Haulotte 45XA, HLA16PX Operator's Maintenance Manual

OPERATOR’S & MAINTENANCE

MANUAL

B33-01-0104 Rev. 4 August 2012

HAULOTTE GROUP

SELF-PROPELLED AERIAL WORK PLATFORM

This equipment is designed and manufactured in compliance with the duties, responsibilities and standards set forth for manufacturers in the ANSI, CSA, AS and / or CE standards in effect at the time of manufacture.

This equipment meets or exceeds applicable ANSI, CSA, AS and / or CE 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.

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. Some countries require that operators are licensed to operate aerial work platforms. Check with all Federal, State, and Local codes and regulations before operation this machine.

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. Check local requirements with your manager.

This includes all manufacturer recommendations as well as

Haulotte Group is dedicated to the continuous improvement of this and all Haulotte Group products. Therefore, equipment information is subject to change without notice. Direct any questions or concerns regarding errors and / or discrepancies in this manual to the Haulotte Group Customer Service Department: at 1-800-537-0540 or visit Haulotte Group online at www.haulotte-usa.com.

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

HAULOTTE GROUP

TABLE OF CONTENTS

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; HAULOTTE NORTH AMERICA ................................................18

WARRANTY CLAIMS PROCEDURE.............................................................................................19

DAMAGED EQUIPMENT POLICY.................................................................................................20

3 OPERATION...................................................................................................................................21

GROUND (LOWER) CONTROL PANEL........................................................................................22

PLATFORM (UPPER) CONTROL PANEL.....................................................................................25

JOYSTICK - PLATFORM (UPPER) CONTROL PANEL................................................................28

NORMAL OPERATING PROCEDURE..........................................................................................29

DRIVE FUNCTION.........................................................................................................................32

MANUAL BRAKE RELEASE..........................................................................................................32

MANUAL BOOM OPERATION.......................................................................................................33

LIFTING THE AERIAL WORK PLATFORM...................................................................................35

TRANSPORTING THE AERIAL WORK PLATFORM ON TO A TRUCK BED...............................36

4 EQUIPMENT MAINTENANCE.......................................................................................................37

BATTERY RECHARGE..................................................................................................................38

BATTERY FAULT CODES.............................................................................................................39

DAILY SERVICE CHECKS ............................................................................................................40

WEEKLY SERVICE CHECKS........................................................................................................43

MONTHLY SERVICE CHECKS .....................................................................................................44

ANNUAL SERVICE CHECKS ........................................................................................................45

STRUCTURAL INSPECTION ........................................................................................................47

MOTOR DRYING INSTRUCTIONS ...............................................................................................47

LEVELING SYSTEM CALIBRATION PROCEDURE .....................................................................48

OVERLOAD PROTECTION CALIBRATION PROCEDURE..........................................................50

ADDITIONAL SERVICE INFORMATION.......................................................................................53

MANUAL OUTRIGGER RETRACTION..........................................................................................54

HYDRAULIC PRESSURE GAUGE................................................................................................55

TROUBLESHOOTING ...................................................................................................................56

ERROR CODE DEFINITIONS – CONTROLS................................................................................57

ERROR CODE DEFINITIONS – MOTOR CONTROLLER.............................................................68

5 CYLINDER REPLACEMENT.........................................................................................................71

MASTER / SLAVE CYLINDER REPLACEMENT...........................................................................71

LIFT CYLINDER REPLACEMENT.................................................................................................73

OUTRIGGER CYLINDER REPLACEMENT...................................................................................75

6 DECAL REPLACEMENT ...............................................................................................................77

DECAL KIT - ANSI .........................................................................................................................78

ID E N T I F I CAT I O N P L ATE S & OPT I O N A L EQU I P MEN T - A N S I............................................................80

DECALS - ANSI..............................................................................................................................82

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

LIST OF TABLES

TABLE 1-1. MINIMUM SAFE APPROACH DISTANCES .....................................................................9

TABLE 1-2. BEAUFORT SCALE ........................................................................................................12

TABLE 4-1. BATTERY CHARGER FAULT CODES...........................................................................39

TABLE 4-2. TROUBLE SHOOTING....................................................................................................56

TABLE 4-3 ERROR CODE DEFINITIONS.........................................................................................57

TABLE 4-4. ERROR CODE DEFINITIONS - MOTOR CONTROLLER ..............................................68

TABLE 9-1. MINIMUM SAFE APPROACH DISTANCES .................................................................115

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. Drive Speed Selector....................................................................................................32

Figure 3-7. Manual Break Release..................................................................................................32

Figure 3-8. Hand Pump Controls for Manual Operation...............................................................33

Figure 3-9. Location of Lift Cylinders for Manual Boom Lowering.............................................34

Figure 3-10. Location of Manual Lowering Valves..........................................................................34

Figure 3-11. Lifting the Aerial Work Platform..................................................................................35

Figure 3-12. Transport the Aerial Work Platform............................................................................36

Figure 4-1. Battery Charger Faceplate...........................................................................................38

Figure 4-2. Outrigger Position Switch............................................................................................41

Figure 4-3. Hydraulic Reservoir......................................................................................................42

Figure 4-4. Wheel Nut Tightening Sequence.................................................................................44

Figure 4-5. Display Run Time Hours..............................................................................................45

Figure 4-6. Machine Position for Slew Ring Measurement..........................................................46

Figure 4-7. Slew Ring Position Measurement ...............................................................................46

Figure 4-8. Platform Position After Rotation.................................................................................46

Figure 4-9. Position Machine for Leveling.....................................................................................48

Figure 4-10. Level Sensor Digitally Based.......................................................................................48

Figure 4-11. Level Sensor Pendulum Based...................................................................................48

Figure 4-12. Ground (Lower) Control Panel for Leveling System .................................................49

Figure 4-13. Platform Position..........................................................................................................50

Figure 4-14. Ground (Lower) Control Panel for Overload Protection ...........................................50

Figure 4-15. Manual Outrigger Control Wire Harness ....................................................................54

Figure 4-16. Bottom Side of the Ground (lower) Control Box. ......................................................54

Figure 4-17. Hydraulic Power Unit....................................................................................................54

Figure 4-18. Attaching the Pressure Gauge to the Hydraulic Power Unit. ...................................55

Figure 4-19. Motor Controller............................................................................................................68

Figure 5-1. Location of Master Cylinder ........................................................................................71

Figure 5-2. Location of Slave Cylinder...........................................................................................72

Figure 5-3. Location of Manual Lowering Valves for Lift Cylinder Replacement ......................73

Figure 5-4. Push “Button” Lowering Valve ...................................................................................73

Figure 5-5. Lift Cylinder Replacement ...........................................................................................73

Figure 5-6. Outrigger Cylinder Replacement.................................................................................75

Figure 5-7. Cylinder Valve Removal...............................................................................................75

Figure 7-1. Disconnect Plug from Load Sense Module................................................................88

Figure 7-2. Remove Platform (Upper) Control Box.......................................................................88

Figure 7-3. Loopback plug..............................................................................................................88

Figure 7-4. Platform Removal.........................................................................................................89

Figure 7-5. Material Lifting Hook Installation ................................................................................89

Figure 7-6. Material Lift “Stowed” Position...................................................................................90

Figure 7-7. Material Lift “In Use” Position.....................................................................................90

Figure 7-8. Manual Platform Rotator..............................................................................................91

Figure 9-1. Minimum Safe Approach Distance............................................................................114

HAULOTTE GROUP

PRIMARY MACHINE COMPONENTS

JIB LIFT

CYLINDER

SLAVE

CYLINDER

PLATFORM CONTROL BOX

PLATFORM

JIB BOOM

EXTENSION BOOM

SECONDARY BOOM

KNUCKLE

POWER UNIT

COMPARTMENT

ENGINE

COMPARTMENT

PRIMARY

BOOM REST

LIFT CYLINDER

PRIMARY BOOM

FORK LIFT POCKETS

SECONDRY

BOOM REST

TURNTABLE

SECONDARY

FUEL TANK

REAR AXLE

MASTER CYLINDER

LOWER LINK

PRIMARY LIFT CYLINDER

GROUND CONTROL BOX

OUTRIGGER

PAD

OUTRIGGER

FOOT

OUTRIGGER

CYLINDER

BOOM

LATCH

FRONT AXLE

OUTRIGGER

LEG

HAULOTTE GROUP 1 SAFETY

1 SAFETY

Proper training is required for the safe operation of any mechanical device. Failure to follow all instructions and safety precautions in this manual and attached to the aerial work platform will result in death or personal injury.

Prior to Operation:  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 instructor before attempting to

operate or maintain the aerial work platform.

The use of intelligence and co mmon sens e is the b est pr actic e when follo wing an y 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.

HAULOTTE GROUP 1 SAFETY

BEFORE OPERATION

Ensure the following general safety precautions are followed before operating the aerial work platform:

ALWAYS inspect the usage area for potential hazards, such as unstable or unlevel surfaces, overhead obstructions and electrically charged wires or conductors. ALWAYS watch for moving vehicles in the operating area.

ALWAYS conduct a thorough visual inspection of the aerial work platform before operation. Check for damaged or worn parts, hydraulic leaks, damaged wiring, loose wiring conductors, damaged outriggers, low tire pressure, uneven tire wear or tire damage. Check for any improperly operating components. NEVER operate the aerial work platform if any damage is observed or suspected. Repair damaged or malfunctioning equipment before operation.

ALWAYS wear proper clothing. Wear protective equipment as required by 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 the “Equipment Maintenance” section of this manual.

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 of 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 (3.05 m) 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

(Phase to Phase)

(Feet) (Meters)

Distance

0 to 300V Avoid Contact Over 300V to 50KV 10 3.05 Over 50KV to 200KV 15 4.60 Over 200KV to 350KV 20 6.10 Over 350KV to 500KV 25 7.62 Over 500KV to 750KV 35 10.67 Over 750KV to 1000KV 45 13.72

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 from ground level until power lines are shut off.

ALWAYS operate only on a firm and level surface. NEVER operate on surfaces that do not support the aerial work platform with its rated load capacity, or on surfaces that do not support force exerted by the outriggers during aerial work platform operation. Operate only on surfaces that can support a pressure of 25 psi (1.8 kg/cm

) to ensure safe operation.

ALWAYS keep personnel away from potential pinch and shear points and from potential crush hazards as indicated by decals attached to the aerial work platform.

ALWAYS keep the safety bar lowered (closed) unless personnel are entering or exiting the work platform.

HAULOTTE GROUP 1 SAFETY

DURING OPERATION (CONTINUED)

ALWAYS use a three (3) point contact (both hands and one foot) when entering or exiting the work platform.

ALWAYS wear proper footgear. ALWAYS keep the platform free of debris. ALWAYS keep personnel and obstructions clear of the aerial work platform when repositioning the

boom or platform. ALWAYS cordon the area surrounding the outriggers to keep personnel, vehicles and moving

equipment away from the aerial work platform while in use.

ALWAYS stay clear of overhead obstructions, including wires and cables. ALWAYS disengage aerial work platform travel latches before raising aerial work platform sections

and reengage aerial work platform travel latches before transporting. ALWAYS exercise caution when rotating the boom from the ground (lower) control panel. ALWAYS

watch for personnel inside the radius of the turntable and boom arm when rotating from the ground (lower) or platform (upper) 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.

ALWAYS maintain joystick enable lever 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 with materials or personnel on board, or while platform 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. NEVER operate aerial work platform in conditions where wind speeds exceed 28 mph (12.5 m/sec or

45 km/h). Steady or gusty winds that exceed the recommended wind speed may affect stability and aerial work platform operation.

NEVER allow ropes, electric cords, hoses or other equipment to become entangled in the aerial work platform.

NEVER exceed the load limits set by the manufacturer / factory. Use only the material lifting hook, supplied as an option and manufactured by Haulotte Group when lifting materials. Safely stow all tools and equipment.

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. 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 machine. NEVER use the boom or platform to place a load against any structure, materials or equipment. NEVER climb on the boom. NEVER leave an elevated platform unattended. NEVER leave the keys in the aerial work platform while unattended or not in use.

DRIVE SAFETY

ALWAYS maintain an awareness of limited sight and blind spots when operating drive functions. ALWAYS limit travel speed according to surface conditions, slope, location of personnel and

obstructions and any other factors which may result in collision.

NEVER operate drive functions on slopes exceeding 45% (24°). NEVER engage in stunt driving, horseplay or any other behavior considered unsafe according to

employer, job site and all Federal, State, and Local codes and regulations.

NEVER operate the internal combustion engine in an area that is not properly ventilated. NEVER fuel the internal combustion engine while smoking, or while near spark or open flame.

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 this manual for manual operation.

 Keep platform floor clear of debris.

 Lower the platform entry mid-rail or close the entry gate before

operating

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). 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 33 ft (10 m) 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. 1 Light Air Direction of wind shown by smoke. 2 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).

10> Storm, Violent

Storm, Hurricane

Trees uprooted, widespread damage to structures, widespread devastation

1-3 4-7 6-11 1.6-3.3

8-12 12-19 3.4-5.4

13-17 20-28 5.5-7.9

18-24 29-38 8.0-10.7

25-30 39-49 10.8-13.8

31-38 50-61 13.9-17.1

39-46 62-74 17.2-20.7

47-54 75-88 20.8-24.4

55> 89> 24.5>

0-1 0-0.3 1-5 0.3-1.5

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 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.  NEVER operate engine unless in a well-ventilated area to avoid carbon monoxide poisoning.

HAULOTTE GROUP 1 SAFETY

MAINTENANCE

Ensure the following general safety precautions are followed while performing maintenance on the aerial work platform:

General Maintenance

ALWAYS perform maintenance procedures according to manufacturer’s guidelines. NEVER

disregard or bypass proper maintenance procedures. ALWAYS inspect hydraulic system to ensure that all lines, connectors and fittings are properly

fastened and are in good condition.

ALWAYS turn the key switch to the “

OFF” position and remove key before performing maintenance.

Whenever possible, ALWAYS perform maintenance with the boom and platform in a fully lowered, “stowed” position.

ALWAYS secure the boom before performing maintenance on hydraulic cylinders. ALWAYS disconnect power to the hydraulic pump drive motor before making electrical checks to the

hydraulic valves. ALWAYS keep all mechanical parts properly adjusted and lubricated according to maintenance

schedule and manufacturer / factory specifications. Refer to the “Equipment Maintenance” section of this manual.

ALWAYS perform a function check of operating controls before each use and after any repairs have been made.

ALWAYS locate and protect against possible pinch points before performing any maintenance or repairs. Be aware of personnel under, and around the aerial work platform.

ALWAYS use only manufacturer-approved parts to repair or maintain aerial work platform. If any portion of this aerial work platform is rebuilt or repaired, retesting is required in accordance with manufacturer / factory instructions.

ALWAYS maintain a safe distance while testing the hydraulic components. ALWAYS relieve hydraulic pressure before loosening or removing hydraulic components. NEVER test or operate the hydraulic components while personnel are near the aerial work platform.

NEVER allow water or foreign particles into the DC electric motor housing. Inclusion of water or foreign particles may cause serious damage to the motor. If the motor becomes wet, refer to the “Motor Drying Instructions” located in the Equipment Maintenance section of this manual, or contact the Haulotte Customer Service Department: at 1-800-537-0540 for proper drying instructions.

NEVER add unauthorized fluids to the hydraulic system or battery. NEVER mix hydraulic oils. Consult manufacturer specifications. Refer to the “Equipment Maintenance” section of this manual for hydraulic system maintenance procedures. Refer to the next page for Battery maintenance.

NEVER exceed the manufacturer’s recommended relief valve settings. NEVER touch or allow metal tools to contact any components that are sensitive to static discharge.

ALWAYS use static discharge prevention mats and grounding devices when handling electronic

components. NEVER adjust, repair, replace or bypass any hydraulic or electrical control or safety device. These

include, but are not limited to; hydraulic load control and flow control valves, solenoid valves and limit switches. ALWAYS consult an authorized Haulotte Group technician 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.

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. ALWAYS avoid contact with battery acid. Battery acid causes serious burns and should be kept

away from skin or eyes. If contact occurs, flush with water and consult a physician immediately.

ALWAYS disconnect ground cable first when removing battery. ALWAYS connect ground cable last when installing battery. ALWAYS charge batteries in open, well-ventilated areas. ALWAYS replace batteries using only parts recommended by manufacturer / factory. ALWAYS use

only batteries with sealed caps over cells.

NEVER smoke while servicing batteries. NEVER charge batteries near flammable materials. NEVER allow batteries to overcharge and boil. NEVER short across battery posts to check for current. NEVER break a live circuit at the battery. NEVER disconnect battery from charger while charger is connected to a live power source. NEVER jump-start other vehicles using the aerial work platform batteries.

HAULOTTE GROUP 2 SPECIFICATIONS

2 SPECIFICATIONS

The following information is based on ideal working conditions. Machine performance may vary based on work environment and on machine options.

Only one telescoping boom motion is permitted at a time and only as long as the telescoping boom is within the safe operating zone. When a selected telescoping boom motion exceeds a safe operating limit, the telescoping boom motion ceases and another telescoping boom motion must be selected within the safe operating zone. Refer to Figure 2-1.

RANGE OF MOTION

Figure 2-1. Range of Motion

HAULOTTE GROUP 2 SPECIFICATIONS

SPECIFICATIONS

Maximum Working Height Maximum Platform Height Up and Over Height Maximum Horizontal Outreach

From Centerline of Rotation 27 ft 0 in (8.2 m) From Outrigger Footpad Edge 21 ft 0 in (6.4 m)

Rated Platform Capacity

Without Platform Rotation 500 lb (227 kg) With Platform Rotation 440 lb (200 kg)

Maximum Number of Occupants Total Weight Turntable Rotation Leveling Capability Wheel Base Turning Radius

Inside 11 ft 0 in (3.4 m) Outside 16 ft 8 in (5.0 m)

Platform Dimensions

Height 3 ft 7 in (1.1 m) Length 2 ft 6 in (0.8 m) Width 5 ft 0 in (1.5 m)

Platform Rotation / Type (Optional) Stowed Dimensions

Height 6 ft 7 in (2.1 m) Length 18 ft 2 in (5.5 m) Width 5 ft 6 in (1.7 m)

Jib Dimensions

Length 4 ft 3 in (1.3 m) Vertical Motion 150° (+70° / -80°)

Outrigger Footprint (To Center of Pad)

Length 12 ft 4 in (3.8 m) Width 11 ft 4 in (3.5 m) Footpad Diameter 12.5 in (0.3 m)

Brake

Maximum Drive Speed

DC 1.75 mph (3 km/h) IC 3.5 mph (6 km/h)

Gradeability Tire Size Control System Battery Charger

220 Volt 50 Hz

Engine

Gas (Air Cooled) Kawasaki 21 hp (15.7 kw) Diesel (Air Cooled) Hatz 16 hp (11.2 kw)

51 ft 0 in (15.7 m) 45 ft 0 in (13.7 m)

20 ft 9 in (6.3 m)

4,900 lb (2,223 kg)

700º Non-Continuous

12.5º

8 ft 8 in (2.7 m)

120° / Manual

Spring Applied

45%

26 x 12 Bar Lug

24V DC

4 x 6V 245 amp-hr

110 Volt 60 Hz

HAULOTTE GROUP 2 SPECIFICATIONS

SPECIFICATIONS (CONTINUED)

Hydraulic Pressure Reservoir Capacity Hydraulic System Capacity Hydraulic Oil (Standard) Maximum Noise Level

DC Mode – Ground (Lower) 60 dBA DC Mode – Platform (Upper) 55 dBA Engine Mode – Ground (Ground) 70 dBA Engine Mode – Platform (Upper 65 dBA

Function Speeds Boom - Primary

Primary, Up - Fast Primary, Up - Slow Primary, Down – Fast Primary, Down - Slow

Boom - Secondary

Secondary Up - Fast Secondary Up - Slow Secondary Down - Fast Secondary Down - Slow

Boom - Jib

Jib, Up – Fast Jib, Up - Slow Jib, Down - Fast Jib, Down - Slow

Extension Boom

Boom Extend - Fast Boom Extend - Slow Boom Retract - Fast Boom Retract - Slow

Turntable 700° Non Continuous Rotation

Turntable Rotation - Fast Turntable Rotation - Slow

Platform

Platform Compensation - Up - Fast Platform Compensation - Up - Slow Platform Compensation - Down - Fast 10-14 sec Platform Compensation - Down - Slow 14-18 sec

Outrigger (Auto Level)

Outrigger Extend Outrigger Retract

Localized (Foot Plate) Pressure per Outrigger Maximum Pressure per Tire - Floor Loading 35 psi (2.5 bar) Operating Temperature Range

-20º to 110º Fahrenheit (-29º to 43º Celsius)

3,000 psi (207 bar) (20,684 kPa)

4.3 Gallons (16.3 L)

6.3 Gallons (23.9 L) HVI AW32

22-26 sec 54-58 sec 22-26 sec 89-93 sec

20-24 sec 38-42 sec 32-36 sec 74-78 sec

8-12 sec 12-16 sec 20-24 sec 38-42 sec

24-28 sec 48-52 sec 28-32 sec 58-62 sec

194-198 sec 326-330 sec

10-14 sec 18-22 sec

18-22 sec 30-34 sec

25 psi (1.8 kg/cm

) (176.5 kPa)

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).

In addition, Haulotte further warrants the structural elements of each new product made by it, as defined in its then current warranty policies and procedures, to be free from defects in material or workmanship for five (5) years from the warranty start date (delivery date).

Haulotte agrees to repair or replace at its own expense; at its facility in Frederick MD, or at an authorized repair facility designated by Haulotte, any part or parts of the product found to be defective in material or workmanship, provided Haulotte is notified of such defect or defects within the applicable warranty period and given a reasonable time to correct the defect. In no case shall any warranty extend to defects in materials, components, or services furnished by third parties. Defects caused by chemical action or the presence of abrasive materials and defects arising following the operation beyond rated capacity or the improper use or application of any products shall not be considered defects within the scope of this warranty. If any repairs or alterations are made or any parts are replaced during the applicable warranty periods by anyone other than Haulotte or an entity authorized by Haulotte for use in its products, customer shall pay for such repairs or parts without recourse against Haulotte, and Haulotte should be relieved of responsibility for fulfillment of this warranty with respect to such repairs, alterations, or replacement so made. Haulotte obligations under this warranty shall at all times be subject to its current warranty policies and procedures. The above mentioned warranty shall not apply to replacement or service parts made and sold by Haulotte. Periodic maintenance, periodic maintenance items (including paint and decals), and minor adjustments are excluded from this warranty. Certain components, including, but not limited to, engines, tires and batteries, which may be part of the product are not manufactured or warranted by Haulotte. Any applicable warranty for such component is provided through the original manufacturer of the component or its distributor organization. Haulotte warranty does not apply to defects caused by negligence, misuse, accidental damage, inadequate or improper use or maintenance, acts of nature and normal wear and tear of the products.

Under no circumstances shall Haulotte be liable for any consequential or special damages which any person or entity may incur or claim to incur as a result of any defect in the product or in any correction or alteration thereof made or furnished by Haulotte or others. Consequential or special damage includes, but not limited to cost of transportation, lost sales, lost orders, lost profits, lost income, increased over head, labor and material costs, and cost of manufacturing variances and operational inefficiencies. Haulotte maximum liability under this warranty shall be the purchase price paid to Haulotte with respect to the product to which such warranty is claimed. This warranty constitutes Haulotte entire and exclusive warranty as to the product and is the sole and exclusive remedy for the product defects in material and workmanship. Haulotte does not assume (and has not authorized any other person to assume on its behalf) any other warranty or liability in connection with any product covered by this warranty. Haulotte expressly disclaims any and all other warranties of any kind whatsoever as to the product furnished hereunder, including but not limited to any express warranties, except for the exclusive warranty provided herein, or implied warranties as to merchantability, or fitness for any particular purpose.

This warranty shall be void, if, upon the occurrence of any incident involving any product made by Haulotte and resulting in any personal injury or property damage, customer shall fail to notify Haulotte within 48 hours of such occurrence or permit Haulotte and its representatives to have immediate access to such product and all records of or within the control of the customer relating to the product and occurrence. For the procedure to apply for warranty please refer to the warranty procedure (document # QC-00001). North America Warranty 2010/4. QC-00002

HAULOTTE GROUP 2 SPECIFICATIONS

WARRANTY CLAIMS PROCEDURE

In order to qualify for warranty coverage, the following conditions must be met:

1) Return of completed “Warranty Registration” form to Haulotte Group|BilJax within 15 days of receipt of product;

2) Notification to Haulotte Group|BilJax Service within 48 hours of any claimed defect, or damage resulting from the claimed defect;

3) Warranty is limited to parts that are determined to be defective by an authorized service dealership in conjunction with Haulotte Group|BilJax Service. This does not include parts worn out due to normal wear and tear.

Haulotte Group|BilJax authorized dealers or distributors are responsible for filing claims under warranty. Listed below is the warranty claims procedure.

1) Contact Haulotte Group|BilJax Customer Service Department: at 1-800-537-0540 or visit Haulotte Group online at www.haulotte-usa.com Machine serial number and machine hours must be provided when call is placed. A call ID number will be created when the call is placed. The service representative will issue the call ID number to you at the end of the call.

2) Identify the components to be claimed under warranty along with description of failure. An RMA number will be issued from Haulotte Group|BilJax to return warranty parts at the time the parts order is placed.

3) Replacement parts will then be sent by Haulotte Group|BilJax to the dealer or distributor. All parts are invoiced at dealer|distributor list price. Credits will be issued when defective parts are returned to Haulotte Group|BilJax under the proper RMA number and found to be defective under warranty.

4) After completing repairs, submit warranty application form and return the defective parts to Haulotte Group|BilJax. Warranty application form and parts must be received within 30 days of claim in order to be eligible for credit. Returned parts are to be sent prepaid and will be credited when part is received and verified. Warranty labor rate will be paid at current rate set by Haulotte Group|BilJax. The amount of labor hours reimbursed will be determined by Haulotte Group|BilJax and will be limited to 4 hours unless approved by Haulotte Group|BilJax Service.

5) The warranty application must include; the issued RMA number, the invoice number for the associated parts, the machine serial number, the machine hours on the date of failure, the issued call ID number, failure and repair description, and requested customer information.

Failure to follow the warranty claims procedure may result in delay in processing claim or denial of the claim. Haulotte Group|BilJax reserves the right to limit or adjust warranty claims with regard to parts, labor, and travel time. Replacement components purchased from suppliers other than Haulotte Group|BilJax are not covered under the terms of this warranty.

to report the claim and verify warranty coverage.

QC-00001

HAULOTTE GROUP 2 SPECIFICATIONS

DAMAGED EQUIPMENT POLICY

Safety Statement

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

Damage Policy

There may be occasions when a Haulotte Group aerial work platform is involved in an incident that results in structural damage to the aerial work platform. Such damage can seriously compromise the ability of the aerial work platform to perform in a safe manner. Therefore, whenever a Haulotte Group aerial work platform has sustained visual structural damage, or when there is suspected internal structural damage, Haulotte Group may require that the aerial work platform be returned to our facility for a complete inspection and recertification. For any questions concerning whether your aerial work platform may have sustained structural damage or the Damaged Equipment Policy, direct any questions to the Haulotte Group Customer Service Department: at 1-800-537-0540 or visit Haulotte Group online at www.haulotte-usa.com

Damage Repair Notice

There may be occasions when a Haulotte Group aerial work platform is involved in an accident resulting in damage to non-structural components. When such damage occurs and repairs are made by the owner or area distributor, please notify Haulotte Group of these non-maintenance repairs and request a repair form to be filled out and returned to Haulotte Group.

HAULOTTE GROUP 3 OPERATION

3 OPERATION

The Haulotte Model 45XA / HLA 16 PX is a Self-Propelled 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.

The aerial work platform drive function has the option to be battery (DC) or fuel (IC) powered, the boom functions are battery (DC) operated only. This machine is operated with electronic pushbutton controls, a hydraulic power unit, a hydraulic gear motor and hydraulic cylinders. The hydraulic power unit includes a reservoir, pump and control valves. Hydraulic cylinders elevate and extend the telescoping boom and maintain the platform leveling during operation. The hydraulic motor and mating worm gear allow the telescoping boom to rotate 700º Non-Continuous around a vertical axis.

The hydraulic power unit uses a 24-Volt DC motor to drive the hydraulic pump. The DC motor is powered by four 6-Volt DC, 245 amp-hour deep charge batteries connected in

series. An automatic onboard battery charger is provided for recharging the batteries at the end of each work period.

The Kawasaki (IC) engine (21 hp (16 kw)) is fueled by gas. The Hatz (IC) engine (16 hp (12 kw)) is fueled by diesel.

The ground (lower) control panel controls the power, outriggers, boom lift elevation, and rotation functions.

The platform (upper) control panel also controls the power, outriggers, boom lift elevation, rotation functions, and drive functions.

NOTE: The elevation and rotation controls are operational only when the outriggers are correctly extended and the extension boom is within a programmed safe operating zone.

The ground (lower) control panel includes a lighted text window that displays the current operating status or an existing error condition.

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

In the event of power loss, control system failure or other malfunction, boom lowering functions may be accomplished manually.

To manually operate boom retraction, and turntable rotation functions, use the hand pump, and “motion selection” valve on the hydraulic pump unit that can be accessed inside the pump compartment.

Manual lowering of the boom and platform may also be performed by actuating the valve plunger found on the base of each boom lift cylinder. Pushing in and holding the valve “button” on the appropriate cylinder retracts that cylinder, thereby retracting that part of the boom. The boom may need to be rotated to a clear area before lowering.

HAULOTTE GROUP 3 OPERATION

GROUND (LOWER) CONTROL PANEL

The ground (lower) control panel is used to operate outriggers and 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.

Figure 3-1. Ground (Lower) Control Panel

1. Key Switch

Turning the KEY SWITCH (1) counter clockwise to the GROUND (1a) icon selects operation from the ground (lower) control panel. Turning the

PLATFORM KEY SWITCH (1) to the vertical position (power “OFF”) interrupts all electric and hydraulic

power operations except emergency lowering

(1b) icon selects operation from the platform (upper) control panel. Turning the

. Removal of the KEY protects against any

KEY SWITCH (1), clockwise to the

unauthorized persons attempting to operate the aerial work platform. The removed with the

KEY SWITCH (1) in any selected position.

2. 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.  A lighted yellow LED indicates the need for charging soon.  A lighted red LED warns that the battery charge level is low; all functional operations

become non-functional until the batteries are recharged.

3-4. Engine Start and Choke / Glow Plug

Start a cold engine by pressing (pushing) in and holding the CHOKE (4) button then press (push) the

ENGINE START (3) button. To start / rest art a warm engine, press (push) the ENGINE START (3)

button only.

GLOW PLUG OPERATION – Press (push) the GLOW PLUG OPERATION (4) button and hold for 30-

60 seconds then press (push) the

ENGINE START (3) button.

KEY may be

HAULOTTE GROUP 3 OPERATION

GROUND (LOWER) CONTROL PANEL (CONTINUED)

5. Display Panel

The DISPL AY PANEL is a lighted text window that displays the current operating status or an existing error condition when the

6. Emergency Stop Button

When pushed in, the EMERGENCY STOP (6) button disconnects electrical power to the ground (lower) and platform (upper) control panels. The pressed (pushed) in to immediately stop all aerial work platform motion. To resume control, “pull out” the

EMERGENCY STOP (6).

7-8. Boom Extend / Retract Buttons

Pressing (pushing) in and holding a desired SPEED (15) button, and the BOOM EXTEND (7) button at the same time extends the secondary boom. Pressing (pushing) in and holding a desired

SPEED (15) button, and the BOOM RETRACT (8) button at the same time retracts the

secondary boom. Telescopic boom motion continues until the buttons are released, or until the boom reaches a hard stop, or a safe travel limit.

9-14. Boom Raise / Down Buttons

 Pressing (pushing) and holding a desired SPEED (15) button, and the PRIMARY BOOM

RAISE

(9) button at the same time will raise the primary boom. Pressing (pushing) and holding a desired same time will retract the primary boom.

 Pressing (pushing) and holding a desired

RAISE (11) button at the same time will raise the secondary boom. Pressing (pushing)

and holding a desired the same time will retract the secondary boom.

 Pressing (pushing) and holding a desired

(13)

button at the same time will raise the JIB BOOM, pressing (pushing) and holding a

desired retract the

SPEED (15) button, and the JIB BOOM DOWN (14) button at the same time will

JIB BOOM.

The selected Boom motion continues until the buttons are released or until the selected boom reaches a hard stop or a safe travel limit

SPEED (15) button, and the PRIMARY BOOM DOWN (10) button at the

SPEED (15) button, and the SECONDARY BOOM DOWN (12) button at

KEY SWITCH (1) is positioned at either (1a) or (1b).

EMERGENCY STOP button should only be

SPEED (15) button, and the S ECONDARY BOOM

SPEED (15) button, and the JIB BOOM RAISE

15. Speed Buttons

The SPEED (15) buttons are located along the lower right side of the control panel, one of the speed buttons must be pressed (pushed) in and held while selecting any boom function. There are four speeds that range from fast ( control the positioning of the Boom and the Jib.

16-17. Platform Tilt Buttons

Press (push) and hold any SPEED (15) button, and the desired PLATFORM TILT UP (16) or

PLATFORM TILT DOWN (17) button at the same time to level the work platform. This levels the

platform only, NOT the aerial work platform.

18-19. Boom Rotation Buttons

Pressing (pushing) and holding a desired SPEED (15) button, and the BOOM ROTATION (18) button at the same time enables the boom to rotate in the CLOCKWISE direction. Pressing (pushing) and holding a desired the same time enables the boom to rotate in the will rotate through 700° of Non-Continuous rotation until the buttons are released or the stop is reached.

RABBIT), to slow (TURTLE), available to help

SPEED (15) button, and the BOOM ROTATION (19) button at

COUNTER CLOCKWISE direction. The boom

HAULOTTE GROUP 3 OPERATION

GROUND (LOWER) CONTROL PANEL (CONTINUED)

Figure 3-1. Ground (Lower) Control Panel

20. 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” position, and the outriggers are functional.

21-24. Outrigger Controls

For simultaneous automatic outrigger extension / retraction of all four (4) outriggers: Select the

EXTEND (21) button or RETRACT (22) button and the AUTO LEVEL (23) button at the same

time. To individually extend or retract the outriggers: Select the

RETRACT

outrigger indicator LEDs (20) lights up when the outriggers are properly deployed and the aerial work platform weight is on the outrigger foot pads. Each of the outer outrigger LEDs (25) indicates load is on the outrigger foot pad. Each of the inner outrigger LEDs (26), when flashing, indicate that side is low, and needs to be further raised for leveling.

(22) button, and one of the four OUTRIGGER (24) buttons at the same time. The

EXTEND (21) button or

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

PLATFORM (1b) icon. Enter the work platform using a three (3) point contact (both hands and one foot).

The platform (upper) control panel includes the following controls and indicators. Refer to Figure 3-2.

KEY SWITCH (1) on the ground (lower) control panel, clockwise to the

Figure 3-2. Platform (Upper) Control Panel

1-2. Engine Start and Choke / Glow Plug

Start a cold engine by pressing (pushing) and holding the CHOKE (2) button and pressing (pushing) the press (push) the

GLOW PLUG OPERATION – Press (push) and hold the GLOW PLUG (2) button for 30-60 seconds

then press (push) the

ENGINE START (1) button to start the Engine. To start / restart a warm Engine,

START (1) button only.

ENGINE START (1) button.

3. Engine Stop

Press (push) the ENGINE STOP (3) button to shut the engine “OFF”.

4. Generator On / Off

To activate and / or deactivate the generator, press (push) the GENERATOR ON / OFF (4) button. When the generator is “

ON” the LED will be lit. The generator provides power to the battery charger as well as

both GFI outlets (one on the wall of the turntable, one on the bulkhead).

5. Fuel Toggle

Press (push) the

FUEL TOGGLE (5) button to change between the different types of fuel.

6. Horn Button

Pressing (pushing) the HORN (6) button will sound the HORN. Use the HORN (6) button to warn personnel in the area of a falling object hazard, impending boom motions, or the need for assistance.

Drive Speed Selector

Press (push) the and high speed / low torque. The Low speed / high torque setting is the machines’ default setting, and is recommended when operating on inclines.

DRIVE SPEED SELECTOR (7) button to switch between low speed / high torque

HAULOTTE GROUP 3 OPERATION

PLATFORM (UPPER) CONTROL PANEL (CONTINUED)

Figure 3-2. Pl atform (Upp er) Cont rol Panel

8. Battery Condition Indicator

Indicator LEDs light up to indicate the level of charge in the batteries.

become non-functional until the batteries are recharged.

9. Diagnostic Indicators

Indicator LED’s warn of machine or engine issues.

9A. General Fault - When lit, refer to the

for an error code.

Refer to Table 4-3 Error Code Definitions, located in the “Equipment Maintenance”

section of this manual.

9B. Load Sense Fault - When lit, this is an indication of too much weight in the work

platform; all functional operations become non-functional until the weight is below the Maximum Allowable Capacity (500 lb (227kg)) rating.

9C. Check Engine – When lit, turn the engine “

refer to the

DISPLAY PANEL on the ground (lower) control panel for an error code.

Refer to Table 4-3 Error Code Definitions, located in the “Equipment Maintenance”

section of this manual.

DISPLAY PANEL on the ground (lower) control panel

OFF” by using the ENGINE STOP (5) button;

10. Emergency Stop Button

When pushed in, the EMERGENCY STOP (10) button disconnects electrical power to the ground (lower) and platform (upper) control panels. The pressed (pushed) to immediately stop all aerial work platform functions. To resume control, pull the

EMERGENCY STOP (10) button out.

11-15 Outrigger Controls

The Outrigger controls on the platform (upper) control panel are identical to the controls on the ground (lower) control panel. Refer to the previous section for details.

EMERGENCY STOP (10) button should only be

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 reached. When referencing moving the operator, backwards is towards the operator.

16. Primary Boom Raise / Boom Lower Button

Press (push) the PRIMARY BOOM RAISE / BOOM LOWER (16) button until the LED is lit. Pressing (squeezing) the direction arrows, move the the primary boom, move the section

17. Boom Rotation Button

Press (push) the BOOM ROTATION (17) button until the LED is lit. To rotate CLOCKWISE press and hold the right side (orange arrow) of the

COUNTER CLOCKWISE press and hold the left side (white arrow) of the TOGGLE button on top of

the

JOYSTICK. To rotate the boom, press (squeeze) the ENABLE LEVER on the JOYSTICK and

move the joystick slightly off center. The boom will rotate through 700° of Non-Continuous rotation until the

18. Boom Extend / Retract Buttons

Press (push) the BOOM EXTEND / RETRACT (18) button until the LED is lit. Pressing (squeezing) the

ENABLE LEVER on the JOYSTICK, enables the function. Using the color-coded direction

arrows, move the secondary boom, move the

JOYSTICK is released, or until the boom reaches a hard stop or a safe travel limit is

JOYSTICK forward or backwards, forward is away from the

ENABLE LEVER on the JOYSTICK, enables the function. Using the color-coded

JOYSTICK slightly off center; move the JOYSTICK forward to raise

JOYSTICK backwards to lower the boom. Refer to the next

JOYSTICK – PLATFORM (UPPER) CONTROL PANEL for a visual of the JOYSTICK.

TOGGLE button on top of the JOYSTICK. To rotate

JOYSTICK is released, or a hard stop is reached.

JOYSTICK slightly off center; move the JOYSTICK back to extend the

JOYSTICK forward to retract the secondary boom.

19. Platform Tilt Button

Press (push) the PLATFORM TILT (19) button until the LED is lit. Pressing (squeezing) the

ENABLE LEVER on the JOYSTICK, enables the function. Using the color-coded direction arrows

move the the

JOYSTICK backwards to lower the platform.

JOYSTICK slightly off center; move the JOYSTICK forward to ra ise the platform, move

This levels the platform only, NOT the aerial work platform.

20. Secondary Boom Raise / Boom Lower Button

Press (push) the SECONDARY BOOM RAISE / BOOM LOWER (20) button until the LED is lit. Pressing (squeezing) the color-coded direction arrows, move the forward to raise the secondary boom, move the

ENABLE LEVER on the JOYSTICK, enables the function. Using the

JOYSTICK slightly off center; move the JOYSTICK

JOYSTICK backwards to lower the boom.

21. Jib Boom Raise / Boom Lower Button

Press (push) the JIB BOOM RAISE / BOOM LOWER (21) button until the LED is lit. Pressing (squeezing) the direction arrows, move the the jib boom, move the

ENABLE LEVER on the JOYSTICK, enables the function. Using the color-coded

JOYSTICK slightly off center; move the JOYSTICK forward to raise

JOYSTICK backwards to lower the boom.

22. Drive Enable LED

Once the outriggers are retracted and in the “stowed” (upright) position, the aerial work platform defaults to the drivable. If the LED is not lit, check the control panel to see if there are any boom function LED’s lit, if so toggle it off to enable the drive mode.

DRIVE MODE, the DRIVE MODE LED (22) will be lit, and the machine is

23. Beyond Leveling Capability

When the BEYOND LEVELING CAPABILITY LED (23) is lit; it is an indication that the aerial work platform is on a grade that is beyond the machines leveling capability. The LED will stay lit until the aerial work platform has reached a location that is within the machines leveling capability.

HAULOTTE GROUP 3 OPERATION

JOYSTICK - PLATFORM (UPPER) CONTROL PANEL

The platform (upper) control panel includes a JOYSTICK that operates the drive and boom functions when the Refer to Figure 3-3.

JOYSTICK TOGGLE SWITCH

The TOGGLE SWITCH is used in conjunction with two separate functions; boom rotation, and steering while driving the aerial work platform.

JOYSTICK ENABLE LEVER

To activate a function, press (push) the desired function (squeezing) the enables the function. Using the color-coded direction arrows move the the neutral position, and in the desired direction.

Moving the position increases the function speed. Boom motion continues until:

 The  The  The boom reaches a hard stop or a safe

Boom Rotation

ENABLE LEVER is pressed (squeezed).

button until the LED is lit, pressing

ENABLE LEVER on the JOYSTICK

JOYSTICK slightly off of

JOYSTICK away from the neutral

JOYSTICK is released. JOYSTICK is returned to center.

travel limit.

TOGGLE SWITCH

LEFT TOGGLE

RIGHT TOGGLE

ENABLE LEVER

Figure 3-3. Platform Controls Joystick

Shown upside down and reversed for clarity.

Use the TOGGLE SWITCH to determine the direction of rotation. To rotate CLOCKWISE press the right side of the

To rotate the boom: press (squeeze) the

TOGGLE SWITCH, to rotate COUNTER CLOCKWISE press the left side of the TOGGLE SWITCH.

ENABLE LEVER, using the TOGGLE SWITCH, select (press) a

direction, then move the joystick in either direction. NOTE: When rotating the turntable, the turntable will rotate in the desired direction regardless of the

direction of the

JOYSTICK.

Driving the aerial work platform

TOGGLE SWITCH on the JOYSTICK is used to steer the machine.

The To drive the aerial work platform, grasp the

the

JOYSTICK slightly off of the neutral position and in the direction of travel desired.

To turn / steer the aerial work platform either right or left, press (squeeze) the press the desired

TOGGLE SWITCH on top of the JOYSTICK.

JOYSTICK and press (squeeze) the ENABLE LEVER, move

ENABLE LEVER and

HAULOTTE GROUP 3 OPERATION

NORMAL OPERATING PROCEDURE

Become familiar with the location and function of all controls. Learn to smoothly START and STOP all boom functions.

Perform the following procedures to operate the machine:

 Read and obey all safety precautions and operating instructions, as well as all Federal, State, and

Local codes and regulations.

 Conduct a Pre-Operation Inspection by performing all recommended Daily Service Checks.

Refer to the “Equipment Maintenance” Section of this manual.

 Position the aerial work platform at the work area. Make sure the aerial work platform is on a firm

and level surface and there are no potential hazards such as overhead obstructions or electrically charged conductors. DO NOT operate the aerial work platform if such hazards exist.

 Release both travel latches, (1) the primary latch on the boom rest, and (2) the secondary latch

on the Primary Boom, by raising the latch handle and swinging the clasp down. Refer to Figure 3-4.

PRIMARY

LATCH

Figure 3-4. Boom Travel Latches

SECONDARY

LATCH

HAULOTTE GROUP 3 OPERATION

NORMAL OPERATING PROCEDURE (CONTINUED)

Become familiar with the location and function of all controls. Learn to smoothly START and STOP all boom functions.

 At the ground (lower) control panel, turn the KEY SWITCH (1) counter clockwise to the GROUND

CONTROLS

buttons; plugged in.

 The control microprocessor will perform self-diagnostics to test the operating system. After

several seconds, the

 Monitor the battery condition indicator during operation and charge the batteries as necessary.

(1a) icon. If power does not come on, make sure that both of the EMERGENCY STOP

GROUND (6), and PLATFORM (5), are pulled out and the main power disconnect plug is

DISPLAY PANEL window will read:

HAULOTTE GROUP

ACCESS SOLUTIONS

 Extend the four outriggers individually, or for simultaneous extension use the

AUTO LEVEL (23)

button on the ground (lower) control panel. When the aerial work platform is leveled properly, a buzzer will sound, the two LEDs at each

LEVEL

(23) button will be lit. Refer to Figure 3-5.

OUTRIGGER (25 and 26) button, and the LED at the AUTO

Figure 3-5. Outrigger Control Panel

o Auto Level: Press (push) and hold the

EXTEND (21) and AUTO LEVEL (23) buttons at the same

time.

o Manual Level: Extend the two outriggers closest to the trailer coupler first. Lower the front

pair of outriggers by pressing (pushing) the

EXTEND (21) button and the two front OUTRIGGER

buttons at the same time. Lower the back pair of outriggers by pressing (pushing) the

(21) button and the two back OUTRIGGER buttons at the same time.

EXTEND

 Verify that the

AUTO LEVEL (23) indicator LED is lit. If the AUTO LEVEL (23) indicator is not lit, the

aerial work platform may not be level, and the weight of the machine may not be on the outrigger foot pad.

NOTE: If the boom is not level or if one or more outriggers are not supporting the

machines load the safety interlock system prevents all boom operations.

NOTE: The Range of Motion Diagrams at the ground (lower) and platform (upper) control

stations displays the range of platform motion (safe operating zone). Verify that the operating zone is clear of obstructions through 700º of Non-Continuous rotation.

+ 88 hidden pages

Haulotte 45XA, HLA16PX Operator's Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual