Haulotte Group HA15IP Manual

OPERATING AND MAINTENANCE
INSTRUCTIONS
SELF-PROPELLED LIFT
HA15IP
242 032 8470 - E 12.05 GB

Distribué par / Distributed by/ Distribuito da
Haulotte France
Tél / Phone [phone]
Fax / Fax [phone]
Centre Mondial Pièces de Rechange
Spare Parts International Centre

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Haulotte Hubarbeitsbühnen
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Tél / Phone + 351 21 955 98 10
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Tél / Phone + 44 (0) 1952 292753
Fax / Fax + 44 (0) 1952 292758
Haulotte U.S. Inc.
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Tél / Phone + 65 6536 3989
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Tél / Phone + 31 162 670 707
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Operating and maintenance instructions
i
Caution!
GENERAL
You have just taken delivery of your mobile elevating work platform
It will give you complete satisfaction if you follow the operating and maintenance
instructions exactly.
The purpose of this instruction manual is to help you in this.
We stress the importance:
• of complying with the safety instructions relating to the machine itself, its use
and its environment,
• of using it within the limits of its performances,
• of proper maintenance upon which its service life depends.
During and beyond the warranty period, our After-Sales Department is at your
disposal for any service you might need.
Contact in this case our Local Agent or our Factory After-Sales Department,
specifying the exact type of machine and its serial number.
When ordering consumables or spares, use this documentation, together with the
«Spares» catalogue so as to receive original parts, the only guarantee of
interchangeability and perfect operation.
This manual is supplied with the machine and is included on the delivery
note.
REMINDER:You are reminded that our machines comply with the provisions of
the «Machines Directive» 89/392/EEC of June 14th 1989 as
amended by the directives 91/368/EEC of June 21st 1991, 93/44/
EEC of June 14th 1993, 93/68/EEC of July 22nd 1993 and 89/336/
EEC of May 3rd 1989, directive 2000/14/CE and directive EMC/89/
336/CE.
The technical data contained
in this manual cannot involve
our responsibility and we
reserve the right to proceed
with improvements or
modifications without
amending this manual.

Operating and maintenance instructions
ii

Why use only Haulotte original spare-parts ?
1. RECALLING THE EEC DECLARATION OF CONFORMITY IN QUESTION
Components, substitutions, or modifications other than the ones recommended by
Haulotte may recall in question the initial security conditions of our Haulotte equipment.
The person who would have intervened for any operation of this kind will take responsibility
and recall in question the EEC marking validity granted by Haulotte. The EEC declaration
will become null and void and Haulotte will disclaim regulation responsibility.
2. END OF THE WARRANTY
The contractual warranty offered by Haulotte for its equipment will no longer be applied
after spare-parts other than original ones are used.
3. PUBLIC AND PENAL LIABILITY
The manufacture and unfair competition of fake spare-parts will be sentenced by public and
penal law. The usage of fake spare-parts will invoke the civil and penal liability of the
manufacturer, of the retailer, and, in some cases, of the person who used the fake spare-
parts.
Unfair competition invokes the civil liability of the manufacturer and the retailer of a “slavish
copy” which, taking unjustified advantage of this operation, distorts the normal rules of
competition and creates a “parasitism” act by diverting efforts of design, perfection,
research of best suitability, and the know-how of Haulotte.
FOR YOUR SECURITY, REQUIRE HAULOTTE ORIGINAL SPARE-PARTS

4. QUALITY
Using Haulotte original spare-parts means guarantee of :
xHigh quality partsl
xThe latest technological evolution
xPerfect security
xPeak performance
xThe best service life of your Haulotte equipment
xThe Haulotte warranty
xHaulotte technicians’ and repair agents’ technical support
5. AVAILABILITY
Using Haulotte original spare-parts allows you to take advantage of 40 000 references
available in our permanent stock and a 98% service rate.
WHY NOT TAKE ADVANTAGE ?

Conduite et Entretien
i
SUMARY
1 - GENERAL RECOMMENDATIONS - SAFETY............................................................ 1
1.1 - GENERAL WARNING................................................................................................. 1
1.1.1 - Manual..................................................................................................................................... 1
1.1.2 - Labels ...................................................................................................................................... 1
1.1.3 - Safety....................................................................................................................................... 1
1.2 - GENERAL SAFETY INSTRUCTIONS......................................................................... 2
1.2.1 - Operators................................................................................................................................. 2
1.2.2 - Work environment.................................................................................................................... 2
1.2.3 - Using the machine................................................................................................................... 2
1.3 - RESIDUAL RISKS.......................................................................................................4
1.3.1 - Risks of jerky movements and tipping over ............................................................................. 4
1.3.2 - Electrical risk............................................................................................................................ 4
1.3.3 - Risk of explosion or burning..................................................................................................... 4
1.3.4 - Risks of collision ...................................................................................................................... 4
1.4 - INSPECTIONS ............................................................................................................ 5
1.4.1 - Periodic inspections................................................................................................................. 5
1.4.2 - Examination of machine suitability........................................................................................... 5
1.4.3 - State of conservation............................................................................................................... 5
1.5 - REPAIRS AND ADJUSTMENTS.................................................................................6
1.6 - VERIFICATIONS WHEN RETURNING TO SERVICE................................................6
1.7 - BEAUFORT SCALE ....................................................................................................6
1.8 - MINIMAL DISTANCES OF SAFETY...........................................................................7
2 - PRESENTATION ......................................................................................................... 1
2.1 - IDENTIFICATION........................................................................................................ 1
2.2 - MAIN COMPONENTS................................................................................................. 2
2.3 - WORKING AREA ........................................................................................................3
2.3.1 - Working area of the HA15IP.................................................................................................... 3

Conduite et Entretien
ii
2.4 - TECHNICAL CHARACTERISTICS..............................................................................4
2.4.1 - Technical characteristics of the HA15IP...................................................................................4
2.4.2 - Dimensions of the HA15IP......................................................................................................5
2.5 - LABELLING..................................................................................................................6
2.5.1 - Position of the labels................................................................................................................6
2.5.2 - «Yellow» labels ........................................................................................................................8
2.5.3 - «Red» labels ............................................................................................................................9
2.5.4 - Other labels............................................................................................................................ 10
2.5.5 - Labels specific to Holland.......................................................................................................11
2.5.6 - Labels specific to Australia.....................................................................................................11
3 - OPERATING PRINCIPLES........................................................................................13
3.1 - HYDRAULIC CIRCUIT...............................................................................................13
3.1.1 - Controlling machine movements............................................................................................13
3.1.2 - Drive movement.....................................................................................................................13
3.1.3 - Emergency manual operation and rescue..............................................................................13
3.2 - ELECTRICAL CIRCUIT AND SAFETY MECHANISMS.............................................14
3.2.1 - General points........................................................................................................................14
3.2.2 - Electronic speed variator........................................................................................................14
3.2.3 - Direct electrical drive movement............................................................................................ 14
3.2.4 - Control of the load in the platform.......................................................................................... 15
3.2.5 - Control of the tilt of the machine............................................................................................15
3.2.6 - High drive speed ....................................................................................................................15
3.3 - BATTERY STATUS/ HOUR METER CONTROLLER (BDI) ......................................15
3.3.1 - BATTERY STATUS................................................................................................................15
3.3.2 - HOUR METER.......................................................................................................................15
3.3.3 - RESETTING..........................................................................................................................15
4 - OPERATION...............................................................................................................17
4.1 - UNLOADING - LOADING - MOVING THE MACHINE...............................................17
4.1.1 - Unloading by lifting.................................................................................................................17
4.1.2 - Unloading using a ramp .........................................................................................................18
4.1.3 - Loading ..................................................................................................................................19
4.1.4 - Transport................................................................................................................................19
4.1.5 - Moving the machine...............................................................................................................19

Conduite et Entretien
iii
4.2 - OPERATIONS PRIOR TO FIRST USE OF THE MACHINE..................................... 21
4.2.1 - Familiarisation with the control panels................................................................................... 21
4.2.2 - Checks before using the machine..........................................................................................22
4.3 - BRINGING INTO SERVICE.......................................................................................24
4.3.1 - Operations at ground level..................................................................................................... 24
4.3.2 - Operations from the platform................................................................................................. 25
4.4 - USING THE ONBOARD BATTERY CHARGER ....................................................... 26
4.4.1 - Characteristics....................................................................................................................... 26
4.4.2 - Starting the recharging process............................................................................................. 26
4.5 - USING AND MAINTAINING THE BATTERIES......................................................... 27
4.5.1 - Using the batteries for the first time....................................................................................... 27
4.5.2 - Discharging............................................................................................................................ 27
4.5.3 - Recharging............................................................................................................................. 27
4.5.4 - Maintenance .......................................................................................................................... 27
4.6 - OPERATING THE MACHINE USING THE EMERGENCY MANUAL PUMP............29
4.7 - RESCUE OPERATIONS...........................................................................................29
4.8 - DECRABOTAGE....................................................................................................... 30
5 - MAINTENANCE......................................................................................................... 31
5.1 - GENERAL RECOMMENDATIONS........................................................................... 31
5.2 - MAINTENANCE PLAN.............................................................................................. 32
5.2.1 - Consumable fluids ................................................................................................................. 32
5.2.2 - Maintenance plan................................................................................................................... 33
5.3 - OPERATIONS........................................................................................................... 34
5.3.1 - Hydraulic oil filter.................................................................................................................... 36
5.3.2 - Hydraulic oil system............................................................................................................... 36
5.3.3 - Drive wheel reduction gears .................................................................................................. 36
6 - INCIDENTS DURING OPERATION........................................................................... 37
6.1 - VARIATOR DISPLAY ................................................................37
6.2 - INCIDENT REFERENCE CHART............................................................................. 38

Conduite et Entretien
iv
7 - SAFETY SYSTEMS....................................................................................................41
7.1 - MACHINE ELEMENTS..............................................................................................41
7.1.1 - Motors ....................................................................................................................................41
7.1.2 - Power supplies and fuses ......................................................................................................41
7.1.3 - Inputs ..................................................................................................................................... 41
7.1.4 - Safety system inputs..............................................................................................................41
7.1.5 - Outputs...................................................................................................................................42
7.1.6 - Relays ....................................................................................................................................42
7.1.7 - On/off electrovalves................................................................................................................42
7.1.8 - Alarms....................................................................................................................................42
7.1.9 - Lights indicator.......................................................................................................................42
8 - HYDRAULICS DIAGRAM ..........................................................................................43
8.1 - HYDRAULICS DIAGRAM .........................................................................................43
9 - ELECTRICAL DIAGRAM...........................................................................................45
9.1 - SHEET 1 ...................................................................................................................45
9.2 - SHEET 2....................................................................................................................46
9.3 - SHEET 3....................................................................................................................47

Operating and maintenance instructions
1
Caution !
1 - GENERAL RECOMMENDATIONS - SAFETY
1.1 - GENERAL WARNING
1.1.1 - Manual
This manual is designed to familiarise the operator with HAULOTTE self-
propelled platforms in order to ensure efficient and safe use. However, it
cannot replace the basic training required by any user of site equipment.
The site manager is bound to inform the operators of the instructions
contained in the manual. He is also responsible for applying the «user
regulations» in force in the country of use.
Before using the machine, it isessential to understand all these instructions
in order to ensure safe and efficient operation.
This manual must be kept available for all operators. Additional copies can
be supplied by the manufacturer on request
1.1.2 - Labels
Potential dangers and machine instructions are indicated on labels and
plates. All instructions on such plates must be read.
All labels conform to the following colour code:
• Red indicates a potentially fatal danger.
• Orange indicates a danger of causing serious injury.
• Yellow indicates a danger that may cause material damage or slight
injury.
The site manager must ensure that these labels are in good condition and
remain legible. Additional copies can be supplied by the manufacturer on
request.
1.1.3 - Safety
Ensure that any persons entrusted with the machine are fit to meet the
safety requirements that its use imposes.
Avoid any working method that may jeopardise safety. Any use not
compliant with the instructions may cause risk and damage to persons and
property.
To attract the reader's attention
instructions are signalled by this
sign.
This manual must be kept by the user throughout the machine’s service
life, including in the case of loan, lease and resale.
Ensure that all plates or labels relative to safety and hazards are complete
and legible.

Operating and maintenance instructions
2
Caution !
1.2 - GENERAL SAFETY INSTRUCTIONS
1.2.1 - Operators
Operators must be aged over 18, and hold an operating license in the
country of use issued by their appropriate autority to prove thatthey are apt
to operate the machine.
Only trained operators can use
Haulotte self-propelled platforms. There must always be one person at ground level who is familiar with the emergency control to:
• Take fast action if necessary.
• Take over the controls in case of accident or malfunction.
• Monitor and prevent movement of vehicles and people near the plat-
form.
• Guide the platform operator if required.
1.2.2 - Work environment
Never use the machine:
• On ground that is soft, unstable, congested.
• On ground that has a slope greater than permissible limit.
• In winds greater than the permissible limit. If used outside, use an an-
emometer to ensure that the wind speed does not exceed the permis-
sible limit (see Chap 1.7, page 6).
• Near power lines (check minimum safe approach distances according
to voltage carried) (see Chap 1.8, page 7).
• In temperatures less than -15°C (especially in refrigerated chambers).
Consult us if it is necessary to work below -15°C.
• In explosive atmospheres.
• In poorly-ventilated areas, since the exhaust fumes are toxic.
• During storms (risk of lightning).
• In the dark, unless the optional floodlight is fitted.
• In the presence of intense electromagnetic fields (radar, moving and
high currents).
DRIVING ON PUBLIC ROADS IS PROHIBITED.
1.2.3 - Using the machine
In normal service (i.e. operating from the platform), the platform/turntable
control select key must be removed and kept at ground level by a person
who is present and trained in rescue/emergency assistance manoeuvres.
Do not use the machine:
• with a load greater than allowed load,
• if wind speed exceeds the maximum
• with more than maximum authorised number of occupants in platform,
• with a side load in the platform greater than permissible limit.
X km/h
Y km/h Y>X
-15
0
˚C

Operating and maintenance instructions
3
Caution !
To reduce the risks of serious falls, operators must respect the
following instructions:
• Hold the guardrail firmly when lifting or driving the platform.
• Remove any traces of oil or grease from the platform steps, floor or
guardrails.
• Wear personal protective equipment suited to working conditions and
conform to local regulations, particularly when working in hazardous
areas.
• Anyone working onboard the platform must wear a safety harness
which should be attached to the usual fixing point with a strap. Attach
one strap only per fixing point.
• Never disable the limit switches of the safety devices.
• The contact with fixed or mobile obstacles can cause the premature
deterioration of the structure, and involve the rupture of certain safety
members of the machine
• Do not increase the platform operating height by means of ladders or
other accessories.
• Never use the guardrails to climb into or out of the platform (use the
steps provided).
• Never climb on the guardrails when the platform is up.
• Avoid driving the machine at high speed in narrow or congested are-
as.
• Never use the machine without putting in place the platform safety bar
or closing the safety gate.
• Never climb on the covers.
Never use the platform as a crane,
hoist or lift.
Never use the machine to pull or
tow.
Never use the boom as a ram or
thruster or to lift the wheels.
To reduce the risks of tipping over, operators must follow these
instructions:
• Never disable the limit switches of the safety devices.
• Never move the control handles from one direction to the other with-
out stopping in the «O» position. (To stop when travelling, gradually
move the handle to «O», keeping your foot down on the pedal.).
• Do not exceed the maximum load or the number of occupants allowed
in the platform.
• Spread the load and if possible place in the centre of the platform.
• Check that the ground resists the pressure and load per wheel.
• The contact with fixed or mobile obstacles can cause the premature
deterioration of the structure, and involve the rupture of certain safety
members of the machine
• Do not drive the platform at high speed in narrow or congested areas.
• Do not drive the platform in reverse gear (poor visibility).
• Do not use the machine with a congested platform.
• Do not use the machine with equipment or objects hanging from the
guardrails or boom.
• Do not use the machine with items liable to increase the wind load
(e.g. panels).
• Never carry out maintenance on the machine with the platform raised,
without first installing the required safety provisions (overhead crane,
crane).
• Perform the daily checks and monitor the machine’s good working or-
der during periods of use.
• Protect the machine from any uncontrolled intervention when it is not
in operation.
NOTE : Do not tow the unit. (The equipement is not designed for tow-
ing. Transport of the unit should be carried out using a vehicle
built for this purpose).

Operating and maintenance instructions
4
Caution !
Caution !
1.3 - RESIDUAL RISKS
1.3.1 - Risks of jerky movements and tipping over
The direction of travel can be
reversed after a 180° turntable
rotation. Take account of the colour
of the arrows on the chassis
compared with the direction of
travel (green = forward, red =
reverse)
Thus, moving the manipulator in the
direction of the green arrow on the
control panel will move the machine
according to the direction indicated
by the green arrow on the chassis.
Similarly, moving a manipulator in
the direction of the red arrow on the
control panel, will move the
machine in the direction of the red
arrow on the chassis
Risks of jerky movement and tipping over are high in the following
situations:
- Sudden action on the controls.
- Overloading of the platform.
- Uneven ground (Be careful during thaw periods in winter).
- Gusts of wind.
- Contact with an obstacle on the ground or at a height.
- Working on platforms, pavements, etc.
Allow sufficient stopping distances:
- 3 meters at high speed,
- 1 meter at low speed.
Allow sufficient stopping distances: 3 metres at high speed and 1 metre at
low speed.
Do not alter or override any components connected in any way to the
machine’s safety or stability.
Do not place or fasten a load so that it overhangs the machine’s parts.
Do not touch adjacent structures with the elevator arm.
1.3.2 - Electrical risk
If the machine has a 220 V 16A max.
plug, the extension must be
connected to a mains socket
protected by a 30 mA differential
circuit breaker.
Electrical risks are high in the following situations:
- Contact with a live line (check safety distances before operation
near electricity lines) (see Chap 1.8, page 7).
- Use during storms.
1.3.3 - Risk of explosion or burning
The risks of explosion or burning are high in the following situations:
- Working in explosive or inflammable atmosphere.
- Filling the fuel tank near naked flames.
- Contact with the hot parts of the motor.
- Use of a machine causes hydraulic leakage.
1.3.4 - Risks of collision
- Risk of crushing people in the machine operation zone (when
travelling or manoeuvring equipment).
- The operator must assess the risks above him before using the
machine.
- Pay attention to the position of the arms during turntable rotation.
- Adapt movement speed to conditions related to the ground, traffic,
slope and movement of people, or any other factor that may cause
a collision.
- When driving down the ramp of a truck, ensure sufficient space is
available for safe unloading.
- Check brake pad wear regularly to avoid all risk of collision.
- Always use a winch line connected to the unit when loading and
unloading off tilt tray vehicules.

Operating and maintenance instructions
5
1.4 - INSPECTIONS Comply with the national regulations in force in the country of machine use.
For AUSTRALIA: ie.AS2550.10.
For FRANCE: Order dated 1st March 2004 + circular DRT 93 dated 22
September 1993 which specify:
1.4.1 - Periodic inspections
The machine must be inspected every 6 months in order to detect any
defects liable to cause an accident.
These inspections are performed by an organisation or personnel specially
designated by the site manager and underhis responsibility (whether ornot
they belong to the company) Articles R 233-5 and R 233-11 of the French
Labour Code.
The results of these inspections are recorded in a safety register kept by
the site manager and constantly available to the labour inspector and the
site safety committee (if one exists) and the list of specially designated
personnel (Article R 233-5 of the French Labour Code).
Moreover, before each use, check the following:
• the operator’s manual is in the storage compartment on the platform,
• the stickers are placed according to the section concerning «Labels
and their positions»,
• oil level and any elements in the maintenance operation table
• look out for any damaged, incorrectly installed, modified or missing
parts.
NOTE : This register can be obtained from trade organisations, and in
some cases from the OPPBTP or private prevention agen-
cies.
The designated persons must be experienced in risk prevention (Articles R
233-11 or order n° 93-41).
No member of personnel is allowed to perform any check whatsoever
during machine operation (Article R 233-11 of the French Labour Code).
1.4.2 - Examination of machine suitability
The manager of the site where the machine is operated must ensure the
machine is suitable, i.e. capable of performing the work in complete safety,
and in compliance with the operating manual. Furthermore, the French
order of 1st March 2004 addresses problems relative to leasing,
examination of the state of conservation, checking upon operation after
repairs, and test conditions (static test coefficient 1.25; dynamic test
coefficient 1.1). All users must consult this order’s requirements and
comply with them.
1.4.3 - State of conservation
Detect any deterioration liable to cause hazardous situations (concerning
safety devices, load limiters, tilt sensor, cylinder leaks, deformation, welds,
bolt tightness, hoses, electrical connections, tyre state, excessive
mechanical gaps).
NOTE : If the machine is rented/leased, the user responsible for the
machine must examine its state of conservation and suitabili-
ty. He must obtain assurance from the leaser that general pe-
riodic inspections and pre-operation inspections have been
performed.

Operating and maintenance instructions
6
Caution !
1.5 - REPAIRS AND ADJUSTMENTS
These cover major repairs, and work on or adjustments to safety systems
or devices (of a mechanical, hydraulic or electrical nature).
These must be performed by personnel from or working for PINGUELY-
HAULOTTE who will use only original parts.
Any modification not controlled by PINGUELY-HAULOTTE is
unauthorised.
The manufacturer cannot be held responsible if non-original parts are used
or if the work specified above is not performed by PINGUELY-HAULOTTE-
approved personnel.
1.6 - VERIFICATIONS WHEN RETURNING TO SERVICE
To be performed after:
• extensive disassembly-reassembly operation,
• repair affecting the essential components of the machine,
• any accident caused by the failure of an essential component.
It is necessary to perform a suitability examination, a state of conservation
examination, a static test, a dynamic test (see coefficient in paragraph (see
Chap 1.4.2, page 5).
These test must be performed by a
competent person.
1.7 - BEAUFORT SCALE The Beaufort Scale of wind force is accepted internationally and is used
when communicating weather conditions. It consistsof number 0 - 17, each
representing a certain strength or velocity of wind at 10m (33 ft) above
ground level in the open.
Description of Wind Specifications for use on land MPH m/s
0Calm Calm; smoke rises vertically 0-1 0-0.2
1 Light Air Direction of wind shown by smoke 1-5 0.3-1.5
2Light Breeze Wind felt on face; leaves rustle; ordinary vanes moved by
wind 6-11 1.6-3.3
3 Gentle Breeze Leaves and small twigs in constant motion; wind extends
light flag 12-19 3.4-5.4
4Moderate Breeze Raises dust and loose paper; small Branches are moved 20-28 5.5-7.9
5 Fresh Breeze Small trees in leaf begin to sway; crested wavelets form
on inland waterways 29-38 8.0-10.7
6Strong Breeze Large branches in motion; whistling heard in telephone
wires; umbrellas used with difficulty 39-49 10.8-13.8
7 Near Gale Whole trees in motion; inconvenience felt when walking
against wind 50-61 13.9-17.1
8Gale Breaks twigs off trees; generally impedes progress 62-74 17.2-20.7
9 Strong Gale Slightstructuraldamage occurs(chimneypotsand slates
removed) 75-88 20.8-24.4

Operating and maintenance instructions
7
1.8 - MINIMAL DISTANCES OF SAFETY
• It is important to hold the machine far away from the lines and equip-
mentof electricalcurrent accordingto the applicablegovernmentalré-
glements and the following diagram
Voltage distance minimum safety in meters
from 0 to 300 V Avoid contact
from 300 V to 50 kV 3.05
from 50 kV to 200 kV 4.60
from 200 kV to 350 kV 6.10
from 350 kV to 500 kV 7.62
from 500 kV to 750 kV 10.67
from 750 kV to 1000 kV 13.72

Operating and maintenance instructions
8