Haulotte Group xlb-4725a User manual

OPERATOR’S & MAINTENANCE
MANUAL
B33-01-0104 Rev. 4 August 2012

HAULOTTE GROUP
2
SELF-PROPELLED AERIAL WORK PLATFORM
This equipment is designed and manufactured in compliance with the duties, responsibilities and
standards set forth for manufacturers in the ANSI, CSA, AS and / or CE standards in effect at the time
of manufacture.
This equipment meets or exceeds applicable ANSI, CSA, AS and / or CE codes and standards when
operated in accordance with manufacturer’s recommendations.
It is the responsibility of the user to follow all Federal, State, and Local codes and regulations that
govern the safe operation of this equipment.
Obtain, read and obey all safety precautions before performing maintenance or repairs or
attempting to operate this equipment. 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 Customer
Service Department: at 1-800-537-0540 or visit Haulotte Group online at www.haulotte-usa.com.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.

HAULOTTE GROUP
3
TABLE OF CONTENTS
1 SAFETY …………………………………………………………………………………………………….7
LEGEND: SAFETY ADVISORIES...................................................................................................7
BEFORE OPERATION.....................................................................................................................8
DURING OPERATION .....................................................................................................................9
DRIVE SAFETY..............................................................................................................................11
FALL PROTECTION ......................................................................................................................11
MANUAL FORCE...........................................................................................................................12
WIND LOADING.............................................................................................................................12
EXPLOSION HAZARD...................................................................................................................12
MAINTENANCE .............................................................................................................................13
2 SPECIFICATIONS..........................................................................................................................15
RANGE OF MOTION .....................................................................................................................15
SPECIFICATIONS..........................................................................................................................16
WARRANTY - NEW PRODUCT; HAULOTTE NORTH AMERICA ................................................18
WARRANTY CLAIMS PROCEDURE.............................................................................................19
DAMAGED EQUIPMENT POLICY.................................................................................................20
3 OPERATION...................................................................................................................................21
GROUND (LOWER) CONTROL PANEL........................................................................................22
PLATFORM (UPPER) CONTROL PANEL.....................................................................................25
JOYSTICK - PLATFORM (UPPER) CONTROL PANEL................................................................28
NORMAL OPERATING PROCEDURE..........................................................................................29
DRIVE FUNCTION.........................................................................................................................32
MANUAL BRAKE RELEASE..........................................................................................................32
MANUAL BOOM OPERATION.......................................................................................................33
LIFTING THE AERIAL WORK PLATFORM...................................................................................35
TRANSPORTING THE AERIAL WORK PLATFORM ON TO A TRUCK BED...............................36
4 EQUIPMENT MAINTENANCE.......................................................................................................37
BATTERY RECHARGE..................................................................................................................38
BATTERY FAULT CODES.............................................................................................................39
DAILY SERVICE CHECKS ............................................................................................................40
WEEKLY SERVICE CHECKS........................................................................................................43
MONTHLY SERVICE CHECKS .....................................................................................................44
ANNUAL SERVICE CHECKS ........................................................................................................45
STRUCTURAL INSPECTION ........................................................................................................47
MOTOR DRYING INSTRUCTIONS ...............................................................................................47
LEVELING SYSTEM CALIBRATION PROCEDURE .....................................................................48
OVERLOAD PROTECTION CALIBRATION PROCEDURE..........................................................50
ADDITIONAL SERVICE INFORMATION.......................................................................................53
MANUAL OUTRIGGER RETRACTION..........................................................................................54
HYDRAULIC PRESSURE GAUGE................................................................................................55
TROUBLESHOOTING ...................................................................................................................56
ERROR CODE DEFINITIONS – CONTROLS................................................................................57
ERROR CODE DEFINITIONS – MOTOR CONTROLLER.............................................................68
5 CYLINDER REPLACEMENT.........................................................................................................71
MASTER / SLAVE CYLINDER REPLACEMENT...........................................................................71
LIFT CYLINDER REPLACEMENT.................................................................................................73
OUTRIGGER CYLINDER REPLACEMENT...................................................................................75
6 DECAL REPLACEMENT...............................................................................................................77
DECAL KIT - ANSI .........................................................................................................................78
IDENTIFICATIONPLATES&OPTIONALEQUIPMENT-ANSI............................................................80
DECALS - ANSI..............................................................................................................................82

HAULOTTE GROUP
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7 OPTIONAL EQUIPMENT ...............................................................................................................87
MATERIAL LIFT HOOK.................................................................................................................88
PLATFORM ROTATOR.................................................................................................................91
8 MATERIAL SAFETY.......................................................................................................................93
LEAD ACID BATTERIES, WET, FILLED WITH ACID – UN 2794.................................................93
POWERFLOW™ AW HVI HYDRAULIC OIL.................................................................................98
9 ANSI REPRINT.............................................................................................................................105
INSPECTION FORM FOR HAULOTTE AERIAL WORK PLATFORMS ..........................................117
LIST OF TABLES
TABLE 1-1. MINIMUM SAFE APPROACH DISTANCES .....................................................................9
TABLE 1-2. BEAUFORT SCALE ........................................................................................................12
TABLE 4-1. BATTERY CHARGER FAULT CODES...........................................................................39
TABLE 4-2. TROUBLE SHOOTING....................................................................................................56
TABLE 4-3 ERROR CODE DEFINITIONS.........................................................................................57
TABLE 4-4. ERROR CODE DEFINITIONS - MOTOR CONTROLLER ..............................................68
TABLE 9-1. MINIMUM SAFE APPROACH DISTANCES .................................................................115

HAULOTTE GROUP
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LIST OF ILLUSTRATIONS
Figure 2-1. Range of Motion............................................................................................................15
Figure 3-1. Ground (Lower) Control Panel ....................................................................................22
Figure 3-2. Platform (Upper) Control Panel...................................................................................25
Figure 3-3. Platform Controls Joystick..........................................................................................28
Figure 3-4. Boom Travel Latches ...................................................................................................29
Figure 3-5. Outrigger Control Panel...............................................................................................30
Figure 3-6. Drive Speed Selector....................................................................................................32
Figure 3-7. Manual Break Release..................................................................................................32
Figure 3-8. Hand Pump Controls for Manual Operation...............................................................33
Figure 3-9. Location of Lift Cylinders for Manual Boom Lowering.............................................34
Figure 3-10. Location of Manual Lowering Valves..........................................................................34
Figure 3-11. Lifting the Aerial Work Platform..................................................................................35
Figure 3-12. Transport the Aerial Work Platform............................................................................36
Figure 4-1. Battery Charger Faceplate...........................................................................................38
Figure 4-2. Outrigger Position Switch............................................................................................41
Figure 4-3. Hydraulic Reservoir......................................................................................................42
Figure 4-4. Wheel Nut Tightening Sequence.................................................................................44
Figure 4-5. Display Run Time Hours..............................................................................................45
Figure 4-6. Machine Position for Slew Ring Measurement..........................................................46
Figure 4-7. Slew Ring Position Measurement ...............................................................................46
Figure 4-8. Platform Position After Rotation.................................................................................46
Figure 4-9. Position Machine for Leveling.....................................................................................48
Figure 4-10. Level Sensor Digitally Based.......................................................................................48
Figure 4-11. Level Sensor Pendulum Based...................................................................................48
Figure 4-12. Ground (Lower) Control Panel for Leveling System .................................................49
Figure 4-13. Platform Position..........................................................................................................50
Figure 4-14. Ground (Lower) Control Panel for Overload Protection ...........................................50
Figure 4-15. Manual Outrigger Control Wire Harness ....................................................................54
Figure 4-16. Bottom Side of the Ground (lower) Control Box. ......................................................54
Figure 4-17. Hydraulic Power Unit....................................................................................................54
Figure 4-18. Attaching the Pressure Gauge to the Hydraulic Power Unit. ...................................55
Figure 4-19. Motor Controller............................................................................................................68
Figure 5-1. Location of Master Cylinder ........................................................................................71
Figure 5-2. Location of Slave Cylinder...........................................................................................72
Figure 5-3. Location of Manual Lowering Valves for Lift Cylinder Replacement ......................73
Figure 5-4. Push “Button” Lowering Valve ...................................................................................73
Figure 5-5. Lift Cylinder Replacement ...........................................................................................73
Figure 5-6. Outrigger Cylinder Replacement.................................................................................75
Figure 5-7. Cylinder Valve Removal...............................................................................................75
Figure 7-1. Disconnect Plug from Load Sense Module................................................................88
Figure 7-2. Remove Platform (Upper) Control Box.......................................................................88
Figure 7-3. Loopback plug..............................................................................................................88
Figure 7-4. Platform Removal.........................................................................................................89
Figure 7-5. Material Lifting Hook Installation ................................................................................89
Figure 7-6. Material Lift “Stowed” Position...................................................................................90
Figure 7-7. Material Lift “In Use” Position.....................................................................................90
Figure 7-8. Manual Platform Rotator..............................................................................................91
Figure 9-1. Minimum Safe Approach Distance............................................................................114

HAULOTTE GROUP
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PRIMARY MACHINE COMPONENTS
REAR
JIB LIFT
OUTRIGGER
LEG
ENGINE
AXLE
CYLINDER
OUTRIGGER
TANK
MASTER
CYLINDER
OUTRIGGER
POCKETS
COMPARTMENT
LATCH AXLE
CYLINDER
LIFT CYLINDER
FRONT
BOOM REST
SECONDARY BOOM
CYLINDER
SLAVE
EXTENSION
KNUCKLE
PRIMARY
PRIMARY
BOOM
TURNTABLE
SECONDRY
BOOM
PRIMARY BOOM
JIB BOOM
BOOM REST
OUTRIGGER
PAD
LOWER LINK
PLATFORM
FOOT
FUEL
FORK LIFT
.
PLATFORM CONTROL BOX
POWER UNIT
COMPARTMENT
GROUND
CONTROL BOX
SECONDARY
LIFT CYLINDER

HAULOTTE GROUP 1 SAFETY
7
1 SAFETY
Proper training is required for the safe operation of any mechanical device. Failure to follow all
instructions and safety precautions in this manual and attached to the aerial work platform will result
in death or personal injury.
Prior to Operation:
Read, understand and obey all instructions and safety precautions in this manual and attached to
the aerial work platform.
Read, understand and obey all Federal, State and Local codes and regulations.
Become familiar with the proper use of all controls.
Inexperienced users should receive instruction by a qualified instructor before attempting to
operate or maintain the aerial work platform.
The use of intelligence and common sense is the best practice when following any safety policy.
LEGEND: SAFETY ADVISORIES
The following safety advisories are used throughout this manual to indicate specific hazards when
operating or maintaining the aerial work platform. Read, understand and obey all safety advisories to
prevent improper service, damage to equipment, personal injury or death.
DANGER
Indicates a hazardous situation which if not avoided, will
result in death or serious injury.
WARNING
Indicates a hazardous situation which if not avoided, could
result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, may
result in minor or moderate injury.
NOTICE
Contains information important in the prevention of errors
that could damage the machine or its components.
NOTE: Contains additional information important for
performing a procedure.

HAULOTTE GROUP 1 SAFETY
8
BEFORE OPERATION
Ensure the following general safety precautions are followed before operating the aerial work
platform:
ALWAYS inspect the usage area for potential hazards, such as unstable or unlevel surfaces,
overhead obstructions and electrically charged wires or conductors. ALWAYS watch for moving
vehicles in the operating area.
ALWAYS conduct a thorough visual inspection of the aerial work platform before operation. Check
for damaged or worn parts, hydraulic leaks, damaged wiring, loose wiring conductors, damaged
outriggers, low tire pressure, uneven tire wear or tire damage. Check for any improperly operating
components. NEVER operate the aerial work platform if any damage is observed or suspected.
Repair damaged or malfunctioning equipment before operation.
ALWAYS wear proper clothing. Wear protective equipment as required by Federal, State and Local
codes and regulations. Keep loose clothing, jewelry, gloves and hair away from moving parts.
ALWAYS wear a Safety Harness and energy-absorbing Lanyard, such as the Safety Harness and
Lanyard available through the Haulotte Group.
ALWAYS inspect platform floor and outrigger footpads for mud, grease, debris or other foreign
material. ALWAYS remove any such material from the aerial work platform before operation.
ALWAYS RED tag any part of this machine known or suspected to be damaged or malfunctioning.
ALWAYS remove a malfunctioning, damaged or defective aerial work platform from service. NEVER
operate an aerial work platform that has any known or suspected defect.
ALWAYS comply with the instructions found in Safety and / or Service Bulletins distributed by the
manufacturer / factory. Bulletins may contain critical procedures that supersede the information
contained in this manual.
NEVER operate this aerial work platform while under the influence of drugs or alcohol, while taking
prescription medications that may leave the operator drowsy or prone to dizziness, or while feeling ill.
NEVER modify, alter or change the aerial work platform in any way that would affect its original
design or operation.
NEVER deface, modify or obscure any decals or markings on the aerial work platform.
NEVER operate this aerial work platform in any way for which it is not intended.
NEVER operate this aerial work platform in explosive or flammable environments.
Before attempting aerial work platform operations, operator(s) should:
Attend a training program as required by all Federal, State, and Local codes and regulations.
Obtain, read and obey all safety precautions as indicated by manufacturer’s recommendations
and all Federal, State and Local codes and regulations.
Become familiar with the location and use of all controls.
Verify that there are no overhead obstructions or live power sources in the work area that could
interfere with the safe operation of the aerial work platform.
Cordon off the area surrounding the aerial work platform to keep personnel, vehicles and moving
equipment away from the aerial work platform while in use.
Position the aerial work platform on a firm and level surface.
Conduct a pre-operation inspection by performing all recommended daily service checks.
Refer to the “Equipment Maintenance” section of this manual.

HAULOTTE GROUP 1 SAFETY
9
DURING OPERATION
Ensure the following general safety precautions are followed while operating the aerial work platform:
ALWAYS position away from power lines, this ensures that no part of the aerial work platform
accidentally reaches into an unsafe area. This includes full extension of the telescoping boom
through 700º of Non-Continuous rotation.
ALWAYS check with local electrical authorities regarding any local requirements which may differ
from those shown in Table 1-1.
ALWAYS keep away from an aerial work platform that is exposed to electrically charged power lines.
If the aerial work platform comes in contact with electrically charged power lines, NEVER touch or
operate the aerial work platform from ground level until power lines are shut off.
ALWAYS operate only on a firm and level surface. NEVER operate on surfaces that do not support
the aerial work platform with its rated load capacity, or on surfaces that do not support force exerted
by the outriggers during aerial work platform operation. Operate only on surfaces that can support a
pressure of 25 psi (1.8 kg/cm2) 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.
DANGER
This aerial work platform is NOT insulated for use near
electrical power lines and DOES NOT provide protection
from contact with or close proximity to any electrically
charged conductor. Operator must maintain safe
clearances at all times (10 ft (3.05 m) minimum) and must
always allow for Platform movement due to gusty winds.
Always contact power company before working near
power lines. Assume every power line is live. Power lines
can be blown by the wind.
Refer to Table 1-1 for minimum safe approach distances
between the machine and electrical power lines.
TABLE 1-1. MINIMUM SAFE APPROACH DISTANCES
Minimum Safe Approach
Distance
Voltage Range
(Phase to Phase) (Feet) (Meters)
0 to 300V Avoid Contact
Over 300V to 50KV 10 3.05
Over 50KV to 200KV 15 4.60
Over 200KV to 350KV 20 6.10
Over 350KV to 500KV 25 7.62
Over 500KV to 750KV 35 10.67
Over 750KV to 1000KV 45 13.72

HAULOTTE GROUP 1 SAFETY
10
DURING OPERATION (CONTINUED)
ALWAYS use a three (3) point contact (both hands and one foot) when entering or exiting the work
platform.
ALWAYS wear proper footgear. ALWAYS keep the platform free of debris.
ALWAYS keep personnel and obstructions clear of the aerial work platform when repositioning the
boom or platform.
ALWAYS cordon the area surrounding the outriggers to keep personnel, vehicles and moving
equipment away from the aerial work platform while in use.
ALWAYS stay clear of overhead obstructions, including wires and cables.
ALWAYS disengage aerial work platform travel latches before raising aerial work platform sections
and reengage aerial work platform travel latches before transporting.
ALWAYS exercise caution when rotating the boom from the ground (lower) control panel. ALWAYS
watch for personnel inside the radius of the turntable and boom arm when rotating from the ground
(lower) or platform (upper) controls.
ALWAYS remove personnel from the aerial work platform before attempting to free an elevated
platform that has become caught or snagged on an adjacent structure or obstacle.
NEVER operate the aerial work platform from a position on a truck-bed, trailer, floating vessel or
scaffolding without written approval from the manufacturer / factory.
ALWAYS maintain joystick enable lever during drive operation.
NEVER allow electrode contact with any part of the aerial work platform while welding from the
platform. NEVER use the aerial work platform as a ground for welding.
NEVER operate without the outriggers fully extended or when the aerial work platform is not level.
NEVER position an elevated platform against another object to steady the platform.
NEVER override or bypass the manufacturer’s safety devices.
NEVER attach a safety harness to an adjacent structure, pole, or to nearby equipment while working
from the platform.
NEVER raise the outriggers with materials or personnel on board, or while platform is raised or
extended.
NEVER sit, stand or climb on platform railing. ALWAYS keep both feet firmly on the platform floor.
NEVER attempt to increase the working height with boxes, ladders, stools or any other materials.
NEVER operate this aerial work platform when exposed to high winds, thunderstorms, ice or any
weather conditions that would compromise operator safety.
NEVER operate aerial work platform in conditions where wind speeds exceed 28 mph (12.5 m/sec or
45 km/h). Steady or gusty winds that exceed the recommended wind speed may affect stability and
aerial work platform operation.
NEVER allow ropes, electric cords, hoses or other equipment to become entangled in the aerial work
platform.
NEVER exceed the load limits set by the manufacturer / factory. Use only the material lifting hook,
supplied as an option and manufactured by Haulotte Group when lifting materials. Safely stow all
tools and equipment.