Haulotte Group xlb-4725a Operator's Maintenance Manual
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Haulotte Group xlb-4725a Operator's Maintenance Manual

Haulotte Group xlb-4725a Operator's Maintenance Manual

Lightweight self-propelled boom
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OPERATOR'S & MAINTENANCE
MANUAL
B33-01-0104 Rev. 4
August 2012

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Summary of Contents for Haulotte Group xlb-4725a

  • Page 1 OPERATOR’S & MAINTENANCE MANUAL B33-01-0104 Rev. 4 August 2012...
  • Page 2 Check local requirements with your manager. Haulotte Group is dedicated to the continuous improvement of this and all Haulotte Group products. Therefore, equipment information is subject to change without notice. Direct any questions or concerns regarding errors and / or discrepancies in this manual to the Haulotte Group Customer Service Department: at 1-800-537-0540 or visit Haulotte Group online at www.haulotte-usa.com.

  • Page 3: Table Of Contents

    HAULOTTE GROUP TABLE OF CONTENTS 1 SAFETY …………………………………………………………………………………………………….7 LEGEND: SAFETY ADVISORIES ....................7 BEFORE OPERATION........................8 DURING OPERATION ........................9 DRIVE SAFETY..........................11 FALL PROTECTION ........................11 MANUAL FORCE ...........................12 WIND LOADING ..........................12 EXPLOSION HAZARD ........................12 MAINTENANCE ..........................13 2 SPECIFICATIONS..........................15 RANGE OF MOTION ........................15 SPECIFICATIONS..........................16 WARRANTY - NEW PRODUCT;...
  • Page 4 HAULOTTE GROUP 7 OPTIONAL EQUIPMENT .......................87 MATERIAL LIFT HOOK ......................... 88 PLATFORM ROTATOR......................... 91 8 MATERIAL SAFETY........................93 LEAD ACID BATTERIES, WET, FILLED WITH ACID – UN 2794 ..........93 POWERFLOW™ AW HVI HYDRAULIC OIL ................. 98 9 ANSI REPRINT ..........................105 INSPECTION FORM FOR HAULOTTE AERIAL WORK PLATFORMS ..........117...
  • Page 5 HAULOTTE GROUP LIST OF ILLUSTRATIONS Figure 2-1. Range of Motion......................15 Figure 3-1. Ground (Lower) Control Panel ..................22 Figure 3-2. Platform (Upper) Control Panel ...................25 Figure 3-3. Platform Controls Joystick ..................28 Figure 3-4. Boom Travel Latches ....................29 Figure 3-5. Outrigger Control Panel ....................30 Figure 3-6.
  • Page 6 HAULOTTE GROUP PRIMARY MACHINE COMPONENTS PLATFORM CONTROL BOX PLATFORM JIB BOOM EXTENSION BOOM JIB LIFT CYLINDER SECONDARY BOOM SLAVE CYLINDER KNUCKLE SECONDARY LIFT CYLINDER MASTER CYLINDER PRIMARY BOOM FORK LIFT POCKETS LOWER LINK SECONDRY BOOM REST PRIMARY LIFT CYLINDER TURNTABLE...

  • Page 7: Safety

    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.

  • Page 8: Before Operation

    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.

  • Page 9: During Operation

    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, this ensures that no part of the aerial work platform accidentally reaches into an unsafe area. This includes full extension of the telescoping boom through 700º...
  • Page 10 NEVER allow ropes, electric cords, hoses or other equipment to become entangled in the aerial work platform. NEVER exceed the load limits set by the manufacturer / factory. Use only the material lifting hook, supplied as an option and manufactured by Haulotte Group when lifting materials. Safely stow all tools and equipment.

  • Page 11: Drive Safety

    HAULOTTE GROUP 1 SAFETY DURING OPERATION (CONTINUED 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.

  • Page 12: Manual Force

    HAULOTTE GROUP 1 SAFETY MANUAL FORCE  Never push off or pull toward any object outside the platform.  Maximum allowable manual force is 90 lb. (400 N). WIND LOADING  Never operate the aerial work platform in strong or winds that exceed 28 mph (12.5 m/s) or 45 km/h).

  • Page 13: Maintenance

    ALWAYS consult an authorized Haulotte Group technician by contacting the Customer Service Department: at 1-800-537-0540 if repairs are necessary. NEVER modify, alter or change the aerial work platform without first consulting an authorized Haulotte Group technician, and NEVER in any way that would affect its original design or operation.
  • Page 14 HAULOTTE GROUP 1 SAFETY MAINTENANCE (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.

  • Page 15: Specifications

    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.

  • Page 16: Specifications

    HAULOTTE GROUP 2 SPECIFICATIONS SPECIFICATIONS Maximum Working Height 51 ft 0 in (15.7 m) Maximum Platform Height 45 ft 0 in (13.7 m) Up and Over Height 20 ft 9 in (6.3 m) Maximum Horizontal Outreach From Centerline of Rotation 27 ft 0 in (8.2 m)
  • Page 17 HAULOTTE GROUP 2 SPECIFICATIONS SPECIFICATIONS (CONTINUED) Hydraulic Pressure 3,000 psi (207 bar) (20,684 kPa) Reservoir Capacity 4.3 Gallons (16.3 L) Hydraulic System Capacity 6.3 Gallons (23.9 L) Hydraulic Oil (Standard) HVI AW32 Maximum Noise Level DC Mode – Ground (Lower) 60 dBA DC Mode –...

  • Page 18: Warranty - New Product; Haulotte North America

    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 operational conditions from the warranty start date (delivery date).

  • Page 19: Warranty Claims Procedure

    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.

  • Page 20: Damaged Equipment Policy

    DAMAGED EQUIPMENT POLICY Safety Statement At Haulotte Group we are dedicated to the safety of all users of our products. All Haulotte Group aerial work platforms are designed, manufactured and tested to comply with current applicable ANSI, CSA, AS and / or CE Standards and regulations.

  • Page 21: Operation

    Safety devices prevent the boom from retracting suddenly in the event of a hydraulic hose or system failure. It is strongly recommended that no one adjust or tamper with these safety devices. If service is required, contact the Customer Service Department: at 1-800-537-0540 or visit Haulotte Group online at www.haulotte-usa.com.

  • Page 22: Ground (Lower) Control Panel

    HAULOTTE GROUP 3 OPERATION GROUND (LOWER) CONTROL PANEL The ground (lower) control panel is used to operate outriggers and all boom functions. To access the ground (lower) control panel, open the control panel access cover found on the turntable. The ground (lower) control panel includes the following controls and indicators. Refer to Figure 3-1.
  • Page 23 HAULOTTE GROUP 3 OPERATION GROUND (LOWER) CONTROL PANEL (CONTINUED) Display Panel is a lighted text window that displays the current operating status or an DISPLAY PANEL existing error condition when the (1) is positioned at either (1a) or (1b). KEY SWITCH...
  • Page 24 HAULOTTE GROUP 3 OPERATION GROUND (LOWER) CONTROL PANEL (CONTINUED) Figure 3-1. Ground (Lower) Control Panel Auto Level LED When this LED is “FLASHING” it indicates that the booms are not in the “stowed” position, and the outriggers are not functional. When this LED is “ON SOLID” it indicates that the booms are in the “stowed”...

  • Page 25: Platform (Upper) Control Panel

    HAULOTTE GROUP 3 OPERATION PLATFORM (UPPER) CONTROL PANEL The platform (upper) control panel is used to control all functions. The platform (upper) control panel is activated by turning the (1) on the ground (lower) control panel, clockwise to the KEY SWITCH (1b) icon.
  • Page 26 HAULOTTE GROUP 3 OPERATION PLATFORM (UPPER) CONTROL PANEL (CONTINUED) Figure 3-2. Platform (Upper) Control Panel Battery Condition Indicator Indicator LEDs light up to indicate the level of charge in the batteries.  A lighted green LED indicates an adequate charge level.
  • Page 27 HAULOTTE GROUP 3 OPERATION PLATFORM (UPPER) CONTROL PANEL (CONTINUED) NOTE: For all Boom Raising and Lowering, Extending and Retracting functions: Boom motion continues until the is released, or until the boom reaches a hard stop or a safe travel limit is JOYSTICK reached.

  • Page 28: Joystick - Platform (Upper) Control Panel

    HAULOTTE GROUP 3 OPERATION JOYSTICK - PLATFORM (UPPER) CONTROL PANEL The platform (upper) control panel includes a that operates the drive and boom functions JOYSTICK when the is pressed (squeezed). ENABLE LEVER Refer to Figure 3-3. TOGGLE JOYSTICK TOGGLE SWITCH...

  • Page 29: Normal Operating Procedure

    HAULOTTE GROUP 3 OPERATION NORMAL OPERATING PROCEDURE Become familiar with the location and function of all controls. Learn to smoothly START STOP boom functions. Perform the following procedures to operate the machine:  Read and obey all safety precautions and operating instructions, as well as all Federal, State, and Local codes and regulations.

  • Page 30: Figure 3-5. Outrigger Control Panel

    HAULOTTE GROUP 3 OPERATION NORMAL OPERATING PROCEDURE (CONTINUED) Become familiar with the location and function of all controls. Learn to smoothly START STOP boom functions.  At the ground (lower) control panel, turn the (1) counter clockwise to the KEY SWITCH GROUND (1a) icon.
  • Page 31 HAULOTTE GROUP 3 OPERATION NORMAL OPERATING PROCEDURE (CONTINUED)  Use the ground (lower) control panel to operate the boom lift functions. Raise, lower, extend and rotate the booms by pressing (pushing) and holding the desired and function buttons at the SPEED same time.

  • Page 32: Drive Function

    HAULOTTE GROUP 3 OPERATION DRIVE FUNCTION The Drive Function allows the operator to drive the aerial work platform, deploy, retract and level the outriggers from the platform (upper) control panel. The platform (upper) control panel is used to control all functions.

  • Page 33: Manual Boom Operation

    HAULOTTE GROUP 3 OPERATION MANUAL BOOM OPERATION Manual retraction, rotation and lowering functions allow the booms to be moved and lowered during hydraulic power interruption or failure. The following procedures for manual retraction, rotation and lowering require a person on the ground to operate the manual controls and hand pump.

  • Page 34: Figure 3-9. Location Of Lift Cylinders For Manual Boom Lowering

    HAULOTTE GROUP 3 OPERATION MANUAL BOOM OPERATION (CONTINUED) Manual Boom Lowering Procedure Each lift cylinder is equipped with a , found at the base of each lift cylinder. MANUAL LOWERING VALVE Use the to lower the platform in case of a complete electrical power failure, a load shift, or any VALVE other emergency.

  • Page 35: Lifting The Aerial Work Platform

    HAULOTTE GROUP 3 OPERATION LIFTING THE AERIAL WORK PLATFORM Refer to Figure 3-11.  Completely retract and lower all booms into the “stowed” position.  Secure both boom travel latches (A).  Remove all loose materials from machine.  Retract all outriggers cylinders to fully “stowed” (upright) position.

  • Page 36: Transporting The Aerial Work Platform On To A Truck Bed

    HAULOTTE GROUP 3 OPERATION TRANSPORTING THE AERIAL WORK PLATFORM ON TO A TRUCK BED Refer to Figure 3-12  Verify that the truck or trailer is parked on a firm and level surface.  Completely retract and lower all booms into the “stowed” position.

  • Page 37: Equipment Maintenance

    Refer to it when inspecting this machine. 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.

  • Page 38: Battery Recharge

    HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE BATTERY RECHARGE Recharge aerial work platform batteries after each 8-hour work shift or as needed. When using the gas engine, press (push) the (4) button on the platform (upper) control panel to charge GENERATOR the batteries. When the aerial work platform is not in use, batteries should be recharged at least once per week.

  • Page 39: Battery Fault Codes

    HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE BATTERY RECHARGE (CONTINUED)  If a Battery fault is detected, a fault code will appear on the display. The red CHARGE CURRENT indicator LED will become lit. Refer to Table 4-1 for battery charger fault codes.

  • Page 40: Daily Service Checks

    HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE DAILY SERVICE CHECKS The following Maintenance Procedures should be performed daily or before each operation: Verify that all decals are legible, correctly applied, and in plain view. Refer to the “Decal Replacement” section of this manual for decal locations.

  • Page 41: Figure 4-2. Outrigger Position Switch

    HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE DAILY SERVICE CHECKS (CONTINUED) Verify that outrigger safety interlocks operate correctly.  Begin with the outriggers fully extended and the aerial work platform leveled. Raise one outrigger until the footpad is not in contact with the ground.

  • Page 42: Figure 4-3. Hydraulic Reservoir

    HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE DAILY SERVICE CHECKS (CONTINUED) Inspect Hydraulic System and Fluid Levels.  Check all hydraulic hoses and fittings for leaks and / or damage. Tighten or replace as necessary to prevent hydraulic oil or pressure loss.

  • Page 43: Weekly Service Checks

    HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE WEEKLY SERVICE CHECKS Perform the following service checks at least once each week in addition to all recommended Daily Service Checks: Check Battery Electrolyte level.  If battery charge is low, add enough water to bring the electrolyte level to the top of the plates.

  • Page 44: Monthly Service Checks

    HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE 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.

  • Page 45: Annual Service Checks

    HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE ANNUAL SERVICE CHECKS Perform the following service checks at least once each year: Replace Hydraulic Oil and Oil Filter.  Wipe away dirt and excess oil from the area around the power unit, hoses and filter(s) using cleaning cloths and alcohol solvent.

  • Page 46: Figure 4-6. Machine Position For Slew Ring Measurement

    If the difference in measurements is greater than 0.25 in (6.35 mm) the slew ring bearing should be replaced. Contact Haulotte Group Customer Service Department: at 1-800-537- TAKE 0540 or visit Haulotte Group online at MEASUREMENT HERE www.haulotte-usa.com if additional information is needed.

  • Page 47: Structural Inspection

    HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE STRUCTURAL INSPECTION A comprehensive structural inspection of the unit shall be performed under any of the following conditions:  Ten 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.

  • Page 48: Leveling System Calibration Procedure

    HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE LEVELING SYSTEM CALIBRATION PROCEDURE Machine Leveling Instructions Deploy all of the outriggers, and slightly raise the base of the machine to position it for leveling. Refer to Figure 4-9. Place a small, standard “level” on the base of the turntable (Level Placement Option A). If a small “level”...

  • Page 49: Figure 4-12. Ground (Lower) Control Panel For Leveling System

    HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE LEVELING SYSTEM CALIBRATION PROCEDURE (CONTINUED) Ground (Lower) Control Box Calibration Instructions Use the ground (lower) control panel to access the control box maintenance menu. Refer to Figure 4-12. Figure 4-12. Ground (Lower) Control Panel for Leveling System...

  • Page 50: Overload Protection Calibration Procedure

    HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE OVERLOAD PROTECTION CALIBRATION PROCEDURE Load Sense Zeroing 1) Remove the securing the to the , allowing CLEVIS PIN PLATFORM PLATFORM MOUNTING BRACKET to pivot about the and rest on the ground. This removes the load...
  • Page 51 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE OVERLOAD PROTECTION CALIBRATION PROCEDURE (CONTINUED) 5) Scroll through the maintenance menu using the (7) button to scroll down, use the TURTLE RABBIT (8) button to scroll back up, until “LOAD SENSE ZERO CALIBRATION UTILITY” is displayed in (3).
  • Page 52 The Ratio should be within 3.50:1 to 4.00:1. If so, continue on to Step 11. If the ratio is not within the above values, contact Haulotte Group Customer Service Department: at 1-800-537-0540 or visit Haulotte Group online at www.haulotte-usa.com...

  • Page 53: Additional Service Information

    HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE 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.

  • Page 54: Manual Outrigger Retraction

    HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE MANUAL OUTRIGGER RETRACTION The Manual Outrigger Retraction procedure allows the outriggers to be retracted into the “stowed” (upright) position during hydraulic power interruption or power failure. The Manual Outrigger Control Kit, Part Number: A-00819, including a wire harness, is required to perform this manual procedure.

  • Page 55: Hydraulic Pressure Gauge

    HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE HYDRAULIC PRESSURE GAUGE The Hydraulic Pressure Gauge Part Number B02-16-0020 is used to measure the aerial work platform’s system pressure. It is used as a diagnostic tool when the Boom is NOT performing as expected.

  • Page 56: Troubleshooting

    HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE TROUBLESHOOTING Refer to the following Table for basic Troubleshooting Operations. Contact Haulotte Group Customer Service Department: at 1-800-537-0540 or visit Haulotte Group online at www.haulotte-usa.com with any questions or before attempting any advanced troubleshooting operations.

  • Page 57: Error Code Definitions - Controls

    If an error condition is detected, the appropriate error code will be displayed on this panel. Refer to Table 4-3 to resolve the error, or contact Haulotte Group Customer Service Department: at 1-800-537-0540 or visit Haulotte Group online at www.haulotte-usa.com...
  • Page 58 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE TABLE 4-3 ERROR CODE DEFINITIONS ERROR MESSAGE ERROR DEFINITION TO SIMULATE ERROR TO CLEAR ERROR COMMENTS 013 PRESSURE Pressure sensor output Disconnect Pressure This is a self clearing Machines with Moment SENSOR IS is out of range Sensor error.
  • Page 59 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE TABLE 4-3 ERROR CODE DEFINITIONS ERROR MESSAGE ERROR DEFINITION TO SIMULATE ERROR TO CLEAR ERROR COMMENTS 027 OPEN CIRCUIT A load of less than 70mA Disconnect a wire from This is a latched error. Checked only at...
  • Page 60 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE TABLE 4-3 ERROR CODE DEFINITIONS ERROR MESSAGE ERROR DEFINITION TO SIMULATE ERROR TO CLEAR ERROR COMMENTS 043 OPEN CIRCUIT A load of less than 70mA Disconnect a wire from This is a latched error. Checked only at...
  • Page 61 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE TABLE 4-3 ERROR CODE DEFINITIONS ERROR MESSAGE ERROR DEFINITION TO SIMULATE ERROR TO CLEAR ERROR COMMENTS 058 SHORTED CIRCUIT Excessive load was Use a piece of wire to This is a latched error. Checked only at...
  • Page 62 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE TABLE 4-3 ERROR CODE DEFINITIONS ERROR MESSAGE ERROR DEFINITION TO SIMULATE ERROR TO CLEAR ERROR COMMENTS 073 OPEN CIRCUIT A load of less than 70mA Disconnect a wire from This is a latched error. Not Used...
  • Page 63 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE TABLE 4-3 ERROR CODE DEFINITIONS ERROR MESSAGE ERROR DEFINITION TO SIMULATE ERROR TO CLEAR ERROR COMMENTS 088 SHORTED CIRCUIT Excessive load was Use a piece of wire to This is a latched error. Checked only at...
  • Page 64 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE TABLE 4-3 ERROR CODE DEFINITIONS ERROR MESSAGE ERROR DEFINITION TO SIMULATE ERROR TO CLEAR ERROR COMMENTS 103 OUTREACH Boom has exceeded Put 500lbs in boom, level This is a self clearing Machines with Moment NEAR MAXIMUM...
  • Page 65 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE TABLE 4-3 ERROR CODE DEFINITIONS ERROR MESSAGE ERROR DEFINITION TO SIMULATE ERROR TO CLEAR ERROR COMMENTS 128 SHORTED CIRCUIT Excessive load was Use a piece of wire to This is a latched error. Checked only at...
  • Page 66 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE TABLE 4-3 ERROR CODE DEFINITIONS ERROR MESSAGE ERROR DEFINITION TO SIMULATE ERROR TO CLEAR ERROR COMMENTS 143 OPEN CIRCUIT A load of less than 70mA Disconnect a wire from This is a latched error. Checked only at...
  • Page 67 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE TABLE 4-3 ERROR CODE DEFINITIONS ERROR MESSAGE ERROR DEFINITION TO SIMULATE ERROR TO CLEAR ERROR COMMENTS 158 SHORTED CIRCUIT Excessive load was Use a piece of wire to This is a latched error. Checked only at...

  • Page 68: Error Code Definitions - Motor Controller

    Refer to Figure 4-19 for a visual of the controller. Refer to Table 4-4 to resolve the Fault, or contact Haulotte Group Customer Service Department: at 1-800-537-0540 or visit Haulotte Group online at www.haulotte-usa.com...
  • Page 69 HAULOTTE GROUP 4 EQUIPMENT MAINTENANCE TABLE 4-4. ERROR CODE DEFINITIONS - MOTOR CONTROLLER FLASH PRIORITY ID FAULT DESCRIPTION SOLUTION FAULT Line Contactor did Line contactor did not close or is Check line contactor wiring and Molex not Close otherwise open circuit.
  • Page 70 HAULOTTE GROUP 5 CYLINDER REPLACEMENT...

  • Page 71: Cylinder Replacement

    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.

  • Page 72: Figure 5-2. Location Of Slave Cylinder

    HAULOTTE GROUP 5 CYLINDER REPLACEMENT MASTER / SLAVE CYLINDER REPLACEMENT (CONTINUED) Master Cylinder (Continued)  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.

  • Page 73: Lift Cylinder Replacement

    HAULOTTE GROUP 5 CYLINDER REPLACEMENT LIFT CYLINDER REPLACEMENT 45XA / HLA 16 PX Aerial Work Platforms have three (3) lift cylinders, use the following procedure to remove and replace faulty or damaged hydraulic cylinders. Refer to Figure 5–3 for the location of these cylinders.
  • Page 74 HAULOTTE GROUP 5 CYLINDER REPLACEMENT LIFT CYLINDER REPLACEMENT (CONTINUED)  Verify that the cylinder is supported by lifting straps and an overhead hoist or equivalent.  Remove the pivot pin using a hammer and a brass or hardwood drift. ...

  • Page 75: Outrigger Cylinder Replacement

    HAULOTTE GROUP 5 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 of the aerial work platform onto the outrigger.
  • Page 76 HAULOTTE GROUP 5 CYLINDER REPLACEMENT OUTRIGGER CYLINDER REPLACEMENT (CONTINUED)  At the base of the cylinder, unbolt and remove the pin retainer from each side of the pivot pin.  Remove the pivot pin using a hammer and a brass or hardwood drift.

  • Page 77: Decal Replacement

    HAULOTTE GROUP 6 DECAL REPLACEMENT 6 DECAL REPLACEMENT WARNING 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.

  • Page 78: Decal Kit - Ansi

    HAULOTTE GROUP 6 DECAL REPLACEMENT DECAL KIT - ANSI...
  • Page 79 HAULOTTE GROUP 6 DECAL REPLACEMENT DECAL KIT - ANSI B06-01-4033 DECAL KIT - Includes the following: ITEM NO. PART NUMBER DESCRIPTION QTY. B06-00-0405 Decal - Warning - Hand Pinch Point B06-00-0403 Decal - Emergency Lower Valve B06-00-0521 Decal - Danger - Tip Over Hazard...

  • Page 80: Identification Plates & Optional Equipment - Ansi

    HAULOTTE GROUP 6 DECAL REPLACEMENT IDENTIFICATION PLATES & OPTIONAL EQUIPMENT - ANSI...
  • Page 81 HAULOTTE GROUP 6 DECAL REPLACEMENT IDENTIFICATION PLATES & OPTIONAL EQUIPMENT – ANSI IDENTIFICATION PLATES (Used on all standard equipment) ITEM NO. PART NUMBER DESCRIPTION QTY. B06-00-0487 Decal - Notice - Unleaded Fuel Only (Gas Engine Option) B06-00-0526 Key Ring Tag...

  • Page 82: Decals - Ansi

    HAULOTTE GROUP 6 DECAL REPLACEMENT DECALS - ANSI B06-00-0034 B06-00-0482 B06-00-0471 B06-00-0484 B06-00-0161B B06-00-0521 B06-00-0536 B06-00-0530 B06-00-0531 45XA / HLA 16 PX 0202-0523 B06-00-0564...
  • Page 83 HAULOTTE GROUP 6 DECAL REPLACEMENT DECALS – ANSI (CONTINUED) B06-00-0505 B06-00-0404 B06-00-0561 B06-00-0475 B06-00-0477 B06-00-0405 B06-00-0037 B06-00-0481...
  • Page 84 HAULOTTE GROUP 6 DECAL REPLACEMENT DECALS – ANSI (CONTINUED) B06-00-0608 B06-00-0541 B06-00-0562 B06-00-0639 B06-00-0495 B06-00-0488 B06-00-0544 B06-00-0581 B06-00-0504 B06-00-0552...
  • Page 85 HAULOTTE GROUP 6 DECAL REPLACEMENT DECALS – ANSI (CONTINUED) B06-00-0403 B06-00-0474 B06-00-00068 B06-00-0503 B06-00-0494 B06-00-0062 B06-00-0487 B06-00-0473 B06-00-0529 B06-00-0485 B06-00-0498 B06-00-0497...
  • Page 86 HAULOTTE GROUP 6 DECAL REPLACEMENT...

  • Page 87: Optional Equipment

    Always use only those components manufactured and / or authorized by Haulotte Group. Never make any adjustments or modifications or otherwise alter the equipment in any way that is not expressly recommended by the manufacturer.

  • Page 88: Material Lift Hook

    HAULOTTE GROUP 7 OPTIONAL EQUIPMENT MATERIAL LIFT HOOK If an aerial work platform is equipped with the Material Lift Hook option, several steps need to be performed to change from the Platform to the Lift Hook. Use the follow procedure to make this change.

  • Page 89: Figure 7-4. Platform Removal

    HAULOTTE GROUP 7 OPTIONAL EQUIPMENT MATERIAL LIFT HOOK (CONTINUED)  Insert the from the platform (upper) control panel into the receptacle on the bottom right of the PLUG ground (lower) control box (replacing the from the previous step). LOOPBACK PLUG ...

  • Page 90: Figure 7-6. Material Lift "Stowed" Position

    HAULOTTE GROUP 7 OPTIONAL EQUIPMENT MATERIAL LIFT HOOK (CONTINUED)  On the ground (lower) control panel, turn the key switch (1) clockwise to the platform control (1b) icon. This provides for optimal control of the lift by using the platform (upper) control panel, and also allows for remote access.

  • Page 91: Platform Rotator

    HAULOTTE GROUP 7 OPTIONAL EQUIPMENT PLATFORM ROTATOR The optional platform rotator allows the operator to rotate the elevated work platform 90º around a vertical axis by actuating a rotator handle found below the platform control panel. Refer to Figure 6-2.
  • Page 92 HAULOTTE GROUP 7 OPTIONAL EQUIPMENT...

  • Page 93: Material Safety

    HAULOTTE GROUP 8 MATERIAL SAFETY 8 MATERIAL SAFETY The following Material Safety Data Sheets describe the correct procedures for the safe handling of chemical components within the Model 45XA HLA 16 PX Self-Propelled Aerial Work Platform, 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.
  • Page 94 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET LEAD ACID BATTERIES, WET, FILLED WITH ACID - UN 2794 (CONT.)
  • Page 95 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET LEAD ACID BATTERIES, WET, FILLED WITH ACID-UN 2794 (CONT.)
  • Page 96 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET LEAD ACID BATTERIES, WET, FILLED WITH ACID - UN 2794 (CONT.)
  • Page 97 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET LEAD ACID BATTERIES, WET, FILLED WITH ACID - UN 2794 (CONT.)

  • Page 98: Powerflow™ Aw Hvi Hydraulic Oil

    HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW™ AW HVI HYDRAULIC OIL...
  • Page 99 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW™ AW HVI HYDRAULIC OIL (CONTINUED)
  • Page 100 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW™ AW HVI HYDRAULIC OIL (CONTINUED)
  • Page 101 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW™ AW HVI HYDRAULIC OIL (CONTINUED)
  • Page 102 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW™ AW HVI HYDRAULIC OIL (CONTINUED)
  • Page 103 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW™ AW HVI HYDRAULIC OIL (CONTINUED)
  • Page 104 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW™ AW HVI HYDRAULIC OIL (CONTINUED)

  • Page 105: Ansi Reprint

    The following sections are reprinted from the ANSI A92.5-2006 code in effect at the time of manufacture and govern the safe use of the Haulotte Group. It is the responsibility of all owners and operators of this machine to read, understand and obey the recommendations set forth by the ANSI code.
  • Page 106 HAULOTTE GROUP 9 ANSI REPRINT (4) Records of repairs accomplished to correct of owners with due consideration of the knowledge that malfunctions and problems. the aerial platform will be carrying personnel. (5) Name of the person(s) trained. Responsibilities Upon Purchase. Upon purchase of the aerial platform, the buyer: (6) Name of the person(s) providing the training.
  • Page 107 HAULOTTE GROUP 9 ANSI REPRINT (3) That has been out of service for a period longer owner shall assume the responsibilities of the user as than 3 months. specified in Section 7 of this standard and shall ensure the person has been:...
  • Page 108 HAULOTTE GROUP 9 ANSI REPRINT trainee. The document evidencing training shall include shall be determined by the manufacturer’s the following information: recommendations and be compatible with operating conditions and the severity of the operating environment. (1) Name of entity providing training or retraining.
  • Page 109 HAULOTTE GROUP 9 ANSI REPRINT (4) Retrained, if necessary, based on the user’s (a) Election of Systems: The user may elect to observation and evaluation of the operator. use either a restraint or an arrest system. Fall Restraint Systems – An anchorage, belt or 7.6.1...
  • Page 110 HAULOTTE GROUP 9 ANSI REPRINT ladders, or any other devices on the platform for (b) Ensure personnel in the worksite area that achieving additional height or reach is prohibited. may be affected are aware of the movement, communicating and maneuvering the aerial (10) Precaution for other moving equipment.
  • Page 111 HAULOTTE GROUP 9 ANSI REPRINT (37) Protecting against unauthorized use. The user shall caution in evaluating each situation. Since the operator direct the operator not to use, rent, lease, or is in direct control of the aerial platform, conformance provide the aerial platform for any form of beneficial with good safety practices in this area is the use unless so authorized.
  • Page 112 HAULOTTE GROUP 9 ANSI REPRINT (8) Safety rules and regulations. Understanding of Hazardous Locations. It shall be the responsibility of the operator to understand the hazard (9) Authorization to operate. classification of the intended location of operation (10) Operator warnings and instructions.
  • Page 113 HAULOTTE GROUP 9 ANSI REPRINT (11) Reporting problems or malfunctions. The operator (26) Altering safety devices. Interlocks or other safety shall immediately report to a supervisor any devices shall not be altered or disabled. problem(s) or malfunction(s) that become evident (27) Snagged platform.

  • Page 114: Figure 9-1. Minimum Safe Approach Distance

    HAULOTTE GROUP 9 ANSI REPRINT Basic principles. Sound principles of safety, training 10.3 Lessee as an Owner. When a lessee uses the aerial inspections, maintenance, application, and operation platform as an owner, the lessee shall have the consistent with all data available regarding the...

  • Page 115: Table 9-1. Minimum Safe Approach Distances

    HAULOTTE GROUP 9 ANSI REPRINT TABLE 9-1. MINIMUM SAFE APPROACH DISTANCES Minimum Safe Approach Distance Voltage Range (Phase to Phase) (Feet) (Meters) 0 to 300V Avoid Contact Over 300V to 50KV 3.05 Over 50KV to 200KV 4.60 Over 200KV to 350KV 6.10...
  • Page 116 HAULOTTE GROUP 9 ANSI REPRINT...

  • Page 117: Inspection Form For Haulotte Aerial Work Platforms

    All service checks shall be performed in accordance with manufacturer’s recommendations (Refer to the Equipment Maintenance section of this manual). Copy this form as needed. Direct any questions to the Haulotte Group Customer Service Department: at 1-800-537-0540 or visit Haulotte Group online at www.haulotte-usa.com.
  • Page 118 Distributed by: 125 Taylor Parkway Archbold, Ohio 43502 Phone (800) 537-0540 (419) 445-8915 (419) 445-0367 www.haulotte-usa.com B33-01-0104 Rev. 4. 45XA HLA 16 PX Operator’s & Maintenance Manual - August 2012...

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