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PARTS AND SERVICE MANUAL NORTH AMERICA B AERIAL WORK PLATFORM This equipment is designed and manufactured in compliance with the duties, responsibilities and standards set forth for manufacturers
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PARTS AND SERVICE MANUAL NORTH AMERICA B AERIAL WORK PLATFORM This equipment is designed and manufactured in compliance with the duties, responsibilities and standards set forth for manufacturers in the ANSI standards in effect at the time of manufacture. This equipment meets or exceeds applicable ANSI codes and standards when operated in accordance with manufacturer s recommendations. It is the responsibility of the user to follow all Federal, State, and Local codes and regulations that govern the safe operation of this equipment. Obtain, read and obey all safety precautions before performing maintenance or repairs or attempting to operate this equipment. This includes all manufacturer recommendations as well as all Federal, State, and Local codes and regulations. To ensure proper and safe use of this equipment, it is strongly recommended that only trained and authorized personnel attempt to operate and maintain the aerial work platform. This manual shall be considered a permanent and necessary component of the aerial work platform and shall be kept with the machine at all times. Owners and Lessors should complete a full inspection of all components and perform a test of all functions, including brake functions, before commissioning or reselling the aerial work platform. Repair or replace all damaged or malfunctioning components. Haulotte Group is dedicated to the continuous improvement of this and all Haulotte Group products. Therefore, equipment information is subject to change without notice. Direct any questions or concerns regarding errors and / or discrepancies in this manual to the Haulotte Group Customer Service Department: at or visit Haulotte Group online at 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. 125 Taylor Parkway Archbold, Ohio Phone 1-(888) Fax (419) TABLE OF CONTENTS 1 SAFETY.5 LEGEND: SAFETY ADVISORIES... 5 BEFORE OPERATION... 6 DURING OPERATION... 7 FALL PROTECTION... 9 MANUAL FORCE... 9 WIND LOADING EXPLOSION HAZARD MAINTENANCE SPECIFICATIONS RANGE OF MOTION SPECIFICATIONS WARRANTY - NEW PRODUCT; HAULOTTE NORTH AMERICA WARRANTY CLAIMS PROCEDURE DAMAGED EQUIPMENT POLICY EQUIPMENT MAINTENANCE BATTERY RECHARGE BATTERY FAULT CODES DAILY SERVICE CHECKS WEEKLY SERVICE CHECKS MONTHLY SERVICE CHECKS ANNUAL SERVICE CHECKS STRUCTURAL INSPECTION MOTOR DRYING INSTRUCTIONS OVERLOAD PROTECTION CALIBRATION PROCEDURE ADDITIONAL SERVICE INFORMATION TROUBLESHOOTING ERROR CODE DEFINITIONS - CONTROLS ERROR CODE DEFINITIONS - MOTOR CONTROLLER CYLINDER REPLACEMENT MASTER / SLAVE CYLINDER REPLACEMENT LIFT CYLINDER REPLACEMENT OUTRIGGER CYLINDER REPLACEMENT DECAL REPLACEMENT DECAL KIT IDENTIFICATION PLATES & OPTIONAL EQUIPMENT REPLACEMENT PARTS SCHEMATICS OPTIONAL EQUIPMENT MATERIAL SAFETY AXLE AND RELATED COMPONENTS SET UP AND ADJUSTMENT HOW TO USE YOUR ELECTRIC BRAKES PROPERLY MAINTENANCE STORAGE TROUBLE SHOOTING ANSI REPRINT INSPECTION FORM FOR HAULOTTE AERIAL WORK PLATFORMS LIST OF ILLUSTRATIONS Figure 2-1. Range of Motion Figure 3-1. Battery Charger Faceplate Figure 3-2. Outrigger Position Switch Figure 3-3. Hydraulic Reservoir Figure 3-4. Wheel Nut Tightening Sequence Figure 3-5. Display Run Time Hours Figure 3-6. Machine Position for Slew Ring Measurement Figure 3-7. Slew Ring Position Measurement Figure 3-8 Machine Position for Measurement After Rotation Figure 3-9. Platform Position to Remove Load Figure 3-10.Ground (Lower) Control Panel for Overload Protection Figure 3-11.Motor Controller Figure 4-1. Location of Master Cylinder Figure 4-2. Location of Slave Cylinder Figure 4-3. Location of Emergency Lowering Valve Handle Figure 4-4. Lift Cylinder Replacement Figure 4-5. Outrigger Cylinder Replacement Figure 4-6. Cylinder Valve Removal Figure 8-1. Disconnect Plug from Load Sense Module Figure 8-2. Remove Platform (Upper) Control Box Figure 8-3. Loopback plug Figure 8-4. Platform Removal Figure 8-5. Material Lifting Hook Installation Figure 8-6. Material Lift Stowed Position Figure 8-7. Material Lift In Use Position Figure 11-1.Minimum Safe Approach Distance LIST OF TABLES TABLE 1-1 MINIMUM SAFE APPROACH DISTANCES...7 TABLE 1-2 BEAUFORT SCALE...10 TABLE 3-1 BATTERY CHARGER FAULT CODES...21 TABLE 3-2 TROUBLE SHOOTING...33 TABLE 3-3 ERROR CODE DEFINITIONS - CONTROLS...34 TABLE 3-4 MOTOR CONTROLLER ERROR CODE DEFINITIONS...46 TABLE 10-1 WHEEL TORQUE REQUIREMENTS TABLE 10-2 TRAILER WIRE SIZE CHART TABLE 10-3 MAINTENANCE SCHEDULE TABLE 10-4 RECOMMENDED WHEEL BEARING LUBRICATION SPECIFICATIONS TABLE 10-5 TIRE WEAR DIAGNOSTIC CHART TABLE 10-6 MAGNET AMPERES CHART TABLE 10-7 TROUBLESHOOTING HYDRAULIC BRAKING SYSTEM TABLE 10-8 TROUBLESHOOTING - ELECTRIC BRAKING SYSTEM TABLE 11-1 MINIMUM SAFE APPROACH DISTANCES 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: Read, understand and obey all instructions and safety precautions in this manual and attached to the aerial work platform. Read, understand and obey all Federal, State and Local codes and regulations. Become familiar with the proper use of all controls. Inexperienced 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 manual to indicate specific hazards when operating or maintaining the aerial work platform. Read, understand and obey all safety advisories to prevent improper service, damage to equipment, personal injury or death. DANGER Indicates a hazardous situation which if not avoided, will result in death or serious injury. WARNING Indicates a hazardous situation which if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury. NOTICE 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. 5 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 equipment before operation. ALWAYS wear proper clothing. Wear protective equipment as required by all Federal, State, and Local codes and regulations. Keep loose clothing, jewelry, gloves and hair away from moving parts. ALWAYS wear a Safety Harness and energy-absorbing Lanyard, such as the Safety Harness and Lanyard available through the Haulotte Group. ALWAYS inspect platform floor and outrigger footpads for mud, grease, debris or other foreign material. ALWAYS remove any such material from the aerial work platform before operation. ALWAYS RED tag any part of this machine known or suspected to be damaged or malfunctioning. ALWAYS remove a malfunctioning, damaged or defective aerial work platform from service. NEVER operate an aerial work platform that has any known or suspected defect. ALWAYS comply with the instructions found in Safety and / or Service Bulletins distributed by the manufacturer / factory. Bulletins may contain critical procedures that supersede the information contained in this manual. NEVER operate this aerial work platform while under the influence of drugs or alcohol, while taking prescription medications that may leave the operator drowsy or prone to dizziness, or while feeling ill. NEVER modify, alter or change the aerial work platform in any way that would affect its original design or operation. NEVER deface, modify or obscure any decals or markings on the aerial work platform. NEVER operate this aerial work platform in any way for which it is not intended. NEVER operate this aerial work platform in explosive or flammable environments. Before attempting aerial work platform operations, operator(s) should: Attend a training program as required by all Federal, State, and Local codes and regulations. Obtain, read and obey all safety precautions as indicated by manufacturer s recommendations and all Federal, State and Local codes and regulations. Become familiar with the location and use of all controls. Verify that there are no overhead obstructions or live power sources in the work area that could interfere with the safe operation of the aerial work platform. Cordon off the area surrounding the aerial work platform to keep personnel, vehicles and moving equipment away from the aerial work platform while in use. Position the aerial work platform on a firm and level surface. Conduct a pre-operation inspection by performing all recommended daily service checks. Refer to Equipment Maintenance section of this manual. 6 1 SAFETY DURING OPERATION Ensure the following general safety precautions are followed while operating the aerial work platform: ALWAYS position away from power lines this ensures that no part of the aerial work platform can accidentally reach into an unsafe area. This includes full extension of the telescoping boom through 700º Non-Continuous rotation. DANGER This aerial work platform is NOT insulated for use near electrical power lines and DOES NOT provide protection from contact with or close proximity to any electrically charged conductor. Operator must maintain safe clearances at all times (10 ft (3.05m) minimum) and must always allow for Platform movement due to gusty winds. Always contact power company before working near power lines. Assume every power line is live. Power lines can be blown by the wind. Refer to Table 1-1 for minimum safe approach distances between the machine and electrical power lines. TABLE 1-1 MINIMUM SAFE APPROACH DISTANCES Minimum Safe Approach Voltage Range Distance (Phase to Phase) (Feet) (Meters) 0 to 300V Avoid Contact Over 300V to 50KV Over 50KV to 200KV Over 200KV to 350KV Over 350KV to 500KV Over 500KV to 750KV Over 750KV to 1000KV ALWAYS check with local electrical authorities regarding any local requirements which may differ from those shown in Table 1-1. 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 capacity or on surfaces that do not support force exerted by the outriggers during aerial work platform operation. Operate only on surfaces that can support a pressure of 25 psi. (1.8 kg/cm 2 ) 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. 7 1 SAFETY DURING OPERATION (CONTINUED) ALWAYS use a three (3) point contact (both hands and one foot) when entering or exiting the work platform. ALWAYS wear proper footgear. ALWAYS keep the platform free of debris ALWAYS keep personnel and obstructions clear of the aerial work platform when repositioning the boom or platform. ALWAYS cordon the area surrounding the outriggers to keep personnel, vehicles and moving equipment away from the aerial work platform while in use. ALWAYS stay clear of overhead obstructions, including wires and cables. ALWAYS unhitch trailer from tow vehicle before operating outriggers. NOTICE Failure to unhitch trailer from tow vehicle prior to outrigger deployment could cause damage to trailer tongue and / or tow vehicle. ALWAYS disengage aerial work platform travel latches before raising aerial work platform sections and reengage aerial work platform travel latches before towing trailer. ALWAYS exercise caution when rotating the boom from the ground control station. ALWAYS watch for personnel inside the radius of the turntable and boom arm when rotating from the ground or platform controls. ALWAYS remove personnel from the aerial work platform before attempting to free an elevated platform that has become caught or snagged on an adjacent structure or obstacle. NEVER operate the aerial work platform from a position on a truck-bed, trailer, floating vessel or scaffolding without written approval from the manufacturer / factory. NEVER operate the Drive function (if equipped) on grades exceeding 4.5º, 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. 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 railing. ALWAYS keep both feet firmly on the platform floor. NEVER attempt to increase the working height with boxes, ladders, stools or any other materials. NEVER operate this aerial work platform when exposed to high winds, thunderstorms, ice or any weather conditions that would compromise operator safety. 8 1 SAFETY DURING OPERATION (CONTINUED ) NEVER operate aerial work platform in conditions where wind speeds exceed 28 mph (12.5 m/sec, or 45 km/h). Steady or gusty winds that exceed recommended wind speeds that may affect stability and aerial work platform operation. 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 or carry materials that would increase the surface area of the platform. Increasing the area exposed to the wind may affect the aerial work platform stability. NEVER attach overhanging loads when raising or lowering the platform. NEVER use the boom or platform to push or pull or to lift any part of the trailer. NEVER use the boom or platform to place a load against any structure, materials or equipment. NEVER climb on the 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 Occupants must wear a safety belt or harness in accordance with all Federal, State, and Local codes and regulations. Attach lanyard to the anchor provided on the work platform. 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. Refer to the Operation section of the Operation manual for manual operation Keep platform floor clear of debris. Lower the platform entry mid-rail or close the entry gate before operating. MANUAL FORCE Never push off or pull toward any object outside the platform. Maximum allowable manual force is 90 lb. (400 N). 9 1 SAFETY WIND LOADING Never operate the aerial work platform in strong or winds that exceed 28 mph (12.5 m/s) or 45 km/h). Never increase the surface area of the platform or the load. Increasing the area exposed to the wind will decrease the aerial work platform stability. The Beaufort scale of wind force is accepted internationally and is used when communicating weather conditions. It consists of a number 0-10 , each representing a certain strength or velocity of wind at 10m (33ft) above ground level in the open. Refer to Table 1-2. TABLE 1-2 BEAUFORT SCALE Description of wind Specifications for use on land m/h Km/Hr m/s 0 Calm Calm; smoke rises vertically Light Air Direction of wind shown by smoke Light Breeze Wind felt on face; leaves rustle; ordinary vanes moved by wind. 3 Gentle Breeze Leaves and small twigs in constant motion; wind exceeds light flag. 4 Moderate Breeze Raises dust and loose paper; small branches are moved. 5 Fresh Breeze Small trees in leaf begin to sway; crested wavelets form on inland waterways. 6 Strong Breeze Large branches in motion; whistling heard in telephone wires; umbrellas used with difficulty. 7 Near Gale Whole trees in motion; inconvenience felt when walking against wind. 8 Gale Breaks twigs off trees; generally impedes progress. 9 Strong Gale Slight structural damage occurs (chimney pots and slates removed) Storm, Violent Storm, Hurricane EXPLOSION HAZARD NEVER operate aerial work platform if you smell or detect Liquid Petroleum Gas (LPG), gasoline, diesel fuel or other explosive substances. 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: NEVER refuel with the engine running. Trees uprooted, widespread damage to structures, widespread devastation 55 89 24.5 NEVER operate engine unless in a well-ventilated area to avoid carbon monoxide poisoning. 10 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 to the OFF position 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 an
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