Haulotte Group OPTIMUM 6 Manual

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OPERATING AND MAINTENANCE
INSTRUCTIONS
SELF-PROPELLED SCISSOR PLATFORM
OPTIMUM 6 and 8
242 032 6160 - E 11.05 Ind. B GB

Distribué par / Distributed by/ Distribuito da
Haulotte France
Tél / Phone [phone]
Fax / Fax [phone]
Centre Mondial Pièces de Rechange
Spare Parts International Centre
Tél / Phone [phone]
Fax / Fax [phone]
Haulotte Hubarbeitsbühnen
Tél / Phone + 49 76 33 806 920
Fax / Fax + 49 76 33 806 82 18
Haulotte Portugal
Tél / Phone + 351 21 955 98 10
Fax / Fax + 351 21 995 98 19
Haulotte UK
Tél / Phone + 44 (0) 1952 292753
Fax / Fax + 44 (0) 1952 292758
Haulotte U.S. Inc.
Main tool free 1-877-HAULOTTE
Service tool free 1-877-HAULOT-S
Haulotte Asia
Tél / Phone + 65 6536 3989
Fax / Fax + 65 6536 3969
Haulotte Netherlands BV
Tél / Phone + 31 162 670 707
Fax / Fax + 31 162 670 710
Haulotte Australia PTY Ltd
Tél / Phone + 61 3 9706 6787
Fax / Fax + 61 3 9706 6797
Haulotte Italia
Tél / Phone + 39 05 17 80 813
Fax / Fax + 39 05 16 05 33 28
Haulotte Do Brazil
Tél / Phone + 55 11 3026 9177
Fax / Fax + 55 3026 9178
Haulotte Scandinavia AB u.b.
Tél / Phone + 46 31 744 32 90
Fax / Fax + 46 31 744 32 99
Haulotte Iberica - Madrid
Tél / Phone + 34 91 656 97 77
Fax / Fax + 34 91 656 97 81
Haulotte Iberica - Sevilla
Tél / Phone + 34 95 493 44 75
Fax / Fax + 34 95 463 69 44

i
REVIEW JOURNAL
Issue Date Subject
10.05 27/10/2005 Created (Index a)
11.05 28/11/2005 § 3.2.2.4 ’Alarm’ ; § 4.4.1 (Index b)

ii

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

Operation and Servicing - OPTIMUM 6 and 8
iii
CONTENTS
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 - Environment............................................................................................................................. 2
1.2.3 - Using the machine ................................................................................................................... 2
1.3 - RESIDUAL RISKS ....................................................................................................... 4
1.3.1 - Risks of jolting - Overturning.................................................................................................... 4
1.3.2 - Electrical risks .......................................................................................................................... 4
1.3.3 - Risks of explosion or burning................................................................................................... 4
1.3.4 - Risks of collision ...................................................................................................................... 4
1.3.5 - Abnormal noise ........................................................................................................................ 4
1.4 - VERIFICATIONS ......................................................................................................... 4
1.4.1 - Routine verifications................................................................................................................. 4
1.4.2 - Examination of suitability of a machine.................................................................................... 5
1.4.3 - State of conservation ............................................................................................................... 5
1.5 - REPAIRS AND ADJUSTMENTS................................................................................. 5
1.6 - VERIFICATIONS AT THE TIME OF PUTTING BACK INTO SERVICE...................... 5
1.7 - BEAUFORT SCALE .................................................................................................... 6
1.8 - MINIMUM SAFETY DISTANCES ................................................................................ 6
2 - PRESENTATION ......................................................................................................... 7
2.1 - IDENTIFICATION ........................................................................................................ 7
2.2 - GENERAL OPERATION ............................................................................................. 7
2.3 - MAIN COMPONENTS ................................................................................................. 8

Operation and Servicing - OPTIMUM 6 and 8
iv
2.4 - WORKING AREA.........................................................................................................9
2.4.1 - Optimum 6............................................................................................................................... 9
2.4.2 - Optimum 8............................................................................................................................. 10
2.5 - TECHNICAL DATA ....................................................................................................11
2.5.1 - Optimum 6 and 8 technical data............................................................................................ 11
2.6 - SIZE ...........................................................................................................................12
2.6.1 - Optimum 6.............................................................................................................................. 12
2.6.2 - Optimum 8.............................................................................................................................. 12
2.7 - LABELS.....................................................................................................................13
2.7.1 - Common "yellow" labels......................................................................................................... 13
2.7.2 - Common "orange" labels........................................................................................................ 13
2.7.3 - Common "red" labels.............................................................................................................. 14
2.7.4 - Other common labels ............................................................................................................. 14
2.7.5 - Model-specific labels.............................................................................................................. 15
2.7.6 - Specific labels : Option........................................................................................................... 15
2.7.7 - Machine label references ...................................................................................................... 16
2.7.8 - Label positions on the machine.............................................................................................. 17
3 - OPERATING PRINCIPLE...........................................................................................19
3.1 - HYDRAULIC CIRCUIT...............................................................................................19
3.1.1 - Lifting the platform.................................................................................................................. 19
3.1.2 - Travel movement (machine movement)................................................................................. 19
3.1.3 - Steering movement ................................................................................................................ 19
3.2 - ELECTRIC CIRCUIT..................................................................................................19
3.2.1 - Electronic variable speed drive .............................................................................................. 19
3.2.2 - Battery charge state / timer controller .................................................................................... 19
3.3 - SAFETY SYSTEMS ...................................................................................................23
3.3.1 - Tilt control............................................................................................................................... 23
3.3.2 - Travel speeds........................................................................................................................ 23
3.3.3 - Safety system against potholes.............................................................................................. 23
3.3.4 - Platform load control .............................................................................................................. 23
4 - USE............................................................................................................................25
4.1 - GENERAL INSTRUCTIONS ......................................................................................25

Operation and Servicing - OPTIMUM 6 and 8
v
4.1.1 - Machine environment............................................................................................................. 25
4.1.2 - Manual extension................................................................................................................... 25
4.2 - UNLOADING - LOADING .......................................................................................... 26
4.2.1 - Unloading by lifting................................................................................................................. 26
4.2.2 - Unloading with ramps ........................................................................................................... 26
4.2.3 - Loading .................................................................................................................................. 26
4.2.4 - Transport instructions ............................................................................................................ 27
4.3 - BEFORE THE FIRST OPERATION .......................................................................... 27
4.3.1 - Getting to know the control stations....................................................................................... 27
4.3.2 - Pre-operation check............................................................................................................... 28
4.4 - OPERATION............................................................................................................. 30
4.4.1 - General recommendations..................................................................................................... 30
4.4.2 - Operation from the ground..................................................................................................... 30
4.4.3 - Operation from the platform ................................................................................................... 31
4.5 - USING THE ON-BOARD CHARGER........................................................................ 31
4.5.1 - Characteristics ....................................................................................................................... 31
4.5.2 - Starting the charge................................................................................................................ 32
4.5.3 - Maintenance charging........................................................................................................... 32
4.5.4 - Charge interruption ............................................................................................................... 32
4.5.5 - Precautions of use ................................................................................................................. 32
4.6 - USING AND SERVICING THE BATTERIES............................................................. 32
4.6.1 - Recommendations ................................................................................................................. 32
4.6.2 - Starting up............................................................................................................................. 33
4.6.3 - Discharge.............................................................................................................................. 33
4.6.4 - Charge ................................................................................................................................... 33
4.6.5 - Servicing ............................................................................................................................... 33
4.7 - RESCUE AND REPAIR OPERATIONS .................................................................... 34
4.7.1 - Emergency lowering .............................................................................................................. 34
4.7.2 - Manual repair ......................................................................................................................... 35
4.8 - BRAKE RELEASE ..................................................................................................... 35
5 - MAINTENANCE ......................................................................................................... 37
5.1 - GENERAL RECOMMENDATIONS ........................................................................... 37

Operation and Servicing - OPTIMUM 6 and 8
vi
5.2 - MAINTENANCE SYSTEM ........................................................................................37
5.3 - MAINTENANCE PLAN..............................................................................................38
5.3.1 - Consumables ......................................................................................................................... 38
5.3.2 - Maintenance diagram............................................................................................................. 39
5.4 - OPERATIONS............................................................................................................40
5.4.1 - Summary table ....................................................................................................................... 40
5.4.2 - Operating instructions ............................................................................................................ 41
5.4.3 - List of consumables............................................................................................................... 41
5.5 - MANUFACTURER’S RECOMMENDATIONS............................................................42
6 - OPERATING INCIDENTS ..........................................................................................43
6.1 - PLATFORM LIFTING SYSTEM ................................................................................43
6.2 - TRAVEL SYSTEM ....................................................................................................44
6.3 - STEERING SYSTEM ...............................................................................................44
7 - ELECTRIC DIAGRAM................................................................................................45
7.1 - ELECTRIC COMPONENTS ......................................................................................46
7.2 - WIRING DIAGRAM 126P253140 A ...........................................................................47
7.3 - POSITION AND FUNCTION OF CONTACT SWITCHES..........................................48
7.3.1 - SQ1: Low position contactor .................................................................................................. 48
7.3.2 - SQ3: Top position contactor................................................................................................... 48
7.3.3 - SQ5 & SQ6: Pothole system out............................................................................................48
7.3.4 - SQ7 : Extension position sensor ............................................................................................ 48
7.3.5 - SQ 10 : Tilt sensor.................................................................................................................. 48
7.3.6 - A1: Angle sensor.................................................................................................................... 48
7.3.7 - G1: Pressure sensor .............................................................................................................. 48
8 - HYDRAULIC DIAGRAM.............................................................................................49
8.1 - HYDRAULIC COMPONENTS....................................................................................50
8.2 - HYDRAULIC DIAGRAM 126P247910B ....................................................................51

Operating and maintenance instructions
1
Caution!
1 - GENERAL RECOMMENDATIONS - SAFETY
1.1 - GENERAL WARNING
1.1.1 - Manual
The purpose of this manual is to help the operator to get to know HAULOTTE self-
propelled lifts so as to use them efficiently and SAFELY. It cannot, however,
replace the basic training necessary for any user of site plant.
The head of establishment has an obligation to ensure that operators know the
instructions in the instruction manual. The head of establishment is also
responsible for the implementation of the "user regulations" in force in the country
of use.
Before using the machine, it is essential for safe use of the platform and its
efficiency to familiarise yourself with all these instructions.
This instruction manual must be kept available to any operator. Additional copies
can be supplied by the manufacturer on request.
1.1.2 - Labels
The potential dangers and instructions concerning the machine are indicated by
labels and plates. It is necessary to read the instructions appearing on them.
All of the labels comply with the following colour code:
• The colour red indicates a potentially mortal danger.
• The colour orange indicates a danger which may cause serious injury.
• The colour yellow indicates a danger which may cause material damage or
slight injury.
The head of the establishment must make sure that these labels are in good
condition, and must take the necessary steps to keep them legible. Additional
labels can be supplied on request by the manufacturer.
1.1.3 - Safety
Ensure that any person to whom you entrust the machine is capable of assuming
the safety requirements of its use.
Avoid any working mode liable to jeopardise safety. Any use not compliant with
the instructions could lead to risks and injury to people and damage to property.
In order to attract the reader's
attention, the instructions will
be preceded by this
standardized sign.
The operating manual must be kept by the user throughout the machine's life
including in the event of loan, hiring-out or re-sale.
Make sure that all the plates or labels relating to safety and danger are complete
and legible.

Operating and maintenance instructions
2
Caution!
1.2 - GENERAL SAFETY INSTRUCTIONS
1.2.1 - Operators
The operators must be over 18 and must hold an operating permit issued by the
employer after he has checked their medical fitness and after they have passed
a practical lift driving/operating test.
Only trained operators can
use Haulotte self-propelled
lifts.
There must be at least two operators so that one of them can:
• Intervene quickly if necessary.
• Take the controls in the event of an accident or breakdown.
• Monitor and prevent machines and pedestrians going round the lift.
• Guide the lift's operator if required.
1.2.2 - Environment
Never use the machine:
• On soft, unstable, cluttered ground.
• On ground with a bank greater than the permissible limit.
• With exposure to a wind greater than the permissible threshold. If used out-
side, make sure, using an anemometer, that the wind speed is less than or
equal to the permissible threshold.
• Near power lines (find out the minimum approach distance depending on the
voltage). In temperatures below -15°C (particularly in cold stores). Consult
us if it is necessary to work below -15°C.
• In explosive areas.
• During storms (risk of lightning).
• At night without floodlighting.
• When there are very strong electromagnetic fields (radar, mobiles and high
currents).
DO NOT TRAVEL ON PUBLIC HIGHWAYS.
1.2.3 - Using the machine
It is important to ensure that in normal use, that is lift operation, the lift post
selection key remains in the lift position so as to be able to control the lift from the
platform. In the event of a problem on the platform, a person present and trained
in emergency/standby manoeuvres can assist by putting the key in the ground
control position.
Do not use the machine with:
• A load greater than the nominal load.
• More people than the authorized number.
• A lift lateral force greater than the permissible value.
• A wind greater than the permissible speed.
X km/h
Y km/h Y>X
-15 0
˚C

Operating and maintenance instructions
3
Caution!
In order to avoid any risk of a serious fall, it is essential for operators to comply
with the following instructions:
• Hold on to the guard rails firmly when the lift is being raised or driven.
• Wipe any traces of oil or grease off the steps, floor and hand rails.
• Wear individual protective equipment suited to the working conditions and
local regulations in force, particularly when working in a dangerous area.
• Do not neutralise the limit switches on the safety devices.
• Avoid hitting fixed or moving obstacles.
• Do not increase the working height by using ladders or other accessories.
• Do not use the guard rails as a means of access for getting onto and off the
platform (use the steps provided for this purpose on the machine).
• Do not climb onto the guard rails when the platform is in the raised position.
• Do not drive the lift at high speed in areas which are narrow or not cleared.
• Do not use the machine without fitting the lift's protective bar or without clo-
sing the safety gate.
• Do not climb onto the covers.
Never use the platform as a
crane, goods lift or lift. Never
use the platform to pull or
tow.
In order to avoid risks of overturning, it is essential for operators to comply with
the following instructions:
• Do not neutralise the limit switches on the safety devices.
• Avoid operating the control levers for one direction in the opposite direction
without stopping in the " 0 " position (in order to stop during travelling, move
the manipulator's lever gradually).
• Comply with the maximum load as well as the number of people authorized
on the lift.
• Distribute the loads and place them if possible in the centre of the lift.
• Verify that the ground can take the pressure and load per wheel.
• Avoid hitting fixed or moving obstacles.
• Do not drive the lift at high speed in areas which are narrow or not cleared.
• Keep speed under control when turning.
• Do not drive the lift in reverse (lack of visibility).
• Do not use the machine with a cluttered lift.
• Do not use the machine with equipment or objects suspended from the
guard rails.
• Do not use the machine with elements which could increase the wind load
(e.g.: panels).
• Do not carry out machine maintenance operations when it is raised without
having put in place the necessary safety devices (travelling crane, crane).
• Carry out the daily checks and monitor proper operation during periods of
use.
• Protect the machine from any unsupervised intervention when it is not in ser-
vice.
NOTE : Do not tow the lift (it has not been designed for that and must be
transported on a trailer).

Operating and maintenance instructions
4
Caution!
1.3 - RESIDUAL RISKS
1.3.1 - Risks of jolting - Overturning
The risks of jolting or overturning are considerable in the following situations:
- sudden operation of the control levers,
- overload of the lift,
- ground weakness (Beware of thawing in winter),
- gusting wind,
- hitting an obstacle on the ground or high up,
- working on quays, bays, pavements, etc...
Allow a sufficient stopping distance:
- 3 metres at high speed,
- 1 metre at low speed.
1.3.2 - Electrical risks
If the machine has a 220 V
power point, max. 16 A, it is
essential for the extension
lead to be connected to a
mains outlet protected by a
30 mA quick-trip circuit-
breaker.
The electrical risks are considerable in the following situations:
- hitting a power line,
- use in stormy weather.
“Minimum safety distances”, page 6
1.3.3 - Risks of explosion or burning
The risks of explosion or burning are considerable in the following situations:
- work in an explosive or flammable atmosphere,
- using a machine with hydraulic leaks.
1.3.4 - Risks of collision
- Risks of crushing people present in the area in which the machine is
operating (during travelling or operation of the equipment).
- Evaluation by the operator, before any use, of the risks above him.
1.3.5 - Abnormal noise
When the platform is started, the user must listen for abnormal noise :
- seizure,
- discharge of an equilibrium valve,
- discharge of a pressure limiter, etc.
If abnormal noise is detected, the user must stop using the equipment
immediately and contact the PINGUELY HAULOTTE After-Sales department to
detect the source of the problem.
1.4 - VERIFICATIONS
Comply with the national regulations in force in the country of use.
For FRANCE: Order of March 1st 2004 + circular DRT 93-22 September 1993
specifying:
1.4.1 - Routine verifications
The machine must be the subject of routine inspections every 6 months so that
any defect liable to cause an accident is detected.
These inspections must be carried out by an organisation or personnel specially
designated by the head of establishment and under the latter's responsibility
(company's personnel or not) (Articles R 233-5 and R 233-11 of the Code du
Travail).
The result of these inspections must be entered in a safety register opened by the
head of establishment and kept constantly available to the works inspector and

Operating and maintenance instructions
5
safety committee of the establishment, if there is one, as well as a list of the
specially designated personnel (Article R 233-5 of the Code du Travail).
NOTE : Such register can be obtained from the trade organisations and
some of them can be obtained from the OPPBTP or private preven-
tion organisations.
The people designated must be experienced in the field of risk prevention
(Articles R 233-11 of Decree n° 93-41).
It is forbidden to allow any worker to proceed, during the operation of the machine,
with any verification whatsoever (Article R 233-11 of the Code du Travail).
1.4.2 - Examination of suitability of a machine
The head of the establishment in which this equipment is put into service must
make sure of the suitability of the machine, that is, that it is appropriate for the
works to be carried out safely and that it is used in accordance with the instruction
manual. In addition, in the above-mentioned French order of March 1st 2004,
problems associated with hiring, the examination of the state of conservation,
verification at the time of putting back into service after repair, as well as
coefficient 1.25 static test and coefficient 1.1 dynamic test conditions are
mentioned. Each person responsible using the machine must acquaint himself
and follow the requirements of this decree.
1.4.3 - State of conservation
Detect any damage liable to be the cause of dangerous situations (safety devices,
load limiters, tilt monitor, leaks from cylinders, deformation, condition of welds,
tightness of bolts, hoses, electrical connections, condition of tyres, excessive
mechanical play).
NOTE : In the case of hiring, the person responsible using the hired machine
has the responsibility of examining the state of conservation and for
examining suitability. He must check with the hirer that the routine
general verifications and verifications before putting into service
have indeed been carried out.
1.5 - REPAIRS AND ADJUSTMENTS
Major repairs, maintenance work or adjustments on the safety elements or
systems (concerns mechanics, hydraulics and electricity).
They must be carried out by PINGUELY-HAULOTTE personnel or personnel
working on behalf of PINGUELY-HAULOTTE who must use original parts only.
Any modification outside PINGUELY-HAULOTTE's control is not authorised.
The manufacturer is not liable if original parts are not used or if the work specified
above is not carried out by PINGUELY-HAULOTTE approved personnel.
1.6 - VERIFICATIONS AT THE TIME OF PUTTING BACK INTO SERVICE
To be carried out after:
• major removal/refitting,
• a repair involving the machine's essential parts,
• any accident caused by the failure of an essential part.
It is necessary to proceed with an examination of suitability, an examination of the
state of conservation, a static test, a dynamic test (see coefficients, § 1.4.2,
page 5).

Operating and maintenance instructions
6
1.7 - BEAUFORT SCALE
The Beaufort Scale of wind force is accepted internationally and is used when
communicating weather conditions. It consists of number 0 - 17, each
representing a certain strength or velocity of wind at 10m (33 ft) above ground
level in the open.
1.8 - MINIMUM SAFETY DISTANCES
Our machines are not insulated, hence, it is important to maintain a safety
distance from the electrical power cables and devices according to applicable
government regulations and the following diagram :
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 Slight structural damage occurs (chimney pots and slates
removed).
75-88 20.8-24.4
Voltage Minimum safety distance in meters
Up to 300V avoid contact
from 300 V to 50 kV 3,05 m
from 50 kV to 200 kV 4,60 m
from 200 kV to 350 kV 6,10 m
from 350 kV to 500 kV 7,62 m
from 500 kV to 750 kV 10,67 m
from 750 kV to 1000 kV 13,72 m

Operating and maintenance instructions - OPTIMUM 6 and 8
7
2 - PRESENTATION
Self-propelled platforms, models Optimum 6 and 8, are designed for all overhead
work within the limits of their characteristics (section § 2.5.1, page 11) and in
conformity with the safety recommendations specific to the equipment and the
area of use.
The main operating station is on the platform.
The operating station from the chassis is an emergency station.
2.1 - IDENTIFICATION
A plate on the front of the chassis bears all the indications (engraved) for machine
identification.
REMINDER:For all information, intervention or spare parts requests, please
specify the machine type and serial number.
2.2 - GENERAL OPERATION
The batteries supply an electropump set controlling all movements. Oil is directed
to the different parts by on/off electrovalves.

Operating and maintenance instructions - OPTIMUM 6 and 8
8
2.3 - MAIN COMPONENTS
8
6
4
2
7
3
17
18
19 20
14 13
5
21
15
1
9
10
12 1116
01 - Front motor-drive wheel 11 - Rear wheel
02 - Platform 12 - Position of lift truck forks
03 - Extensions 13 - Box
04 - Document case 14 - Pothole (retracted)
05 - Platform control desk 15 - Position of lift truck forks
06 - Protective bar 16 - Chassis
07 - Socket 220V 17 - Platform access bar
08 - Access ladder 18 - Battery drawer lock
09 - Chassis control desk 19 - Anchoring points
10 - Anchoring point 20 - Battery drawer
21 - Anchoring points