the aerial work platform on the trailer wheels Remove the bolts securing the outrigger cylinder guard Remove the cylinder guard Refer to Figure 4 3 CYLINDER Figure 4 3 Outrigger Cylinder Replacement At the piston rod end of the cylinder unbolt and remove the retainer plate from each side of the pivot pin Place a block of wood shoring between the outrigger beam and cylinder Remove the pivot pin using a hammer and a brass or hardwood drift Fully retract the cylinder Turn the key at the ground control station to the OFF position and remove the key Tag and number all hydraulic hoses that attach to the cylinder valve block Use a marker to label the valve block ports with the appropriate hose numbers Unplug the cylinder valve solenoid Refer to Figure 4 4 Place absorbent cloths below the cylinder ports and detach hydraulic hoses from the cylinder Elevate hoses to prevent leakage Plug or cap exposed hose fittings and cylinder ports Figure 4 4 Cylinder Valve Removal 49 HAULOTTE GROUP 4 CYLINDER REPLACEMENT OUTRIGGER CYLINDER REPLACEMENT CONTINUED 50 At the base of the cylinder unbolt and remove retainer plate from each side of the pivot pin Remove the pivot pin using a hammer and a brass or hardwood drift Lift and remove the cylinder using an overhead hoist and lifting straps Replace or reinstall the cylinder by followi
156. 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 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 optio
157. on 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 inspections 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
158. 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 Machines with Moment Sense option only HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE x TABLE 3 3 ERROR CODE DEFINITIONS 104 OUTREACH AT MAXIMUM OVER MAXIMUM CYLINDER PRESSURE OUTREACH SENSING ERROR ENGINE TEMP HIGH CHECK WATER LEVEL CHECK ALTERNATOR NOT CHARGING ENGINE RPM ERROR 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 SHORTED CIRCUIT FS RET FWS C24 Boom has reached maximum outreach setting Cylinder pressure has exceeded maximum pressure setting Cylinder safety pressure switch has detected 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 70mA was detected when RS Ret FWS C22 circuit was energi
159. ons 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 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
160. ontroller miswire detected frame If cables and pump are OK then replace motor controller 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 contactor and wiring are OK then replace motor controller range 2 5 Sequence Error Enable line is active at power up Check enable line B wiring and Molex connector Make sure pump terminals are not shorted to Line Contactor The line contactor is welded or Check line contactor wiring If wiring is OK Welded otherwise shorted then replace line contactor resistance it should be around 50 ohms If 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 High Battery Battery voltage is too high Make sure battery charger is off Check for poor or corroded battery connections 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 Thermal Cutback Maximum power available to Remove power and allow controller to cool If motor has been reduced due to err
161. or 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 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
162. or repeatedly occurs look for binding on excessive heat sink temperature the hydraulic cylinders or sticking valves Otherwise the pump motor may be failing Pump Current Maximum power available to Recycle power If error 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 10 N A Not used in this N A N A application 44 HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE TABLE 3 4 MOTOR CONTROLLER ERROR CODE DEFINITIONS FLASH PRIORITY ID ERROR DESCRIPTION SOLUTION ERROR 11 18 Auto Zero Out of Internal pump current Replace motor controller Range measurement circuit could not be calibrated 11 24 System Monitor Illegal system condition sensed Replace motor controller due to internal hardware error Single flash MOSFETs MOSFETs did not pulse when the Check for reversed cables among B B 19 then off internal failsafe circuit was and A terminals If no miswire is found enabled replace motor controller Single flash 20 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 22 Contactor Drive Off Contactor output did not pulse Replace motor controller Single flash th
163. ort the Primary Down Coil Disconnect a wire from Secondary Up coil Use a piece of wire to short the Secondary Up coil Disconnect a wire from Secondary Down coil 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 be cycled to clear error This is a latched error Power must be cycled to clear error 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 p
164. ower 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 33 HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE x O TABLE 3 3 ERROR CODE DEFINITIONS 028 SHORTED CIRCUIT SECONDARY DOWN OPEN CIRCUIT JIB UP SHORTED CIRCUIT JIB UP OPEN CIRCUIT JIB DOWN SHORTED CIRCUIT JIB DOWN 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 OPEN CIRCUIT PLATFORM CCW 34 Excessive load was detected when Secondary Down circuit was energized A load of less than 7 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 was 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
165. perly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury or death 2 Remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate 3 With a screwdriver or standard adjusting tool rotate the star wheel of the adjuster assembly to expand the brake shoes Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn Note For drop spindle axles a modified adjusting tool may be necessary 4 Then rotate the star wheel in the opposite direction until the wheel turns freely with a slight lining drag 5 Replace the adjusting hole cover and lower the wheel to the ground 6 Repeat the above procedure on all brakes For best results the brakes should all be set at the same clearance 183 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS SET UP AND ADJUSTMENT CONTINUED 184 Braking Systems Electric Synchronizing Your Trailer Brakes To insure safe brake performance and synchronization read the brake controller manufacturer s instructions completely before attempting any synchronization procedure Before road testing make sure the area is clear of vehicular and pedestrian traffic Failure to brake safely could result in an accident and personal injury to yourself and or others Make several hard stops from 20 m p h on a dry paved
166. ply See 49 CFR 171 22 23 amp 25 International Civil Aviation Org International Air Transport Assoc ICAO IATA UNID Not regulated 177 HAULOTTE GROUP 9 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET DEXRON III MERCON AUTOMATIC TRANSMISSION FLUID HYDRAULIC OIL CONTINUED 814636 Powerflow AW HVI Hydraulic Oil All Grades Page 6 7 Date of Issue 14 Nov 2008 Status Final portation Information LTD QTY Passenger Aircraft Cargo Aircraft Only Packagiginstruction Ed Net Qty Per Package Eh 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 No Pressure Hazard No Reactive Hazard No 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 wth 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 t
167. ponsibilities 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 Devices 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 223 HAULOTTE GROUP 11 3 2 11 4 1 224 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 avoidan
168. quipment before operation ALWAYS wear proper clothing Wear protective equipment as required by government 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 the aerial work platform 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 critical procedures that supersede the information contained in the 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 the aerial work platform in any way for whic
169. r 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 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
170. ration e Repair or replace as necessary 25 HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE MONTHLY SERVICE CHECKS Perform the following service checks at least once each month Check battery for loose connections or damaged wires Clean all battery terminals Verify proper operation of manual lowering valves and hand pump e For manual boom operating procedures refer to the Operation section of the Operation Manual Lubricate slew ring and mating gear e Use NLGI Grade 2 multi purpose grease Check wheel nut torque e For correct wheel nut tightening sequence refer to Figure 3 4 e Evenly tighten wheel nuts to 25 lb ft 34 N m in the tightening sequence shown Repeat tightening sequence tighten wheel nuts to 60 lb ft 81 N m and then to 100 Ib ft 136 N m Figure 3 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 section located in the Axle and Related Components section of this Manual for more detailed information 26 HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE MONTHLY SERVICE CHECKS CONTINUED Verify that Level Sensor is operating correctly Fully deploy outriggers until all outrigger LEDs and
171. re could result in motion of the platform s shall meet the Structural Welding Code AWS D1 1 2006 or AWS DI 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 device 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 Inspecti
172. re materials or equipment NEVER climb on the telescoping boom Refer to the Operation Section of the Operation Manual for manual operation 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 a safety belt or harness in accordance li with governmental regulations Attach lanyard to the anchor _ 8 gt provided on the work platform M i Never sit stand or climb on the platform guard rails Maintain a firm footing on the platform floor at all times 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 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 Ib 400 WIND LOADING e Never operate the aerial work platform in strong or gusty winds Never increase the surface area of the platform or the load Increasing the area exposed to the wind will affect the work platform cage stability HAULOTTE GROUP 1 SAFETY WIND LOADING CONTINUED The Beaufort scale of wind force is accepted internationally and is used when communicating weather conditions It consists of a number 0 17 each representi
173. re equipped with high quality electromagnets that are designed to provide the proper input force and friction characteristics Your magnets should be inspected and replaced if worn unevenly or abnormally As indicated below a straightedge should be used to check magnet condition For best results the magnet should be flat Even if wear is normal as indicated by your straightedge the magnets should be replaced if any part of the magnet coil has become visible through the friction material facing of the magnet It is also recommended that the drum armature surface be refaced when replacing magnets see section on Brake Drum Inspection Magnets should also be replaced in pairs both sides of an axle Use only genuine Dexter replacement parts when replacing your magnets NN AA Straight Edge lt ES 4 2107 Gaps show ABNORMAL WEAR replace magnet NORMAL WEAR 10 AXLE AND RELATED COMPONENTS 211192913 5 15 6 Hulyelg HAULOTTE GROUP MAINTENANCE CONTINUED Braking Systems Electric Brake Cleaning and Inspection Your trailer brakes must be inspected and serviced immediately if a loss of performance is indicated With normal use servicing at one year intervals is usually adequate With increased usage this work should be done more frequently as required Magnets and shoes must be changed when they become excessively worn or scored a condition which can reduce vehicle braking Clean the backing plate
174. riager the warning requirements of California Proposition 65 Canadian Reg ulations 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 exempt 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 SARA Superfund Amendments and Reauthorization Act STEL Short Term Exposure Limit 15 minutes TLV Threshold Limit Value ACGIH TWA Time Weighted Average 8 hours UEL
175. rial Lift Stowed Position Figure 8 6 Material Lift In Use Position ALWAYS observe the manufacturer s weight lifting limitations when using the material lifting hook Always use lifting straps or wire rope slings that are rated at a minimum 500 16 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 166 HAULOTTE GROUP 8 OPTIONAL EQUIPMENT LOAD CELL CALIBRATION PROCEDURE 1 2 9 Remove the clevis pin securing the basket to the platform mount bracket Enter the maintenance mode by pressing both rotate keys and the outrigger extend key on the lower control panel simultaneously and holding for 5 seconds Scroll through the maintenance menu using the turtle key until Load Sense Zero Calibration Utility is found Press both mid speed keys on the lower control panel simultaneously Three consecutive beeps will sound and the display will read Load Sense Has Been Zero Calibrated confir
176. rial 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 this manual for proper drying instructions NEVER add unauthorized 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 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
177. rifying 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 ANSI 286 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 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 60 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 nBuAc 1 Flash Point Test Method LEL vol in air U
178. rigger 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 Excessive load was detected when LR Outrigger circuit was energized Use a piece of wire to short the Plattorm 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 RF Outrigger coil Use a piece of wire to short the RF Outrigger coil Disconnect a wire from LR Outrigger coil Use a piece of wire to short the LR Outrigger 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 b
179. ro AG 30 50 8 AWG 188 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS MAINTENANCE Maintenance Schedule 3 Months or 6Monthsor 12 Months Item Function Required Weekly 3 000 Miles 6 000 Miles 12 000 Miles Test that they are i At Every Use operational Brakes Brake Adjust to proper operating Adjustment clearance Inspect for wear and Inspect for wear or contamination Brake Linings Check for correct Brake Controller amperage and modulation Brake Cylinders Check for leaks sticking Inspect for cracks leaks Brake Lines Kinks Trailer Brake Inspect wiring for bare Wiring spots fray etc Breakaway Check battery charge and At Every Use System switch operation Inspect for abnormal wear Wheel Bearings Inspect for corrosion or and Cups wear Clean and repack Inspect for leakage Seals Replace if removed Springs Inspect for wear loss of arch Suspension Inspect for bending loose Parts fasteners and wear Hangers Inspect welds Wheel Nuts Tighten to specified torque and Bolts values Inspect for cracks dents Inflate tires to mfq s specifications Tire Inflation Pressure Inspect for cuts wear Tire Condition bulging etc Maintenance Schedule 189 HAULOTTE GROUP MAINTENANCE CONTINUED 190 Magnets Your electric brakes a
180. rolyte 171 HAULOTTE GROUP 9 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 SKIN 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 L
181. rror 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 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 4WS option only Machines with 4WS option only 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
182. rs 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 HAULOTTE GROUP 11 ANSI REPRINT BUS BARS NN DENOTES PROHIBITED ZONE Figure 11 1 Minimum Safe Approach Distance 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 TABLE 11 1 MINIMUM SAFE APPROACH DISTANCES Voltage Range Minimum Safe Approach Distance Phase to Phase Feet Meters 225 INSPECTION FORM FOR HAULOTTE GROUP AERIAL WORK PLATFORMS AAA 2 s Machine Model No SeidNo Date of Manufacture __ Inspection Performedby U O O Insecta Location A 2 22 A A 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 see the appropriate Parts and Service Manual and ANSI SIA A92 Standard Copy this form as needed Direct any
183. sengage EMERGENCY STOP buttons Battery charge is low b Recharge as needed No lights on panel when key switch is turned to the on position c Inspect and repair battery Battery ground or in series cable is connections loose Battery main disconnect unplugged 9 Plug in main disconnect Blown Fuse Error code displayed on a Error detected by Control Box a Refer to Error Code Definitions Ground Control Panel Table 3 3 Green light flashing on a Error detected by Motor a Refer to 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 Refer to error code definitions message electronic failure Table 3 3 Outrigger indicator LED a Key switch turned to the OFF or Turn key switch to ground controls lights do not function platform controls position position b EMERGENCY STOP engaged Disengage EMERGENCY STOP buttons Replace Fuse as necessary Outriggers not deployed Deploy all outriggers One or more telescoping 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 Battery charge is low Recharge battery OR EMERGENCY STOP engaged Disengage EMERGENCY STOP buttons
184. 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 145 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 ANS 249 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
185. shop shop Check bearing Cupping Out of balance adjustment and balance tires Wheel lockup Avoid sudden stops aum skidding u possible ang Cand adjust brakes Wheels and Tires 206 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS MAINTENANCE CONTINUED How to Measure Voltage System voltage is measured at the magnets by connecting the voltmeter to the two magnet lead wires at any brake This may be accomplished by using a pin probe inserted through the insulation of the wires The engine of the towing vehicle should be running when checking the voltage so that a low battery will not affect the readings Voltage in the system should begin at O volts and as the controller bar is slowly actuated should gradually increase to about 12 volts If the controller does not produce this voltage control consult your controller manual The threshold voltage of a controller is the voltage applied to the brakes when the controller first turns on Lower threshold voltage will provide for smoother braking If the threshold voltage is too high the brakes may feel grabby and harsh How to Measure Amperage System amperage is the current flowing in the system when all the magnets are energized The amperage will vary in proportion to the voltage The engine of the tow vehicle should be running with the trailer connected when checking the trailer braking system One place to measure system amperage is at the BLUE wire of the controll
186. steel wheels manufactured before that date the following wheel torque information will be applicable If your trailer is equipped with wheels produced by other manufacturers you must consult with the vehicle manufacturer to determine the appropriate torque level for your wheels However you must not exceed the limits of the wheel mounting studs on the axles It is extremely important to apply and maintain proper wheel mounting torque on your trailer axle Torque is a measure of the amount of tightening applied to a fastener nut or bolt and is expressed as length force For example a force of 90 pounds applied at the end of a wrench one foot long will yield 90 Ft Lbs of torque Torque wrenches are the best method to assure the proper amount of torque is being applied to a fastener Wheel nuts or bolts must be tightened and maintained at the proper torque levels to prevent loose wheels broken studs and possible dangerous separation of wheels from your axle which can lead to an accident personal injuries or death Be sure to use only the fasteners matched to the cone angle of your wheel usually 60 or 90 The proper procedure for attaching your wheels is as follows 1 Start all bolts or nuts by hand to prevent cross threading 10 AXLE AND RELATED COMPONENTS 185 HAULOTTE GROUP SET UP AND ADJUSTMENT CONTINUED 2 Tighten bolts or nuts in the sequence shown for Wheel Torque Requirements 3 The tighteni
187. t Self Locking MB 6 6 0090000 Cap 43846554702 0096 0002 9 009 0089 Self Locking M6 4 Optional Swivel provides 360 Rotation and includes item numbers 1 6 above 169 HAULOTTE GROUP 9 MATERIAL SAFETY 170 HAULOTTE GROUP 9 MATERIAL SAFETY 9 MATERIAL SAFETY The following Material Safety Data Sheets describe the correct procedures for the safe handling of chemical components within the Model 3632T HTT 13 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 applicable federal and state 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 5 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 LEAD SULFATES 0 05 mg m3 0 05 mg m3 LEAD OXIDES 0 05 mg m3 0 05 mg m3 POLYPROPYLENE CASE MTL SEPARATORS SULFURIC ACI
188. t stage of the charge cycle The bulk mode CHARGE CURRENT will be displayed on the Battery Charger Faceplate e Press and hold the Battery Voltage button to display the detected battery voltage Linear Battery Charger i CHARGE CURRENT 80 CHARGED BATTERY VOLTAGE e C H ECK BATT E RY Figure 3 1 Battery Charger Faceplate 20 HAULOTTE GROUP 3 EQUIPMENT MAINTENANACE BATTERY RECHARGE CONTINUED l a Battery error is detected the appropriate error code will appear on the charge current display The red check battery indicator LED will become lit See Table 3 1 for battery charger error codes Do Not disconnect any output leads or connectors between the batteries and the charger when the charger is on To stop a charge in progress always unplug the extension cord from the AC Power source e 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 00 Unplug the extension cord from the outlet and the charger receptacle on the aerial work platform Store the extension cord for next use Code Description Limits Cause after 6 hrs Max Error Standby extr
189. ted 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 surfaces The removal and subsequent reinstallation of a gradient control device is not considered a major 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 gt 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 e
190. tenance 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 2006 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 applicab
191. 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 that compromise insulation Then these components and system s shall be tested for compliance with the rating of the aerial device in accordance with one of the applicable 8 2 5 10 gt 16 gt 220 11 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 tes
192. tion 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 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 res
193. tion 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 Date of Issue Status Final 173 HAULOTTE GROUP 9 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET DEXRON III MERCON AUTOMATIC TRANSMISSION FLUID HYDRAULIC OIL CONTINUED 814636 Powerflow AW HVI Hydraulic All Grades Page 2 7 Date of Issue 14 Nov 2008 status Final Component CASRN Concentration Lubricant Base Oil Petroleum VARIOLIS gt 90 PROPRIETARY lt 10 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
194. tract 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 70mA 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 70mA was detected when Secondary Up circuit was energized Excessive load was detected when Secondary Up circuit was energized A load of less than 70mA was detected when Secondary Down circuit was energized 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 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 sh
195. ts 18 3 EQUIPMENT NIAINTENANGE 19 BATTERY RECHARGE aaa 20 BAUT SERVICE CIES e lm 22 WEEKLY SERVIGE tw taeda ein 25 MONTHLY SERVICE CHECKS ee ee are 26 ANNUAL SERVICE Snake 2 STRUCTURAL INGE EG TION GES ea 29 MOTOR DRYING INSTRUCTION S Eee En 29 ADDITIONAL SERVICE INFORMA FON aa 30 TROUBLESHOOTING uuu qu suba a ana ab a tubum Ba cipue 31 ERROR CODE DEFINITIONS CONTROLS uuu un u u uu ana u l unu ic 32 ERROR CODE DEFINITIONS MOTOR CONTROLLER sees 44 _______________ 47 VEIND Ei LAG EIVIEIN Itti ias xerunt dat a euentu iP 47 OUTRIGGER GYEINDER REPLACEMENT ie io ds 49 DEGAL REPLACEMENT mem 51 DECAL REPLACEMENT DECAL MM 52 DECAL REPLACEMENT IDENTIFICATION PLATES 8 OPTIONAL EQUIPMENT 54 6 PEPLAGENENT PANITSu u uuu x ganas alice be seam ts ana a ga aa S caet DEDE aaa 5 H 121 OPTIONALBEGUIPNMEBI nisse age ind dad ta Quota tope awed 155 I MATERIAL idrico 171 10 AXLE AND RELATED 181 ES gari IBN ADJUSTNENTu uu ee 181 HOW TO USE YOUR BRAKES PROPER ann 188 MAINTENANCE SE ee 189 STORAGE 210 TROUBLE em 213 iu ella
196. 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 3 EQUIPMENT MAINTENANACE x TABLE 3 3 ERROR CODE DEFINITIONS 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 2 158 SHORTED CIRCUIT FWS SPARE 2 Excessive load was detected when FWS C32 circuit was energized A load of less than 70mA was detected when FWS C33 circuit was energized Excessive load was detected when FWS C33 circuit was energized A load of less 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
197. ust be cycled to clear error 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 Not Used HAULOTTE GROUP 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 DRIVE 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 SHORTED CIRCUIT TURN RIGHT C23 3 EQUIPMENT MAINTENANACE TABLE 3 3 ERROR CODE DEFINITIONS 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
198. uum hydraulic electric hydraulic or air hydraulic system should not require any special attention with the exception of routine maintenance as defined by the manufacturer If problems occur the entire tow vehicle trailer braking system should be analyzed by a qualified mechanic Typical problems in a hydraulic braking system are e Air or vacuum leaks e Hydraulic system leaks e Air in brake lines e Water or other impurity in brake fluid e Rusted or corroded master or wheel cylinders e Actuation system malfunction Please consult the following troubleshooting charts to determine the causes and solutions for common problems found in trailer braking systems The operating pressure required for Dexter brakes o 7 diameter drum brakes maximum operating pressure is 750 psi e 10 diameter and larger drum brakes maximum operating pressure is 1 000 psi Hydraulic disc brakes all sizes maximum operating pressure is 1 600 psi 10 AXLE AND RELATED COMPONENTS 213 HAULOTTE GROUP TROUBLE SHOOTING CONTINUED Troubleshooting SYMPTOM CAUSES Broken or Kinked Brake Line No Brakes Severs Underadjustment _ Malfunctioning Actuation System Brake Adjustment Not Correct Excessively Worn Brake Linings x Grease or Fluid Soaked Lining Frozen Master Cylinder or Wheel Cylinder Pistons Weak Brakes Glazed Lining Trapped Air in Lines Overloaded Trailer Malfunctioni
199. vision Lubriplate APG 90 Fiske Brothers Refining Mobil Oil Corporation Mobilube SHC Mobil 1 Synthetic Gear Lube Phillips 66 Petroleum Superior Multi Purpose Gear Oil Philguard Gear Oil Philsyn Gear Oil Pennzoil Products Co Gear Plus 80W 90 GL 5 Gear Plus Super 75W 90 Gear Plus Super EW 80W 90 Multi Purpose 4092 Gear Lube Oil Center Research Liquid O Ring 750 GX Sun Refining and Sonoco Ultra Marketing Company Sonoco Dura Gear Shell Oil Company Spirax A Spirax G Spirax HD Spirax S Texaco Oil Company Multigear EP I Multigear SS _ Troco Division Multigear Select Gear Oil Royal Manufacturing BE Union Oil Company Unocal MP Gear Lube 76 Triton Syn Lube 199 HAULOTTE GROUP 10 AXLE AND RELATED COMPONENTS MAINTENANCE CONTINUED 200 Hubs Drums Bearings Note The convenient lubrication provisions of the E Z Lube and the oil lubrication must not replace periodic inspection of the bearings Seal Inspection and Replacement Whenever the hub is removed inspect the seal to assure that is not nicked or torn and is still capable of properly sealing the bearing cavity If there is any question of condition replace the seal Use only the seals specified in the Seal Replacement Chart Bad Seal Nicks and Tears REPLACE SEAL To replace the seal 1 Pry the seal out of the hub with a screwdriver Never drive the seal out with the inner bearing as
200. vity Seal Pina White Brake Switeh gt B01 09 0093 Wire seal Label CK Ohm Solder Resistor connections y gt m Resistor amp Heat shrink over wires 8 Resistor T JARING lt A D Nl A u OHEI 8 y J Pin rg Be NG LY 5 3 01 09 0152 C38 Yellow CEmabie a Pin12 4 14 Loom 23 Pin Black Plug CM gt pint 3 9 39 01 2120 45 Black Pin 8 12 Pin Plug Ohm Solder Resistor connections Ya Ring Resistor 8 Heat shrink over wires amp Resistor Terminal rae BY pin CO e 10 Loom A 38 Pin 5 Kegel yesterday woe eet tes EA ACI Ein 12 MAT eg L 39 01 2120 NE O P L 12 Pin Plug Switch Run MCN cu i NM Black 45 Pin 8 MG Terminals S Loom 01 09 0146 Female Terminal J NT B B01 09 0118 Female Terminal Tone RER C 1 Female Spade Terminal Ce OS 2 Dc ee 85 CRETE s ER fy Red CAD OD 87 Splice amp Heat 10 Loo ink CGaal QAM Shrink Seal CEP xS S CE Dal Pump is de P AU 75 ee C02 Red Level Sensor 22 Wain
201. 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 A load of less than 70mA was detected when Platform CCW circuit was energized 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 Use 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 Disconnect a wire from Platform CCW 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 cy
202. with Nylon Insert 5 81 2 WE GM o A al 5 Amp Battery and Battery Charger d Brake Away Switch EN i2 00960004 Screw Hex Head 6 5 n 18 0096 0089 7 Hex Nut with Nylon Insert M Z 1 14 07 06 5865 StrapMount BreekAway 2 15 0096 0103 Screw HexHeadCap M8x140 4 16 0096 0104 gt 17 10096 00409 Hex Nut with Nylon Insert M8 __ 4 18A A 00192 Brake Lever 1 Replaces A 00167 Effective 2006 2 B03000017 Chain Assembly 21 B01 09 0104 Butt Splice Heat Shrink Not Shown 63 6 REPLACEMENT PARTS HAULOTTE GROUP DOLLY WHEEL ASSEMBLY 64 HAULOTTE GROUP 6 REPLACEMENT PARTS DOLLY WHEEL ASSEMBLY Replaces 0096 0075 Effective 2006 _ 0S Replaces Effective 2006 Replaces A 00144 Effective 2006 0096 0022 Screw Hex Head Cap M12 x 75 0096 0042 Hex Nut with Nylon Insert M12 3 gt lt 65 6 REPLACEMENT PARTS HAULOTTE GROUP DOLLY WHEEL ASSEMBLY FOR DRIVE amp SET OPTION HAULOTTE GROUP 6 REPLACEMENT PARTS DOLLY WHEEL ASSEMBLY FOR DRIVE amp SET OPTION 6 0096 044 HexNutwithNylon 16 1 8 0096 0076 Screw HexHeadCap Mi0x120 14 9 0096 0004 Nut with Nylon Insert MO Replaces A 00144 Effective 2006 16 0096007 7 FlaWashenM20 76 67 HAULOTTE GROUP 6 REPLACEMENT PARTS DOLLY WHEEL WITH TAPERED SWIVEL amp YOKE ASSEMBLY OPTI
203. xternal 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 before the unit is returned to service Return to service shall be approved by a qualified person Inspection and Test Records Frequent ltems 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 Main
204. y 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 3 Hydraulic and pneumatic relief valve settings 4 Hydraulic system for proper oil level 5 Hydraulic 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
205. y 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 1 8 kg cm 25 psi 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 ALWAYS wear proper footgear ALWAYS keep the platform free of debris HAULOTTE GROUP 1 SAFETY DURING OPERATION CONTINUED ALWAYS keep personnel and obstructions clear of the aerial work platform when repositioning the telescoping boom or cage 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 unhitch 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
206. zed Excessive load was detected when RS Ret FWS C22 circuit was energized A load of less than 70mA 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 70mA was detected when FS Ret FWS C24 circuit was energized Excessive load 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 lower cylinder pressure setting using configuration program and extend boom until alarm sounds and error is displayed Disconnect safety pressure switch wires Hemove 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 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 Use a piece of wire to short the FS Ret FWS C24 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 e

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