Operator's manual
S
UMMIT
S
ERIES
2420341380 E 02.12 USA
Operator's manual
SUMMIT SERIES
3632T - HTT13
3522A - HTA13P - 4527A - HTA16P - 5533A - HTA19P
24203 0
X
USA
3
CONTENTS
Operator's manual
CONTENTS
1 - Aerial work platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
2 - Primary machine components. . . . . . . . . . . . . . . . . . . . . .
7
A
SAFETY
1 - Legend : Safety advisories . . . . . . . . . . . . . . . . . . . . . . .
11
2 - Before operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
3 - During operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
4 - Drive safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
5 - Fall protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
6 - Manual force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
7 - Wind loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
8 - Explosion hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
9 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
9.1 - General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.2 - Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
B
SPECIFICATIONS
1 - Range of motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
2 - Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
3 - Warranty - New product -
HAULOTTE® North America . . . . . . . . . . . . . . . . . . . . . . . .
33
4 - Warranty claims procedure . . . . . . . . . . . . . . . . . . . . . . .
34
5 - Damaged equipment policy . . . . . . . . . . . . . . . . . . . . . . .
35
5.1 - Safety statement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.2 - Damage Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.3 - Damage Repair Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
C
OPERATION
1 - Ground (lower) control panel. . . . . . . . . . . . . . . . . . . . . .
38
2 - Platform (upper) control panel . . . . . . . . . . . . . . . . . . . .
44
3 - Normal operating procedure . . . . . . . . . . . . . . . . . . . . . .
50
4 - Manual boom operation . . . . . . . . . . . . . . . . . . . . . . . . . .
55
4.1 - Manual retraction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.2 - Manual rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.3 - Manual Boom Lowering Procedure-
Telescopic model(s). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
4.4 - Manual Boom Lowering Procedure-
Articulating model(s). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5 - Towing the aerial work platform . . . . . . . . . . . . . . . . . . .
60
6 - Hitch and Tow procedure. . . . . . . . . . . . . . . . . . . . . . . . .
61
7 - Lifting the aerial work platform . . . . . . . . . . . . . . . . . . . .
62
8 - Transporting the aerial work platform on to a
truck bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
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Operator's manual
D
EQUIPMENT MAINTENANCE
1 - Battery recharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
2 - Daily service checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
3 - Weekly service checks. . . . . . . . . . . . . . . . . . . . . . . . . . .
71
4 - Monthly service checks . . . . . . . . . . . . . . . . . . . . . . . . . .
72
5 - Annual service checks. . . . . . . . . . . . . . . . . . . . . . . . . . .
73
6 - Structural inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
7 - Motor drying instructions . . . . . . . . . . . . . . . . . . . . . . . .
76
8 - Leveling system calibration procedure . . . . . . . . . . . . .
77
8.1 - Machine levelling instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.2 - Level Sensor Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.3 - Ground (Lower) Control Box Calibration Instructions . . . . . . . . . . . . . . 79
9 - Overload protection calibration procedure . . . . . . . . . .
80
9.1 - Load Sense Zeroing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
10 - Load Sense Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82
11 - Additional service information . . . . . . . . . . . . . . . . . . .
83
12 - Manual outrigger retraction. . . . . . . . . . . . . . . . . . . . . .
84
13 - Hydraulic pressure gauge . . . . . . . . . . . . . . . . . . . . . . .
86
14 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87
15 - Error code definitions- Controls . . . . . . . . . . . . . . . . . .
88
16 - Error code definitions - Motor controller . . . . . . . . . .
101
E
CYLINDER REPLACEMENT
1 - Master / slave cylinder replacement -
Articulating models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
105
1.1 - Master cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.2 - Slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.3 - Lift cylinder replacement -
Articulating models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
107
2 - Master / slave cylinder replacement -
Telescopic models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110
2.1 - Master cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.2 - Slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3 - Lift cylinder replacement -
Telescopic models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
112
4 - Outrigger cylinder replacement . . . . . . . . . . . . . . . . . .
114
F
DECALS REPLACEMENT
1 - Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
118
5
CONTENTS
Operator's manual
G
OPTIONAL EQUIPMENT
1 - Drive and set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
137
2 - Drive and set safety . . . . . . . . . . . . . . . . . . . . . . . . . . . .
137
3 - Drive and set controls . . . . . . . . . . . . . . . . . . . . . . . . . .
138
4 - Drive and set use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
140
5 - Material lift hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
141
6 - Load cell calibration procedure. . . . . . . . . . . . . . . . . . .
146
7 - Platform rotator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147
H
SPECIAL PROCEDURES
1 - Axle and related components . . . . . . . . . . . . . . . . . . . .
149
1.1 - Set up and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.2 - General maintenance -
Electric Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.2.1 - Drum Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.3 - General maintenance -
Hydraulic brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
150
1.3.1 - Drum Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.3.2 - Synchronizing Your Trailer Brakes . . . . . . . . . . . . . . . . . . . . . . 151
1.3.3 - Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.3.4 - Maximum Wheel Fastener Torque . . . . . . . . . . . . . . . . . . . . . . 153
1.4 - How to use your electric brakes properly. . . . . . . . . . . . . . . . . . . . . . . . 154
1.5 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.5.1 - Magnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.5.2 - Break cleaning and inspection . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.5.3 - Brake lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.5.4 - Shoes and Linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.5.5 - Hubs / Drums / Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.5.6 - Hub removal - Standard bearings. . . . . . . . . . . . . . . . . . . . . . . 159
1.5.7 - Brake Drum Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.5.8 - Bearing inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.5.9 - Bearing lubrication - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.5.10 - Bearing Lubrication - Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.5.11 - SEAL INSPECTION AND REPLACEMENT . . . . . . . . . . . . . . . 163
1.5.12 - BEARING ADJUSTMENT AND HUB REPLACEMENT . . . . . . 164
1.5.13 - BEARING REPLACEMENT AND DRUM INSTALLATION. . . . 166
1.5.14 - Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.5.15 - How to measure voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.5.16 - How to measure amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.6 - Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.6.1 - Storage preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.6.2 - After prolonged storage inspection procedure . . . . . . . . . . . . . 170
1.6.3 - Trip preparation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.7 - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.7.1 - Introduction to troubleshooting -
Hydraulic braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
171
1.7.2 - Introduction to troubleshooting -
Electric braking system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.7.2.1 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
2 - Brake adjustment bradley running gear. . . . . . . . . . . .
176
2.1 - Aerial work platforms with standard brakes. . . . . . . . . . . . . . . . . . . . . . 176
2.2 - THIRTEEN PERCENT (13 %) GRADE TEST . . . . . . . . . . . . . . . . . 178
2.3 - AERIAL WORK PLATFORMS WITH DRIVE AND SET BRAKES178
2.4 - TROUBLESHOOTING THE BRADLEY RUNNING GEAR. . . . . 180
I
MATERIAL SAFETY
6 2420341380 E 02.12 USA
Summit Series
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. This includes all manufacturer recommendations as well as all Federal, State, and Local codes and
regulations.
To ensure proper and safe use of this equipment, it is strongly recommended that only trained and authorized personnel
attempt to operate and maintain the aerial work platform.
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.
HAULOTTE Group is dedicated to the continuous improvement of this and all HAULOTTE Group products. Therefore,
equipment information is subject to change without notice. Direct any questions or concerns regarding errors and / or
discrepancies in this manual to the HAULOTTE Group Service Department.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and
other reproductive harm.
9
2420341380 E 02.12 USA
Summit Series
3522A (HTA13P) - 4527A (HTA16P) - 5533A (HTA19P)
20. Platform
21. Jib boom
22. Extension boom
23. Secondary boom
24. Knuckle
25. Master cylinder
26. Lower link
27. Primary lift cylinder
28. Outrigger cylinder
29. Outrigger leg
30. Axle
10 2420341380 E 02.12 USA
Summit Series
31. Outrigger foot
32. Outrigger pad
33. Primary boom rest
34. Latch release
35. Dolly wheel
36. Trailer hitch
37. Coupler
38. Jack
39. Generator interface plate
40. Turntable
41. Secondary boom rest
42. Primary boom
43. Secondary lift cylinder
44. Slave cylinder
45. Jib lift cylinder
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2420341380 E 02.12 USA
Summit Series
A
- Safety
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.
1 - 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.
Legend
N.B.-:-Contains additional information important for performing a procedure.
The use of intelligence and common sense is the best practice when following any safety policy.
Symbol Meaning
Indicates a hazardous situation which if not avoided, will result
in death or serious injury.
Indicates a hazardous situation which if not avoided, could
result in death or serious injury.
Indicates a hazardous situation which, if not avoided, may
result in minor or moderate injury.
Contains information important in the prevention of errors that
could damage the machine or its components.
12 2420341380 E 02.12 USA
Summit Series
A
- Safety
2 - 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 the machines 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 the aerial work platform in any way for which it is not intended.
• NEVER operate the 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.
"Equipment Maintenance" section.
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2420341380 E 02.12 USA
Summit Series
A
- Safety
3 - 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 700 ° Non-Continuous rotation.
Minimum safe approach distances
• ALWAYS check with local electrical authorities regarding any local requirements which may differ
from those shown in Table "MINIMUM SAFE APPROACH DISTANCES".
• 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 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 1,8 kg/cm² (25 psi) to ensure safe operation.
• ALWAYS keep personnel away from potential pinch and shear points and from potential crush
hazards as indicated by decals attached to the aerial work platform.
• ALWAYS keep the safety bar lowered (closed) unless personnel are entering or exiting the work
platform.
• ALWAYS use a 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.
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 (
3.05 m (10 ft) minimum 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.
Voltage range Minimum safe approach distances
(Phase to phase) Feet Mètre
0 - 300 V Avoid contact
300 V - 50 kV 10 3.05
50 - 200 kV 15 4.57
200 - 350 kV 20 6.10
350 - 500 kV 25 7.62
500 - 750 kV 35 10.67
750 - 1000 kV 45 13.72
14 2420341380 E 02.12 USA
Summit Series
A
- Safety
• ALWAYS unhitch trailer from tow vehicle before operating outriggers.
• 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.
• NEVER operate the Drive function (if equipped) on surfaces exceeding 4.5 °, or with more than one
person in the platform.
• 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 45 km/h ( 28 mph or
12.5 m/sec). 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.
• 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.
Failure to unhitch trailer from tow vehicle prior to outrigger deployment could cause damage to trailer tongue and / or tow
vehicle.
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2420341380 E 02.12 USA
Summit Series
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• 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.
4 - 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.
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5 - Fall protection
6 - Manual force
• Never push off or pull toward any object outside the platform.
• Maximum allowable manual force is 400 N (90 lb.).
• 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.
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7 -
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 10 m(32 ft10 in) above ground level in the open. Beaufort scale.
Beaufort scale
Force
Meteorological
description
Observed effects m/s km/h mph
0 Calm Calm; smoke rises vertically 0 - 0,3 0 - 1 0 - 0.62
1 Light Air
Direction of wind shown by
smoke.
0,3 - 1,4 1 - 5 0.62 - 3.11
2 Light breeze
Wind felt on the face. Leaves
rustle. Ordinary vanes moved by
wind.
1,7 - 3,1 6 - 11 3.73 - 6.84
3 Gentle breeze
Leaves and small twigs in
constant motion. Wind exceeds
light flag.
3,3 - 5,3 12 - 19 7.46 - 11.81
4 Moderate breeze
Raised dust and loose papers.
Small branches are moved.
5,6 - 7,8 20 - 28 12.43 - 17.4
5 Fresh breeze
Small trees in leaf to sway.
Crested wavelets form on inland
waterways.
8,1 - 10,6 29 - 38 18.02 - 23.61
6 Strong breeze
Large branches in motion.
Whistling heard in telephone
wires. Umbrellas used with
difficulty.
10,8 - 13,6 39 - 49 24.23 - 30.45
7 Near gale
Whole trees in motion.
Inconvenience felt when walking
against wind.
13,9 - 16,9 50 - 61 31.07 - 37.9
8 Gale
Breaks twigs off trees. Generally
impedes progress.
17,2 - 20,6 62 - 74 38.52 - 45.98
9 Strong gale
Slight structural damage occurs.
Chimney pots and slates
removed.
20,8 - 24 75 - 88 46.60 - 54.68
10 >
Storm, Violent Storm,
Hurricane
Trees uprooted, widespread
damage to structures,
widespread devastation.
24,7 > 89 > 55.3 >
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8 - Explosion hazard
• NEVER operate aerial work platform if you smell or detect Liquid Petroleum Gas (LPG), gasoline,
diesel fuel or other explosive substances.
• ALWAYS charge Batteries only in an open, well-ventilated area away from sparks, flames and lighted
tobacco.
If this aerial work platform is equipped with a generator :
• NEVER refuel with the engine running.
• NEVER operate engine unless in a well-ventilated area to avoid carbon monoxide poisoning.
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9 - Maintenance
Ensure the following general safety precautions are followed while performing maintenance on the
aerial work platform.
9.1 - 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 its 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.
• 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.
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• 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.
9.2 - 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.
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3522A (HTA13P)
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Technical characteristics-For 3522A (HTA13P)
Machine 3522A (HTA13P)
Characteristics
Metric
Imperial
Maximum work height 12.73 m(41 ft9 in)
Maximum platform height 10.90 m(35 ft9 in)
Up and over height 5.79 m(19 ft0 in)
Maximum horizontal outreach
• From centerline : 6.86 m(22 ft6 in)
• From outrigger footpad edge : 5.31 m(17 ft5 in)
Rated platform capacity
• Without platform rotation : 227 kg(500 lb)
• With platform rotation : 200 kg(440 lb)
Maximum occupants 2
Total weight
Without option : 1542 kg(3400 lb)
Drive and set option adds 113 kg(250 lb), Engine option
adds 86 kg(190 lb), all other options add 68 kg(150 lb) to
weight
Turntable rotation 700 °Non continuous
Leveling capability 12.5 °
Platform dimensions
• Height : 1.09 m(3 ft7 in)
• Length : 0.76 m(2 ft6 in)
• Width : 1.22 m(4 ft0 in)
Platform rotation / Type (Optional) 120 °-Manual
Stowed dimensions
• Height : 1.96 m(6 ft5 in)
• Length : 4.96 m(16 ft3 in)
• Width : 1.65 m(5 ft5 in)
Jib dimensions
• Length : 1.3 m(4 ft3 in)
• Vertical Motion : 150° (+70° / -80°)
Outrigger footprint (To center of pad)
• Length : 3.38 m(11 ft1 in)
• Width : 3.02 m(9 ft11 in)
• Footpad diameter : 0.25 m(0 ft10 in)
Parking brake Mechanical
Towing brake
Hydraulic Surge
Mechanical
Electrical
Rated towing speed 105 km/h (65 mph)
Tire size ST 205/75 R14C
Control system 24V DC
Battery 4 x 6V 245 amp-hr
Charger type
• 110 Volt 60 Hz
• 220 Volt 50 Hz
Hydraulic pressure 207 bar(3,000 psi)
Reservoir capacity 12 l(3.1 gal US)
Hydraulic system capacity 19 l(5.1 gal US)
Hydraulic oil (Standard) HVI AW32
Maximum decibel level
• DC mode - Ground : 60 dBA
• DC mode - Platform : 55 dBA
• Engine mode - Ground : 70 dBA
• Engine mode - Platform : 65 dBA
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Function speeds
Primary boom :
• Primary, up - Fast : 14-18 sec
• Primary, up - Slow : 33-37 sec
• Primary, Down - Fast : 14-18 sec
• Primary, Down - Slow : 46-60 sec
Secondary boom :
• Secondary Up - Fast : 12-16 sec
• Secondary Up - Slow : 24-28 sec
• Secondary Down - Fast : 18-22 sec
• Secondary Down - Slow : 62-66 sec
Boom Jib :
• Jib, Up - Fast : 16-10 sec
• Jib, Up - Slow : 12-16 sec
• Jib, Down - Fast : 10-14 sec
• Jib, Down - Slow : 26-30 sec
Extension boom :
• Boom extend - Fast : 10-14 sec
• Boom extend - Slow : 22-26 sec
• Boom retract - Fast : 14-18 sec
• Boom retract - Slow : 30-34 sec
Turntable 700 ° Non Continuous Rotation
:
• Turntable rotation - Fast : 154-158 sec
• Turntable rotation - Slow : 218-222 sec
Platform :
• Platform compensation up- Fast : 8-12 sec
• Platform compensation up - Slow : 10-14 sec
• Platform compensation down - Fast : 5-9 sec
• Platform compensation down - Slow : 5-9 sec
Outrigger (auto level) :
• Outrigger extend : 12-16 sec
• Outrigger retract : 22-26 sec
Localized Pressure per Outrigger 1.76 kg/cm² (25 psi)
Operation temperature range - 29 °C(-20 °F) to 43 °C(110 °F)
Machine 3522A (HTA13P)
Characteristics
Metric
Imperial
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Operation
The Haulotte Telescoping Boom Lift model(s) 3632T (HTT13) and Articulating Boom Lift model(s) 3522A-4527A-5533A
(HTA13-16-19P) are Summit Series trailer-mounted aerial work platforms, designed and manufactured to position personnel with their tools and equipment at overhead work locations. The platform load capacity is rated at 227 kg(500 lb).
During all aerial work platform operations, four extended outriggers support the unit.
The aerial work platform is battery powered and 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 at level during operation. The
hydraulic motor and mating worm gear allow the boom to rotate 700 ° Non-Continuous around a vertical axis.
The hydraulic power unit uses a 24 Volt, one horsepower DC motor to drive the hydraulic pump. The DC motor is powered by four 6 Volt DC, 245 Ah 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 ground (lower) control panel controls the power, outriggers, boom lift elevation, and rotation functions.
The platform (upper) control panel only controls boom lift elevation, and rotation.
N.B.-:-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 selected valves on the
hydraulic pump unit that can be accessed inside the pump compartment.
Manual lowering of telescoping aerial work platforms :
Manual lowering of the platform is performed by actuating a valve plunger found on the base of the boom lift cylinder.
Pulling and holding the valve plunger retracts the boom lift cylinder. The boom may need to be rotated to a clear area
before lowering.
Manual lowering of articulating aerial work platforms :
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.
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Ground (lower) control panel-Articulating model(s)
Marking Description Function
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 KEY SWITCH ( 1 ), clockwise to the
PLATFORM ( 1b ) icon selects operation from the platform
(upper) control panel.
Turning the KEY SWITCH ( 1 ) to the vertical position (power
"OFF") interrupts all electric and hydraulic power operations
except emergency lowering.
Removal of the KEY protects against any unauthorized
persons attempting to operate the aerial work platform. The
KEY may be removed with the KEY SWITCH ( 1 ) in any
selected position
1a Ground Controls Position
1b Platform Controls 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
Engine start (Models with engines
only)
Start a cold engine by pressing (pushing) in and holding the
CHOKE ( 4 ) button then press (push) the ENGINE
START ( 3 ) button.
To start / restart a warm engine, press (push) the ENGINE
START ( 3 ) button only.
Glow plug operation : Press (push) the GLOW PLUG ( 4 )
button and hold for 30 - 60 seconds then press (push) the
ENGINE START ( 4 ) button.
4
Engine choke (Models with engines
only)
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5 Display panel
The DISPLAY PANEL is a lighted text window that displays
the current operating status or an existing error condition
when the KEY SWITCH ( 1 ) is positioned at either ( 1a )
or ( 1b ).
6 Emergency stop button
When pushed in, the EMERGENCY STOP button ( 6 )
disconnects electrical power to the ground (lower) and
platform (upper) control panels.
The EMERGENCY STOP button ( 6 ) should only be pressed
(pushed in) to immediately stop all aerial work platform
motion.
To resume control, "pull out" the EMERGENCY STOP
button ( 6 ).
7 Boom extend button Pressing (pushing) in and holding a desired SPEED
button ( 15 ) and the BOOM EXTEND button ( 7 ) at the same
time extends the secondary boom.
Pressing (pushing) in and holding a desired SPEED
button ( 15 ), and the BOOM RETRACT button ( 8 ) at the
same time retracts the secondary boom.
Telescoping boom motion continues until the buttons are
released or until the boom reaches a hard stop or a safe travel
limit.
8 Boom retract button
9 Primary boom raise button • 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 SPEED ( 15 ) button, and the
PRIMARY BOOM DOWN ( 10 ) button at the same time will
retract the primary boom.
• Pressing (pushing) and holding a desired SPEED ( 15 )
button, and the SECONDARY BOOM RAISE ( 11 ) button at
the same time will raise the secondary boom. Pressing
(pushing) and holding a desired SPEED ( 15 ) button, and the
SECONDARY BOOM DOWN ( 12 ) button at the same time
will retract the secondary boom
• Pressing (pushing) and holding a desired SPEED ( 15 )
button, and the JIB BOOM RAISE ( 13 ) button at the same
time will raise the JIB BOOM, pressing (pushing) and holding
a desired SPEED ( 15 ) button, and the JIB BOOM
DOWN ( 14 ) button at the same time will retract the 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
10 Primary boom down button
11 Secondary boom raise button
12 Secondary boom down button
13 Jib boom raise button
14 Jib boom down button
15 Speed buttons
The SPEED buttons ( 15 ) 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 (RABBIT), to slow
(TURTLE), available to help control the positioning of the
Boom and the Jib.
16 Platform tilt button - Up Press (push) and hold any SPEED button ( 15 ), and the
desired PLATFORM TILT UP button ( 16 ) or PLATFORM
TILT DOWN button ( 17 ) at the same time to level the work
platform.
This levels the platform only, NOT the aerial work platform.
17 Platform tilt button - Down
Marking Description Function
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18 Boom rotation buttons - Clockwise Pressing (pushing) and holding a desired SPEED button ( 15 )
and the BOOM ROTATION button ( 18 ) at the same time
enables the boom to rotate in the CLOCKWISE direction.
Pressing (pushing) and holding a desired SPEED button ( 15 )
and the BOOM ROTATION button ( 19 ) at the same time
enables the boom to rotate in the COUNTERCLOCKWISE
direction.
The boom will rotate through 700° of Non-Continuous rotation
until the buttons are released or the stop is reached.
19
Boom rotation buttons Counterclockwise
20 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" position, and the outriggers can be operated
(functional).
21 Outrigger extend button For simultaneous automatic outrigger extension/retraction of
all four (4) outriggers : Select the EXTEND button ( 21 ) or
RETRACT button ( 22 ) and the AUTO LEVEL button ( 23 ) at
the same time.
To individually extend or retract the outriggers : Select the
EXTEND button ( 21 ) or RETRACT button ( 22 ) and one of
the four OUTRIGGER buttons ( 24 ) at the same time.
The outrigger indicator LED ( 20 ) lights up when the
outriggers are properly deployed and the aerial work platform
weight is on the outrigger footpads.
(25) : Each of the outer outrigger LEDs indicates load is on the
outrigger footpad.
(26) : Each of the inner outrigger LEDs, when flashing,
indicates that side is low and needs to be further raised for
leveling.
22 Outrigger retract button
23 Auto Level button
24 Outrigger buttons
Marking Description Function
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Platform (upper) control panel-Articulating model(s)
Marking Description Function
1
Engine start (Models with engines
only)
Start a cold engine by pressing (pushing) in and holding the
CHOKE ( 2 ) button then press (push) the ENGINE
START ( 1 ) button.
To start / restart a warm engine, press (push) the ENGINE
START ( 1 ) button only.
Glow plug operation : Press (push) the GLOW PLUG ( 2 )
button and hold for 30 - 60 seconds then press (push) the
ENGINE START ( 1 ) button.
2
Engine choke (Models with engines
only)
3 Horn button
Pressing (pushing) the HORN button ( 3 ) will sound the
HORN.
Use the horn button to warn personnel in the area of a falling
object hazard, impending boom motions or the need for
assistance.
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4 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.
5 Emergency stop button
When pushed in, the EMERGENCY STOP button ( 5 )
disconnects electrical power to the ground (lower) and
platform (upper) control panels.
The EMERGENCY STOP button ( 5 ) should only be pressed
(pushed in) to immediately stop all aerial work platform
motion.
To resume control, "pull out" the EMERGENCY STOP
button ( 5 ).
6 Speed buttons
The SPEED buttons ( 6 ) 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 (RABBIT), to slow
(TURTLE), available to help control the positioning of the
Boom and the Jib.
7 Boom rotation buttons - Clockwise Pressing (pushing) and holding a desired SPEED button ( 6 )
and the BOOM ROTATION button ( 7 ) at the same time
enables the boom to rotate in the CLOCKWISE direction.
Pressing (pushing) and holding a desired SPEED button ( 6 )
and the BOOM ROTATION button ( 8 ) at the same time
enables the boom to rotate in the COUNTERCLOCKWISE
direction.
The boom will rotate through 700° of Non-Continuous rotation
until the buttons are released or the stop is reached.
8
Boom rotation buttons Counterclockwise
9 Primary boom raise button • Pressing (pushing) and holding a desired SPEED ( 6 )
button, and the PRIMARY BOOM RAISE ( 9 ) button at the
same time will raise the primary boom. Pressing (pushing)
and holding a desired SPEED ( 6 ) button, and the PRIMARY
BOOM DOWN ( 10 ) button at the same time will retract the
primary boom.
• Pressing (pushing) and holding a desired SPEED ( 6 )
button, and the SECONDARY BOOM RAISE ( 11 ) button at
the same time will raise the secondary boom. Pressing
(pushing) and holding a desired SPEED ( 6 ) button, and the
SECONDARY BOOM DOWN ( 12 ) button at the same time
will retract the secondary boom
• Pressing (pushing) and holding a desired SPEED ( 6 )
button, and the JIB BOOM RAISE ( 13 ) button at the same
time will raise the JIB BOOM, pressing (pushing) and holding
a desired SPEED ( 6 ) button, and the JIB BOOM
DOWN ( 14 ) button at the same time will retract the 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
10 Primary boom down button
11 Secondary boom raise button
12 Secondary boom down button
13 Jib boom raise button
14 Jib boom down button
Marking Description Function
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9 Boom raise button Pressing (pushing) and holding a desired SPEED button ( 6 )
and the BOOM RAISE button ( 9 ) at the same time will raise
the boom.
Pressing (pushing) and holding a desired SPEED button ( 6 )
and the BOOM DOWN button ( 10 ) at the same time will
lower the boom.
Telescoping boom motion continues until the buttons are
released or until the boom reaches a hard stop or a safe travel
limit.
10 Boom down button
15 Boom extend button Pressing (pushing) in and holding a desired SPEED
button ( 6 ) and the BOOM EXTEND button ( 15 ) at the same
time extends the secondary boom.
Pressing (pushing) in and holding a desired SPEED
button ( 6 ), and the BOOM RETRACT button ( 16 ) at the
same time retracts the secondary boom.
Telescoping boom motion continues until the buttons are
released or until the boom reaches a hard stop or a safe travel
limit.
16 Boom retract button
17 Platform tilt button - Up Press (push) and hold any SPEED button ( 6 ), and the
desired PLATFORM TILT UP button ( 17 ) or PLATFORM
TILT DOWN button ( 18 ) at the same time to level the work
platform.
This levels the platform only, NOT the aerial work platform.
18 Platform tilt button - Down
Outlet
An outlet has been provided as a power source for running
electrical power tools, while in the work platform. The power
plug is located on the trailer frame, in front of the accessory
equipment stowage plate. A connecting power cord must be
plugged into a suitable power source. The outlet is rated for a
15 A load. Do not overload the accessory power circuit.
Marking Description Function
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Releasing travel latches-Articulating model(s) :
• 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.
Boom Travel Latches
• At the ground (lower) control panel, turn the KEY SWITCH ( 1 ) counter clockwise to the GROUND
CONTROLS ( 1a ) icon. If power does not come on, make sure that both of the EMERGENCY STOP
buttons; GROUND ( 6 ), and PLATFORM ( 5 ), are pulled out and the main power disconnect plug is
plugged in.
• The control microprocessor will perform self-diagnostics to test the operating system. After several
seconds, the DISPLAY PANEL window will read :
• Monitor the battery condition indicator during operation and charge the batteries as necessary.
• 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 OUTRIGGER ( 25 - 26 ) button, and the LED at the AUTO
LEVEL ( 23 ) button will be lit.
• Auto Level : Press (push) and hold the EXTEND ( 21 ) and AUTO LEVEL ( 23 ) buttons at the same time.
• 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 EXTEND ( 21 ) button and the two back
OUTRIGGER buttons at the same time.
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Outrigger Control Panel
• 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.
N.B.-:-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.
N.B.-:-The Range of Motion Diagrams at the ground (lower) and platform (upper) control stations
displays the range of platform motion (safe operating zone) FACING AWAY FROM THE TRAILER
TONGUE. Verify that the operating zone is clear of obstructions through 700° of Non-Continuous
rotation
• 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 SPEED ( 6 ) and function buttons at
the same time.
• Fully lower the boom onto the boom rest to enter the platform using a 3 point contact (both hands
and one foot).
• Raise the safety bar and enter the work platform by using a 3point contact (both hands and one foot).
Put on a safety harness and attach the lanyard to the ANCHORAGE (attachment point) on the side
of the platform support beam.
• Should the platform become tilted out of the normal vertical axis, press (push) and hold the desired
SPEED button ( 6 ) and one of the PLATFORM TILT buttons ( 16-17 ) at the same time to level the
platform back into the normal vertical axis.
• Use the platform (upper) control panel to operate the boom lift functions. Raise, lower, extend and
rotate the booms by pressing (pushing) and holding the desired SPEED ( 6 ) and function buttons at
the same time. Become familiar with the location and function of all controls. Learn to smoothly
START and STOP all boom motions.
• When all aerial work platform operations are complete, fully retract all boom extension(s). Center the
boom over the boom rest and fully lower the boom until seated in the "stowed" position for transport.
N.B.-:-Always fully retract, rotate and lower the boom to the "stowed" position before exiting the
platform.
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• Turn the key switch to the GROUND CONTROL ( 1a ) position.
• Unfasten the safety harness and exit the platform by using a 3 point contact (both hands and one
foot).
Telescopic model(s) :
• Disengage the PLATFORM LOCKING PINS by squeezing the LATCH KNOBS together; return the
platform to its "stowed" position. Engage the platform travel latch.
Articulating model(s) :
• Engage both travel latches.
N.B.-:-Refer back earlier in this section for a visual of these latches.
• Inspect the area beneath the aerial work platform and trailer for obstructions before retracting
outriggers. Press (push) and hold the outrigger RETRACT ( 22 ) button and the AUTO LEVEL ( 23 )
button until all outriggers are fully retracted to their "stowed" (upright) positions.
N.B.-:-Safety switches prevent outrigger retraction until the boom is completely lowered and in the
"stowed" position.
• At the ground (lower) control panel turn the KEY SWITCH ( 1 ) to the vertical (power "OFF") position,
and remove the key.
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C
D
E
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4 - Manual boom operation
Manual retraction, rotation and lowering functions allow the boom(s) 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.
The hydraulic hand pump is located in the pump compartment. In case of a power failure, the hand
pump and selected hydraulic valve can be used to manually retract the booms or rotate the boom
turntable.
4.1 - MANUAL RETRACTION
Telescopic model(s) : Begin manual retraction or rotation, by turning the proportional valve
counterclockwise until it stops; insert the pump handle into the pump handle fitting. Pushing
and holding the RETRACT button while simultaneously actuating the HAND PUMP will retract
the extension boom.
Articulating model(s) : Begin manual retraction or rotation, by turning the proportional valve
counterclockwise until it stops; insert the pump handle into the pump handle fitting. Pushing
and holding the RETRACT button while simultaneously actuating the HAND PUMP will retract
the secondary boom.
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4.2 - MANUAL ROTATION
To rotate the TURNTABLE clockwise :
• Push and hold the ROTATION button IN.
• Simultaneously actuate the HAND PUMP.
To rotate the TURNTABLE counterclockwise :
• Pull the ROTATION button OUT.
• Simultaneously actuate the HAND PUMP.
N.B.-:-Turn the PROPORTIONAL VALVE clockwise to return it to its original position before lowering
the booms or resuming normal operation..
Hand Pump Controls for Manual Operation
Marking Description
1 Rotation button
2 Hand pump
3 Proportional valve
4 Retract button
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4.4 - MANUAL BOOM LOWERING PROCEDURE-ARTICULATING MODEL(S)
Each lift cylinder is equipped with a MANUAL LOWERING VALVE, found at the base of each
lift cylinder. Use the VALVE to lower the platform in case of a complete electrical power failure,
a load shift, or any other emergency. The booms may be lowered in any order, but the logical
order would be :
• The PRIMARY boom first.
• The SECONDARY boom next.
• The JIB boom last.
To lower the boom, push in on the MANUAL LOWERING VALVE "button" on the cylinder that
controls the boom that is to be lowered. Follow this procedure until the boom is completely
lowered and in the "stowed" position.
Location of Lift Cylinders for Manual Boom Lowering
Marking Description
1 Secondary lift cylinder
2 Primary lift cylinder
3 Jib lift cylinder
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Location of manual lowering valves
Primary lift cylinder
1 : Turntable
2 : Valve "push" button
Secondary lift cylinder
1 : Knuckle
2 : Valve "push" button
Jib lift cylinder 1 : Valve "push" button
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5 - 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 attachment and inspection of these components before towing.
Verify the following before towing the aerial work platform. Make adjustments as necessary :
• The TONGUE JACK/DOLLY WHEEL and outriggers are in their travel positions. The TONGUE
JACK/DOLLY WHEEL is rotated up so that the TONGUE JACK/DOLLY WHEEL assembly is parallel
with the tongue tube. The outrigger cylinders are fully retracted.
• Boom travel latches are engaged, securing the telescoping boom(s) in their fully "stowed" positions.
• Telescopic model(s) : these include the boom rest latch and the platform travel latch.
• Articulating model(s) : these include the boom rest latch and the primary boom latch.
• All on-board equipment is secured.
• The key switch is in the OFF position. Remove the key.
• The parking brake is disengaged. When the parking brake is engaged, it is parallel with the tongue
tube; when disengaged, it is perpendicular to the tongue.
• The trailer tires are adequately and evenly inflated. See the side wall of the tire for proper inflation.
Periodically check the Wheel Nut torque according to manufacturer’s recommendations. Refer to
Monthly Service check section, in the Equipment Maintenance of this manual. .
NEVER tow an aerial work platform with worn or damaged wheel components.
Prior to towing, while the trailer wheels are elevated for aerial work
platform operation, inspect for loose wheels and for lug nuts wear.
If a loose wheel mounting is suspected, remove and inspect lug
nuts for damage. If a loose wheel mounting is suspected, remove
and inspect lug nuts for damage.
Obtain, read and obey all recommendations set forth by the tow
vehicle manufacturer before attempting to transport aerial work
platform. Verify that aerial work platform weight does not exceed
the vehicle’s towing capacity. Exceeding the tow vehicle’s rated
capacity may result in damage to tow vehicle or aerial work
platform.
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6 - Hitch and Tow procedure
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.
Trailer hitching
• Lift the RELEASE LEVER on the TRAILER HITCH and lower the hitch onto the ball using the
TONGUE JACK/DOLLY WHEEL. Push down on the RELEASE LEVER to secure the ball.
• Use the TONGUE JACK/DOLLY WHEEL to verify that the coupling is secure. If using the jack raises
the bumper of the tow vehicle 2-3 inches, the ball hitch coupling is secure.
• Release the PARKING BRAKE by rotating the handle down until it is parallel with the tongue tube.
• On the TONGUE JACK/DOLLY WHEEL, pull the CLEVIS PIN and swivel the TONGUE JACK/DOLLY
WHEEL 90 ° to the travel position. Re-engage the CLEVIS PIN.
• Attach the safety chains to the tow vehicle. Verify that the chains cross under the trailer tongue.
• For models with the breakaway cable; connect it to the tow vehicle. Leave adequate slack to prevent
brakes from dragging.
• Connect the trailer lights to the tow vehicle power plug.
Marking Description
1 Breakaway cable
2 Release lever
3 Clevis pin
4 Tongue jack
5 Dolly wheel
6 Parking brake
7 Power plug
8 Safety chains
9 Trailer hitch
Failure to attach safety chains properly before towing will allow trailer
tongue to drop in case of ball hitch failure, resulting in damage to tow
vehicle and aerial work platform
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7 - Lifting the aerial work platform
• Completely retract and lower all booms into the "stowed" position.
• Secure both boom travel latches ( A ).
• Remove all loose materials from machine.
• Retract all outriggers cylinders to fully "stowed" (upright) position.
• When using a crane, use only the designated crane (fork lift) pockets ( B ). Follow all crane operating
instructions as indicated by the crane manufacturer.
• When using a forklift, use only the designated forklift pockets ( B ). Follow all forklift operating
instructions as indicated by the forklift manufacturer.
• Adjust rigging to keep the machine level and to minimize the risk of damage to machine.
N.B.-:-Only trained and authorized personnel should attempt to lift the aerial work platform.
Lifting the Aerial Work Platform-Telescopic model(s)
Lifting the Aerial Work Platform-Articulating model(s)
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8 - Transporting the aerial work platform on to a truck bed
• Verify that the truck or trailer is parked on a firm and level surface.
• Completely retract and lower all booms into the "stowed" position.
• Secure both boom travel latches ( A ).
• Retract all OUTRIGGER CYLINDERS to the fully “"stowed" (upright) position.
• Load boom onto the truck bed or trailer.
• Chock the wheels ( B ) and apply the PARKING BRAKE.
• Place a wooden block ( C ) under the TONGUE, near the TRAILER HITCH.
• Lower the TONGUE JACK/DOLLY WHEEL ( D ) until the TRAILER TONGUE rests on the wooden
block. Swing up and lock the TONGUE JACK/DOLLY WHEEL ( D ) so that the weight of the
TONGUE now rests on the wooden block.
• Secure the aerial work platform to the trailer bed using straps or chains. Use only the four attachment
points ( E ) beneath the machine, adjacent to the outriggers.
• Adjust as necessary to prevent damage to rigging or machine.
Telescopic model(s)
Articulating model(s)
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C
D
E
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Equipment Maintenance
Performing the appropriate maintenance procedures will extend the life of the aerial work platform and will help ensure
the safety of personnel operating the equipment.
Repair, replacement or adjustment of any hydraulic or electrical control device should be performed only by fully trained
and authorized personnel. These include, but are not limited to, hydraulic load valves, hydraulic flow control valves, solenoid valves, and limit switches. These are safety related controls. Improper adjustment or tampering with these devices may impair aerial work platform function and result in safety or damage hazards.
Persons performing maintenance or repairs on the aerial work platform should be trained in accordance with the manufacturer’s recommendations. Contact Haulotte Group Customer Service Department: at 1-800-537-0540 or visit
Haulotte Group online at www.haulotte-usa.com for additional information.
Critical or suspect areas identified during any scheduled inspection of the aerial work platform shall be examined by qualified personnel in accordance with all Federal, State, and Local codes and regulations.
NEVER operate the aerial work platform if a defect or malfunction is identified or suspected. All defects and malfunctions
must be repaired, and all maintenance performed, before returning an aerial work platform to service.
This manual contains a list of recommended maintenance procedures to be performed daily, weekly, monthly and annually. 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.
ALWAYS follow the maintenance schedule, regardless of use.
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1 - 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. However, a full recharge may
take up to 24 hours if the battery charge is extremely low.
To recharge the aerial work platform batteries :
• Move the aerial work platform to a well-ventilated area with direct access to a AC electrical outlet.
Keep the aerial work platform and batteries away from open flame or other potential ignition sources.
• Attach a 12 AWG multi-strand, grounded EXTENSION CORD with a maximum length of 15.24 m(50
ft0 in) to the receptacle located on the GENERATOR INTERFACE PLATE in front of the turntable
N.B.-:-Using an underrated or long power cord will reduce the output of the battery charger and may
extend charge time.
• Plug the extension cord into outlet. Verify that the green charging indicator LED is lit on the battery
charger faceplate.
• The CHARGING indicator LED remains lit continuously during the first stage of the charge cycle. The
charge current will be displayed on the BATTERY CHARGER FACEPLATE.
• To display the Battery Voltage, press (push) in and hold the BATTERY VOLTAGE button.
Battery charger faceplate
• If a battery fault is detected, the appropriate fault code will appear on the CHARGE CURRENT
display. The red CHECK BATTERY indicator LED will become lit.
Recharge batteries in a well-ventilated area only. . Do not charge batteries near fire, spark or other potential ignition
sources. Batteries may emit highly explosive hydrogen gas while charging. Failure to properly ventilate the charge gasses
could result in death or serious injury. Always charge aerial work platform batteries away from flammable materials.
Charging
80% Charged
Check Battery
Battery Voltage
Charge Current
Press to
Reset
Push
For
Linear Battery Charger
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• When the battery charge reaches 80 % of capacity, the yellow 80 % CHARGED indicator LED will
become lit and the green CHARGING indicator LED will begin to flash.
• When the batteries have reached a full charge, the green and yellow indicator LEDs will turn
themselves off. CC (Charge Complete) will appear on the CHARGE CURRENT display. After 2
hours, this display will fade and the CHARGE CURRENT will read 00.
• Unplug the extension cord from the outlet and the charger receptacle on the aerial work platform.
Store the extension cord for next use.
Battery fault codes
Do not disconnect any output leads or connectors between the batteries and the charger when the charger is on. To stop a
charge in progress, always unplug the extension cord from the AC power source.
Code Description Limits Cause
F0 No battery < 10 volts
Loose connection or battery
missing
F1 Over voltage
More than 112 % charge
voltage
Connected to wrong battery
voltage
F2 Over current More than 60 amperes
Operating machine while
charging
F3 Bulk mode timeout Less than 80 % at 16 hours Battery fault
F4 ARD mode timeout
More than 80 % and less
than full charge after 6
hours max
Battery fault
F9
Current Measurement Error
Standby
Board fault or charger exposed
to extreme cold
FA Triac Error Board shorted
FF
Full Power to Transformer,
No Current Output
Battery shorted or low AC line
voltage or charger fault
CO Charger Off
Charger resting between
pulses ( AGM batteries only)
CC Charge Mode Complete Batteries charged
Always unplug the battery charger power cord before moving the aerial work platform. Failure to disconnect power cord
could cause damage to the equipment.
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2 - 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. "Decal Replacement" section of
this manual for decal locations.
• Verify that all controls and indicators at the ground (lower) and platform (upper) control stations
operate properly.
• Lower outriggers to level the aerial work platform.
• Operate all boom functions, including all jib functions.
• Press (push) the EMERGENCY STOP button. Verify that all functions are deactivated.
• Verify that the cylinders are functional and there is no internal leakage, an indication of this is that the booms
would not remain elevated, and / or they may drift.
• Pull out the EMERGENCY STOP button, all functions will now be activated. Lower the booms.
• If either control panel is unresponsive, refer to the Trouble Shooting procedures. TABLE
TROUBLESHOOTING is located later in this section.
• If the GROUND (LOWER) CONTROL DISPLAY PANEL displays an error code, refer to the Control Panel Error
Code definitions. TABLE ERROR CODE DEFINITIONS is located later in this section.
• If the MOTOR CONTROLLER’S green light is flashing there is an error, refer to the Motor Controller Error Code
Definitions. TABLE ERROR CODE DEFINITIONS – MOTOR CONTROLLER, is located later in this section.
• If the aerial work platform has the Drive and Set option, operate the drive function from the platform (upper)
control panel.
• Verify correct operation of turn signals, brakes and running lights.
• Verify proper tire inflation. See the side wall of the tire for proper inflation.
• Inspect tires for damage or loose or missing lug nuts.
• Repair or replace as necessary.
• Inspect structural components and platform for obvious damage or debris.
• Repair or replace as necessary.
• Inspect the aerial work platform for missing, loose or damaged fasteners, including pins and bolts.
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• Verify that the boom / jib limit switches operate correctly :
• Limit switches are actuated when the primary, secondary and jib booms are in the fully lowered "stowed"
position. Limit switches must be activated to raise or lower outriggers.
• If outrigger controls are unresponsive when the booms are fully lowered and "stowed", inspect the limit switches
for loose mounting or visible damage.
• Repair or replace as necessary.
• 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.
• Verify that boom functions are unresponsive when one outrigger is raised.
• Repeat this procedure for each outrigger.
• Raise all outriggers until the footpads are not in contact with the ground. Verify that all outrigger status LEDs
on the ground (lower) control panel are unlit.
• Lower one outrigger until the footpad makes contact with the ground and the outrigger begins lifting the trailer.
• If the LED is lit before the footpad makes contact with the ground or if the LED remains unlit after the weight is
transferred to the outrigger, the position switch or wiring is faulty.
• Repeat this procedure for each outrigger.
• Repair or replace as necessary.
Outrigger Position Switches
Marking Description
1 Position switch
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• 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
• The hydraulic oil level should be checked with the booms down, all outriggers raised, and in the "stowed"
(upright) position, and the trailer wheels on a level surface.
• Hydraulic oil level should be visible in, but not above, the sight gauge.
• If the hydraulic oil level is not visible to at least half way up the sight gauge, add clean Hydraulic Fluid while all
booms are in the "stowed" (down) position, and the outriggers are fully retracted and in the "stowed" (upright)
position Pour slowly to avoid creating air pockets in the reservoir. DO NOT fill above the sight gauge.
• Overfilling the hydraulic reservoir may cause damage to hydraulic lines and may result in aerial work platform
malfunction.
• The hydraulic reservoir is originally filled with HVI AW32 hydraulic oil. A minimum Viscosity Index of 175 is
recommended for this aerial lift platform.
Hydraulic reservoir
Do not mix hydraulic oils. Do not add any fluid to the hydraulic system that is not expressly recommended by the
manufacturer. Adding unauthorized fluids to the hydraulic system could cause damage to the aerial work platform.
Reference Description of the components
1 Filter element
2 Fill port
3 Sight gauge
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C
D
E
F
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3 - 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.
• If batteries are fully charged, raise electrolyte level to full mark in each cell.
• Inspect all electrical wiring.
• Check for cuts, loose terminals, broken wires, chaffing and corrosion.
• Repair all damage, remove corrosion and seal with proper materials.
• Inspect transport hitch components for damage. Applicable to trailer mounted aerial lift platforms only.
• Inspect the aerial work platform for missing, loose or damaged hardware :
• Repair or replace as necessary.
• Inspect all hydraulic system components including the pump, motor and cylinders for damage, leaks,
loss of pressure or speed, and unusual noise or vibration.
• Repair or replace as necessary.
• Inspect Jib Bushings for damage. :
• Check the Jib Bushings, the bushings should not spin or separate from the retaining bore.
• Replace annually, or more frequently as necessary.
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4 - Monthly service checks
Perform the following service checks at least once each month in addition to all recommended daily
and weekly service checks :
• Clean all battery terminals.
• Check battery for loose connections or damaged wires.
• Verify proper operation of manual lowering valves and hand pump.
• Refer to the "Operation" section for manual boom operating procedures.
• Lubricate slew ring and mating gear
• Use NLGI Grade 2 multi-purpose grease.
• Check wheel nut torque.
• Refer to Figure below for correct wheel nut tightening sequence.
• Evenly tighten wheel nuts to 34 Nm (25 lb-ft) in the tightening sequence shown.
• Repeat tightening sequence, tighten wheel nuts to 81 Nm (60 lb-ft) and then to 136 Nm (100 lb-ft).
Wheel Nut Tightening Sequence
• Check parking brakes.
• Set up and Adjustment section located in the axle and related components section of this manual for more
detailed information.
Verify that the Level Sensor is operating correctly :
• Fully deploy outriggers until all outrigger LEDs and AUTO LEVEL LED's are lit, and the buzzer at the
ground (lower) control panel sounds.
• Verify that the aerial work platform is level, and that the level sensor located on the control side of the
turntable, is giving an accurate reading.
When wheels are newly installed or replaced, verify wheel nut torque monthly. Follow this procedure each time the wheel
is removed and reinstalled. Improperly torqued wheel nuts could result in wheel separation, pre-mature tire wear, or
damage to the equipment.
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B
C
D
E
F
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• Repair or replace as necessary.
For aerial work platforms with material hook option :
• Verify the weight reading displayed on the ground (lower) control panel is within 10% of actual weight
tested. Recalibrate load cell if needed. See the "Overload Protection Calibration" procedure located
later in this section.
5 - 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.
• Drain reservoir by removing the hex plug located on the bottom side of the reservoir.
• After oil is drained, remove oil filter(s) from top of tank.
• Replace the filter being careful not to introduce any debris into the system. Do not over-tighten.
• Replace oil with HVI AW32 or equivalent Hydraulic oil with a minimum viscosity rating of 175.
• With the fill port cap on but not tightened, completely raise and lower the telescoping boom to bleed
trapped air from the lift cylinders. Repeat as necessary.
• Repeat every 100 RUN hours, or annually, which ever comes first. Run hours are displayed by
simultaneous pressing (pushing) the RABBIT ( 2 ) and the TURTLE SPEED ( 3 ) buttons on the
ground (lower) control panel and reading the DISPLAY PANEL ( 1 ).
Display Run Time Hours
Inspect pivot pins and cylinders, including rod ends, for wear or damage. Replace as necessary.
Visually inspect welds and structural components for wear, damage and corrosion :
• Follow all manufacturer's recommendations when making repairs to critical components.
• Personnel making repairs to welds should be certified in accordance with the Structural Welding
Code AWS D1 and Haulotte design standards.
Inspect outriggers for wear or damage. Repair or replace as necessary.
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Inspect and adjust axle and parking brakes
Load test telescoping boom lift operations with 227 kg (500 lb) load.
Machines equipped with Platform Rotator, must be tested with 200 kg (440 lb).
Replace Jib Bushings :
• Check the Jib Bushings weekly, the bushings should not spin or separate from the retaining bore.
• Replace annually, or more frequently as necessary.
Check slew bearing for wear or damage :
• Deploy the outriggers using the AUTO LEVEL and EXTEND buttons on the ground (lower) control
panel. The tires will be slightly off the ground in this position.
• Place a 79 kg (175 lb) load in the platform and raise the PRIMARY boom to the full out position.
Machine Position for Slew Ring Measurement
Reference Description of the components
1 Take measurement here
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B
C
D
E
F
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• Measure the distance between the slew ring gear and the horizontal plate above, using a 50 mm (2
in.) caliper or bore micrometer
Slew ring position measurement
• Record the measurement.
• Rotate the platform 180° and re-record the measurement.
• If the difference in measurements is greater than 6.35 mm (0.25 in) the slew ring bearing should be
replaced. Contact Haulotte Group Customer Service Department: at 1-800-537-0540 or visit
Haulotte Group online at www.haulotte-usa.com for additional information.
Platform Position After Rotation
Reference Description of the components
1 Take measurement here
2 Slew ring
3 Tow end of trailer
Reference Description of the components
1 Take measurement here
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6 - Structural inspection
A comprehensive structural inspection of the unit shall be performed under any of the following
conditions :
• 10 years from the date of manufacture and every 5 years thereafter.
• After any actual, suspected or potential damage is sustained that could affect the structural integrity
or stability of the aerial platform.
• After a change in ownership. Owners should provide a complete service history when reselling the
unit. The structural inspection shall include the following considerations :
• The service history of the unit, including hours of service, work performed and environmental conditions.
• The inspection and maintenance record of the aerial work platform.
• The effectiveness of all controls and components.
• A visual inspection of the aerial work platform for wear or damage.
• Manufacturer recommendations.
• A visual weld inspection, to be performed by qualified personnel in accordance with the Structural Welding
Code AWS D1 and Haulotte design standards.
7 - Motor drying instructions
Inclusion of water or foreign particles into the DC electric motor housing may cause serious damage to
the motor. If the motor becomes wet, follow these instructions or contact an authorized Haulotte Group
service technician :
• Remove brush cover band.
• Blow warm air into motor using a heat gun.
• Spray electrical contact cleaner solution into motor armature area.
• Replace brush cover band.
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8 - Leveling system calibration procedure
8.1 - MACHINE LEVELLING INSTRUCTIONS
Deploy all of the outriggers, and slightly raise the base of the machine to position it for leveling.
Place a small, standard "level" on the base of the turntable (Level Placement Option A). If a
small "level" is not available, place any size, standard "level" on the base of the machine (Level
Placement Option B). Using the outriggers individually, level the base of the machine.
Position Machine for Leveling
8.2 - LEVEL SENSOR CALIBRATION INSTRUCTIONS
If your level sensor resembles the image in Figure ( A ),
(digitally based level sensor), follow these instructions.
Be aware that the LED's ( 1 ) on the top of the sensor
will need to be observed, the "Max Tilt Level Exceeded"
LED is red, and the "TILT OK" LED is green :
• Press (push) and hold the SET ZERO button ( 2 ), located
on the rear of the sensor, for 5 seconds. Both LED's will
begin to flash.
• While they are flashing, release the SET ZERO button, and
press (push) again 5 times within the next 3 seconds.
• Both the red and the green LED will be "ON SOLID", after
several moments the red LED should turn "OFF", the
"green" LED will stay lit. This is an indication that the
sensor "recognizes" this level position.
• Proceed to the "Ground (Lower) Control Box Calibration
Instructions".
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If your level sensor resembles the image in Figure ( B )
(pendulum based level sensor), follow these
instructions. Be aware that the "Bubble Level" on the
top of the sensor will need to be observed :
• Using the nuts on the top of sensor adjust the sensor until
the bubble is centered in the smallest circle.
• Proceed to the "Ground (Lower) Control Box Calibration
Instructions".
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8.3 - GROUND (LOWER) CONTROL BOX CALIBRATION INSTRUCTIONS
Use the ground (lower) control panel to access the control box maintenance menu.
Ground (Lower) Control Panel for Leveling System
1. Verify that the KEY SWITCH ( 1 ) is turned to the GROUND ( 1A ) icon, and that both EMER-
GENCY STOP ( 2 ) buttons (ground and platform) are "pulled out".
2. Enter the maintenance mode by pressing (pushing) both ROTATE ( 5 ) buttons and the OUTRIG-
GER EXTEND ( 6 ) button on the ground (lower) control panel simultaneously and holding for 5
seconds.
3. Scroll through the maintenance menu using the TURTLE ( 7 ) button to scroll down, use the
RABBIT ( 8 ) button to scroll back up, until "LEVEL SENSOR CALIBRATION UTILITY" is displayed in the DISPLAY PANEL ( 3 ). The display will automatically change to "LEVEL MACHINE
THEN PRESS MID-SPEED KEYS".
4. Press (push) both MID SPEED buttons [MID-HIGH ( 9A ) / MID-LOW ( 9B )] on the ground (low-
er) control panel simultaneously. 3 consecutive beeps will sound indicating the calibration is confirmed.
5. Exit the maintenance mode by scrolling through the menu using the TURTLE ( 7 ) button.
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9 - Overload protection calibration procedure
9.1 - LOAD SENSE ZEROING
1. Remove the CLEVIS PIN securing the PLATFORM to the PLATFORM MOUNTING BRACKET,
allowing the PLATFORM to pivot about the PLATFORM PIN and rest on the ground. This removes the load from the LOAD CELL. Figure Platform Position.
2. Use the ground (lower) control panel to access the control box maintenance menu. Figure
ground (lower) control panel for overload protection.
3. Verify that the KEY SWITCH ( 1 ) is turned to the GROUND ( 1A ) icon, and that both EMER-
GENCY STOP ( 2 ) buttons (ground and platform) are "pulled out".
4. Enter the maintenance mode by pressing (pushing) both ROTATE ( 5 ) buttons and the OUTRIG-
GER EXTEND ( 6 ) button on the ground (lower) control panel simultaneously and holding for 5
seconds.
5. Scroll through the maintenance menu using the TURTLE ( 7 ) button to scroll down, use the
RABBIT ( 8 ) button to scroll back up, until "LOAD SENSE ZERO CALIBRATION UTILITY" is displayed in the DISPLAY PANEL ( 3 ). The display will automatically change to "REMOVE
WEIGHT THEN PRESS MID-SPEED KEYS"
6. Press (push) both MID SPEED buttons [MID-HIGH ( 9A ) / MID-LOW ( 9B )] on the ground (low-
er) control panel simultaneously. 3 consecutive beeps will sound and the DISPLAY PANEL ( 3 )
will read "LOAD SENSE HAS BEEN ZERO CALIBRATED" confirming the operation. The maintenance mode will then go to "LOAD SENSE SCALING UTILITY".
Plateform position
Reference Description of the components
A Ground
B Clevis pin
C Platform mounting bracket
D Platform pin
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C
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Ground (lower) control panel for overload protection
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10 - Load Sense Scaling
1. Return the platform to the upright position and re-install the CLEVIS PIN.
2. Exit the maintenance mode by scrolling through the menu using the TURTLE ( 7 ) button.
3. Press (push) the PLATFORM TILT UP ( 4A ) button and PLATFORM TILT DOWN ( 4B ) button
simultaneously to display the platform's weight ( +/- 10% ) in the DISPLAY PANEL ( 3 ).
• 4 Foot Platform = 29 kg (65 lbs)
• 5 Foot Platform = 34 kg (75 lbs)
• 4 Foot platform with platform rotate = 57 kg (125 lbs)
• 5 Foot platform with platform rotate = 61 kg (135 lbs)
Note : To change the display from pounds (LBS) to kilograms (KGS), or vice versa :
• Verify that the KEY SWITCH ( 1 ) is turned counter clockwise to the GROUND ( 1A )
icon, and that both EMERGENCY STOP ( 2 ) buttons (ground and platform) are
"pulled out".
• Enter the maintenance mode by pressing (pushing) both ROTATE ( 5 ) buttons and
the OUTRIGGER EXTEND ( 6 ) button on the ground (lower) control panel simultaneously and holding for 5 seconds.
• Scroll through the maintenance menu using the TURTLE ( 7 ) button to scroll down,
use the RABBIT ( 8 ) button to scroll back up, until the DISPLAY PANEL ( 9A ) reads
"TO CHANGE LBS TO KGS PRESS MID-SPEED KEYS SIMULTANEOUSLY" [MIDHIGH ( 9B ) / MID-LOW ( 3 )]. Change to the desired mode.
• Exit the maintenance mode by scrolling through the menu using the TURTLE ( 7 ) button.
4. Add between 159 - 181 kg (350 - 400 lbs) to platform.
5. Determine the total "Boom Load" (Platform weight plus the added weight), and make a note of it.
6. Press (push) the PLATFORM TILT UP ( 4A ) button and PLATFORM TILT DOWN ( 4B ) button
simultaneously to display the platform's weight in the DISPLAY PANEL ( 3 ).
• If the displayed weight is within +/- 10%, of the determined "Boom Load", calibration
is complete. Proceed to step ( 11 ).
• If the displayed weight is above +/- 10%, of the determined "Boom Load", calibration
is complete. Continue on to step ( 7 ).
7. Verify that the KEY SWITCH ( 1 ) is turned counter clockwise to the GROUND ( 1A ) icon, and
that both EMERGENCY STOP ( 2 ) buttons (ground and platform) are "pulled out".
8. Enter the maintenance mode by pressing (pushing) both ROTATE ( 5 ) buttons and the OUTRIGGER EXTEND ( 6 ) button on the ground (lower) control panel simultaneously and holding for 5
seconds.
9. Scroll through the maintenance menu using the TURTLE ( 7 ) button to scroll down, use the
RABBIT ( 8 ) button to scroll back up, until "LOAD SENSE SCALING UTILITY" is displayed in the
DISPLAY PANEL ( 3 ). The DISPLAY PANEL ( 3 ) should read a ratio of "3.68:1=0XXX" (platform plus load).
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10. Adjust displayed weight by pressing (pushing) the MID-HIGH ( 9A ) or MID-LOW ( 9B ) SPEED
buttons until the weight is within tolerances. The Ratio should be within 3.50:1 to 4.00:1. If so,
continue on to Step 11. If the ratio is not within the above values, contact Haulotte Group Customer Service Department: at 1-800-537-0540 or visit Haulotte Group online at www.haulotteusa.com.
11. Exit the maintenance mode by scrolling through the menu using the TURTLE ( 7 ) button. Remove the weight from the platform. The Boom Load should now return to the weight of the platform.
12. Operate all functions in all speeds from both the ground (lower) and platform (upper) control panels to verify proper operation.
13. Recalibration is complete.
11 - Additional service information
Seals on hydraulic cylinders should be replaced every 5 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 30 days.
Check for air in the hydraulic system if the aerial work platform has been stored without use for a period
exceeding 30 days, or if the aerial work platform was stored without use during a seasonal climate
change. Air trapped in the hydraulic system will affect aerial work platform performance. Follow
procedures for bleeding air from the hydraulic system, found in the "cylinder replacement" section of
this manual.
Owners and lessors should complete a full inspection of all components and perform a test of all
functions, including brake functions, before commissioning or reselling aerial work platform. Always
repair or replace all damaged or malfunctioning components before commissioning or reselling aerial
work platform
When a change in ownership occurs, it is the responsibility of the seller to provide the new owner with
all manuals for the aerial work platform. It is the responsibility of the buyer to notify the manufacturer of
the unit model, serial number and the name and address of the new owner within 60 days of the
purchase.
Use the service checklists found at the back of the manual to record all service checks as well as any
maintenance, repairs or alterations performed on the aerial work platform.
Records of frequent safety checks need not be made. However, where a safety hazard is found, it shall
be reported in writing to the owner of the aerial work platform, and a record of any corrective action
shall be maintained for 5 years or as required by the authority having jurisdiction.
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12 - 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. Figure Manual outrigger control wire harness.
Manual outrigger Control Wire Harness
1. Attach outrigger wire harness
2. Receptacle
3. Ping plug B01-09-0136 2
4. Socket terminal B01-09-0080
5. Wedge B01-09-0137
6. Outrigger controls cable
The hand pump is a component of the hydraulic power unit which is located in the pump compartment.
The hand pump and the hydraulic valve ( C7 ); must be used to manually retract the outriggers. Figure
Hydraulic Power Unit.
The boom(s) must be completely lowered and in the "stowed" position prior to raising the outriggers.
"Manual boom operation" section in this manual, if necessary. .
Procedure to raise the outriggers manually :
• Disconnect the outrigger's wire harness from the lower control (lower) box. Figure Bottom side of the
ground (lower) control box.
• Plug it into the receptacle on the Manual Outrigger Control Wire Harness. Figure Manual outrigger
control wire harness.
• Disconnect the wire harness from ( C7 ) VALVE on the hydraulic power unit and replace it with the
Outrigger controls cable. Figure Manual outrigger control wire harness-Figure Hydraulic Power Unit.
• Turn the PROPORTIONAL VALVE counterclockwise until it stops.
• Attach battery +/- clips to the battery. If the battery on the lift has no charge, use an alternate 12 V
power source.
• Insert the tire iron into the PUMP HANDLE RECEPTACLE on hydraulic power unit and actuate the
PUMP HANDLE to raise the outriggers. Figure Hydraulic Power Unit.
N.B.-:-Before resuming normal operation, turn the proportional valve clockwise to return it to its original
position.
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Bottom Side of the Ground (lower) Control Box
Hydraulic Power Unit
Reference Description of the components
1 Outrigger wire harness
Reference Description of the components
1 Valve C7
2 Pump handle receptacle
3 Proportional valve
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13 - 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.
The female quick disconnect is attached to the Hydraulic Power Unit at the "TP1" port.
The Pressure Gauge is composed of :
• Pressure Gauge that measures from 0-5000 psi (351 kg/cm2) (34473 kPa) : B02-00-0064
• Female Quick Disconnect : B02-02-0316
• Male Quick Disconnect (mates to B02-02-0316) : B02-00-0269
Attaching the Pressure Gauge to the Hydraulic Power Unit
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14 - 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.
Troubleshooting
Problem Cause Solution
No lights on panel when key switch is
turned to the on position
Emergency STOP engaged Disengage Emergency stop buttons
Battery charge is low Recharge as needed
Battery ground or in-series cable is
loose
Inspect and repair battery connections
Battery main disconnect unplugged Plug in main disconnect
Blown fuse Replace fuse as necessary
Error code displayed on Ground
Control Panel
Error detected by Control Box
Refer to the table for error code
definitions
Green light flashing on Motor
Controller
Error detected by Motor Controller
Refer to the table for error code
definitions - motor controller
Hydraulic function does not work and
display window shows an error
message
Error detected by safety interlock
microprocessor
Refer to the table for error code
definitions
Aerial work platform electric or
electronic failure
Refer to the table for error code
definitions
Outrigger indicator LED lights do not
function
Key switch turned to the off or platform
controls position
Turn key switch to ground controls
position
Emergency STOP engaged Disengage emergency stop buttons
Outriggers not deployed Deploy all outriggers
One or more Boom controls do not
functionOr One or more Boom
Controls function improperly Or One
or more Boom Controls function
intermittently
Key switch is turned to the off or
incorrect control position
Turn key switch to ground or platform
controls position
Battery charge is low Recharge battery
Emergency STOP engaged Disengage Emergency stop buttons
Battery ground or in-series cable is
loose
Inspect and repair battery connections
All outriggers not properly deployed
Deploy all outriggers and level boom
lift
Hydraulic pump inoperative
Inspect pump. Repair or replace as
needed.
Loose wiring connector
Check wiring terminals in control box
and at valve manifold. Repair or
replace as needed.
Valve solenoid not operating properly
Clean valve solenoid and recheck
function(s). Repair or replace as
needed.
Fault detected by system interlock
Check display for system status.
Refer to the table for error code
definitions.
Broken or loose wire
Inspect wiring in control box and at
valve manifold and valve coil. Repair
or replace as needed.
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15 - Error code definitions-Controls
The DISPLAY PANEL located on the ground (lower) control panel indicates the present operating
status of the aerial work platform. If an error condition is detected, the appropriate error code will be
displayed on this panel.
Refer to Table following paragraph 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 for any
additional questions.
Error
message
Error definition To simulate error To clear error Comments
001
MACHINE IS
IN DOWN
ONLY MODE
Machine went out of
level with use, moment
sense or load sense
circuits have detected
an overload
Level machine, raise
boom and tilt level
sensor
This is a self clearing
error. When error
condition is corrected,
error is cleared.
Error will be displayed
only if boom is raised
002LOSS OF
PLATFORM
COMMUNICA
TION
Lower Control has lost
RS485 communication
with Platform Control
Open Platform Control
and remove green wire
from J1
This is a latched error.
Power must be cycled
to clear error.
The Platform Control
"Engine On" LED will
also blink a 2 blink
error code
003 LOSS OF
DRIVE
COMMUNICA
TION
Lower Control has lost
RS485 communication
with Drive Control
Open Drive Control and
remove green wire
from J1
This is a latched error.
Power must be cycled
to clear error.
Machines with Drive
option only. The Drive
Control "Engine On"
LED will also blink a 2
blink error code
004 LOSS OF
PC
COMMUNICA
TION
Lower Control has lost
RS232 communication
with PC
Connect a PC without
running the
configuration program
This is a self clearing
error. When error
condition is corrected,
error is cleared.
Error message will only
be display if connected
to a PC that is not
communicating
005
PLATFORM
CONTROL
HAS STUCK
KEY
Platform Control has
detected a stuck or
pressed key on power
up
On Platform Control
hold down a key at
power up
This is a latched error.
Power must be cycled
to clear error.
The Platform Control
"Engine On" LED will
also blink a 1 blink
error code
006DRIVE
CONTROL
HAS STUCK
KEY
Drive Control has
detected a stuck or
pressed key on power
up
On Drive Control hold
down a key at power up
This is a latched error.
Power must be cycled
to clear error.
Machines with Drive
option only. The Drive
Control "Engine
On"LED will also blink
a 1 blink error code
007 DRIVE
CONTROL
HAS STUCK
JOYSTICK
Drive Control has
detected a stuck or
pressed joystick on
power up
On Drive Control hold
joystick to side at power
up
This is a latched error.
Power must be cycled
to clear error.
Machines with Drive
option only. The Drive
Control "Engine
On"LED will also blink
a 3 blink error code
008 GROUND
CONTROL
HAS STUCK
KEY
Lower Control has
detected a stuck or
pressed key on power
up
On Lower Control hold
down a key at power up
This is a latched error.
Power must be cycled
to clear error.
The Lower Control
"Power" LED will also
blink a 1 blink error
code
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009 BOOM
UP WITHOUT
OUTRIGGER
S ON
GROUND
Lower Control has
detected the boom is up
and all four outriggers
are not on the ground
Disconnect a wire from
either the boom down
or any outrigger switch
and turn on machine
This is a self clearing
error. When error
condition is corrected,
error is cleared.
010LEVEL
SENSOR
HAS
ERRATIC
OUTPUT
The Lower Control has
detected an erratic
output from the level
sensor
Shaking the level
sensor after machine
has been leveled
This is a self clearing
error. When error
condition is corrected,
error is cleared.
This error is
suppressed during
extending and
retracting outriggers
011 TRYING
TO DRIVE W/
TRAILER
BRAKE OFF
An attempt was made
to drive machine
without engaging the
trailer brake
Trying to drive machine
with trailer brake off
This is a self clearing
error. When error
condition is corrected,
error is cleared.
Machines with Drive
and Set option only
012ANGLE
SENSOR IS
DISCONNEC
TED OR BAD
Angle sensor output is
out of range
Disconnect Angle
Sensor
This is a self clearing
error. When error
condition is corrected,
error is cleared.
Machines with Moment
Sense option only
013PRESSU
RE SENSOR
IS
DISCONNEC
TED OR BAD
Pressure sensor output
is out of range
Disconnect Pressure
Sensor
This is a self clearing
error. When error
condition is corrected,
error is cleared.
Machines with Moment
Sense option only
014CHECK
ENGINE LOW
OIL
PRESSURE
Engine had low oil
pressure while running
Kawasaki Engine :
While engine is
running, disconnect
engine oil pressure
sense wire
Kubota Engine : While
engine is running,
disconnect engine oil
pressure sense wire
and connect wire to
ground
This is a latched error.
Power must be cycled
to clear error.
X-Boom Machines
with Kawasaki or
Kubota engines
015MACHINE
IS NOT
LEVEL
Machine has gone out
of level with use
Tilt level sensor
This is a self clearing
error. When error
condition is corrected,
error is cleared.
016LIFT
BOOM
A Boom Rotate, Extend
or Retract function has
been requested while
boom is down
Try to Rotate, Extend or
Retract the boom while
boom is down
This is a self clearing
error. When error
condition is corrected,
error is cleared.
017STOW
BOOM
An Outrigger function
has been requested
while boom is up
Try to move an
outrigger while boom is
up
This is a self clearing
error. When error
condition is corrected,
error is cleared.
018LOSS OF
LOAD SENSE
COMMUNICA
TION
Lower Control has lost
RS485 communication
with Load Sense
Module
Remove Load Sense
Module from machine
This is a latched error.
Power must be cycled
to clear error.
Machines with Load
Sense option only
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019 BOOM
FUNCTION
DISABLED
Load Sense Module
has detected an
overloaded boom and
disabled boom
functions
Overload Boom
This is a latched error.
Power must be cycled
to clear error.
Machines with Load
Sense option only
020LOSS OF
LOAD CELL
CONNECTIO
N
Load Sense Module
has lost connection with
Load Cell
Disconnect Load Cell
from Load Sense
Module
This is a self clearing
error. When error
condition is corrected,
error is cleared.
Machines with Load
Sense option only
021 OPEN
CIRCUIT
PRIMARY UP
A load of less than 70
mA was detected when
Primary Up circuit was
energized
Disconnect a wire from
Primary Up coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
022
SHORTED
CIRCUIT
PRIMARY UP
Excessive load was
detected when Primary
Up circuit was
energized
Use a piece of wire to
short the Primary Up
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
023 OPEN
CIRCUIT
PRIMARY
DOWN
A load of less than 70
mA was detected when
Primary Down circuit
was energized
Disconnect a wire from
Primary Down coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up Articulating Boom
Models
024
SHORTED
CIRCUIT
PRIMARY
DOWN
Excessive load
detected when primary
down circuit was
energized
Use a piece of wire to
short the Primary Down
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up Articulating Boom
Models
025 OPEN
CIRCUIT
SECONDARY
UP
A load of less than 70
mA was detected when
Secondary Up circuit
was energized
Disconnect a wire from
Secondary Up coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up Articulating Boom
Models
026
SHORTED
CIRCUIT
SECONDARY
UP
A load of less than 70
mA was detected when
Secondary Up circuit
was energized
Use a piece of wire to
short the Secondary Up
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up Articulating Boom
Models
027 OPEN
CIRCUIT
SECONDARY
DOWN
A load of less than 70
mA detected when
secondary down circuit
was energized
Disconnect a wire from
Secondary Down coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up Articulating Boom
Models
028
SHORTED
CIRCUIT
SECONDARY
DOWN
Excessive load was
detected when
Secondary Down circuit
was energized
Use a piece of wire to
short the Secondary
Down coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up Articulating Boom
Models
029 OPEN
CIRCUIT JIB
UP
A load of less than 70
mA was detected when
Jib Up circuit was
energized
Disconnect a wire from
Jib Up coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up Articulating Boom
Models
030
SHORTED
CIRCUIT JIB
UP
Excessive load was
detected when Jib Up
circuit was energized
Use a piece of wire to
short the Jib Up coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up Articulating Boom
Models
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031 OPEN
CIRCUIT JIB
DOWN
A load of less than 70
mA was detected when
Jib Down circuit was
energized
Disconnect a wire from
Jib Down coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up Articulating Boom
Models
032
SHORTED
CIRCUIT JIB
DOWN
Excessive load was
detected when Jib
Down circuit was
energized
Use a piece of wire to
short the Jib Down coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up Articulating Boom
Models
033 OPEN
CIRCUIT
EXTEND
A load of less than 70
mA was detected when
Extend circuit was
energized
Disconnect a wire from
Extend coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
034
SHORTED
CIRCUIT
EXTEND
Excessive load was
detected when Extend
circuit was energized
Use a piece of wire to
short the Extend coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
035 OPEN
CIRCUIT
RETRACT
A load of less than 70
mA was detected when
Retract circuit was
energized
Disconnect a wire from
Retract coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
036
SHORTED
CIRCUIT
RETRACT
Excessive load was
detected when Retract
circuit was energized
Use a piece of wire to
short the Retract coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
037 OPEN
CIRCUIT
PLATFORM
LEVEL UP
A load of less than 70
mA was detected when
Platform Level Up
circuit was energized
Disconnect a wire from
Platform Level Up coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
038
SHORTED
CIRCUIT
PLATFORM
LEVEL UP
Excessive load was
detected when Platform
Level Up circuit was
energized
Use a piece of wire to
short the Platform Level
Up coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
039OPEN
CIRCUIT
PLATFORM
LEVEL
DOWN
A load of less than 70
mA was detected when
Platform Level Down
circuit was energized
Disconnect a wire from
Platform Level Down
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
040SHORTE
D CIRCUIT
PLATFORM
LEVEL
DOWN
Excessive load was
detected when Platform
Level Down circuit was
energized
Use a piece of wire to
short the Platform Level
Down coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
041OPEN
CIRCUIT
PLATFORM
CW
A load of less than 70
mA was detected when
Platform CW circuit was
energized
Disconnect a wire from
Platform CW coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up Articulating Boom
Models
042SHORTE
D CIRCUIT
PLATFORM
CW
Excessive load was
detected when Platform
CW circuit was
energized
Use a piece of wire to
short the Platform CW
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up Articulating Boom
Models
92 2420341380 E 02.12 USA
Summit Series
D
- Equipment Maintenance
043OPEN
CIRCUIT
PLATFORM
CCW
A load of less than 70
mA was detected when
Platform CCW circuit
was energized
Disconnect a wire from
Platform CCW coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up Articulating Boom
Models
044SHORTE
D CIRCUIT
PLATFORM
CCW
Excessive load was
detected when Platform
CCW circuit was
energized
Use a piece of wire to
short the Platform CCW
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up Articulating Boom
Models
045OPEN
CIRCUIT
TURNTABLE
CW
A load of less than 70
mA was detected when
Turntable CW circuit
was energized
Disconnect a wire from
Turntable CW coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
046SHORTE
D CIRCUIT
TURNTABLE
CW
Excessive load was
detected when
Turntable CW circuit
was energized
Use a piece of wire to
short the Turntable CW
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
047OPEN
CIRCUIT
TURNTABLE
CCW
A load of less than 70
mA was detected when
Turntable CCW circuit
was energized
Disconnect a wire from
Turntable CCW coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
048SHORTE
D CIRCUIT
TURNTABLE
CCW
Excessive load was
detected when
Turntable CCW circuit
was energized
Use a piece of wire to
short the Turntable
CCW coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
049OPEN
CIRCUIT
OUTRIGGER
RETRACT
A load of less than 70
mA was detected when
Outrigger Retract circuit
was energized
Disconnect a wire from
Outrigger Retract coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
050SHORTE
D CIRCUIT
OUTRIGGER
RETRACT
Excessive load was
detected when
Outrigger Retract circuit
was energized
Use a piece of wire to
short the Outrigger
Retract coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
051OPEN
CIRCUIT
OUTRIGGER
EXTEND
A load of less than 70
mA was detected when
Outrigger Extend circuit
was energized
Disconnect a wire from
Outrigger Extend coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
052SHORTE
D CIRCUIT
OUTRIGGER
EXTEND
Excessive load was
detected when
Outrigger Extend circuit
was energized
Use a piece of wire to
short the Outrigger
Extend coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
053OPEN
CIRCUIT LF
OUTRIGGER
A load of less than 70
mA was detected when
LF Outrigger circuit was
energized
Disconnect a wire from
LF Outrigger coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
054SHORTE
D CIRCUIT
LF
OUTRIGGER
Excessive load was
detected when LF
Outrigger circuit was
energized
Use a piece of wire to
short the LF Outrigger
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
055OPEN
CIRCUIT RF
OUTRIGGER
A load of less than 70
mA was detected when
RF Outrigger circuit
was energized
Disconnect a wire from
RF Outrigger coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
A
B
C
D
E
F
G
H
I
93
2420341380 E 02.12 USA
Summit Series
D
- Equipment Maintenance
056SHORTE
D CIRCUIT
RF
OUTRIGGER
Excessive load was
detected when RF
Outrigger circuit was
energized
Use a piece of wire to
short the RF Outrigger
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
057OPEN
CIRCUIT LR
OUTRIGGER
A load of less than 70
mA was detected when
LR Outrigger circuit
was energized
Disconnect a wire from
LR Outrigger coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
058SHORTE
D CIRCUIT
LR
OUTRIGGER
Excessive load was
detected when LR
Outrigger circuit was
energized
Use a piece of wire to
short the LR Outrigger
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
059OPEN
CIRCUIT RR
OUTRIGGER
A load of less than 70
mA was detected when
RR Outrigger circuit
was energized
Disconnect a wire from
RR Outrigger coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
060SHORTE
D CIRCUIT
RR
OUTRIGGER
Excessive load was
detected when RR
Outrigger circuit was
energized
Use a piece of wire to
short the RR Outrigger
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
061OPEN
CIRCUIT
ENGINE
THROTTLE
A load of less than 70
mA was detected when
Engine Throttle circuit
was energized
Disconnect a wire from
Engine Throttle coil
This is a latched error.
Power must be cycled
to clear error.
Error Suppressed due
to low current draw
062SHORTE
D CIRCUIT
ENGINE
THROTTLE
Excessive load was
detected when Engine
Throttle circuit was
energized
Use a piece of wire to
short the Engine
Throttle coil
This is a latched error.
Power must be cycled
to clear error.
Error Suppressed due
to low current draw
063OPEN
CIRCUIT
ENGINE
STARTER
A load of less than 70
mA was detected when
Engine Starter circuit
was energized
Disconnect a wire from
Engine Starter coil
This is a latched error.
Power must be cycled
to clear error.
Not tested. Do not want
to crank engine on
power up
064SHORTE
D CIRCUIT
ENGINE
STARTER
Excessive load was
detected when Engine
Starter circuit was
energized
Use a piece of wire to
short the Engine Starter
coil
This is a latched error.
Power must be cycled
to clear error.
Not tested. Do not want
to crank engine on
power up
065OPEN
CIRCUIT
ENGINE
CHOKE
A load of less than 70
mA was detected when
Engine Choke circuit
was energized
Disconnect a wire from
Engine Choke coil
This is a latched error.
Power must be cycled
to clear error.
Error Suppressed due
to low current draw
066SHORTE
D CIRCUIT
ENGINE
CHOKE
Excessive load was
detected when Engine
Choke circuit was
energized
Use a piece of wire to
short the Engine Choke
coil
This is a latched error.
Power must be cycled
to clear error.
Error Suppressed due
to low current draw
067OPEN
CIRCUIT
ENGINE
STOP
A load of less than 70
mA was detected when
Engine Stop circuit was
energized
Disconnect a wire from
Engine Stop coil
This is a latched error.
Power must be cycled
to clear error.
Error Suppressed due
to low current draw
068SHORTE
D CIRCUIT
ENGINE
STOP
Excessive load was
detected when Engine
Stop circuit was
energized
Use a piece of wire to
short the Engine Stop
coil
This is a latched error.
Power must be cycled
to clear error.
Error Suppressed due
to low current draw
94 2420341380 E 02.12 USA
Summit Series
D
- Equipment Maintenance
069OPEN
CIRCUIT
PROPORTIO
NAL
A load of less than 70
mA was detected when
Proportional circuit was
energized
Disconnect a wire from
Proportional coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
070SHORTE
D CIRCUIT
PROPORTIO
NAL
Excessive load was
detected when
Proportional circuit was
energized
Use a piece of wire to
short the Proportional
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
071OPEN
CIRCUIT
MOTOR
CONTROL
ENABLE
A load of less than 70
mA was detected when
Motor Control Enable
circuit was energized
Disconnect a wire from
Motor Control Enable
coil
Error Suppressed due
to low current draw
072SHORTE
D CIRCUIT
MOTOR
CONTROL
ENABLE
Excessive load was
detected when Motor
Control Enable circuit
was energized
Use a piece of wire to
short the Motor Control
Enable coil
Error Suppressed due
to low current draw
073OPEN
CIRCUIT
SPARE
OUTPUT
A load of less than 70
mA was detected when
Spare Output circuit
was energized
Disconnect a wire from
Spare Output coil
This is a latched error.
Power must be cycled
to clear error.
Not used
074SHORTE
D CIRCUIT
SPARE
OUTPUT
Excessive load was
detected when Spare
Output circuit was
energized
Use a piece of wire to
short the Spare Output
coil
This is a latched error.
Power must be cycled
to clear error.
Not used
075OPEN
CIRCUIT AC
SWITCH
A load of less than 70
mA was detected when
AC Switch circuit was
energized
Disconnect a wire from
AC Switch coil
Error Suppressed due
to low current draw
076SHORTE
D CIRCUIT
AC SWITCH
Excessive load was
detected when AC
Switch circuit was
energized
Use a piece of wire to
short the AC Switch coil
Error Suppressed due
to low current draw
077OPEN
CIRCUIT
STROBE
A load of less than 70
mA was detected when
Strobe circuit was
energized
Disconnect a wire from
Strobe
Error Suppressed due
to low current draw
078SHORTE
D CIRCUIT
STROBE
Excessive load was
detected when Strobe
circuit was energized
Use a piece of wire to
short the Strobe coil
Error Suppressed due
to low current draw
079OPEN
CIRCUIT
DRIVE PWM
A load of less than 70
mA was detected when
Drive PWM circuit was
energized
Disconnect a wire from
Drive PWM coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with Drive
option only
080SHORTE
D CIRCUIT
DRIVE PWM
Excessive load was
detected when Drive
PWM circuit was
energized
Use a piece of wire to
short the Drive PWM
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with Drive
option only
A
B
C
D
E
F
G
H
I
95
2420341380 E 02.12 USA
Summit Series
D
- Equipment Maintenance
081OPEN
CIRCUIT
DRIVE
ENABLE
A load of less than 70
mA was detected when
Drive Enable circuit
was energized
Disconnect a wire from
Drive Enable coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with Drive
option only
082SHORTE
D CIRCUIT
DRIVE
ENABLE
Excessive load was
detected when Drive
Enable circuit was
energized
Use a piece of wire to
short the Drive Enable
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with Drive
option only
083OPEN
CIRCUIT
DRIVE DUMP
(C21)
A load of less than 70
mA was detected when
Drive Dump ( C21)
circuit was energized
Disconnect a wire from
Drive Dump ( C21) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
084SHORTE
D CIRCUIT
DRIVE DUMP
(C21)
Excessive load was
detected when Drive
Dump ( C21) circuit
was energized
Use a piece of wire to
short the Drive Engage
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
085OPEN
CIRCUIT
TURN LEFT
(C22)
A load of less than 70
mA was detected when
Turn Left ( C22) circuit
was energized
Disconnect a wire from
Turn Left ( C22) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
086SHORTE
D CIRCUIT
TURN LEFT
(C22)
Excessive load was
detected when Turn
Left ( C22) circuit was
energized
Use a piece of wire to
short the Turn Left (
C22) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
087OPEN
CIRCUIT
TURN RIGHT
(C23)
A load of less than 70
mA was detected when
Turn Right ( C23)
circuit was energized
Disconnect a wire from
Turn Right ( C23) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
088SHORTE
D CIRCUIT
TURN RIGHT
(C23)
Excessive load was
detected when Turn
Right ( C23) circuit was
energized
Use a piece of wire to
short the Turn Right (
C23) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
089OPEN
CIRCUIT
FORWARD 1
(C24)
A load of less than 70
mA was detected when
Forward 1 ( C24)
circuit was energized
Disconnect a wire from
Forward 1 ( C24) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
090SHORTE
D CIRCUIT
FORWARD 1
(C24)
Excessive load was
detected when Forward
1 ( C24) circuit was
energized
Use a piece of wire to
short the Forward 1 (
C24) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
091OPEN
CIRCUIT
REVERSE 1
(C25)
A load of less than 70
mA was detected when
Reverse 1 ( C25)
circuit was energized
Disconnect a wire from
Reverse 1 ( C25) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
092SHORTE
D CIRCUIT
REVERSE 1
(C25)
Excessive load was
detected when
Reverse 1 ( C25)
circuit was energized
Use a piece of wire to
short the Reverse 1 (
C25) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
093OPEN
CIRCUIT
FORWARD 2
(C27)
A load of less than 70
mA was detected when
Forward 2 ( C27)
circuit was energized
Disconnect a wire from
Forward 2 ( C27) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
96 2420341380 E 02.12 USA
Summit Series
D
- Equipment Maintenance
094SHORTE
D
CIRCUITFOR
WARD 2
(C27)
Excessive load was
detected when Forward
2 ( C27) circuit was
energized
Use a piece of wire to
short the Forward 2 (
C27) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
095OPEN
CIRCUIT
REVERSE 2
(C28)
A load of less than 70
mA was detected when
Reverse 2 ( C28)
circuit was energized
Disconnect a wire from
Reverse 2 ( C28) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
096SHORTE
D CIRCUIT
REVERSE 2
(C28)
Excessive load was
detected when
Reverse 2 ( C28)
circuit was energized
Use a piece of wire to
short the Reverse 2 (
C28) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
097OPEN
CIRCUIT
TORQUE H/L
(C29)
A load of less than 70
mA was detected when
Torque H/L ( C29)
circuit was energized
Disconnect a wire from
Torque H/L ( C29) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
098SHORTE
D CIRCUIT
TORQUE H/L
(C29)
Excessive load was
detected when Torque
H/L ( C29) circuit was
energized
Use a piece of wire to
short the Torque H/L (
C29) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
099OPEN
CIRCUIT
TORQUE H/L
(C30)
A load of less than 70
mA was detected when
Torque H/L ( C30)
circuit was energized
Disconnect a wire from
Torque H/L ( C30) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
100SHORTE
D CIRCUIT
TORQUE H/L
(C30)
Excessive load was
detected when Torque
H/L ( C30) circuit was
energized
Use a piece of wire to
short the Torque H/L (
C30) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
101OPEN
CIRCUIT
TORQUE H/L
(C31)
A load of less than 70
mA was detected when
Torque H/L ( C31)
circuit was energized
Disconnect a wire from
Torque H/L ( C31) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
102SHORTE
D CIRCUIT
TORQUE H/L
(C31)
Excessive load was
detected when Torque
H/L ( C31) circuit was
energized
Use a piece of wire to
short the Torque H/L (
C31) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WD
option only
103OUTREA
CH NEAR
MAXIMUM
Boom has exceeded
95% of maximum
outreach
Put 500 lbs in boom,
level boom and extend
until alarm sounds and
error is displayed
This is a latched error.
Power must be cycled
to clear error.
Machines with Moment
Sense option only
104OUTREA
CH AT
MAXIMUM
Boom has reached
maximum outreach
setting
Put 500 lbs in boom,
level boom and extend
until alarm sounds and
error is displayed
This is a latched error.
Power must be cycled
to clear error.
Machines with Moment
Sense option only
105OVER
MAXIMUM
CYLINDER
PRESSURE
Cylinder pressure has
exceeded maximum
pressure setting
Put 500 lbs in boom,
lower cylinder pressure
setting using
configuration program
and extend boom until
alarm sounds and error
is displayed
This is a latched error.
Power must be cycled
to clear error.
Machines with Moment
Sense option only
A
B
C
D
E
F
G
H
I
97
2420341380 E 02.12 USA
Summit Series
D
- Equipment Maintenance
106OUTREA
CH SENSING
FAULT
Cylinder safety
pressure switch has
detected maximum
pressure setting
Disconnect safety
pressure switch wires
This is a latched error.
Power must be cycled
to clear error.
Machines with Moment
Sense option only
107ENGINE
TEMP HIGH
CHECK
WATER
LEVEL
Excessive engine
temperature was
detected
Remove wire from
engine temperature
sensor and connect
wire to ground
This is a latched error.
Power must be cycled
to clear error.
Machines with 4WS
option only
108CHECK
ALTERNATO
R NOT
CHARGING
Engine alternator is not
charging
Remove P wire from
alternator and connect
wire to ground
This is a latched error.
Power must be cycled
to clear error.
Machines with 4WS
option only
109ENGINE
RPM FAULT
HIGH RPM IS
TOO LOW
When driving, engine
high RPM was too low
Misadjust engine high
RPM to a value less
than 3000 RPM and
attempt to drive
This is a latched error.
Power must be cycled
to clear error.
Machines with 4WS
option only
121OPEN
CIRCUIT
BRAKE (FWS
C21)
A load of less than 70
mA was detected when
Brake (FWS C21)
circuit was energized
Disconnect a wire from
Brake (FWS C21) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
122SHORTE
D CIRCUIT
BRAKE (FWS
C21)
Excessive load was
detected when Brake
(FWS C21) circuit was
energized
Use a piece of wire to
short the Brake (FWS
C21) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
123OPEN
CIRCUIT RS
RET (FWS
C22)
A load of less than 70
mA was detected when
RS Ret (FWS C22)
circuit was energized
Disconnect a wire from
RS Ret (FWS C22) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
124SHORTE
D CIRCUIT
RS RET
(FWS C22)
Excessive load was
detected when RS Ret
(FWS C22) circuit was
energized
Use a piece of wire to
short the RS Ret (FWS
C22) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
125OPEN
CIRCUIT RS
EXT (FWS
C23)
A load of less than 70
mA was detected when
RS Ext (FWS C23)
circuit was energized
Disconnect a wire from
RS Ext (FWS C23) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
126SHORTE
D CIRCUIT
RS RET
(FWS C23)
Excessive load was
detected when RS Ext
(FWS C23) circuit was
energized
Use a piece of wire to
short the RS Ext (FWS
C23) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
127OPEN
CIRCUIT FS
RET (FWS
C24)
A load of less than 70
mA was detected when
FS Ret (FWS C24)
circuit was energized
Disconnect a wire from
FS Ret (FWS C24) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
128SHORTE
D CIRCUIT
FS RET (FWS
C24)
Excessive load was
detected when FS Ret
(FWS C24) circuit was
energized
Use a piece of wire to
short the FS Ret (FWS
C24) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
98 2420341380 E 02.12 USA
Summit Series
D
- Equipment Maintenance
129OPEN
CIRCUIT FS
EXT (FWS
C25)
A load of less than 70
mA was detected when
FS Ext (FWS C25)
circuit was energized
Disconnect a wire from
FS Ext (FWS C25) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
130SHORTE
D CIRCUIT
FS RET (FWS
C25)
Excessive load was
detected when FS Ext
(FWS C25) circuit was
energized
Use a piece of wire to
short the FS Ext (FWS
C25) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
131OPEN
CIRCUIT DC
D FWD (FWS
C26)
A load of less than 70
mA was detected when
DC D Fwd (FWS C26)
circuit was energized
Disconnect a wire from
DC D Fwd (FWS C26)
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
132SHORTE
D CIRCUIT
DC D FWD
(FWS C26)
Excessive load was
detected when DC D
Fwd (FWS C26) circuit
was energized
Use a piece of wire to
short the DC D Fwd
(FWS C26) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
133OPEN
CIRCUIT DC
D REV (FWS
C27)
A load of less than 70
mA was detected when
DC D Rev (FWS C27)
circuit was energized
Disconnect a wire from
DC D Rev (FWS C27)
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
134SHORTE
D CIRCUIT
DC D REV
(FWS C27)
Excessive load was
detected when DC D
Rev (FWS C27) circuit
was energized
Use a piece of wire to
short the DC D Rev
(FWS C27) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
135OPEN
CIRCUIT DC
D (FWS C28)
A load of less than 70
mA was detected when
DC D (FWS C28)
circuit was energized
Disconnect a wire from
DC D (FWS C28) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
136SHORTE
D CIRCUIT
DC D (FWS
C28)
Excessive load was
detected when DC D
(FWS C28) circuit was
energized
Use a piece of wire to
short the DC D (FWS
C28) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
137OPEN
CIRCUIT DC
D (FWS C29)
A load of less than 70
mA was detected when
DC D (FWS C29)
circuit was energized
Disconnect a wire from
DC D (FWS C29) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
138SHORTE
D CIRCUIT
DC D (FWS
C29)
Excessive load was
detected when DC D
(FWS C29) circuit was
energized
Use a piece of wire to
short the DC D (FWS
C29) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
139OPEN
CIRCUIT DC
D (FWS C30)
A load of less than 70
mA was detected when
DC D (FWS C30)
circuit was energized
Disconnect a wire from
DC D (FWS C30) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
140SHORTE
D CIRCUIT
DC D (FWS
C30)
Excessive load was
detected when DC D
(FWS C30) circuit was
energized
Use a piece of wire to
short the DC D (FWS
C30) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
141OPEN
CIRCUIT DC
D (FWS C31)
A load of less than 70
mA was detected when
DC D (FWS C31)
circuit was energized
Disconnect a wire from
DC D (FWS C31) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
A
B
C
D
E
F
G
H
I
99
2420341380 E 02.12 USA
Summit Series
D
- Equipment Maintenance
142SHORTE
D CIRCUIT
DC D (FWS
C31)
Excessive load was
detected when DC D
(FWS C31) circuit was
energized
Use a piece of wire to
short the DC D (FWS
C31) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
143OPEN
CIRCUIT
(FWS C32)
A load of less than 70
mA was detected when
(FWS C32) circuit was
energized
Disconnect a wire from
(FWS C32) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
144SHORTE
D CIRCUIT
(FWS C32)
Excessive load was
detected when (FWS
C32) circuit was
energized
Use a piece of wire to
short the (FWS C32)
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
145OPEN
CIRCUIT
(FWS C33)
A load of less than 70
mA was detected when
(FWS C33) circuit was
energized
Disconnect a wire from
(FWS C33) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
146SHORTE
D CIRCUIT
(FWS C33)
Excessive load was
detected when (FWS
C33) circuit was
energized
Use a piece of wire to
short the (FWS C33)
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
147OPEN
CIRCUIT
(FWS C34)
A load of less than 70
mA was detected when
(FWS C34) circuit was
energized
Disconnect a wire from
(FWS C34) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
148SHORTE
D CIRCUIT
(FWS C34)
Excessive load was
detected when (FWS
C34) circuit was
energized
Use a piece of wire to
short the (FWS C34)
coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
149OPEN
CIRCUIT
(FWS R2)
A load of less than 70
mA was detected when
(FWS R2) circuit was
energized
Disconnect a wire from
(FWS R2) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
150SHORTE
D CIRCUIT
(FWS R2)
Excessive load was
detected when (FWS
R2) circuit was
energized
Use a piece of wire to
short the (FWS R2) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
151OPEN
CIRCUIT
(FWS GEN
G1)
A load of less than 70
mA was detected when
(FWS GEN G1) circuit
was energized
Disconnect a wire from
(FWS GEN G1) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
152SHORTE
D CIRCUIT
(FWS GEN
G1)
Excessive load was
detected when (FWS
GEN G1) circuit was
energized
Use a piece of wire to
short the (FWS GEN
G1) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
153OPEN
CIRCUIT
(FWS CON
24V)
A load of less than 70
mA was detected when
(FWS CON 24V) circuit
was energized
Disconnect a wire from
(FWS CON 24V) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
154SHORTE
D CIRCUIT
(FWS CON
24V)
Excessive load was
detected when (FWS
CON 24V) circuit was
energized
Use a piece of wire to
short the (FWS CON
24V) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
100 2420341380 E 02.12 USA
Summit Series
D
- Equipment Maintenance
155OPEN
CIRCUIT
(FWS SPARE
1)
A load of less than 70
mA was detected when
(FWS SPARE 1) circuit
was energized
Disconnect a wire from
(FWS SPARE 1) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
156SHORTE
D CIRCUIT
(FWS SPARE
1)
Excessive load was
detected when (FWS
SPARE 1) circuit was
energized
Use a piece of wire to
short the (FWS
SPARE 1) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
157OPEN
CIRCUIT
(FWS SPARE
2)
A load of less than 70
mA was detected when
(FWS SPARE 2) circuit
was energized
Disconnect a wire from
(FWS SPARE 2) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
158SHORTE
D
CIRCUIT(FW
S SPARE 2)
Excessive load was
detected when (FWS
SPARE 2) circuit was
energized
Use a piece of wire to
short the (FWS
SPARE 2) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
159OPEN
CIRCUIT
(FWS SPARE
3)
A load of less than 70
mA was detected when
(FWS SPARE 3) circuit
was energized
Disconnect a wire from
(FWS SPARE 3) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
160SHORTE
D CIRCUIT
(FWS SPARE
3)
Excessive load was
detected when (FWS
SPARE 3) circuit was
energized
Use a piece of wire to
short the (FWS
SPARE 3) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
161OPEN
CIRCUIT
(FWS PROP
A1)
A load of less than 70
mA was detected when
(FWS PROP A1)
circuit was energized
Disconnect a wire from
(FWS PROP A1) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
162SHORTE
D CIRCUIT
(FWS PROP
A1)
Excessive load was
detected when (FWS
PROP A1) circuit was
energized
Use a piece of wire to
short the (FWS PROP
A1) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
163OPEN
CIRCUIT
(FWS PROP
A2)
A load of less than 70
mA was detected when
(FWS PROP A2)
circuit was energized
Disconnect a wire from
(FWS PROP A2) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
164SHORTE
D CIRCUIT
(FWS PROP
A2)
Excessive load was
detected when (FWS
PROP A2) circuit was
energized
Use a piece of wire to
short the (FWS PROP
A2) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
165OPEN
CIRCUIT
(FWS PROP
B1)
A load of less than 70
mA was detected when
(FWS PROP B1)
circuit was energized
Disconnect a wire from
(FWS PROP B1) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
166SHORTE
D CIRCUIT
(FWS PROP
B1)
Excessive load was
detected when (FWS
PROP B1) circuit was
energized
Use a piece of wire to
short the (FWS PROP
B1) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
167OPEN
CIRCUIT
(FWS PROP
B2)
A load of less than 70
mA was detected when
(FWS PROP B2)
circuit was energized
Disconnect a wire from
(FWS PROP B2) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
A
B
C
D
E
F
G
H
I
101
2420341380 E 02.12 USA
Summit Series
D
- Equipment Maintenance
16 - Error code definitions - Motor controller
The Motor Controller indicates the operational status of the controller, it is located under the power
compartment cover (left / drivers side), and behind the ground (lower) control panel. If an error
condition is detected, the appropriate error code will be displayed by a flashing indicator light. Figure
Motor controller for a visual of the controller.
Table "Error code definitions - Motor controller" to resolve the Fault, or contact Haulotte Group
Customer Service Department: at 1-800-537-0540 or visit Haulotte Group online at www.haulotteusa.com with any questions.
Motor controller
168SHORTE
D CIRCUIT
(FWS PROP
B2)
Excessive load was
detected when (FWS
PROP B2) circuit was
energized
Use a piece of wire to
short the (FWS PROP
B2) coil
This is a latched error.
Power must be cycled
to clear error.
Checked only at power
up
Machines with 4WS
option only
Reference Description of the components
1 Indicator light
102 2420341380 E 02.12 USA
Summit Series
D
- Equipment Maintenance
Error code definitions - Motor controller
Flash fault Priority ID Fault Description Solution
Steady ON, no
flashing
1None
System is operating
normally
None required
111
Configuration
Range Error
One or more controller
personality settings are
out of range
Use Sevcon calibrator to enter correct
settings from latest Personality Sheet
1 12 CRC Error
The controller
personality checksum
is incorrect
Use Sevcon calibrator to enter correct
settings from latest Personality Sheet.
Otherwise, replace motor controller.
2 5 Sequence Fault
Enable line is active at
power up
Check enable line, B- wiring, and
Molex connector
2 6 Accelerator Fault
Invalid accelerator
personality setting
Check speed input line, B- wiring,
Molex connector, and 1000 Ohm
resistor
317
MOSFET Short
Circuit
MOSFET short circuit
or controller miswire
detected
Check for miswired B+, B-, or pump
cables. Make sure pump terminals
are not shorted to frame. If cables and
pump are OK, then replace motor
controller.
414
Line Contactor
Welded
The line contactor is
welded or otherwise
shorted
Check line contactor wiring. If wiring is
OK, then replace line contactor.
415
Line Contactor did
not Close
Line contactor did not
close or is otherwise
open circuit
Check line contactor wiring and Molex
connector. Measure the contactor coil
resistance; it should be around 50
Ohm. If contactor and wiring are OK,
then replace motor controller.
5 16 Motor open circuit
Pump motor cable
disconnected
Check pump-motor and controller
cables. Measure pump motor
resistance it should be near zero ohms
6N/A
Not used in this
application
N/A N/A
7 7 Low battery
Battery voltage is too
low
Recharge the batteries.
7 8 High battery
Battery voltage is too
high
Make sure battery charger is off.
Check for poor or corroded battery
connections.
710
High Battery with
Line Contactor
Open
High battery voltage
was detected at power
up before line contactor
closed
Make sure battery charger is off or that
the battery is not overcharged.
8 1 Thermal Cutback
Maximum power
available to motor has
been reduced due to
excessive heat sink
temperature
Remove power and allow controller to
cool. If fault repeatedly occurs, look
for binding on the hydraulic cylinders
or sticking valves. Otherwise, the
pump motor may be failing.
A
B
C
D
E
F
G
H
I
103
2420341380 E 02.12 USA
Summit Series
D
- Equipment Maintenance
83
Pump ITT Current
Limit Cutback
Maximum power
available to pump
motor has been
reduced by the Current
Limit Cutback function.
Recycle power. If fault repeatedly
occurs, look for binding on the
hydraulic cylinders or sticking valves.
If fault repeatedly occurs, look for
binding on the hydraulic cylinders or
sticking valves.
9N/A
Not used in this
application
N/A N/A
10 N/A
Not used in this
application
N/A N/A
11 18
Auto Zero Out of
Range
Internal pump current
measurement circuit
could not be calibrated.
Replace motor controller.
11 24 System Monitor
Illegal system condition
sensed due to internal
hardware fault. .
Replace motor controller.
Single flash
then off
19 MOSFETs Off
MOSFETs did not
pulse when the internal
failsafe circuit was
enabled.
Check for reversed cables among B+,
B-, and A terminals. If no miswire is
found, replace motor controller.
Single flash
then off
20 MOSFETs On
MOSFETs pulsed while
the internal failsafe
circuit was disabled.
MOSFETs pulsed while the internal
failsafe circuit was disabled. If no
miswire is found, replace motor
controller.
Single flash
then off
22
Contactor Drive
Off
Contactor output did
not pulse with the
internal failsafe circuit
enabled.
Replace motor controller.
Single flash
then off
23
Contactor Drive
On
Contactor output
pulsed while the
internal failsafe circuit
was disabled.
Replace motor controller.
A
B
C
D
E
F
G
H
I
105
2420341380 E 02.12 USA
Summit Series
E
- Cylinder replacement
Cylinder replacement
1 - Master / slave cylinder replacement - Articulating models
Use the following procedure to remove and replace faulty cylinders.
1.1 - MASTER CYLINDER
• With the boom in the "stowed" position, raise the upper boom until there is adequate exposure of the
pin retainer and pivot pin.
• Verify that the upper boom is supported by lifting straps and an overhead hoist or equivalent.
• Unbolt and remove the pin retainer at the rod end of the cylinder.
• Remove the pivot pin using a hammer and a brass or hardwood drift.
• Tag and number all hydraulic hoses that attach to the cylinder valve block.
• Use a marker to label the valve block ports with the appropriate hose numbers.
Location of master cylinder
• 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.
• Unbolt and remove the pin retainer at the base end of the cylinder.
• Remove the pivot pin using a hammer and a brass or hardwood drift.
• Replace or reinstall the cylinder by following the above instructions in the reverse order of removal.
• Actuate the hydraulic system and check for leakage. Tighten hydraulic fittings as needed.
• Bleed trapped air from the hydraulic system by raising and lowering the telescoping boom with the
reservoir fill port cap on, but not tightened. Allow several cycles of operation for trapped air to escape.
Repeat as necessary.
Reference Description of the components
1 Cylinder base end
2 Master cylinder
3 Cylinder rod end
4 Pivot pin
5 Pin retainer
6 Pivot pin
106 2420341380 E 02.12 USA
Summit Series
E
- Cylinder replacement
1.2 - SLAVE CYLINDER
• With the boom in the "stowed" position, extend the telescoping boom until there is adequate exposure
of the pin retainer and pivot pin (Approximately 0.7 m (2 ft)).
• Verify that the upper boom is supported by lifting straps and an overhead hoist or equivalent.
• Unbolt and remove the pin retainer at the rod end of the cylinder.
• Remove the pivot pin using a hammer and a brass or hardwood drift.
• Tag and number all hydraulic hoses that attach to the cylinder valve block. Use a marker to label the
valve block ports with the appropriate hose numbers.
• Place absorbent cloths below the cylinder ports and detach hydraulic hoses from the cylinder. Elevate
hoses to prevent leakage. Plug or cap exposed hose fittings and cylinder ports.
• Unbolt and remove both pin retainers at the base end of the cylinder.
• Remove the pivot pin using a hammer and a brass or hardwood drift.
• Replace or reinstall the cylinder by following the above instructions in the reverse order of removal.
• Actuate the hydraulic system and check for leakage. Tighten hydraulic fittings as needed.
• Bleed trapped air from the hydraulic system by raising and lowering the telescoping boom with the
reservoir fill port cap on, but not tightened. . Repeat as necessary.
Location of slave cylinder
Reference Description of the components
1 Cylinder base end
2 Master cylinder
3 Cylinder rod end
4 Pivot pin
5 Pin retainer
6 Pivot pin
A
B
C
D
E
F
G
H
I
107
2420341380 E 02.12 USA
Summit Series
E
- Cylinder replacement
1.3 - LIFT CYLINDER REPLACEMENT - ARTICULATING MODELS
HLA16PX, 45XA, HLA19PX, 55XA, HTA13P, 3522A, HTA16P, 4527A, HTA19P, 5533A
Aerial Work Platforms have three (3) lift cylinders, use the following procedure to remove and
replace faulty or damaged hydraulic cylinders.
location of manual lowering valves for lift cylinder replacement - Primary lift cylinder
location of manual lowering valves for lift cylinder replacement - Secondary lift cylinder
Reference Description of the components
1 Turntable
2 Valve "push button"
Reference Description of the components
1 Knuckle
2 Valve "push button"
108 2420341380 E 02.12 USA
Summit Series
E
- Cylinder replacement
location of manual lowering valves for lift cylinder replacement - Jib lift cylinder
• With the boom in the "stowed" position, press (push) in and hold the emergency lowering valve
"button" on the lift cylinder to relieve all hydraulic pressure to the cylinder.
• Turn the key switch at the ground (lower) control panel, to the "OFF" position and remove the key.
• Locate the piston rod end of the cylinder to be removed. Unbolt and remove the pin retainer from each
side of the pivot pin.
Push "Button" lowering valve
Reference Description of the components
3 Valve "push button"
A
B
C
D
E
F
G
H
I
109
2420341380 E 02.12 USA
Summit Series
E
- Cylinder replacement
Lift cylinder replacement
• 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.
• Use an overhead crane or lifting gear to raise the boom section. Adequate clearance is necessary to
reach the cylinder valve block (base end) and hydraulic hose ports.
• Remove the valve solenoid by unscrewing the cap, sliding the coil off, then unscrewing the valve.
• Tag and number all hydraulic hoses that attach to the cylinder valve block. Use a marker to label the
valve block ports with the appropriate hose numbers.
• Place absorbent cloths below the cylinder ports and detach hydraulic hoses from the cylinder. Elevate
hoses to prevent leakage. Plug or cap exposed hose fittings and cylinder ports.
• At the base of the cylinder, unbolt and remove the pin retainer from each side of the pivot pin.
• Remove the pivot pin using a hammer and a brass or hardwood drift.
• Lift and remove the cylinder using an overhead hoist and lifting straps or equivalent. .
• Replace or reinstall the cylinder by following the above instructions in the reverse order of removal.
• Actuate the hydraulic system and check for leakage. Tighten hydraulic fittings as needed.
• Bleed trapped air from the hydraulic system by raising and lowering the boom with the reservoir fill
port cap on, but not tightened. Allow several cycles of operation for trapped air to escape. Repeat as
necessary.
Reference Description of the components
1 Cylinder
2 Pin retainer
3 Pin
4 Piston end
5 Base end
110 2420341380 E 02.12 USA
Summit Series
E
- Cylinder replacement
2 - Master / slave cylinder replacement - Telescopic models
Use the following procedure to remove and replace faulty cylinders.
2.1 - MASTER CYLINDER
• With the boom in the "stowed" position, raise the boom until there is adequate exposure of the pin
retainer and pivot pin.
• Verify that the boom is supported by lifting straps and an overhead hoist or equivalent.
• Unbolt and remove the pin retainer at the rod end of the cylinder.
• Remove the pivot pin using a hammer and a brass or hardwood drift.
• Tag and number all hydraulic hoses that attach to the cylinder valve block.
• Use a marker to label the valve block ports with the appropriate hose numbers.
Location of master cylinder
• 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.
• Unbolt and remove the pin retainer at the base end of the cylinder.
• Remove the pivot pin using a hammer and a brass or hardwood drift.
• Replace or reinstall the cylinder by following the above instructions in the reverse order of removal.
• Actuate the hydraulic system and check for leakage. Tighten hydraulic fittings as needed.
Reference Description of the components
1 Cylinder base end
2 Master cylinder
3 Cylinder rod end
4 Pivot pin
5 Pin retainer
6 Pivot pin
7 Pivot pin
A
B
C
D
E
F
G
H
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111
2420341380 E 02.12 USA
Summit Series
E
- Cylinder replacement
• Bleed trapped air from the hydraulic system by raising and lowering the telescoping boom with the
reservoir fill port cap on, but not tightened. Allow several cycles of operation for trapped air to escape.
Repeat as necessary.
2.2 - SLAVE CYLINDER
• With the boom in the "stowed" position, extend the boom until there is adequate exposure of the pin
retainer and pivot pin (approximately 0,7 m (2 ft)).
• Verify that the upper boom is supported by lifting straps and an overhead hoist or equivalent.
• Unbolt and remove the pin retainer at the rod end of the cylinder.
• Remove the pivot pin using a hammer and a brass or hardwood drift.
• Tag and number all hydraulic hoses that attach to the cylinder valve block. Use a marker to label the
valve block ports with the appropriate hose numbers.
• Place absorbent cloths below the cylinder ports and detach hydraulic hoses from the cylinder. Elevate
hoses to prevent leakage. Plug or cap exposed hose fittings and cylinder ports.
• Unbolt and remove both pin retainers at the base end of the cylinder.
• Remove the pivot pin using a hammer and a brass or hardwood drift.
• Replace or reinstall the cylinder by following the above instructions in the reverse order of removal.
• Actuate the hydraulic system and check for leakage. Tighten hydraulic fittings as needed.
• Bleed trapped air from the hydraulic system by raising and lowering the telescoping boom with the
reservoir fill port cap on, but not tightened. . Repeat as necessary.
Location of slave cylinder
Reference Description of the components
1 Cylinder base end
2 Master cylinder
3 Cylinder rod end
4 Pivot pin
5 Pin retainer
6 Pivot pin
112 2420341380 E 02.12 USA
Summit Series
E
- Cylinder replacement
3 - Lift cylinder replacement - Telescopic models
Use the following procedure to remove and replace a faulty or damaged hydraulic cylinder on the aerial
work platform :
• Lower the boom until it is resting in the "stowed" position.
• Pull and hold the emergency lowering valve handle on the lift cylinder to relieve all hydraulic pressure
to the cylinder.
• Turn key switch at the ground (lower) control panel, to the "OFF" position and remove the key.
• Locate the piston rod end of the cylinder to be removed. Unbolt and remove the pin retainer from
each side of the pivot pin.
• 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.
• Use an overhead crane or lifting gear to raise the boom section. Adequate clearance is necessary to
reach the cylinder valve block (base end) and hydraulic hose ports.
Location of Emergency Lowering Valve Handle
• Remove the valve solenoid by unscrewing the set screw in the top of the valve handle; then slide the
valve handle, coil and guide off the solenoid, unscrew the valve solenoid.
• Tag and number all hydraulic hoses that attach to the cylinder valve block. Use a marker to label the
valve block ports with the appropriate hose numbers.
• Place absorbent cloths below the cylinder ports and detach hydraulic hoses from the cylinder.
Elevate hoses to prevent leakage. Plug or cap exposed hose fittings and cylinder ports.
• At the base of the cylinder, unbolt and remove the pin retainer from each side of the pivot pin.
• Remove the pivot pin using a hammer and a brass or hardwood drift.
Reference Description of the components
1 Valve handle
2 Lift cylinder
3 Master cylinder
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2420341380 E 02.12 USA
Summit Series
E
- Cylinder replacement
Lift cylinder replacement
• Lift and remove the cylinder using an overhead hoist and lifting straps or equivalent.
• Replace or reinstall the cylinder by following the above instructions in the reverse order of removal.
• Replace or reinstall the cylinder by following the above instructions in the reverse order of removal.
Tighten hydraulic fittings as needed.
• Bleed trapped air from the hydraulic system by raising and lowering the telescoping boom with the
reservoir fill port cap on, but not tightened. Allow several cycles of operation for trapped air to
escape. Repeat as necessary.
Reference Description of the components
1 Pin
2 Pin retainer
3 Cylinder
3 Piston end
114 2420341380 E 02.12 USA
Summit Series
E
- Cylinder replacement
4 - Outrigger cylinder replacement
Use the following procedure to remove and replace faulty or damaged hydraulic cylinders on
theoutriggers :
• Lower the outrigger until the footpad is touching the ground. DO NOT transfer the weight of the aerial
work platform onto the outrigger. Leave the weight of the aerial work platform on the trailer wheels.
• Remove the bolts securing the outrigger cylinder guard. Remove the cylinder guardRemove the
cylinder guard.
Outrigger cylinder replacement
• At the piston rod end of the cylinder, unbolt and remove the pin retainer from each side of the pivot pin.
• Place a block of wood shoring between the outrigger tube and the cylinder.
• Remove the pivot pin using a hammer and a brass or hardwood drift.
• Fully retract the cylinder.
• Turn the key at the ground (lower) control station to the "OFF" position and remove the key.
• Tag and number all hydraulic hoses that attach to the cylinder valve block. Use a marker to label the
valve block ports with the appropriate hose numbers.
• Remove the valve solenoid by unscrewing the cap, sliding the coil off, then unscrewing the valve.
• 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.
Reference Description of the components
1 Piston end
2 Bolts
3 Cylinder guard
4 Cylinder
5 Pin
6 Pin retainer
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2420341380 E 02.12 USA
Summit Series
E
- Cylinder replacement
Cylinder valve removal
• 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.
• Lift and remove the cylinder using an overhead hoist and lifting straps or equivalent.
• Replace or reinstall the cylinder by following the above instructions in the reverse order of removal.
• Actuate the hydraulic system and check for leakage. Tighten hydraulic fittings as necessary.
• Bleed trapped air from the hydraulic system by extending and retracting the outrigger with the
reservoir fill port cap on but not tightened. Allow several cycles of operation for trapped air to escape.
Repeat as necessary.
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2420341380 E 02.12 USA
Summit Series
F
- Decals replacement
Decal Replacement - Decal kit - ANSI standard - Articulating aerial work platform
124 2420341380 E 02.12 USA
Summit Series
F
- Decals replacement
Decal Replacement - Decal kit - ANSI standard - HTA13P - 3522A
Item no. Part number Description
Quantit
y
B06-01-4012 Decal kit - Includes the following
1 B06-00-0550 Decal (s) - Warning - Unhitch To Operate 2
2 B06-00-0551 Decal (s) - Caution - Latch / Jack / Brake 1
3 B06-00-0405 Decal (s) - Warning - Hand Pinch Point 16
4 B06-00-0403 Decal (s) - Emergency Lower Valve 6
5 B06-00-0521 Decal (s) - Danger - Tip Over Hazard 6
6 B06-00-0404 Decal (s) - Warning - Outrigger Crush Foot 8
7 B06-00-0161b Decal (s) - HAULOTTE Biljax - 5 inBlack / Red on clear 2
8 B06-00-0477 Decal (s) - Warning - Fork Lift Use 2
9 B06-00-0539
Decal (s) - HTA13P - 3522A - Black clear vinyl with black
letters
2
10 B06-00-0481 Decal (s) - Transport latch 1
11 B06-00-0535 Decal (s) - Notice - Range of motion - 3522A 2
12 B06-00-0482 Decal (s) - Danger - Electrocution 2
13 B06-00-0037 Decal (s) - Lubricate Semi - Annually 1
14 B06-00-0471 Decal (s) - Danger - Main Instruction / Hazard - Platform 1
15 B06-00-0475 Decal (s) - Warning - Read / Understand Manual 1
16 B06-00-0473 Decal (s) - Notice - Operator Manual Missing 1
17 B06-00-0534 Decal (s) - Warning - Platform operation 1
18 B06-00-0062 Decal (s) - Notice - AC Power 2
19 B06-00-0530 Decal (s) - Air - 120 PSI 2
20 B06-00-0531 Decal (s) - Water - 3000 PSI 2
21 B06-00-0552 Decal (s) - Notice - La,yard attachment 1
22 B06-00-0474 Decal (s) - Notice - Platform maximum load 1
23 0202-0523 Decal (s) - Flag, Made In USA 1
24 B06-00-0503 Decal (s) - Notice - Handle applications 1
25 B06-00-0504 Decal (s) - Notice - Emergency hand pump 1
26 B06-00-0068 Decal (s) - Notice - Loaw Foam Hyd Oil 1
27 B06-00-0494 Decal (s) - Notice - Contains hazardous material 1
28 B06-00-0541 Decal (s) - Manual Rotate / Retract 1
29 B06-00-0495 Decal (s) - Caution - Compartment Access 2
30 B06-00-0505 Decal (s) - Danger - Main instruction / Hazard - Base 1
31 B06-00-0034 Decal (s) - Danger - Battery / Charger Safety 1
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2420341380 E 02.12 USA
Summit Series
F
- Decals replacement
32 B06-00-0533
Decal (s) - Warning - Ground operation instructions Articulating
2
33 B06-00-0484 Decal (s) - Danger - Battery / Charger instruction 1
34 B06-00-0543 Decal (s) - Warning - Crush hazard 2
35 B06-00-0496 Decal (s) - Generator Plate Maximum 200 1
36 B06-00-0478 Decal (s) - Notice - AC Power Connection 1
37 B06-00-0542 Decal (s) - Warning - Maximum Tow Speed 65 1
38 B06-00-0544 Decal (s) - Warning - Tow hazard 65 mph 2
Item no. Part number Description
Quantit
y
130 2420341380 E 02.12 USA
Summit Series
F
- Decals replacement
Identification plates and optional equipment - Articulating aerial work platform
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131
2420341380 E 02.12 USA
Summit Series
F
- Decals replacement
Decal Replacement - Identification plate - ANSI standard - Used on all standard equimpent
Decal Replacement - Decals for optional equipment - ANSI standard
Item no. Part number Description Quantity
39 B06-00-0526 Key ring tag 1
40 B06-00-0524 Annual Inspection Plate 1
41 B06-00-0490 VIN Plate 1
42 B06-00-0499 ANSI ID Plate 1
Item no. Part number Description Quantity
43 B06-00-0529
Decal (s) - Notice - Platform rotate - (Manual rotation
option)
1
44 B06-00-0527
Decal (s) - Warning - Drive and set - (Drive and set
option)
1
45 B06-00-0528
Decal (s) - Notice - Drive and set - (Drive and set
option)
1
46 B06-00-0553
Decal (s) - Warning - Jockey wheel - (Drive and set
option)
1
47 B06-00-0485
Decal (s) - Notice - Material lift set up - (Material lift
option)
1
48 B06-00-0497
Decal (s) - Notice - Material lift max 500 - (Material lift
option)
1
49 B06-00-0487
Decal (s) - Notice - unleaded fuel only - (Gas engine
option)
1
50 B06-00-0488
Decal (s) - Caution - Component damage - (Gas
engine option)
1
51 B06-00-0486
Decal (s) - Notice - Engine specifics - (Gas engine
option)
1
52 B06-00-0547
Decal (s) - Warning - Engine operate - Hot - (Gas
engine option)
1
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2420341380 E 02.12 USA
Summit Series
F
- Decals replacement
Decal (s) - ANSIAll aerial work platforms
B06-00-0551
B06-00-0533
B06-00-0403
B06-00-0534
134 2420341380 E 02.12 USA
Summit Series
F
- Decals replacement
Decal (s) - ANSIAll aerial work platforms
B06-00-0539 B06-00-0540
B06-00-0538
B06-00-0535
3522A / HTA 13 P
B06-00-0536
4527A / HTA 16 P
B06-00-0537
5533A / HTA 19 P
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135
2420341380 E 02.12 USA
Summit Series
F
- Decals replacement
Decal (s) - ANSIOptional equipment
B06-00-0528
B06-00-0547
B06-00-0487
B06-00-0485
B06-00-0497
B06-00-0486
B06-00-0529
B06-00-0488
B06-00-0527
B06-00-0553
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