Haulotte Group 3522A Operator's Maintenance Manual
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Haulotte Group 3522A Operator's Maintenance Manual

Summit series trailer-mounted booms
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OPERATOR'S & MAINTENANCE
MANUAL
B33-01-0093 Rev 4
May 2013

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  • Page 1 OPERATOR’S & MAINTENANCE MANUAL B33-01-0093 Rev 4 May 2013...
  • Page 2 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 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 FALL PROTECTION ........................11 MANUAL FORCE........................... 11 WIND LOADING ..........................12 EXPLOSION HAZARD........................12 MAINTENANCE ..........................13 2 SPECIFICATIONS .......................... 15 RANGE OF MOTION ........................
  • Page 4 HAULOTTE GROUP DECAL KIT - AU ..........................88 IDENTIFICATION PLATES & OPTIONAL EQUIPMENT – AU............90 7 OPTIONAL EQUIPMENT........................93 DRIVE AND SET ........................... 94 MATERIAL LIFT HOOK ......................... 97 PLATFORM ROTATOR....................... 100 8 MATERIAL SAFETY ........................101 LEAD ACID BATTERIES, WET, FILLED WITH ACID – UN 2794 ..........101 POWERFLOW™...
  • 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. Boom Travel Latches ....................... 28 Figure 3-4. Outrigger Control Panel ....................29 Figure 3-5.
  • Page 6 HAULOTTE GROUP PRIMARY MACHINE COMPONENTS PLATFORM JIB BOOM EXTENSION BOOM SECONDARY BOOM JIB LIFT CYLINDER SLAVE CYLINDER KNUCKLE MASTER CYLINDER SECONDARY LIFT CYLINDER PRIMARY BOOM SECONDARY BOOM REST LOWER LINK PRIMARY LIFT CYLINDER TURNTABLE GENERATOR INTERFACE PLATE JACK OUTRIGGER COUPLER...

  • 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 HAULOTTE GROUP 1 SAFETY DURING OPERATION (CONTINUED) ALWAYS use a three (3) point contact (both hands and one foot) when entering or exiting the work platform. ALWAYS wear proper footgear. ALWAYS keep the platform free of debris. ALWAYS keep personnel and obstructions clear of the aerial work platform when repositioning the boom or platform.

  • Page 11: Fall Protection

    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.

  • Page 12: Wind Loading

    HAULOTTE GROUP 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.

  • 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 boom function is permitted at a time, this function is only operable as long as the boom is within the safe operating zone.

  • Page 16: Specifications

    HAULOTTE GROUP 2 SPECIFICATIONS SPECIFICATIONS 41 ft 9 in (12.9 m) Maximum Working Height 35 ft 9 in (10.9 m) Maximum Platform Height 19 ft (5.8 m) Up and Over Height Maximum Horizontal Outreach From Centerline 22 ft 6 in (6.9 m) From Outrigger Footpad Edge 17 ft 5 in (5.3 m)
  • Page 17 HAULOTTE GROUP 2 SPECIFICATIONS SPECIFICATIONS (CONTINUED) 3,000 psi (207 bar) (20,684 kPa) Hydraulic Pressure 3.1 Gallons (11.7 L) Reservoir Capacity 5.1 Gallons (19.3 L) Hydraulic System Capacity HVI AW32 Hydraulic Oil (Standard) Maximum Decibel 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: Haulotte Group

    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

    3 OPERATION 3 OPERATION The 3522A / HTA 13 P Articulating Boom Lift is a Summit Series™ trailer-mounted aerial work platform, designed and manufactured to position personnel with their tools and equipment at overhead work locations. The platform load capacity is rated at 500 pounds (227 kilograms). During all aerial work platform operations, four extended outriggers support the unit.

  • 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.
  • 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 cannot be operated (non-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) 7-8. Boom Rotation Buttons Pressing (pushing) in and holding a desired (6) button and the SPEED BOOM ROTATION button at the same time enables the boom to rotate in the direction. Pressing...

  • Page 28: 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 Haulotte Articulating Boom Lift. Read and obey all safety precautions and operating instructions, as well as all Federal, State, and ...

  • Page 29: Figure 3-4. 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 30 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 31: 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 32: Figure 3-6. 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 33: Towing The Aerial Work Platform

    HAULOTTE GROUP 3 OPERATION TOWING THE AERIAL WORK PLATFORM The aerial work platform trailer includes a single axle, two-inch ball hitch, hydraulic surge brakes, mechanical parking brake, safety chains, brake lights and side marker lights. Proper aerial work platform transport requires the proper inspection and attachment of these components before towing.

  • Page 34: Figure 3-8. Trailer Hitching

    HAULOTTE GROUP 3 OPERATION TOWING THE AERIAL WORK PLATFORM (CONTINUED) Procedure to hitch and tow the aerial work platform. Back the tow vehicle to the trailer. Verify that the ball and trailer hitch are aligned and that the trailer hitch has proper clearance above the ball.

  • Page 35: Lifting The Aerial Work Platform

    HAULOTTE GROUP 3 OPERATION LIFTING THE AERIAL WORK PLATFORM Refer to Figure 3-9.  Completely lower and retract 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 A Truck Bed

    HAULOTTE GROUP 3 OPERATION TRANSPORTING THE AERIAL WORK PLATFORM ON A TRUCK BED Refer to Figure 3-10.  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 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.

  • 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

    0.25 in (6.35 mm) the slew ring bearing should be replaced. Contact Haulotte Group Customer TAKE Service Department: at 1-800-537-0540 MEASUREMENT HERE or visit Haulotte Group online at www.haulotte-usa.com for additional information. GROUND LEVEL Figure 4-8. Platform Position After Rotation...

  • 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 (3) button to scroll down, use the TURTLE RABBIT (5) button to scroll back up, until “Load Sense Zero Calibration Utility” is found.

  • Page 52: 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 53: 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 54: 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 55: 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 56: 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 57 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 58 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 59 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 60 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 61 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 62 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 63 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 64 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 65 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 66 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 67: Error Code Definitions - Motor Controller

    Refer to Figure 4-15. Refer to Figure 4-15 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 with any questions.
  • Page 68 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 69: 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 70: 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 71: Lift Cylinder Replacement

    5 CYLINDER REPLACEMENT LIFT CYLINDER REPLACEMENT 3522A / HTA 13 P 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 72 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 73: 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 74 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 75: 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 76: Decal Kit - Ansi

    HAULOTTE GROUP 6 DECAL REPLACEMENT DECAL KIT - ANSI...
  • Page 77 Decal - Warning - Fork Lift Use B06-00-0538 Decal - 3522A Transfer - Black B06-00-0481 Decal - Caution - Transport Latch B06-00-0535 Decal - Notice - Range of Motion - 3522A B06-00-0482 Decal - Danger - Electrocution B06-00-0037 Decal - "Lubricate Semi - Annually" B06-00-0471...

  • Page 78: Identification Plates & Optional Equipment - Ansi

    HAULOTTE GROUP 6 DECAL REPLACEMENT IDENTIFICATION PLATES & OPTIONAL EQUIPMENT - ANSI...
  • Page 79 HAULOTTE GROUP 6 DECAL REPLACEMENT IDENTIFICATION PLATES & OPTIONAL EQUIPMENT – ANSI IDENTIFICATION PLATES (Used on all standard equipment) ITEM NO. PART NUMBER DESCRIPTION QTY. B06-00-0526 Key Ring Tag B06-00-0524 Annual Inspection Plate B06-00-0490 VIN Plate B06-00-0499 ANSI ID Plate REPLACEMENT DECALS FOR OPTIONAL EQUIPMENT –...

  • Page 80: 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 B06-00-0535 B06-00-0530 B06-00-0531 3522A / HTA 13 P 0202-0523 B06-00-0538...
  • Page 81 HAULOTTE GROUP 6 DECAL REPLACEMENT DECALS – ANSI (CONTINUED) B06-00-0505 B06-00-0533 B06-00-0404 B06-00-0534...
  • Page 82 HAULOTTE GROUP 6 DECAL REPLACEMENT DECALS – ANSI (CONTINUED) B06-00-0550 B06-00-0405 B06-00-0544 B06-00-0542 B06-00-0543 B06-00-0475 B06-00-0481 B06-00-0477 B06-00-0495 B06-00-0496 B06-00-0541 B06-00-0037 B06-00-0551 B06-00-0504 B06-00-0478 B06-00-0552...
  • Page 83 HAULOTTE GROUP 6 DECAL REPLACEMENT DECALS – ANSI (CONTINUED) B06-00-0473 B06-00-00068 B06-00-0503 B06-00-0403 B06-00-0062 B06-00-0487 B06-00-0474 B06-00-0494 B06-00-0488 B06-00-0486 B06-00-0527 B06-00-0485 B06-00-0528 B06-00-0497 B06-00-0547 B06-00-0553 B06-00-0529...

  • Page 84: Decal Kit - Ce

    HAULOTTE GROUP 6 DECAL REPLACEMENT DECAL KIT - CE...
  • Page 85 QTY. B06-00-0538-CE Decal - HTA 13 P - Black Clear Vinyl with Black Letters B06-00-0537-CE Decal - Notice - Range of Motion - 3522A B06-01-4021-DU DECAL KIT - Dutch - Includes the following: B06-01-4021-EN DECAL KIT - English International - Includes the following:...

  • Page 86: Identification Plates & Optional Equipment - Ce

    HAULOTTE GROUP 6 DECAL REPLACEMENT IDENTIFICATION PLATES & OPTIONAL EQUIPMENT - CE...
  • Page 87 HAULOTTE GROUP 6 DECAL REPLACEMENT IDENTIFICATION PLATES & OPTIONAL EQUIPMENT - CE IDENTIFICATION PLATES (Used on all standard CE equipment) ITEM NO. PART NUMBER DESCRIPTION QTY. B06-00-0499-CE ID Plate B06-00-0490 VIN Plate DECALS FOR OPTIONAL EQUIPMENT - CE ITEM NO.

  • Page 88: Decal Kit - Au

    HAULOTTE GROUP 6 DECAL REPLACEMENT DECAL KIT - AU...
  • Page 89 DESCRIPTION QTY. B06-00-0538-CE Decal - HTA 13 P - Black Clear Vinyl with Black Letters B06-00-0535-CE Decal - Notice - Range of Motion - 3522A B06-01-4021- EN DECAL KIT - English International - Includes the following: ITEM NO. PART NUMBER DESCRIPTION QTY.

  • Page 90: Identification Plates & Optional Equipment - Au

    HAULOTTE GROUP 6 DECAL REPLACEMENT IDENTIFICATION PLATES & OPTIONAL EQUIPMENT – AU...
  • Page 91 HAULOTTE GROUP 6 DECAL REPLACEMENT IDENTIFICATION PLATES & OPTIONAL EQUIPMENT - AU IDENTIFICATION PLATES (Used on all standard equipment) ITEM NO. PART NUMBER DESCRIPTION QTY. B06-00-0524 Annual Inspection Plate B06-00-0490 VIN Plate B06-00-0499 ANSI ID Plate REPLACEMENT DECALS FOR OPTIONAL EQUIPMENT - AU ITEM NO.
  • Page 92 HAULOTTE GROUP 6 DECAL REPLACEMENT...

  • Page 93: Optional Equipment

    7 OPTIONAL EQUIPMENT 7 OPTIONAL EQUIPMENT The Haulotte Model 3522A HTA 13 P is a Summit Series™ trailer-mounted aerial work platform that may be may be equipped with one or more optional components designed for the convenience and safety of operators when using the equipment to accomplish specific tasks.

  • Page 94: Drive And Set

    HAULOTTE GROUP 7 OPTIONAL EQUIPMENT DRIVE AND SET The Drive and Set Option allows the operator to drive the aerial work platform over a short distance on level ground, deploy, retract and level the outriggers from the platform (upper) control panel. The platform (upper) control panel, which has additional controls added, is used to control all boom motions, as well as all Drive and Set functions.
  • Page 95 HAULOTTE GROUP 7 OPTIONAL EQUIPMENT DRIVE & SET CONTROLS (CONTINUED) Drive Enable Button. Press (push) in and hold the (2) button to activate the (1). To stop, release DRIVE ENABLE JOYSTICK either the (2) button or the (1). DRIVE ENABLE JOYSTICK Diagnostic Indicators.
  • Page 96 HAULOTTE GROUP 7 OPTIONAL EQUIPMENT DRIVE AND SET USE (CONTINUED) During Operation Utilize the Drive and Set option to advance to the next work location. Use the following procedure to operate the Drive and Set option.  Completely lower the platform into its “stowed” position.

  • Page 97: 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 98: Figure 7-5. 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 99: Figure 7-7. 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 100: 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 101: Material Safety

    The following Material Safety Data Sheets describe the correct procedures for the safe handling of chemical components within the Model 3522A HTA 13 P Articulating 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.
  • Page 102 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET LEAD ACID BATTERIES, WET, FILLED WITH ACID - UN 2794 (CONT.)
  • Page 103 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET LEAD ACID BATTERIES, WET, FILLED WITH ACID-UN 2794 (CONT.)
  • Page 104 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET LEAD ACID BATTERIES, WET, FILLED WITH ACID - UN 2794 (CONT.)
  • Page 105 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET LEAD ACID BATTERIES, WET, FILLED WITH ACID - UN 2794 (CONT.)

  • Page 106: Powerflow™ Aw Hvi Hydraulic Oil

    HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW™ AW HVI HYDRAULIC OIL...
  • Page 107 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW™ AW HVI HYDRAULIC OIL (CONTINUED)
  • Page 108 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW™ AW HVI HYDRAULIC OIL (CONTINUED)
  • Page 109 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW™ AW HVI HYDRAULIC OIL (CONTINUED)
  • Page 110 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW™ AW HVI HYDRAULIC OIL (CONTINUED)
  • Page 111 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW™ AW HVI HYDRAULIC OIL (CONTINUED)
  • Page 112 HAULOTTE GROUP 8 MATERIAL SAFETY MATERIAL SAFETY DATA SHEET POWERFLOW™ AW HVI HYDRAULIC OIL (CONTINUED)

  • Page 113: Axle And Related Components

    HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS 9 AXLE AND RELATED COMPONENTS If you have a North American - ANSI aerial lift platform refer to section 9A Dexter Axle and Related Components. If you have a European - CE aerial lift platform refer to section 9B Bradley Brake Adjustment section.
  • Page 114 HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS SET UP AND ADJUSTMENT (CONTINUED) GENERAL MAINTENANCE – HYDRAULIC BRAKES Drum Brake Adjustment - Manual Most Dexter 12 1/4” hydraulic 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 (322 Kilometers), of operation when the brake shoes and drums have “seated”, (2) at 3,000 mile (4,828 Kilometers) intervals, (3) or as use and...
  • Page 115 HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS SET UP AND ADJUSTMENT (CONTINUED) 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.

  • Page 116: Table 9-1. Wheel Torque Requirements

    HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS SET UP AND ADJUSTMENT (CONTINUED) Wheel nuts / bolts should be torqued before the first road use and after each wheel removal. Check and re-torque after the first 10, 25, and 50 miles (16, 40, and 80 kilometers). Check periodically thereafter.

  • Page 117: How To Use Your Electric Brakes Properly

    HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS 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.

  • Page 118: Maintenance

    HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS MAINTENANCE TABLE 9-3. MAINTENANCE SCHEDULE Item Function Required Weekly 3 Months or 6 Months or 12 Months or 3,000 Miles 6,000 Miles 12,000 Miles (4,828 Km) (9,656 Km) (19,312 Km) At Every Use Brakes Test That They Are Operational.
  • Page 119 HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS MAINTENANCE (CONTINUED) MAGNETS Your electric brakes are 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.
  • Page 120 HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS MAINTENANCE (CONTINUED) BRAKE LUBRICATION Before reassembling, apply a light film of grease or anti-seize compound on the brake anchor pin, the actuation arm bushing and pin, and the areas on the backing plate that are in contact with the brake shoes and magnet lever arm.
  • Page 121 HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS MAINTENANCE (CONTINUED)  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.
  • Page 122 HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS MAINTENANCE (CONTINUED) When turning the drum surface, the maximum rebore diameter is as follows:  7” Brake Drum – 7.090” (18.0 cm) diameter  10” Brake Drum – 10.090” (25.6 cm) diameter ...
  • Page 123 HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS MAINTENANCE (CONTINUED) BEARING LUBRICATION – GREASE CAUTION 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.

  • Page 124: Table 9-4. Recommended Wheel Bearing Lubrication Specifications

    HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS MAINTENANCE (CONTINUED) TABLE 9-4. RECOMMENDED WHEEL BEARING LUBRICATION SPECIFICATIONS Grease Thicker Type Lithium Complex Dropping Point 215°C (419°F) Minimum Consistency NLGI No. 2 Additives EP, Corrosion & Oxidation Inhibitors Viscosity Index 80 Minimum...
  • Page 125 HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS MAINTENANCE (CONTINUED) 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 it is not kicked or torn and is still capable of properly sealing the bearing cavity.
  • Page 126 HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS MAINTENANCE (CONTINUED) E-Z LUBE® LUBRICATION The Procedure is as follows: 1. Remove the rubber plug from the end of the grease cap. 2. Place a standard grease gun into the grease fitting located in the end of the spindle. Make sure the grease gun nozzle is fully engaged on the fitting.
  • Page 127 HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS MAINTENANCE (CONTINUED) 7. Install drum assembly onto spindle (DO NOT Force). 8. Install steel washer into spindle end. 9. Start self-locking nut into spindle thread by hand. Complete installation using a 1 1/2” or 1 7/16” socket and torque wrench.

  • Page 128: Table 9-5. Tire Wear Diagnostic Chart

    HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS MAINTENANCE (CONTINUED) TABLE 9-5. TIRE WEAR DIAGNOSTIC CHART 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 wires.

  • Page 129: Table 9-6. Magnet Amperes Chart

    HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS MAINTENANCE (CONTINUED) TABLE 9-6. MAGNET AMPERES CHART Brake Size Amps / Magnet Two Brakes Four Brakes Six Brakes Magnet / Ohms 7” x 1 1/4” 10.0 15.0 10” x 1 1/2” 12.0 18.0 10”...

  • Page 130: Storage

    HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS STORAGE STORAGE PREPARATION If 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. 1. Remove the emergency breakaway battery and store inside, out of the weather. Charge the battery at lease every 90 days.
  • Page 131 HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS STORAGE (CONTINUED) 8. Inspect oil or grease seals for wear or nicks. Replace if necessary. 9. Lubricate hub bearings. Refer to procedure in this manual. 10. Reinstall hubs and adjust bearings per instructions in this manual.

  • Page 132: Trouble Shooting

    HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS TROUBLE SHOOTING INTRODUCTION TO TROUBLESHOOTING – HYDRAULIC BRAKING SYSTEM Proper brake function is critical to the safe operation of any vehicle. A properly installed vacuum / hydraulic, air / hydraulic system should not require any special attention with the exception of routine maintenance as defined by the manufacturer.

  • Page 133: Table 9-7. Troubleshooting - Hydraulic Braking System

    HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS TROUBLE SHOOTING (CONTINUED) TABLE 9-7. TROUBLESHOOTING – HYDRAULIC BRAKING SYSTEM Symptom Causes Remedies No Brakes Broken or Kinked Brake Line Repair or Replace Severe Under Adjustment Adjust Brakes Malfunctioning Actuation System Troubleshoot System...
  • Page 134 HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS TROUBLESHOOTING (CONTINUED) INTRODUCTION TO TROUBLESHOOTING – ELECTRIC BRAKING SYSTEM 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.

  • Page 135: Table 9-8. Troubleshooting - Electric Braking System

    HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS TROUBLE SHOOTING (CONTINUED) TABLE 9-8. TROUBLESHOOTING - ELECTRIC BRAKING SYSTEM Symptom Causes Remedies No Brakes Open Circuits Find and Correct Severe Under Adjustment Adjust Brakes Faulty Controller Test and Correct Short Circuits Find and Correct...

  • Page 136: 9B Bradley Brake Adjustment

    HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS 9B BRADLEY BRAKE ADJUSTMENT AERIAL WORK PLATFORMS WITH STANDARD BRAKES All brake adjustments must be done with the aerial work platform’s wheels off the ground, with completely slack (no tension). BRAKE CABLES Refer to Figure 9-1 for steps 2 through 7.

  • Page 137: Figure 9-1. Standard Brake Adjustment Procedure

    HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS Figure 9-1. Standard Brake Adjustment Procedure...

  • Page 138: Thirteen Percent (13 %) Grade Test

    HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS Verify that the rod’s front end is connected at the , through the , and secured COUPLER CLEVIS PIN with a M10 lock nut. The rod should not protrude more than 5/8” past the lock nut.

  • Page 139: Aerial Work Platforms With Drive And Set Brakes

    HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS AERIAL WORK PLATFORMS WITH DRIVE AND SET BRAKES All brake adjustments must be done with the aerial work platform’s wheels off the ground, with completely slack (no tension). BRAKE CABLES Refer to Figure 2 for steps 2 through 7.

  • Page 140: Troubleshooting The Bradley Running Gear

    HAULOTTE GROUP 9 AXLE AND RELATED COMPONENTS Verify that the rod’s front end is connected at the , through the , and secured COUPLER CLEVIS PIN with a M10 lock nut. The should not protrude more than 5/8” past the lock nut.

  • Page 141: 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 142 Distributed by: 125 Taylor Parkway Archbold, Ohio 43502 Phone (800) 537-0540 (419) 445-8915 (419) 445-0367 www.haulotte-usa.com B33-01-0093 Rev. 4. 3522A / HTA 13 P Operator’s & Maintenance Manual - May 2013...

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