Haulotte OPTIMUM 8 Product guide

Maintenance Book
OPTIMUM 8 - OPTIMUM 1931 E
4001069810 E 12.19 USA / GB
Maintenance Book
OPTIMUM 8 - OPTIMUM 1931 E
USA

2 4001069810 E 12.19 USA / GB
OPTIMUM 8 - OPTIMUM 1931 E

3
CONTENTS
Maintenance Book
CONTENTS
A
Preface -
Foreword
1 - Symbols and colors . . . . . . . . . . . . . . . . . . . . . . 8
B
Safety
1 - General safety rules . . . . . . . . . . . . . . . . . . . . . 11
1.1- Maintenance implementation.. .............. .. .. .. .. .. . .. .. .. .. 11
1.2- UncontrolledmovementHazard............. .. ................. 12
1.3- ElectrocutionHazards . .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. .. .. .. 13
1.4- Explosion /Fire Hazards .. .. .. .. .. .. .. .. .. .. .. .. .. ............. 14
2 - Maintenance and repair training . . . . . . . . . . . 15
2.1- Owner's responsability. .. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. . 15
2.2 - Technician'sresponsability . . .. .. .. . .. .. .. .. .. . .. .. .. . .. .. .. .. . . 15
2.3- HAULOTTEServices®. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 15
2.4- Training . .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. . .. .. . .. .. . 15
2.5- Product modification.. .. .. .. .. .. .. .......... .. .. . .. .. .. .. .. .. .. 16
2.6- AfterSalesService .. .. .. .. .. .. .. .. .. ....... .. .. .. .. .. .. .. .. ... 16
2.7- Productinformation......................... .. .. .. .. .. .. .. .. .. . 16
3 - Manufacturer's warranty . . . . . . . . . . . . . . . . . 17
3.1- Warranty acceptance.. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. 17
3.2- Warrantyperiod..... .. .. .. .. .. .. ........... .. .. .. .. .. .. .. ..... 17
3.3- Conditions ofwarranty . .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. 17
3.4- Warranty conditions .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. . .. .. .. . 18

4
Maintenance Book
C
Familiarization
1 - Primary machine components . . . . . . . . . . . . 20
1.1- Layout. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . 20
1.2- Maintenance support. .. .. .. .. . .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. . 22
1.3- Extensiondeck...... .. .. .. .. .. ............. .. .. .. .. .. .. ....... 23
1.4- Ground control box. . .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. . 24
1.4.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.4.2 - HAULOTTE Activ'Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.4.2.1 - LCD screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.5- Platform controlbox . .. .. .. .. . .. .. .. .. .. . ... . .. .. .. .. .. . .. .. .. . 30
1.5.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 - List of actuators and sensors . . . . . . . . . . . . . 32
2.1- Sensorsand actuators...................... .. .. .. .. .. ......... 32
2.2- Sensorsdetail. .. .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... 34
2.2.1 - Limit switchs for potholes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.2.2 - Steering potentiometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.2.3 - Angle transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.2.4 - Pressure transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.2.5 - Slope sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2.6 - Battery charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2.7 - Battery charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.2.8 - Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3 - Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4 - Ingredient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.1- Hydraulicoil. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 40
5 - Lubrication diagram. . . . . . . . . . . . . . . . . . . . . 41
5.1- Greasingpointslocalization.................. .. .. .. .. .. .. .. ..... 42
6 - Machine specifications . . . . . . . . . . . . . . . . . . 43
6.1- Movementspeed . ......................... .. .. .. .. .. ......... 43

5
CONTENTS
Maintenance Book
D
Inspection and
maintenance
schedule
1 - Inspection program . . . . . . . . . . . . . . . . . . . . . 45
2 - Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . 46
3 - Preventive maintenance . . . . . . . . . . . . . . . . . 47
4 - Periodic inspection . . . . . . . . . . . . . . . . . . . . . 50
5 - Major inspection. . . . . . . . . . . . . . . . . . . . . . . . 52
Machine sheet
MS0001 - Structural part inspection. . . . . . . . . . . . . . . 53
MS0002 -
Pins and bearing inspection. . . . . . . . . . . . . 57
MS0003 -
Cylinder inspection . . . . . . . . . . . . . . . . . . . . 61
MS0004 -
Braking test procedure . . . . . . . . . . . . . . . . . 65
MS0005 - Torque Values . . . . . . . . . . . . . . . . . . . . . . . . 67
MS0020 -
Hoses inspection - Replacement . . . . . . . . . 73
MS0025 -
Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . 75
MS0072 - Pressure adjustment . . . . . . . . . . . . . . . . . . . 77
MS0073 -
Scissor arms screw - Periodical checks . . . 79
MS0084 -
Removal / Replacement of motor reducer
assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81
MS0090 -
Removal / replacement of steering pivot
assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85
MS0095 -
Removal / replacement of platform
assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
91
MS0096 -
Removal / replacement of Scissor pack . . . 97
MS0097 - Calibration steering. . . . . . . . . . . . . . . . . . . 107
MS0098 -
Calibration Load management system . . . 111
MS0099 -
Calibration arm angle sensors . . . . . . . . . . 117
MS0106 - HAULOTTE Activ'Screen . . . . . . . . . . . . . . 121
MS0133 -
Universal plug . . . . . . . . . . . . . . . . . . . . . . . 139
MS0174 -
Platform extension lock assembly. . . . . . . 143
MS0175 -
Removal - Replacement of the motor/pump
assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147
MS0176 -
Hydraulic filter . . . . . . . . . . . . . . . . . . . . . . . 151
MS0177 -
Assembly electro-brake unit. . . . . . . . . . . . 157
MS0178 - Brake unit protection installation. . . . . . . . 167
MS0179 -
Assembly moto - reducer . . . . . . . . . . . . . . 175
MS0242 -
Check of tilt sensor . . . . . . . . . . . . . . . . . . . 187
MS0245 - Dismantling/Reassembling the Tilt Sensor 193
MS0283 -
Assembly electro-brake unit (For the Asia-
Pacific market only) . . . . . . . . . . . . . . . . . . . . . . . . . .
201

6
Maintenance Book
E
Trouble
shooting and
diagram
1 - Trouble shooting . . . . . . . . . . . . . . . . . . . . . . 211
1.1- Recommendations.. . . . . . . . . . . . . . . . . . . . . . ....................211
1.2- Description ......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
1.3- Requirements....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
2 - Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
2.1- Systemarchitecture . . . . . . . . . . . . . . . . . . . . . . ....................226
2.1.1 - Power circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
2.1.2 - Control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3 - Electric diagram . . . . . . . . . . . . . . . . . . . . . . . 229
4 - Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . 235
F
Records
1 - Intervention register. . . . . . . . . . . . . . . . . . . . 237

74001069810 E 12.19 USA / GB
OPTIMUM 8 - OPTIMUM 1931 E
A - Preface - Foreword
Preface - Foreword
You have just purchased a HAULOTTE® product and we would like to thank you for your business.
The Aerial Work Platform is a mechanical device primarily designed and manufactured with the intent to position people
with the necessary tools and material to overhead elevated temporary workplaces. All other uses or alterations/modifi-
cations to the aerial work platform must be approved by HAULOTTE®.
This manual shall be considered a permanent component of the machine and shall be kept with the aerial work platform
in the designated Manual Holder, at all times.
Safe operation of this product can only be assured if you follow the operating instructions contained in this manual are
followed. To ensure proper and safe use of this equipment, it is strongly recommended that only trained and authorized
personnel operate and maintain the aerial work platform.
We would particularly like to draw your attention to 2 essential points :
• Compliance with safety instruction (machine, use, environment).
• Use of the equipment within the performance limits.
With regard to the designation of our equipment, we stress that this is purely for commercial purposes and not to be
confused with the technical specifications. Only the specifications in this manual should be used to study the suitability
of the equipment for the intended use.
This maintenance and repairs book is specific to the HAULOTTE® products listed on the cover page of this manual. The
maintenance book is intended for the on-site maintenance technician.
It is the on-site maintenance technician's duty to carry out the regular maintenance work recommended by HAULOTTE
Services®.
This maintenance work is essential for correct machine operation.
If regular maintenance is not carried out, this may :
• Void the warranty.
• Cause machine malfunction.
• Reduce machine reliability and shorten its service life.
• Jeopardize operator safety.
To ensure that the regular maintenance requirements are fully satisfied, contact HAULOTTE Services®.
HAULOTTE Services® technicians are specially trained to carry out extensive repairs, interventions or adjustments on
the safety systems or elements of HAULOTTE® machines. They carry genuine HAULOTTE spare parts and tools as
required, and also provide fully documented reports on all work completed.

8 4001069810 E 12.19 USA / GB
OPTIMUM 8 - OPTIMUM 1931 E
A - Preface - Foreword
1 - Symbols and colors
Symbols and colors are used to alert the operator of safety precautions and/or to highlight important safety
information.
The following safety symbols are used throughout this manual to indicate specific hazards and the hazard
severity level when operating or maintaining the Aerial Work Platform.
Symbol
Symbol Description
Danger : Risk of injury or death
Caution : Risk of material damage
Prohibition relating to work safety and quality
Reminder to use good practice or follow pre-operation checks
Cross-reference to another part of the manual
Cross-reference to another manual
Cross-reference to repair (contact HAULOTTE Services®)
Maintenance sheet
Recommended tools
Recommended part
Safety
N.B. : Additional technical information

94001069810 E 12.19 USA / GB
OPTIMUM 8 - OPTIMUM 1931 E
A - Preface - Foreword
Decals
N.B.-:-THE FOLLOWING SAFETY ADVISORIES ARE USED THROUGHOUT THIS MANUAL TO INDICATE SPECIFIC
HAZARDS WHEN OPERATING OR MAINTAINING THE TELEHANDLER.
Color Title Description
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 : Failure to comply could result in minor or moderate
injury.
Notice : Indicates practices not related to personal injury.
Procedure : Indicates a maintenance operation.

10 4001069810 E 12.19 USA / GB
OPTIMUM 8 - OPTIMUM 1931 E
A - Preface - Foreword
Notes