Training manual OPTIMUM 8 - OPTIMUM 1931 E 4000595920 E 05.17 USA / (1 Training manual OPTIMUM 8 - OPTIMUM 1931 E USA 2 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E 3 CONTENTS Training manual CONTENTS A FOREWORD 1 - Revision. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 B MAIN FEATURES AND FUNCTIONS 1 - Models description. . . . . . . . . . . . . . . . . . . . . . . 9 2 - Primary machine components . . . . . . . . . . . . 10 2.1 - Working area / Range of motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.2 - Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.2.1 - Machine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.3 - Ground control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.3.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.3.2 - HAULOTTE Activ'Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2.3.2.1 - LCD screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2.4 - Platform control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2.4.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 C STUDY OF THE WIRING DIAGRAM 1 - System architecture . . . . . . . . . . . . . . . . . . . . . 21 1.1 - Power circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 1.2 - Logic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1.3 - Drive circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 1.3.1 - Function of the variators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 1.3.1.1 - Control of the traction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1.3.1.2 - Control of the pump (other movements). . . . . . . . . . . . . . . . . . . 27 1.3.1.3 - Details of sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 1.3.1.4 - System of unbraking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 1.3.1.5 - Detail of the connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 1.3.2 - Scissors arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 4 Training manual 2 - List of actuators and sensors . . . . . . . . . . . . . 32 2.1 - Sensors and actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 2.2 - Sensors detail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 - Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 2.3 - Actuators and their location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 2.3.1 - List of actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 2.3.2 - Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 2.3.3 - Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 2.3.4 - Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 2.3.5 - Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 2.4 - Cut out conditions of every function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 2.4.1 - Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 2.4.2 - Power supply/commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 2.4.3 - Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 2.4.3.1 - Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 2.4.4 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 2.4.4.1 - Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 2.4.4.2 - Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 2.4.5 - Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 2.4.5.1 - Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 2.4.5.2 - Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 2.4.6 - Brake release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 2.4.7 - Potholes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 2.4.7.1 - Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 2.4.7.2 - Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 5 CONTENTS Training manual D STUDY OF THE HYDRAULIC SCHEMA 1 - Hydraulic units . . . . . . . . . . . . . . . . . . . . . . . . . 65 1.1 - General overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 1.1.1 - The hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 1.1.1.1 - Pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 1.1.1.2 - Selection valve potholes/steering. . . . . . . . . . . . . . . . . . . . . . . . 66 1.1.1.3 - Lifting cylinder valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 E ADJUSTMENTS 1 - Adjustments with diag pad console . . . . . . . . 69 2 - List of menus . . . . . . . . . . . . . . . . . . . . . . . . . . 70 2.1 - Machine settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 2.1.1 - Speeds and ramps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 2.1.2 - Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 2.1.3 - Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 2.1.4 - Countries and models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 2.2 - Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 2.2.1 - Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 2.2.2 - States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 3 - Failures list . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 3.1 - List of failures per category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 4 - Maximum height adjustment. . . . . . . . . . . . . . 87 5 - Cutback speed position height adjustment . . 88 6 - Load management system . . . . . . . . . . . . . . . 89 6.1 - Calibration procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 6.2 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 6.2.1 - Steering calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .92 6.3 - Calibration arm angle sensors (HONEYWELL Sensors) . . . . . . . . . 93 6.4 - Calibration arm angle sensors (ELOBAU Sensors) . . . . . . . . . . . . . . 94 7 - Adjustment of pressures . . . . . . . . . . . . . . . . . 95 7.1 - Main pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 7.2 - The speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 6 Training manual F SIMPLIFIED BREAKDOWN GUIDE 1 - No start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 2 - No lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 3 - No drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 4 - No steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 G VERSION SUMMARY 1 - Version summary . . . . . . . . . . . . . . . . . . . . . . . 99 2 - List of schematics . . . . . . . . . . . . . . . . . . . . . . 99 3 - List of wiring harnesses . . . . . . . . . . . . . . . . . 99 A B C D E F G H I 7 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E A - Foreword Foreword You are in possession of the summary document provided during the HAULOTTE® technical training programme. It will allow you to find the information necessary for performing maintenance and repairs on your HAULOTTE® machine. The following guide will help you to rapidly access the required chapter. Section A : Foreword You will find there the elements as following : • A resume of any update made since the creation of the manual. Section B : Main characteristics and functions You will find there the elements as following : • The list of the models. • Their main datas. • Their overall dimensions. • Their working envelop. • Controls boxes. • Some maintenance topics on specific components (charger, engine ..). Section C : Study of the wiring diagram It will include the following elements : • Structure of the system. • Localization/photo of each safety components. • The location/function of each component in schematics. • Cut out conditions of every function. Section D : Study of the hydraulic diagram It will include the following elements : • The localization of every manifolds. • The location/function of each component on block. How to use this document ? MAINTENANCE AND REPAIR OPERATIONS ON YOUR HAULOTTE® MACHINE MAY ONLY BE PERFORMED BY TRAINED AND EXPERIENCED TECHNICIANS 8 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E A - Foreword Section E : The adjustments It will include the following elements : • The way to use/connect the console of diagnostic. • The list of main menus and its architecture. • The list of alarms with their explanation. • Any calibration/settings required for the model of the machine. • The way to check/adjust the pressures for the model. Section F : Repair guide It will include the following elements : • A summary of every function and items to be checked in case of breakdowns. Section G : Summary of the versions It will include the following elements : • A summary of the different versions made per model. • Any schematics (electric /hydraulic) linked to the models studied. • Coloured schematics (electric/hydraulic) per function. • List of main harnesses in the models studied. 1 - Revision REVISION EDITION SUBJECT CREATED BY VALIDATED BY MODIFIED BY TRANSLATED BY LANGUAGE 00 10.16 Creation ASA MGD ASA ITC USA / EN 01 05.17 Add Failures codes, new schematics, new load management system calibration process ASA MGD ASA ITC USA / EN A B C D E F G H I 9 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E B - Main features and functions Main features and functions 1 - Models description REGULATION MODELS ANSI and CSA standards OPTIMUM 1931 E CE, AS and EAC standards OPTIMUM 8 10 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E B - Main features and functions 2 - Primary machine components 2.1 - WORKING AREA / RANGE OF MOTION OPTIMUM 8 - OPTIMUM 1931 E A B C D E F G H I 11 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E B - Main features and functions 2.2 - TRANSPORTATION 2.2.1 - Machine layout 12 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E B - Main features and functions 2.3 - GROUND CONTROL BOX 2.3.1 - Layout General view Controls and indicators MARKING DESCRIPTION FUNCTION 15 E-stop button Pulled out : Ground control box energized Pushed in : De-energizes control system 43 Horn button Not used 92 Control box activation key selector Right : Ground control box energized Center : De-energizes control system Left : Platform control box energized 93 Battery charging indicator Battery charger status 105 Beacon light (Optional) Move upwards : Flashing light turn ON Move downwards : Flashing light turn OFF 253 Diagnostic tool socket Connection to the diagnostic tool (HaulotteDiag) 92 253 ACTIV’ Screen 15 43 105 93 A B C D E F G H I 13 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E B - Main features and functions 2.3.2 - HAULOTTE Activ'Screen Upon starting and during operation of the machine, the LCD screen "Activ'Screen" located on the ground control box displays in real time the machine operating status. HAULOTTE Activ'Screen Controls and indicators MARKING DESCRIPTION FUNCTION 1 Platform raising control Platform raises 2 LCD screen Display status of operation of the machine 3 Navigation button Navigation of menu to select function - Scroll up 4 Confirmation button Confirmation of the selected function 5 Cancellation button Go back 6 Platform overload indicator Platform overload indicator 7 Machine fault indicator light Constantly lit in the event of an operation malfunction 8 Navigation button Navigation of menu to select function - Scroll down 9 'Enable Switch' selector Press in and hold : Enable switch 10 Platform lowering control Platform lowers 14 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E B - Main features and functions 2.3.2.1 - LCD screen At startup At startup with the ground or platform controls selected; system initiates a self check : • Bar gets filled up. • Home screen comes on with status icon of the machine - okay to proceed functioning the controls. SYMBOL DESCRIPTION 1 Information icons 2 Information text 3 Status icon of the machine SYMBOL DESCRIPTION Battery status Maintenance use Fault / alarms Hour meter A B C D E F G H I 15 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E B - Main features and functions • After pressing on : • After again pressing on • Access code screen comes on - refer to maintenance manual for entering the access code • Validation by pressing on is active only if access code is known and entered - refer to maintenance manual for the procedure for the different level code useage SYMBOL DESCRIPTION 1 Software part number 2 Software version + Screen software version + Screen version 3 Screen identification + Screen software version 4 Machine serial number displayed 16 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E B - Main features and functions Alarm status Alarm status displayed as applicable - samples shown below • Tilt • Overload • Low battery A B C D E F G H I 17 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E B - Main features and functions • Present fault • Platform control box E-stop button pressed in (de-energized) 18 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E B - Main features and functions 2.4 - PLATFORM CONTROL BOX 2.4.1 - Layout General view A B C D E F G H I 19 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E B - Main features and functions Controls and indicators MARKING NAME DESCRIPTION FUNCTION 27 HL800 Tilt indicator Machine on excessive slope 30 HL802 Overload indicator Platform overloaded 43 SA907 Horn button Move upwards and hold to activate horn 46 SB802 E-stop button Pulled out : Platform control box power supply energized Pushed in : De-energizes control system 85 HL903 Fault indicator Fault indicator Faulty or tilting or overloaded machine 91 HL904 Battery charging indicator Battery charged Flashing : Batteries have 40 % charge left Constantly on : Batteries have only 20 % charge left 108 SM901 Movement joystick Move forward : Forward drive or platform raising Move backwards : Reverse drive or platform lowering Front axle steering selector Press right side of button : Right-hand steering Press left side of button : Left-hand steering 110 HL420 Raising / lowering selector On : Raising / Lowering selection activated Off : Raising / Lowering movement is not selected 111 HL100 Driving selection indicator On : Driving function activated Off : Driving movement is not selected 112 SA908 2-position selector Move to the left : Platform raising / lowering Move to the right : Drive movements 123 SA905 'Enable Switch' selector Press in and hold : Associated command is validated Release : Associated command movement is halted 100% 40% 20% 20 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E B - Main features and functions Notes A B C D E F G H I 21 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E Study of the wiring diagram 1 - System architecture 22 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram 1.1 - POWER CIRCUIT A B C D E F G H I 23 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E 1.2 - LOGIC CIRCUIT 24 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram 1.3 - DRIVE CIRCUIT The traction is controlled by 2 asynchronous 3 phases motors (24VAC - 1KW). Each motor is piloted by one variator ( COMBIACX master for RR motor and ACEX slave for RL motor) through CAN - BUS network. Each variator consists of : • One thermistor for temperature control (ST302/ST303). • One encoder for speed control (SV300/SV301). • One electromagnetic brake at negative excitation (YB100/YB101). A B C D E F G H I 25 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E The whole unit is located in the chassis (rear side as shown below) 26 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram 1.3.1 - Function of the variators • The COMBIACX variator is the master and controls the traction of the RR motor and a chopper for the DC pump motor and some I/O too. • The software upload process is done by connecting the DIAG PAD console or HAULOTTE DIAG application. • The ACEX variator (slave) controls the traction of RL motor (no need to upload software on it). • The 2 variators has the regenerative braking function (deceleration). • Each variator is protected with a speed and temperature sensor and electromagnetic brake disc. • In case of low battery charge, the maximum current is reduced to the half of the maximum current programmed (an alarm message is displayed). • The 2 variators are protected against reverse battery polarity. Overview A B C D E F G H I 27 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E 1.3.1.1 - Control of the traction 1.3.1.2 - Control of the pump (other movements) 28 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram 1.3.1.3 - Details of sensors • The speed rotation of each motor is controlled through an encoder with 2 signals shifted at 90° each and 48 impulses per round. • The temperature of each motor is controlled through a thermistor located inside the winding (from 85°C the current is reduced in proportion the temperature increases until reaching 105°C where the current is null and traction stopped). 1.3.1.4 - System of unbraking The electro magnetic brakes are at negative excitation (remains stuck if not or lack of current). In case of necessity, it’s possible to release the brakes using the toggle switch SA103 located behind the variator’s support (see below). A B C D E F G H I 29 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E 1.3.1.5 - Detail of the connections 30 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram Detail of the connectors on variators. For any connector, the pin 1 always starts at the lower right corner as shown below. Connector are labelled as follow : • CXA/B/C/D for COMBIACX. • AXA/B/C/D for ACEX. (See below and refer to electric schematic) Connectors (power side) : • U/V/W are the 3 motors phases. • B+ : positive of the battery. • BF+ : positive of the battery protected by a Fuse of 160A. • B- : negative of the battery. • P+ : output of the pump motor ( COMBIACX only). A B C D E F G H I 31 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E 1.3.2 - Scissors arm The arms stack are independent and equipped with standards axles secured by clips and ring (see below). 32 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram 2 - List of actuators and sensors 2.1 - SENSORS AND ACTUATORS Sensors and actuators A B C D E F G H I 33 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E NAME DESCRIPTION SP400 Pressure sensor SQ144 Pothole limit sensor SQ145 Pothole limit sensor SQ800 Tilt sensor SR150 Steering potentiometer SR420 Tilt sensor low position SR722 Arm angle sensor YV120 6 tracks / 2 positions for potholes or steering switch (priority for potholes) YV121 Right steering or pothole entry valve YV122 Left steering or pothole exit valve YV420 PWM platform raising/lowering proportional valve YV903 Valve by-pass (pump pressurization) 34 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram 2.2 - SENSORS DETAIL 2.2.1 - Limit switchs for potholes MARKING FUNCTION DESCRIPTION 1 SQ144 Sensors = 1 when potholes are retracted 2 SQ145 A B C D E F G H I 35 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E 2.2.2 - Steering potentiometer MARKING FUNCTION DESCRIPTION 1 SR150 Value 2.5 kΏ, supply in 12 VDC (coming from ACEX variator) Before to launch the calibration, the pre-setting has to be done at mid- range value then use the consoles in order to set the potentiometer values to adjust current/voltage of the internal motor depends the direction of steering (left/right) 36 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram 2.2.3 - Angle transducers MARKING FUNCTION DESCRIPTION 1 SR420 Analogic sensor (0.5/4.5VDC), detection of low position Value adjustable according to scissors angle (~ 74 – 535 pts) Calibration system angle/pressure through consoles or active screen 2 SR722 Detection of upper position Value adjustable according to scissors angle (~ 420 – 135 pts) Calibration system angle/pressure through consoles or active screen A B C D E F G H I 37 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E 2.2.4 - Pressure transducer MARKING FUNCTION DESCRIPTION 1SP400 Analogic transducer (4-20mA), value variable depends of the pressure on big chamber of the lifting cylinder Calibration system angle/pressure through consoles or active screen 38 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram 2.2.5 - Slope sensor 2.2.6 - Battery charger Version 230VAC - 24V - 20A MARKING FUNCTION DESCRIPTION 1 SQ800 Tilt Y = 1.5° / X =3° (wire 12 = Vbat if machine on flat surface) 1=red=+Batt / 2=white=signal / 3=black=GND A B C D E F G H I 39 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E 2.2.7 - Fuses and relays MARKING FUNCTION DESCRIPTION 1 FU2 Protection electrovalve circuit (10A) 2 FU3 Protection main circuit (10A) 3 FU4 Protection accessories circuit (10A) 4 SA103 Toggle switch for manual brake release function 5 KA1 Relay for horn 6 KAH Relay for main modules power supply 40 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram 2.3 - ACTUATORS AND THEIR LOCATION 2.3.1 - List of actuators In the following tables : • The column n°2 indicates the position on the connector on modules (if required). • The state noted "0" corresponds to 0 V, opened contact or not activated. • The state noted "1" corresponds to the tension of the circuit, closed or activated contact. Glossary 2.3.2 - Modules MARKING DESCRIPTION FWD Forward drive REV Reverse drive FL Front left FR Front right RL Rear left RR Rear right PF Platform LS Low speed drive LS valve/adj Load sensing valve/adjustment MS Medium speed drive HS High speed drive ILS Magnet reed sensor UCB Upper control box LCB Lower control box ECU Electronic Control Unit PWM Pulse Width Modulation PCB Printed circuit board MODULES NAME LOCATION FUNCTION 01 Multi function CAN display (Activ screen) 02 COMBIACX Variator (Master) 02 ACEX Variator U4 03 CAN tiller board (UCB) A B C D E F G H I 41 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E 2.3.3 - Fuses 2.3.4 - Inputs FUSES NAME LOCATION CONNECTOR FUNCTION FU1A 01 - 03 Protection ACEX variator (125 A) FU1C 01 - 07 Protection COMBIACX variator (300 A) FU2 01 - 08 Protection electrovalve circuit (10 A) FU3 01 - 05 Protection main circuit (10 A) FU4 01 - 12 Protection accessories circuit (10 A) INPUTS NAME LOCATION CONNECTOR FUNCTION SA103 02 - 17 AXC.2 Manual brake release switch (21) SA901 01 - 12 Key selection (upper/lower controls) (133/135) SA903 01 - 15 Flashing light (Option) (32) SA904 03 - 05 Option working light (134) SA907 03 - 16 B.4 Horn switch (Upper controls) (34) SA907B 02 - 20 AXB.4 Horn switch (Lower controls) (Option) SA908 03 - 17 B.12/B.13 Selection function (movements/drive) (76/85) SB800 03 - 12 B.1 Foot pedal switch ( US option = 1 for any movement)(37) SB801 01 - 13 Emergency stop button (Lower controls) (84) SB802 03 - 14 Emergency stop button (Upper controls) SM901 03 - 10 A.10 Joystick ( 39: value 0.5 / 2.5 / 4.5VDC) 42 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram SENSORS NAME LOCATION CONNECTOR FUNCTION SP400 02 - 06 CXC.9 Pressure transducer 4 - 20 mA located in large chamber of lifting cylinder (14) SQ144 / SQ145 02 - 18 AXA.4 Potholes position ( = 1 if retracted; out in lift mode) (15) SQ800 02 - 02 CXA.12 Tilt Y = 1.5° / X =3° (wire 12 = Vbat if machine on flat surface) 1=red=+Batt / 2=white=signal / 3=black=GND SR150 02 - 14 AXC.4 Potentiometer for steering wheels angle (value 2.5 O) (47) SR420 02 - 04 CXC.4 Angle transducer for scissors arm position (13) SR722 02 - 16 AXC.9 Angle transducer for platform height detection (20) ST302 02 - 08 CXD.3/6 Temperature probe inside AC RR drive motor (if at 105° C current null and no drive) ST303 02 - 15 AXD.3/6 Temperature probe inside AC RL drive motor (if at 105° C current null and no drive) ST903 02 - 16 AXC.7 Temperature sensor (Option RUS/UKR) SV300 02 - 09 CXD.1/2/4/5 Controls the motor speed through an encoder with 2 signals shifted at 90° each and 48 pulses per revolution SV301 02 - 13 AXD.1/2/4/5 Controls the motor speed through an encoder with 2 signals shifted at 90° each and 48 pulses per revolution A B C D E F G H I 43 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E 2.3.5 - Outputs RELAYS-MOTORS NAME LOCATION CONNECTOR FUNCTION KAH 01 - 07 Main relay for commands (115) KA1 02 - 17 AXB.7 Horn command (70) KA2 02 - 20 AXA.8 Flashing light command (89) KA3 02 - 10 CXB.1/5 Brake release command (remote control) KA4 04 - 04 Option KM900 01 - 06 Battery charger relay (If activated, no function on machine) (98) M370 02 - 06 U/V/W AC drive motor (RR) M371 02 - 13 U/V/W AC drive motor (RL) SB801 01 - 13 Main line contactor for ECU modules (84) VALVES NAME LOCATION CONNECTOR FUNCTION YB100 02 - 11 CXB.1/5 Electromagnetic brake at negative excitation for RR motor YB101 02 - 12 AXB.1/5 Electromagnetic brake at negative excitation for RL motor YV120 02 - 03 CXB.3 Valve 6 ways/ 2 positions for selection potholes or steering (priority for potholes) (56) YV121 02 - 05 CXA.1 Right steering or potholes retraction (54) YV122 02 - 06 CXA.8 Left steering or potholes out/extended (53) YV420 02 - 18 AXB.3 PWM valve for platform lift/descent (Slow descent when PF < 3 meters) (19) YV903 02 - 19 AXA.2 Discharge valve (by-pass: pump is in pressure) (55) 44 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram BUZZER AND LIGHTS NAME LOCATION CONNECTOR FUNCTION HA901 05 - 13 CXA.9 Buzzer (04) HA907 03 - 13 Horn (184) EL901/B 06 - 05 Option flashing light (32) EL904 09 - 19 Option working light (134) HL100 09 - 11 E.7 Drive selection indicator (94) HL420 08 - 09 E.6 Movement selection indicator (46) HL800 09 - 10 F.3 Slope (tilt) indicator (45) HL802 09 - 10 F.1 Overload indicator (44) HL903 09 - 10 F.5 Other alarms indicator (43) HL904 09 - 10 F.2 Battery level indicator (42) A B C D E F G H I 45 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E 2.4 - CUT OUT CONDITIONS OF EVERY FUNCTION 2.4.1 - Glossary MARKING DESIGNATION U Up D Down L Left R Right F/FWD Forward REV/B Reverse/backward SETP Setpoint A IN Analogic input D IN Digital input D OUT Digital output A OUT Analogic output PWM Pulse Width Modulation (Proportionnal valve in current square modulated signal) VAR Internal variable in the module (not accessible with the console) I/O Inputs/Outputs I Input O Output µS Micro speed drive MS Medium speed drive HS High speed drive 2WS 2 wheels steering 4WS 4 wheels steering 46 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram 2.4.2 - Power supply/commands N.B.-:- • The diagnostic menu is very important on this model as it will permit to the technician to focuse only on the dysfunction encountered and then save time to repair the machine. • The explanation done below is built on the same basis for all movements. COMMANDS ALL COMMANDS COMING FROM LOWER/UPPER CONTROLS Inputs Digitals or analogic inputs (ETOR-EANA) Setpoint (0-100%) In Diagnostic menu, it's the parameter Internal setpoint for the function described Neutral to Fwd/ up/left or Rev/down/Right (0-1000pts) This setpoint is null when no movement is performed or there is a failure on the josytick Cuttings Conditions for cutting the movements : • Null movement is authorized • 1 movement is inhibited Validation and formatting the command Conditions for validation of the movement Slow down Condtions for slowing down the movement (from 0 to 100%) Control (0-100%) In Diagnostic menu, it’s the parameter Internal control for the internal command of the function (0- 1000pts) Outputs Digitals or Analogic outputs (STOR-SPWM-SANA) Actuator Any device like valves/cylinders/motors/relays A B C D E F G H I 47 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E Explanation of the cinematic Explanation of the Cuttings function This is valid for every movement including drive mode. BIT CUT-OFF CONDITIONS DESCRIPTION 0 Enable General movement deactivation 1 General General Inhibition 2 Simultaneous movements Inhibition due to numerous movements activated at the same time 3 Overload Inhibition due to machine is in overload mode 4 Tilt Inhibition due to machine is in tilt/slope 5 Reach limit Inhibition due to machine is in outreach limitation mode 6 Failure Inhibition due to Faliures 7 Specific Inhibition due to specific conditions /options 48 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram REQUIREMENTS DEFINITION PS001.1 Machine is powered ON with key SA901 of lower control box if no emergency stop is pushed (EMSTOP=ON and PowerON=1). At power on, the relays close : SB801=ON & KAH=ON • Supply 24 V of power part (motor, pump and electro valves). • Supply 24 V of lower signal part (switches and sensors). • Supply the upper part. During machine use, the SB801 main contactor is controlled through high level software to save some energy ( 150 mA to 200 mA current consumption) : SB801 = CTRL[MainContactor] PS002 At power ON, the software automatically compares identifier stored into EEPROM with identifier embedded in the loaded soft. If identifiers are different (blank ECU or new soft type loaded), then : • All failures are reinitialized (reset of counters and log). • Default speed, ramps, options and configurations vales are reloaded. • Hour-meter stored into EEPROM is set to 0. • Failure F12.04 is triggered. PS003 If one of the emergency stop is pushed ( EMSTOP = OFF) until end of saves in EEPROM, machine is on power hold mode. • SB801=0: supply for power and upper parts is cut. • CAN Failure F12.01 is inhibited. • KAH doesn’t change : Supply 12 V and 24 V for lower signal parts are hold. • Start of EEPROM saves before stop. PS004 On power hold mode; when all EEPROM saves are done : KAH=ON • The machine is switch off when KAH=OFF. PS005 Machine counters (hours and service) are stored into ECU EEPROM in order to detect when the screen is changed and then to reload automatically the old values stored into the new screen. For that, at machine power ON : • If Hourmeter(EEPROM) > Hourmeter(SCREEN) => Counters (hours and service) are reloaded from values stored into ECU EEPROM. • Otherwise current counters values are stored into ECU EEPROM. A B C D E F G H I 49 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E 2.4.3 - Drive 2.4.3.1 - Validation REQUIREMENTS DEFINITION DSV01 The drive movement happens relative to the activated panel, in the specified direction and set point and regarding to validation and slowdown conditions : SETP[Drive]=FWD|N|REV:[0-100]% REQUIREMENTS DEFINITION DSV02.1 Forward (F) and/or reverse (R) drive movement is allowed if all validation conditions are satisfied and none of cut-offs condition is true (see DVR03) VALIDATION F R ENABLE CONDITIONS 0Enable 1 1 1 Machine powered on for more than 3s 2 1 1 Machine is set 3 1 1 User is identified 1: The condition enables the movement (All conditions to '1': movement enabled) REQUIREMENTS DEFINITION DSV03 The following conditions (General to Specific) inhibit the drive movement ( F: forward/ R: reverse) CUT-OFF F R GENERAL CUT-OFF CONDITIONS 1 General 111 Machine unfolded and potholes not extended out of production mode 211 Battery charge level low (< 20%) And machine unfolded out of production mode 311 Machine not low and "Drive restrictions when lifted" option is set to "0.5m" value 411 Machine unfolded and "Drive restrictions when lifted" option is active 5 1 1 Time out after drive movement REQUIREMENTS DEFINITION DSV03 CUT-OFF F R SIMULTANEOUS MOVEMENTS CUT-OFF CONDITIONS 2 Simultaneous movements 5 1 1 Manual brake release is active REQUIREMENTS DEFINITION DSV03 CUT-OFF F R OVERLOAD CUT-OFF CONDITIONS 3Overload 1 1 1 Overload alarm is active 2 1 1 Overload learning is running 50 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram REQUIREMENTS DEFINITION DSV03 CUT-OFF F R TILT CUT-OFF CONDITIONS 4Tilt 111 Tilt activated with unfolded machine and tilt cut-off activated (some countries or tilt safety configuration) out of production mode REQUIREMENTS DEFINITION DSV03 CUT-OFF F R REACH LIMIT CUT-OFF CONDITIONS 5 Reach limit N/A N/A N/A N/A REQUIREMENTS DEFINITION DSV03 CUT-OFF F R FAILURE CUT-OFF CONDITIONS 6Failure 1 1 1 Power contactor stuck 211 Machine unfolded and load management system not calibrated and serial number is set 311 The two arm angle sensors are out of range and load management is active 411 Serious incoherence in measuring arm angle and load management is active 5 1 1 Machine unfolded and pressure failure 611Power failure 7 1 1 Steering valve failure 8 1 1 Movement selection valve YV120 shorted 9 1 1 Arm incoherence ( YV903 failure) REQUIREMENTS DEFINITION DSV03 CUT-OFF F R SPECIFIC CUT-OFF CONDITIONS 7 Specific 1 1 1 Extreme temperature (for Russia country) and machine unfolded A B C D E F G H I 51 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E REQUIREMENTS DEFINITION DSV04.2 Following limits are applied on the set point (SETP[Drive]): DIRECTIONS MOVEMENT SET POINT LIMIT CONDITIONS F R SPEED[uS Drive Fwd] SPEED[uS Drive Rev] 1 Unfolded machine (micro speed) and not masked SPEED[uS Drive Fwd] SPEED[uS Drive Rev] 2 Steer angle not calibrated or steer angle out of range and not masked SPEED[uS Drive Fwd] SPEED[uS Drive Rev] 3 Arm angle function not calibrated or failing and not masked ( 100% = max speed) REQUIREMENTS DEFINITION DSV05 When machine is unfolded, drive speed is set to 'Micro' value REQUIREMENTS DEFINITION DSV06.1 The three conditions listed in DSV04 requirement are inhibited in case of : • Machine serial number is "000000". • Steer angle must be calibrated. • Both angle sensors are not electrically out of range (> 100 mV and < 4900 mV) And angle computed is less than 18°. • Pressure sensor indicates low pressure. (< 5 pts) Serial number="000000" " & F10.16(A) & F10.14(A) & (SP400 < 50pts) & ( ( (10pts < SR420 < 478pts ) & (10pts < SR722 < 478pts ) & VAR[Angle] < 18° ) | ( (10pts < SR420 < 478pts ) & VAR[Angle_SR420] < 18°) | ( (10pts < SR722 < 478pts ) & VAR[Angle_SR722] < 18°) ) 52 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram 2.4.4 - Steering 2.4.4.1 - Validation REQUIREMENTS DEFINITION STV01 The steering movement happens in the specified direction and set point, regarding to validation and slow down conditions : SETP[Steering]=LEFT|N|RIGHT:[0-100]% REQUIREMENTS DEFINITION STV02.1 Steering (both directions, each mode) is allowed if all validation conditions are satisfied and none of cut-off conditions is true (see DRV03) VALIDATION L R ENABLE CONDITIONS 0Enable 1 1 1 Machine powered on for more than 3s 2 1 1 Hydraulic pump is ready 3 1 1 Machine is set 4 1 1 User is identified 1: The condition enables the movement (All conditions to '1': movement enabled) REQUIREMENTS DEFINITION STV03 The following conditions (General to Specific) inhibit the steering movement ( L: left / R: right) CUT-OFF L R GENERAL CUT-OFF CONDITIONS 1 General 111 Machine unfolded and potholes not extended out of production mode 211 Battery charge level low (< 20%) And machine unfolded out of production mode 311 Machine not low and "Drive restrictions when lifted" option is set to "0.5m" value 411 Machine unfolded and "Drive restrictions when lifted" option is active 5 1 1 Time out after drive movement REQUIREMENTS DEFINITION STV03 CUT-OFF L R SIMULTANEOUS MOVEMENTS CUT-OFF CONDITIONS 2 Simultaneous movements 5 1 1 Manual brake release is active REQUIREMENTS DEFINITION STV03 CUT-OFF L R OVERLOAD CUT-OFF CONDITIONS 3Overload 1 1 1 Overload alarm is active 2 1 1 Overload learning is running A B C D E F G H I 53 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E REQUIREMENTS DEFINITION STV03 CUT-OFF L R TILT CUT-OFF CONDITIONS 4Tilt 111 Tilt activated with unfolded machine and tilt cut-off activated (some countries or tilt safety configuration) out of production mode REQUIREMENTS DEFINITION STV03 CUT-OFF F R REACH LIMIT CUT-OFF CONDITIONS 5 Reach limit N/A N/A N/A N/A REQUIREMENTS DEFINITION STV03 CUT-OFF L R FAILURE CUT-OFF CONDITIONS 6 Failure 1 1 1 Power contactor stuck 211 Machine unfolded and load management system not calibrated and serial number is set 311 The two arm angle sensors are out of range and load management is active 411 Serious incoherence in measuring arm angle and load management is active 5 1 1 Machine unfolded and pressure failure 6 1 1 Power failure 7 1 1 Steering valve failure 8 1 1 Movement selection valve YV120 shorted 9 1 1 Arm incoherence ( YV903 failure) REQUIREMENTS DEFINITION STV03 CUT-OFF L R SPECIFIC CUT-OFF CONDITIONS 7 Specific 11N/A 1 seconds of left steering control and no variation of steering angle OR steering angle < mechanical limit -1° 2N/A1 1 seconds of right steering control and no variation of steering angle OR steering angle > mechanical limit +1° 311 Extreme temperature (for Russia country) and machine unfolded 54 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram 2.4.4.2 - Actuators REQUIREMENTS DEFINITION STV04 There is not limitation of steering set point REQUIREMENTS DEFINITION STA01 The formatted control (CTRL[Steering]) is applied on the actuators driving the movement CTRL Pump YV122 YV121 YV903 LEFT CTRL[PumpSteering] 1 0 1 NEUTRAL 0 0 0 0 RIGHT CTRL[PumpSteering] 0 1 1 A B C D E F G H I 55 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E 2.4.5 - Arm 2.4.5.1 - Validation REQUIREMENTS DEFINITION AMV01 Steering movements happen in the specified direction and set point regarding to validation and slowdown conditions : SETP[Arm]=UP|N|DOWN:[0-100]% REQUIREMENTS DEFINITION AMV02 Raise (U:up) or descent (D:down) of arm is allowed if all validation conditions are satisfied VALIDATION U D ENABLE CONDITIONS 0Enable 1 1 1 Machine powered on for more than 3s 2 1 N/A Pump is ready N/A 1 Always true (descent with gravity) 3 1 1 Machine is set 4 1 1 User is identified 1: The condition enables the movement (All conditions to '1': movement enabled) REQUIREMENTS DEFINITION AMV03 The following conditions (General to Specific) inhibit the arm movement ( U: raise / D: descent) CUT-OFF U D GENERAL CUT-OFF CONDITIONS 1 General 1 1 N/A Machine in high position 2 1 N/A Low battery level REQUIREMENTS DEFINITION AMV03 CUT-OFF U D SIMULTANEOUS MOVEMENTS CUT-OFF CONDITIONS 2 Simultaneous movements 5 1 1 Manual brake release is active REQUIREMENTS DEFINITION AMV03 CUT-OFF U D OVERLOAD CUT-OFF CONDITIONS 3 Overload 1 1 1 Overload alarm is active 21N/A Load management system calibration running and stop requested 56 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram REQUIREMENTS DEFINITION AMV03 CUT-OFF U D TILT CUT-OFF CONDITIONS 4 Tilt 1 1 N/A Tilt activated with unfolded machine and tilt cut-off activated (some countries or movement tilt safety option) REQUIREMENTS DEFINITION AMV03 CUT-OFF U D REACH LIMIT CUT-OFF CONDITIONS 5 Reach limit N/A N/A N/A N/A REQUIREMENTS DEFINITION AMV03 CUT-OFF U D FAILURE CUT-OFF CONDITIONS 6 Failure 1 1 1 Power contactor stuck 211 Machine unfolded and load management system not calibrated and upper controls and serial number is set 311 The two arm angle sensors have been detected out of range and load management is active and upper controls 411 Serious incoherence in measuring arm angle and load management is active and upper controls 51N/A Machine unfolded and pressure failure has been detected and angle sensor calibrated 6 1 1 Power failure 7 1 1 Movement selection valve YV120 shorted 8 1 N/A Arm incoherence detected REQUIREMENTS DEFINITION AMV03 CUT-OFF U D SPECIFIC CUT-OFF CONDITIONS 7 Specific 1N/A1 3 s stop at folded position detection change of state during descent (scissor unfolded to scissor folded) for STD or RUK countries out of descent speed setting 2N/A1 1.5 s stop at descent set point resumption when scissor is folded for STD or RUK countries out of descent speed setting 31N/A Extreme temperature detected and unfolded machine and Russia/Ukraine country A B C D E F G H I 57 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E REQUIREMENTS DEFINITION AMV04 Following limits are applied on the set point ((SETP[Arm])) DIRECTIONS MOVEMENT SET POINT LIMIT CONDITIONS U D 50% 50% 1 Tilt and machine unfolded 75% 75% 2 Chassis control box active and load management calibration not in progress N/A 50% 3 Descent when machine is folded machine N/A 50% 5 Failure F07.06 ( (id 01 and 02) or id 8) ( 100% = max speed) 58 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram 2.4.5.2 - Actuators REQUIREMENTS DEFINITION AMA01 The formatted control (CTRL[Arm]) is applied on the actuators driving the movement Raise movement : • Hydraulic pump guarantees the proportionality of raise movement: control pump value (CTRL[PumpArm]) is computed from the arm raise value (CTRL[Arm]). • YV420 proportional electro valve is used as digital electro valve (proportionality guaranteed by hydraulic pump) : • Its aperture is timed (Ton 100 ms ) after the control of hydraulic pump to avoid over-pressure. • Its closure is done when pump control value is below VALUE_TO_BE_DEFINED (between acceleration bias and deceleration bias to be sure movement is stopping). • YV903 digital electro valve is active to enable the raise movement Descent movement : • Hydraulic pump is unused (CTRL[PumpArm] = 0). • YV420 proportional electro valve enables the descent movement and guarantees the proportionality • YV903 digital electro valve is unused => set to 0. CTRL PUMP YV420 YV903 RAISE CTRL[PumpArm] 100% 1 NEUTRAL 0 0 0 DESCENT 0 CTRL[Arm] 0 With : • -CTRL[PumpArm] value = CTRL[Arm] Value when arm raise is in progress A B C D E F G H I 59 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E REQUIREMENTS DEFINITION AMA02 After a movement of raise or descent, if the country is not USA, the arm cylinder valve YV420 is controlled at low values to suppress the pressure due to dynamics and then enable a reliable and repetitive measure of pressure for load management system. The values of control are automatically adjusted during load management system calibration. The duration of the control is height dependant (longer with the height: from 1500 ms to 3000 ms ) and this control happens 500 ms after the end of arm raise or arm descent movements. This special control is inactivated for USA version (no measure of load). 60 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram 2.4.6 - Brake release REQUIREMENTS DEFINITION BRV01 The release of brake is controlled : • Automatically during the normal operating mode. • Or on special conditions during test mode. • Or manually via the SA103 switch. Init Machine is powered off Automatic Release of brake is controlled based on the drive motion control Test Test mode for brakes Wait for confirmation Wait for falling edge of manual brake releasing set point Manual Brake is released Power ON Machine powered ON Active test Periodical activation of test Stop test Test ended Begin manual activation Out of tilt position and with folded scissor, manual release of brake set point is active for more than 3 s consecutively Manual activation confirmed Falling edge detected in the next 10 s Not detected No falling edge detected in the next 10 s (short circuit to VBAT of the switch) End of manual activation Manual release of brake set point is active (and has been detected inactive) or change in control box selection or joystick out of neutral or switch active A B C D E F G H I 61 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E 2.4.7 - Potholes 2.4.7.1 - Validation REQUIREMENTS DEFINITION POV01.1 Steering movements happen in the specified direction and set point regarding to validation and slowdown conditions. The potholes set point is automatically computed based on the control of drive movement or arm movement : CTRL[Drive]≠N:0 & F07.06(D) & (F10.16(D) | VAR[MaskMicroSpeedForProduction]= 1) --> SETP[Potholes]=IN:100% CTRL[Arm]=UP:[1;100]% | (SETP[Drive]≠N:0 & (F07.06(D) | (F10.16(A) & VAR[MaskMicroSpeedForProduction]= 0) ) --> SETP[Potholes]=OUT:100% CTRL[Drive]=N:0 & CTRL[Arm]≠UP:[1:100]%--> SETP[Potholes]=N:0 REQUIREMENTS DEFINITION POV02 Extension (O: out) and/or retraction (I: in) of potholes movement is allowed if all validation conditions are satisfied and none of cut-offs condition is true (see DRV_03) VALIDATION O I ENABLE CONDITIONS 0Enable 1 1 1 Machine powered on for more than 3s 2 1 1 Hydraulic pump is ready 3 1 1 Machine is set 1: The condition enables the movement (All conditions to 1: movement enabled) REQUIREMENTS DEFINITION POV03.1 The following conditions (General to Specific) inhibit the potholes movement (O:Out / I:In) CUT-OFF O I GENERAL CUT-OFF CONDITIONS 1 General 11N/A Drive is the selected movement when failures F07.06 is not detected and F10.16 not active 2 N/A 1 Arm is the selected movement 3 N/A 1 Scissor is unfolded out of production mode 4 1 N/A Potholes extended (with timer) REQUIREMENTS DEFINITION POV03.1 CUT-OFF O I SIMULTANEOUS MOVEMENTS CUT-OFF CONDITIONS 2 Simultaneous movements 2 1 1 Steering is active 5 1 1 Manual brake release is active REQUIREMENTS DEFINITION POV03.1 CUT-OFF O I OVERLOAD CUT-OFF CONDITIONS 3 Overload N/A N/A N/A N/A 62 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram REQUIREMENTS DEFINITION POV03.1 CUT-OFF O I TILT CUT-OFF CONDITIONS 4 Tilt N/A N/A N/A N/A REQUIREMENTS DEFINITION POV03.1 CUT-OFF O I REACH LIMIT CUT-OFF CONDITIONS 5 Reach limit N/A N/A N/A N/A REQUIREMENTS DEFINITION POV03.1 CUT-OFF O I FAILURE CUT-OFF CONDITIONS 6 Failure 1 1 1 Power contactor stuck 2 1 1 Failure on pothole/steering selection valve REQUIREMENTS DEFINITION POV03.1 CUT-OFF O I SPECIFIC CUT-OFF CONDITIONS 7 Specific 1N/A1 Drive movement is in progress and steering is requested 2N/A1 Ended timer (consecutive or discrete) of potholes retraction since power on or since last extension, the value of the timer is 2 s in normal mode or 10 s in production mode REQUIREMENTS DEFINITION STV04 There is not limitation of potholes set point A B C D E F G H I 63 4000595920 E 05.17 USA / (1 C - Study of the wiring diagram OPTIMUM 8 - OPTIMUM 1931 E 2.4.7.2 - Actuators REQUIREMENTS DEFINITION STA01 The formatted control (CTRL[Steering]) is applied on the actuators driving the movement CTRL Pump YV121 YV122 YV903 IN CTRL[PumpSteering] 1 0 1 NEUTRAL 0 0 0 0 OUT CTRL[PumpSteering] 0 1 1 Potholes extension : Potholes retraction : 64 4000595920 E 05.17 USA / (1 OPTIMUM 8 - OPTIMUM 1931 E C - Study of the wiring diagram Notes A B C D E F G H I 65 4000595920 E 05.17 USA / (1 D - Study of the hydraulic schema OPTIMUM 8 - OPTIMUM 1931 E Study of the hydraulic schema 1 - Hydraulic units 1.1 - GENERAL OVERVIEW 1.1.1 - The hydraulic components 1.1.1.1 - Pump unit MARKING FUNCTION DESCRIPTION 1 YV903 By-pass valve (pump is in pressure) 2 YV122 Left steering or potholes exit 3 YV121 Right steering or potholes retraction 66 4000595920 E 05.17 USA / (1 D - Study of the hydraulic schema OPTIMUM 8 - OPTIMUM 1931 E 1.1.1.2 - Selection valve potholes/steering MARKING FUNCTION DESCRIPTION 1YV120 Valve 6 ways / 2 positions for selection potholes or steering (priority for potholes) A B C D E F G H I 67 4000595920 E 05.17 USA / (1 D - Study of the hydraulic schema OPTIMUM 8 - OPTIMUM 1931 E 1.1.1.3 - Lifting cylinder valve MARKING FUNCTION DESCRIPTION 1YV420 Valve PWM (Pulse Width Modulation) lift/descent of platform (Slow descent when PF < 3 meters. Information coming from angle sensor SR420) 68 4000595920 E 05.17 USA / (1 D - Study of the hydraulic schema OPTIMUM 8 - OPTIMUM 1931 E Notes A B C D E F G H I 69 4000595920 E 05.17 USA(1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E Adjustments 1 - Adjustments with diag pad console The adjustments/parameters settings /list of alarms, calibration of the machine are accessible on on-board activ screen console, as well as this console below or Haulotte Diag application installed in laptop. The VCI (Vehicle Computer Interface) adapter could be connected from any controls (turret or in platform) using wireless or cable connection. The full description of how to use that console and its menus is explained in a technical note PI144 (for more information refer to your nearest HAULOTTE Services® of your area) VCI 70 4000595920 E 05.17 USA / (1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E 2 - List of menus See end of manual 2.1 - MACHINE SETTINGS 2.1.1 - Speeds and ramps See end of manual : Annex 1 2.1.2 - Options See end of manual : Annex 2 2.1.3 - Configurations See end of manual : Annex 3 2.1.4 - Countries and models See end of manual : Annex 4 2.2 - DIAGNOSTIC 2.2.1 - Inputs/Outputs See end of manual : Annex 5 2.2.2 - States See end of manual : Annex 6 A B C D E F G H I 71 4000595920 E 05.17 USA(1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E 3 - Failures list • For any type A (ACTIVE) failure code, it will appear on display in lower control and the warning light will flicker on upper controls (see below). • For any type D (DETECTED) failure code, it will also appear on display in lower control and the warning light will flicker on upper controls. • For any type N failure code, it means that this alarm will never appear on display. • An internal code (column C) with 5 digits, visible only on the console, allows specifying the trigger conditions of the failure. Each trigger condition is associated with a single code number (16 possible single codes in decimal format corresponding to a single bit in binary format) : • If several conditions are active at the same time, single codes are added to form the resulting code displayed. For example, il conditions 1 and 4 of single code are active, then the resulting code displayed will be 5 (1+4=5). All alarms codes are gathered per category (ex F02xxx contactors) 72 4000595920 E 05.17 USA / (1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E 3.1 - LIST OF FAILURES PER CATEGORY FAILURES N C DESCRIPTION INVERTER F01.01 Inverter Master A 1 COMBIACX: Failure in the high current hardware protection circuit. • Internal fault. • Replace the inverter. 2 COMBIACX: When no current is applied to the traction motor, the current feedbacks are out of permitted standby range. • Type of default not related to external components. • Cycle power to clear the fault. • If the fault is not cleared, replace the controller. 4 COMBIACX: Driver of main contactor coil is damaged (not able to close). • Type of default not related to external components. • Cycle power to clear the fault. • If the fault is not cleared, replace the controller. 8 COMBIACX: The driver of the electromechanical brake coil is not able to drive the load. • Internal fault. • Replace the controller. 16 COMBIACX: Pump current sensor out of range (at start-up or standby). • Internal fault. • Replace the controller. 32 COMBIACX: At start-up, the amplifiers voltage (used to measure the motor voltage) is too low or too high (< 2 V or > 3 V). • Internal fault. • Replace the controller. F01.05 Pump failure A 1 COMBIACX: The software waits for the motor pump to stop at start-up. • If the motor connected to "-P" is still moving, wait for it to be still. • If not, wait 30 seconds until alarm "PUMP VMN NOT OK" appears. • Refer to corresponding alarm chapter. 2 COMBIACX: Pump driving voltage different than the expected one. • Key OFF/ON. 4 COMBIACX: The pump motor output voltage is lower than expected, considering the control applied. • Check the motor power wiring and connections. • Check the motor phases for proper insulation with the chassis. • Check that MC DRIVE power contact close properly, with a good contact. • If no problem is found on the motors, replace the controller. 8 COMBIACX: The pump motor output voltage is higher than expected, considering the control applied. • Check the motor power wiring and connections. • Check the motor phases for proper insulation with the chassis. • Check that main contactor drive power contact close properly, with a good contact. • If no problem is found on the motors, replace the controller. 16 COMBIACX: The pump current sensor feedback is always 0A, even if pump motor is running. • Check the pump motor connection and continuity. • Type of default not related to external components. • Cycle power to clear the fault. • If the fault is not cleared, replace the controller. A B C D E F G H I 73 4000595920 E 05.17 USA(1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E F01.06 Overheating A 1 COMBIACX: The controller has reached thermal cutout (temperature of the controller base plate is higher than 85°C). • Power down and allow to cool. • Do not operate in ambient temperatures over to 60°C. • Check for jammed or obstructed drive motor. • Check for excessively high drive motor current consumption while driving on the level (over 70A). • Check controller for proper installation. • If the controller is cold when the default appears, replace it. 2 ACEX: The controller has reached thermal cutout (temperature of the controller base plate is higher than 85°C). • Power down and allow to cool. • Do not operate in ambient temperatures over to 60°C. • Check for jammed or obstructed drive motor. • Check for excessively high drive motor current consumption while driving on the level (over 70A). • Check controller for proper installation. • If the controller is cold when the default appears, replace it. F01.08 Low Battery A1 Low battery voltage ( estimated value < 10%). • Check for damaged batteries, battery cables or connections. • Recharge batteries. • Measure batteries voltage and compare it with the value BATTERY VOLTAGE parameter in the TESTER menu. • If they are different, adjust the value of the ADJUST BATTERY function. F01.09 Electrical park brake 1 A 1 COMBIACX: Short circuit detected on electromechanical brake or main contactor output (overcurrent). • Main contactor drive coil : Check connections and wiring for interruptions between controller and coil. • Motor brake coil : Check connections and wiring for interruptions between controller coil. • If the wiring is correct, the problem is in the controller : Replace it. 2 COMBIACX: The driver of the electromechanical brake coil is shorted. • Check if there is a short or a low impedance pulldown between NEB CNA#4 and –BATT. • The driver circuit is damaged in the controller, which has to be replaced. 4 COMBIACX: The driver of the electromechanical brake is shorted to +Vbatt. The output of the built in Smart Driver, which supplies the positive to the electromechanical brake coil is high when the Tiller and the H and S switch are opened. • Check the harness, in order to verify if a positive is connected to the Smart driver output CNB#1. • If, even disconnecting the wire from the connector pin, the output stays at high value, the problem is inside the controller and the Smart Driver is probably shorted. 8 COMBIACX: A short circuit on the power outputs of the controller has been detected. • Check the EB driver output for a short circuit with +Vbatt. • If, even disconnecting the wire from the connector pin, the output stays at high value, the problem is inside the controller : Replace it. 16 COMBIACX: Voltage on PEB present but not expected. • Check external wiring. • If the wiring is correct and no problem is found on the coil, replace the controller. 32 COMBIACX: Internal Smart driver KO and ACEX : internal Smart driver is not KO (if both signals are KO failure F08.10). • Check the driver output for a short circuit with -Vbatt. • If, even disconnecting the wire from the connector pin, the output stays at low value, the problem is inside the controller : Replace it. FAILURES N C DESCRIPTION 74 4000595920 E 05.17 USA / (1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E F01.10 Electrical park brake 2 A 1 ACEX: Short circuit detected on electromechanical brake or main contactor output (overcurrent). • Main contactor drive coil : Check connections and wiring for interruptions between controller and coil. • Motor brake coil : Check connections and wiring for interruptions between controller coil. • If the wiring is correct, the problem is in the controller : Replace it. 2 ACEX: The driver of the electromechanical brake coil is shorted. • Check if there is a short or a low impedance pulldown between NEB CNA# and –BATT. • The driver circuit is damaged in the controller, which has to be replaced. 4 ACEX: The driver of the electromechanical brake is shorted to +Vbatt. The output of the built in Smart Driver, which supplies the positive to the electromechanical brake coil is high when the Tiller and the H and S switch are opened. • Check the harness, in order to verify if a positive is connected to the Smart driver output CNB#1. • If, even disconnecting the wire from the connector pin, the output stays at high value, the problem is inside the controller and the Smart Driver is probably shorted. 8 ACEX: A short circuit on the power outputs of the controller has been detected. • Check the EB driver output for a short circuit with +Vbatt. • If, even disconnecting the wire from the connector pin, the output stays at high value, the problem is inside the controller : Replace it. 16 ACEX: Voltage on PEB present but not expected. • Check external wiring. • If the wiring is correct and no problem is found on the coil, replace the controller. 32 ACEX: Internal Smart driver KO and ACEX : internal Smart driver is not KO (if both signals are KO failure F08.10). • Check the driver output for a short circuit with -Vbatt. • If, even disconnecting the wire from the connector pin, the output stays at low value, the problem is inside the controller : Replace it. F01.11 Inverter Slave A 1 COMBIACX: Failure in the high current hardware protection circuit. • Internal fault. • Replace the inverter. 2 COMBIACX: When no current is applied to the traction motor, the current feedbacks are out of permitted standby range. • Type of default not related to external components. • Cycle power to clear the fault. If the fault is not cleared, replace the controller. 4 COMBIACX: Driver of main contactor coil is damaged (not able to close). • Type of default not related to external components. • Cycle power to clear the fault. If the fault is not cleared, replace the controller. 8 COMBIACX: The driver of the electromechanical brake coil is not able to drive the load. • Internal fault. • Replace the controller. 16 COMBIACX: Pump current sensor out of range (at start-up or standby). • Internal fault. • Replace the controller. 32 COMBIACX: At start-up, the amplifiers voltage (used to measure the motor voltage) is too low or too high (< 2 V or > 3 V). • Internal fault. • Replace the controller. F01.12 Wrong controller hardware D 1 COMBIACX : Hardware version is not the expected one. 2 COMBIACX : Hardware version is not the expected one. FAILURES N C DESCRIPTION A B C D E F G H I 75 4000595920 E 05.17 USA(1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E FAILURES N C DESCRIPTION CONTACTOR F02.04 Power Contactor SB801 D 1 The driver of main contactor drive coil is shorted, or its coil is disconnected. • Ensure there is no short or low-impedance pull-down between MC and -Vbatt. • Check connections and wiring for interruptions of MC DRIVE coil. • If wiring and connection are correct, the problem is in the controller : Replace it. 2 The main contactor coil has been driven by the controller, but the contactor does not close. • Check the contact in the main contactor drive contactor and if it is not working, replace the main contactor drive. 4 Before driving the LC coil, the controller checks if the contactor is stuck. The controller drives the bridge for some tens milliseconds, trying to discharge the capacitors bank. If they don't discharge the fault condition is entered. • Check the power contact of the main contactor drive and replace it if necessary. 8 Supervisor status is "alarm" or "wait reset" and main contactor is not forced open. • Key OFF/ON. FAILURES N C DESCRIPTION ELECTROVALVES F04.01 Steering YV121/YV122 D 1 Short circuit detected on steering front left electro valve : --> YV121 = FAIL 2 Short circuit detected on steering front right electro valve : --> YV122 = FAIL F04.04 Arm YV420 D Short circuit detected on arm descent electro valve : --> YV420 = FAIL F04.11 Principal movements YV903 D1 Short circuit detected on pump discharge electro valve : --> YV903 = FAIL F04.40 Potholes YV121/YV122 D 1 Short circuit detected on pothole extend electro valve : --> YV122 = FAIL 2 Short circuit detected on pothole retract electro valve : --> YV121 = FAIL F04.41 Movement Selection valve D 1 Short circuit detected on steering / potholes selection electro valve : --> YV120 = SHORT CIRCUIT FAILURE 2 Short circuit detected on steering / potholes selection electro valve : --> YV120 = OPEN CIRCUIT FAILURE 76 4000595920 E 05.17 USA / (1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E FAILURES N C DESCRIPTION JOYSTICKS F05.01 Arm/Drive joystick SM901 D 1 Analog signal SM901 is out of allowed range : --> SM901 < 0.2V | SM901 > 4.8V 2 Incoherence between analog signal and out of neutral signals for SM901 joystick : --> SM901N = 1 & (2,45V < SM901Y < 2,55V) --> or SM901N = 0 & (SM901Y < 2.0V | SM901Y > 3.0V) F05.11 Joystick neutral SM901 D1 Neutral position of arm and drive joystick SM901 not detected after upper control box selection : --> SM901 < 2.35V | SM901 > 2.65V FAILURES N C DESCRIPTION LOAD MANAGEMENT SYSTEM F06.01 No Loading Cal Calibration required A Angle/pressure weighting system missing or not calibrated and EU|AU|RUK A B C D E F G H I 77 4000595920 E 05.17 USA(1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E FAILURES N C DESCRIPTION SENSORS F07.05 Motor temperature sensor D 1 COMBIACX: The motor temperature sensor is not correctly connected or damaged. • Key OFF/ON. • Check wiring. 2 ACEX: The motor temperature sensor is not correctly connected or damaged. • Key OFF/ON. • Check wiring. F07.06 Arm Angle D 1 SR420 Arm angle sensor is out of allowed range when calibrated : --> VAR[SR722_OutOfRange]=1 2 SR722 Arm angle sensor is out of allowed range when calibrated : --> VAR[SR722_OutOfRange]=1 4 SR420 and SR722 arm angle measured are not coherent when calibrated (with no error of out of range), first level of incoherence : --> VAR[ArmAngleIncoherent]=1 8 SR420 and SR722 arm angle measured are not coherent when calibrated (with no error of out of range), second level of incoherence : --> VAR[ArmAngleIncoherent]=2 F07.21 Pressure sensor D 1 Pressure sensor is considered as out of range : Scissor arm angle is above 18° and pressure sensor measures less than 10b (to handle the arm on kickstand --> pressure is null) And arm descent is not running : --> SP400 < (=0.2V) & VAR[ArmAngle] > 18 & CTRL[Arm]≠D 2 Pressure sensor is considered as out of range: pressure sensor voltage is above 10.5 V : --> SP400 > (=10.5V) F07.33 Steer angle D1 Steer angle sensor is out of range : -->VAR[SteerAngle] > 55.65° | VAR[SteerAngle] < -83.19° F07.35 Motor encoder From version v2.07: fix issue when driving in 25% ramp and steering at same time : In some cases, failure F07.35 appeared, now fix. D 1 COMBIACX: Problem on the encoder during drive. • Check connections and wiring for interruptions between controller and motor encoder. • Check the harness for proper installation. • Check the encoder mechanical installation. If the encoder slips inside its compartment, replace the encoder or change the drive motor. 2 ACEX: Problem on the encoder during drive. • Check connections and wiring for interruptions between controller and motor encoder. • Check the harness for proper installation. • Check the encoder mechanical installation. If the encoder slips inside its compartment, replace the encoder or change the drive motor. F07.36 ECU temperature D 1 COMBIACX: The ECU thermal sensor is out of range. • Key OFF/ON. • Replace the controller. 2 ACEX: The ECU thermal sensor is out of range. • Key OFF/ON. • Replace the controller. 78 4000595920 E 05.17 USA / (1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E FAILURES N C DESCRIPTION ELECTRIC CIRCUIT F08.04 Supply A 1 COMBIACX: Power capacitors voltage does not increase at start-up. • Ensure that no external device is connected to the batteries. • Check battery, power cables and connections. 2 COMBIACX: The controller detects an overvoltage or under voltage condition. Overvoltage threshold is 35 V, under voltage threshold is 9.5 V. • If the fault appears at start-up or during standby : Check that no external device (relays switching, solenoids energizing/de-energizing... ) is connected to the batteries, creating down-going pulses. • If no voltage transient is detected on the supply line and the alarm appears every time the key is switched ON : Replace the controller. • Check if the fault appears during driving acceleration (under voltage condition detected) : Check battery charge ; check for damaged batteries, battery cables and connections. • Check if the fault appears during release braking (overvoltage condition detected) : Check line contactor contact, battery power cable connection. 4 COMBIACX: At start-up, the battery voltage is too low or too high (< 0,8 Vbatt or >1,2 Vbatt). • Check that the controller SET BATTERY parameter value matches the battery nominal voltage (24VDC). • Check that the TESTER MENU / BATTERY VOLTAGE parameter shows same value as the battery voltage measured with a voltmeter. • If it does not match, then do a ADJUST BATTERY function. • If the default still appears, replace the battery. 8 COMBIACX: A low logic level of Key-Off has been detected during start-up diagnosis. • Check that no external device (relays switching, solenoids energizing/de,energizing...) is connected to the batteries, creating downgoing pulses. • Check the connection of power cabled to the battery terminal, positive and negative, to MC DRIVE and to +Batt and -Batt, which must be screwed with a torque comprised in the range 5,6 Nm - 8,4 Nm. • If no voltage transient is detected on the supply line and the alarm appears every time the key is switched ON : Replace the controller. 16 ACEX: Power capacitors voltage does not increase at start-up. • Ensure that no external device is connected to the batteries. • Check battery, power cables and connections. 32 ACEX: The controller detects an overvoltage or under voltage condition. Overvoltage threshold is 35 V, under voltage threshold is 9.5 V. • If the fault appears at start-up or during standby : Check that no external device (relays switching, solenoids energizing/de-energizing... ) is connected to the batteries, creating down-going pulses. • If no voltage transient is detected on the supply line and the alarm appears every time the key is switched ON : Replace the controller. • Check if the fault appears during driving acceleration (under voltage condition detected) : Check battery charge ; check for damaged batteries, battery cables and connections. • Check if the fault appears during release braking (overvoltage condition detected) : Check line contactor contact, battery power cable connection. 64 ACEX: At start-up, the battery voltage is too low or too high (< 0,8 Vbatt or >1,2 Vbatt). • Check that the controller SET BATTERY parameter value matches the battery nominal voltage (24VDC). • Check that the TESTER MENU / BATTERY VOLTAGE parameter shows same value as the battery voltage measured with a voltmeter. • If it does not match, then do a ADJUST BATTERY function. • If the default still appears, replace the battery. 128 ACEX: A low logic level of Key-Off has been detected during start-up diagnosis. • Check that no external device (relays switching, solenoids energizing/de,energizing...) is connected to the batteries, creating downgoing pulses. • Check the connection of power cabled to the battery terminal, positive and negative, to MC DRIVE and to +Batt and -Batt, which must be screwed with a torque comprised in the range 5,6 Nm - 8,4 Nm. • If no voltage transient is detected on the supply line and the alarm appears every time the key is switched ON : Replace the controller. A B C D E F G H I 79 4000595920 E 05.17 USA(1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E F08.07 Circuit selector A 1 Two panels are selected : Check selector key : --> SA901T=ON & S0901PF=ON 2 No panel is selected : Check selector key : --> SA901T=OFF & S0901PF=OFF F08.09 Common output supply A 1 COMBI ACX: The PEV connector (B2) is not connected to the battery or the voltage is different. • Check B2 connector is connected to +Vbatt. • If the harness connections are correct, replace the controller. 2 ACEX: The PEV connector (B2) is not connected to the battery or the voltage is different. • Check B2 connector is connected to +Vbatt. • If the harness connections are correct, replace the controller. F08.10 Power supply D 1 ACEX: Internal Smart driver KO and COMBIACX : Internal Smart driver KO. • Check the driver output for a short circuit with -Vbatt. • If, even disconnecting the wire from the connector pin, the output stays at low value, the problem is inside the controller : Replace it. 2 ACEX: Problem on supply. • Check supply wiring (B+). • Check wiring between COMBIACX and ACEX. 4 ACEX: Problem on supply. • Check supply wiring (B+). • Check wiring between COMBIACX and ACEX. FAILURES N C DESCRIPTION 80 4000595920 E 05.17 USA / (1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E FAILURES N C DESCRIPTION FUNCTIONS F10.14 Steering angle not calibrated A Steer angle is not calibrated. Perform steer angle calibration. F10.16 Arm angle not calibrated A Arm angle is not calibrated. Perform arm angle calibration. FAILURES N C DESCRIPTION SAFETIES F11.09 Arm incoherence D Arm raise is controlled and arm angle is decreasing, out of calibration process (arm angle or pressure angle table). Check YV903 valve (wiring and connection). A B C D E F G H I 81 4000595920 E 05.17 USA(1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E FAILURES N C DESCRIPTION INTERNAL FAULTS F12.01 CAN Fault Check wires A For all failure details : • Check wiring. • Check the Can Bus connections. • Ensure that all the connectors pins are properly in place and the connectors are free of moisture or oxidation. • Machine powered off, measure the resistance between CN03.F and CN03.G. If it is not 60 Ohm ±5%, check continuity of the bus wires : • CAN LOW / 1001: From CN03.G (diagnostic connector) to ACTIV SCREEN X2.8 to COMBIACX CXC.10 to ACEX AXC.10 to CANTILLER C.4. • CAN HIGH / 1002: From CN03.F (diagnostic connector) to ACTIV SCREEN X2.7 to COMBIACX CXC.5 to ACEX AXC.5 to CANTILLER C.6. 1 No data is received from upper control box card. 2 No data is received from lower control box screen. 4 COMBIACX Module doesn't receive any CAN messages from ACEX module. 8 ACEX Module doesn't receive any CAN messages from COMBI ACX module. 16 No time (date/hour) update (problem with screen communication). F12.02 E2P Read/ Write Error Change calc. D 1 EEPROM failure status error. 2 EEPROM failure stack full. 4 COMBIACX: Wrong slip profile parameters or EEPROM damage. • Perform a CLEAR EEPROM. • If problem persists, replace the controller. 8 COMBIACX: Software or hardware error has been detected, default parameters are applied. • Execute a CLEAR EEPROM operation. • Cycle power to clear the fault : • If the alarm disappears, the previously stored parameters will have been replaced by the default parameters. • If the fault is not cleared, replace the controller. 16 ACEX: Wrong slip profile parameters or EEPROM damage. • Perform a CLEAR EEPROM. • If problem persists, replace the controller. 32 ACEX: Software or hardware error has been detected, default parameters are applied. • Execute a CLEAR EEPROM operation. • Cycle power to clear the fault : • If the alarm disappears, the previously stored parameters will have been replaced by the default parameters. • If the fault is not cleared, replace the controller. 64 Problem reading EEPROM at start-up. Restart machine. F12.04 E2P Param Reset Check settings D 1 ID of software loaded into machine is different from the ID stored into EEPROM: all machine parameters have been reset and must then be set again (speeds, ramps, options, configs, access code level 2, failure counters and calibration data). 2 Machine speeds and ramps have been reset and must be set again. 4 Machine options have been reset and must be set again. 8 Machine configurations. 16 Machine maintenance counters have been reset. 32 Machine daily log have been reset. 64 Machine events counters have been reset. 128 Machine events log counters have been reset. 82 4000595920 E 05.17 USA / (1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E F12.05 E2P Param Not Set D 1 Model not set (not possible => always Optimum8) Model = Not Set 2 Country not set : Set country Country = Not Set 4 Serial number = 0: set serial number SerialNumber = "000000" 8 At least one of the parameter used and not set ; Check all speeds and ramps SPEED[xxx] = Not Set | RAMP[xxx] = Not Set 16 At least one option used and not set ; Check all options OPT[xxx] = Not Set 32 At least one config not set ; Check all configurations CFG[xxx] = Not Set F12.07 ECU software version incoherence A 1 Zapi software version different on COMBIACX and on ACEX. F12.08 ECU fault (master) A 1 COMBIACX: Software watchdog active. • Key OFF/ON. 2 COMBIACX: Problem on the Analog/Digitial conversion of micro controller. • Key OFF/ON. 4 COMBIACX: Watchdog circuit output became high due to hardware or software problem (WDG1). • Alarm caused by a hardware failure in one of two (or both) controllers or due to a software execution problem. • Type of default not related to external components. • Cycle power to clear the fault. • If the fault is not cleared, replace the controller. 8 COMBIACX: Watchdog circuit output became high due to hardware or software problem (WDG2). • Alarm caused by a hardware failure in one of two (or both) controllers or due to a software execution problem. • Type of default not related to external components. • Cycle power to clear the fault. • If the fault is not cleared, replace the controller. 16 COMBIACX: Current gain acquisition has not been performed or EEPROM damaged. • Key OFF/ON. • If fault persists, a new current gain acquisition has to be performed. 32 COMBIACX: Wrong client software. • Load the software to COMBIACX and ACEX controllers. 64 COMBIACX: RAM checksum failed. • Internal fault. • Replace the controller. 128 COMBIACX: Timeout of client function (execution time exceed maximum allowable time). • Key OFF/ON. FAILURES N C DESCRIPTION A B C D E F G H I 83 4000595920 E 05.17 USA(1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E F12.09 ECU fault (slave) A 1 ACEX: Software watchdog active. • Key OFF/ON. 2 ACEX: Problem on the Analog/Digitial conversion of micro controller. • Key OFF/ON. 4 ACEX: Watchdog circuit output became high due to hardware or software problem (WDG1). • Alarm caused by a hardware failure in one of two (or both) controllers or due to a software execution problem. • Type of default not related to external components. • Cycle power to clear the fault. • If the fault is not cleared, replace the controller. 8 ACEX: Watchdog circuit output became high due to hardware or software problem (WDG2). • Alarm caused by a hardware failure in one of two (or both) controllers or due to a software execution problem. • Type of default not related to external components. • Cycle power to clear the fault. • If the fault is not cleared, replace the controller. 16 ACEX: Current gain acquisition has not been performed or EEPROM damaged. • Key OFF/ON. • If fault persists, a new current gain acquisition has to be performed. 32 ACEX: Wrong client software. • Load the software to COMBIACX and ACEX controllers. 64 ACEX: RAM checksum failed. • Internal fault. • Replace the controller. 128 ACEX: Timeout of client function (execution time exceed maximum allowable time). • Key OFF/ON. F12.10 Parameters reload Restart machine A This failure could happen when changing the software of the machine. Check evolution log. If happening, restart machine. 1 Incoherence of Battery Parameters ; new value forced, restart mandatory. 2 Incoherence of Motor Accessories Parameters ; new value forced, restart mandatory. 4 Incoherence of Motor Parameters ; new value forced, restart mandatory. 8 Incoherence of Option Parameters ; new value forced, restart mandatory. 16 Incoherence of Input Output Parameters ; new value forced, restart mandatory. 32 Incoherence of Machine Parameters ; new value forced, restart mandatory. 128 No parameters check / internal use for R and D only. F12.11 Parameters reload Restart machine A This failure happens at first power-on when reloaded on machine with software version 2.11 or on machine never loaded before. If happening out of these cases, power off and power on again after 5 s. 1 Wrong parameter : out of expected range. 2 Wrong parameter : EEPROM problem or RAM problem. 4 Wrong parameter : parameter current value is different from parameter initialized value. 8 Wrong parameter : incoherence between master and slave parameter source. FAILURES N C DESCRIPTION 84 4000595920 E 05.17 USA / (1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E FAILURES N C DESCRIPTION SWITCHES F13.02 Platform switches Check switches D 1 Incoherence between the 2 signals of front steering switch of platform box (both active) : --> SM901L = 1 & SM901R = 1 2 Incoherence between the 2 signals of movement selection : --> SM903A = 1 & SM903B = 1 F13.10 Neutral switch Check chassis switches A 1 Neutral position of arm switch of turret box not detected after power on : --> SA420U = 1 | SA420D = 1 2 Neutral position of enable switch of turret box not detected after power on : --> SA905 = 1 4 Neutral position of horn switch of turret box not detected after power on : --> SA907B = 1 8 Neutral position of brake release switch of turret box not detected after power on : --> SA103 = 1 F13.11 Switches neutral 2 Check plat. switches A 1 Neutral position of front steering switch of platform box not detected after power on : --> SM901L = 1 | SM901R = 1 2 Neutral position of enable trigger of platform box not detected after power on : --> SM901DM = 1 4 Neutral position of movement selection of platform box not detected after power on : --> SM908A = 1 | SM908B = 1 8 Neutral position of klaxon switch of platform box not detected after power on : --> SM907 = 1 16 Neutral position of brake release switch not detected after power on : --> SM103 = 1 FAILURES N C DESCRIPTION CAN J1939 F15.06 J1939 D 1 Error on CAN BUS. A B C D E F G H I 85 4000595920 E 05.17 USA(1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E FAILURES N C DESCRIPTION ENGINE F16.01 Overheating A 1 COMBIACX: Motor maximum temperature reached. • Check the thermal sensor wiring and ohm value. • Improve the air cooling of the motor. • If the warning is present when the motor is cool, then the problem is inside the controller : Replace it. 2 ACEX: Motor maximum temperature reached. • Check the thermal sensor wiring and ohm value. • Improve the air cooling of the motor. • If the warning is present when the motor is cool, then the problem is inside the controller : Replace it. F16.02 Speed problem A 1 COMBIACX: The drive motor has been detected stalled or the encoder is not working. 2 ACEX: The drive motor has been detected stalled or the encoder is not working. 86 4000595920 E 05.17 USA / (1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E F16.03 Motor supply A 1 COMBIACX: During drive, motor output voltage is lower than expected. • Check the motor power wiring and connections. • Check the motor phases for proper insulation with the chassis. • Check that MC DRIVE power contact close properly, with a good contact. • If no problem is found on the motors, replace the controller. 2 COMBIACX: During drive, motor output voltage is higher than expected. • Check the motor power wiring and connections. • Check the motor phases for proper insulation with the chassis. • Check that MC DRIVE power contact close properly, with a good contact. • If no problem is found on the motors, replace the controller. 4 COMBIACX: Motor voltage feedback circuits are damaged. • Check the motor power wiring and connections. • If the wiring is correct, the controller is damaged : Replace it. 8 COMBIACX: The motor output voltage is lower than expected, before MC DRIVE switch ON. • Check the motor phase to phase impedance. • Check the motor power cables connections. • Check the motor phases for proper insulation with the chassis. • If the motor connections are correct, replace the controller. 16 COMBIACX: The motor output voltage is higher than expected, before MC DRIVE switch ON. • Check the motor phase to phase impedance. • Check the motor power cables connections. • Check the motor phases for proper insulation with the chassis. • If the motor connections are correct, replace the controller. 32 ACEX: During drive, motor output voltage is lower than expected. • Check the motor power wiring and connections. • Check the motor phases for proper insulation with the chassis. • Check that MC DRIVE power contact close properly, with a good contact. • If no problem is found on the motors, replace the controller. 64 ACEX: During drive, motor output voltage is higher than expected. • Check the motor power wiring and connections. • Check the motor phases for proper insulation with the chassis. • Check that MC DRIVE power contact close properly, with a good contact. • If no problem is found on the motors, replace the controller. 128 ACEX: Motor voltage feedback circuits are damaged. • Check the motor power wiring and connections. • If the wiring is correct, the controller is damaged : Replace it. 256 ACEX: The motor output voltage is lower than expected, before drive main contactor switches ON. • Check the motor phase to phase impedance. • Check the motor power cables connections. • Check the motor phases for proper insulation with the chassis. • If the motor connections are correct, replace the controller. 512 ACEX: The motor output voltage is higher than expected, before drive main contactor switches ON. • Check the motor phase to phase impedance. • Check the motor power cables connections. • Check the motor phases for proper insulation with the chassis. • If the motor connections are correct, replace the controller. FAILURES N C DESCRIPTION A B C D E F G H I 87 4000595920 E 05.17 USA(1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E 4 - Maximum height adjustment 88 4000595920 E 05.17 USA / (1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E 5 - Cutback speed position height adjustment A B C D E F G H I 89 4000595920 E 05.17 USA(1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E 6 - Load management system 6.1 - CALIBRATION PROCEDURES N.B.-:- Before starting the calibration, check that the sensors are well mounted mechanically (Lift the scissors in order to get access to theses sensors). Then preset them to the indicated values. The sensors/fixation screws must be in the same axis as shown below and the support must be parallel with axis. 90 4000595920 E 05.17 USA / (1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E Pre setting of the transducers MARKING SENSORS LOW POSITION UPPER POSITION 1 SR420 ~ 74 pts ~ 530 pts 2 SR722 ~ 420 pts ~ 530 pts A B C D E F G H I 91 4000595920 E 05.17 USA(1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E 6.2 - STEERING The calibration is required for multiple reasons : • When the variator COMBIACX or one component linked to the steering has been changed. • When the pump doesn't stop when steering at full lock (left or right). Machine must be in stowed position and on flat surface ( SQ800 not activated) Reminder : • Machine must be in stowed position and on flat surface. • When wheel angle is out of range [-5;+5]°, a slowdown is applied on the external wheel (considering the steering direction) : • When wheels steer to the left the steer angle decreases : Its limit is set to -75.2°. • When wheels steer to the right the steer angle increases : Its limit is set to +47.6°. 92 4000595920 E 05.17 USA / (1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E 6.2.1 - Steering calibration procedure Preadjust the potentiometer so as to obtain the "steer angle" parameter at 0° to Activ’ Screen display ANGLE SENSORS CALIBRATION VALID RANGE pts V (approx.) SR150 Left (-75.19°) Counter clockwise (CCW) [150 ; 270] [01.539 ; 02.770] SR150 Right (+47.65°) Clockwise (CW) [755 ; 975] [07.746 ; 10.003] A B C D E F G H I 93 4000595920 E 05.17 USA(1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E 6.3 - CALIBRATION ARM ANGLE SENSORS (HONEYWELL SENSORS) ANGLE SENSORS CALIBRATION VALID RANGE pts V (approx.) SR420 Low (0°) [60 ; 160] [0.615 ; 1.641] SR722 Low (0°) [320 ; 420] [3.283 ; 4.309] SR420 High (57°) [320 ; 420] [3.283 ; 4.309] SR722 High (57°) [60 ; 160] [0.615 ; 1.641] 94 4000595920 E 05.17 USA / (1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E 6.4 - CALIBRATION ARM ANGLE SENSORS (ELOBAU SENSORS) ANGLE SENSORS CALIBRATION VALID RANGE pts V (approx.) SR420 Low (0°) [60 ; 160] [0.615 ; 1.641] SR722 Low (0°) [320 ; 420] [3.283 ; 4.309] SR420 High (57°) [320 ; 420] [3.283 ; 4.309] SR722 High (57°) [60 ; 160] [0.615 ; 1.641] A B C D E F G H I 95 4000595920 E 05.17 USA(1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E 7 - Adjustment of pressures 7.1 - MAIN PRESSURE The setting and minimess plug is unique for all movements. 7.2 - THE SPEEDS MARKING DESIGNATION VALUE 1 Main pressure 180bar +-5b MARKING DESIGNATION VALUE 1 High speed 9 s for 10 m / 33 ft 2 Micro speed 31 s for 5 m / 16 ft 3 PF lift/descent 22 s 4 Steering lock to lock 3.5 s 96 4000595920 E 05.17 USA / (1 E - Adjustments OPTIMUM 8 - OPTIMUM 1931 E Notes A B C D E F G H I 97 4000595920 E 05.17 USA / (1 F - Simplified breakdown guide OPTIMUM 8 - OPTIMUM 1931 E Simplified breakdown guide This guide does not replace the cut out conditions described previously in this manual. It allows the technician to have a logical step of breakdown service, detailing the successive steps to be followed starting from general tips until the details. The checking of the electric part is carried out in priority because less sensitive to the external parameters than the hydraulics part (Temperature, pollution, viscosity). The denomination of the movements describes below implies the 2 phases (Example not lifting, neither raise, nor descent from both controls, up and down). For a quicker diagnostic : Do check the failures code on Activ’screen display and refer to the alarms list before scrolling this breakdown guide. Do check all fuses. Beware as some options once activated might prohibit some movements (the option ASB, Active Shield Bar device). 1 - No start • Battery set. • Emergency stops(SB801/SB802 ). • Key selector SA901. • Relay battery charge KM900. • Main relay KAH. • Variators COMBIACX/ACEX. • Main pump. • Temperature sensor ST903 ( RUS only). 2 - No lift • Battery set. • Activ’screen touch pad. • Toggle switch SA908 (Upper controls). • Joystick SM901 out of range. • Foot pedal switch SB800 (Upper controls) US option. • CAN Tiller card. • Valves YV420/YV903. • Potholes system YV120/SQ144/SQ145. • Angle transducers SR420/SR722 not adjusted or not calibrated. • Pressure transducer SP400. • Machine in slope/tilt mode (SQ800), not for US mode. • Machine in overload (not for US/CDN mode). • Load Management System not calibrated. • No lifting pressure. 98 4000595920 E 05.17 USA / (1 F - Simplified breakdown guide OPTIMUM 8 - OPTIMUM 1931 E 3 - No drive • Toggle switch SA908. • Joystick SM901. • Foot pedal switch SB800( US only). • AC motor M370 - M371. • Brakes YB100 - YB101. • Temperature probes ST301 - ST302. • Speed sensors SV300 - SV301. • Angle transducers SR722 - SR420. • Machine in overload (not for US). • Machine in tilt (not for US). 4 - No steering • Toggle switch SA908. • Joystick SM901 (Rocker). • Steering calibration. • Angle sensor SR150. • Brakes YB100 - YB101. • Valves YV903 – YV121 – YV122 – YV120. • Relief valve RV2 (180b - 2520psi). A B C D E F G H I 99 4000595920 E 05.17 USA / (1 G - Version summary OPTIMUM 8 - OPTIMUM 1931 E Version summary 1 - Version summary 2 - List of schematics See end of manual 3 - List of wiring harnesses See end of manual OPTIMUM 8 - OPTIMUM 1931E STANDARDS WIRING DIAGRAM HYDRAULIC DIAGRAM Standard version All countries 4000311260 4000349350 100 4000595920 E 05.17 USA / EN G - Version summary OPTIMUM 8 - OPTIMUM 1931 E Notes xxxxx.A Movement Parameter [Target] Factory tolerance Configuraon Drive forward Min [deeps -0 ; +0] Hidden seng Drive forward Min [deeps -0 ; +0] Hidden seng (Australia mode) Drive forward Max speed [8.000000 ; 10.000000] [-10 ; +0] High speed selected, drive on 10m/33 length Drive forward Max speed micro [30.000000 ; 33.000000] [-10 ; +0] Machine unfolded, drive on 5m/16f t Drive forward Max speed [orcim -10 ; +0] Machine unfolded, drive on 5m/16f t Drive forward [noitareleccA -5 ; +5] Drive forward [noitareleceD -5 ; +5] 1 m/3.3 ± 0,2 m/0.6 in high spee d Drive reverse Min [deeps -0 ; +0] Hidden seng Drive reverse Min [deeps -0 ; +0] Hidden seng (Australia mode) Drive reverse Max speed [8.000000 ; 10.000000] [-10 ; +0] High speed selected, drive on 10m/33 length Drive reverse Max speed micro [30.000000 ; 33.000000] [-10 ; +0] Machine unfolded, drive on 5m/16f t Drive reverse Max speed [orcim -10 ; +0] Machine unfolded, drive on 5m/16f t Drive reverse [noitareleccA -5 ; +5] Drive reverse [noitareleceD -5 ; +5] 1 m/3.3 ± 0,2 m/0.66 in high speed Steering le Max speed [3.000000 ; 4.000000] [-100 ; +0] Plaorm controls, from lock to lock (le or right) Steering right Max speed [3.000000 ; 4.000000] [-100 ; +0] Plaorm controls, from lock to lock (le or right) Potholes extend Max [deeps -100 ; +10] Hidden seng Potholes retract Max [deeps -100 ; +10] Hidden seng Arm Raise Min [deeps -10 ; +10] Hidden seng Arm Raise Max speed raise [20.000000 ; 24.000000] [-100 ; +0] Plaorm controls, from lower to upper stop Arm Raise Acceleraon [esiar -5 ; +5] Arm Raise Deceleraon [esiar -5 ; +5] Arm Descent Min [deeps -100 ; +10] Arm Descent Max speed [26.000000 ; 32.000000] [-100 ; +0] Plaorm controls, from upper to lower stop Arm Descent Acceleraon [tnecsed -5 ; +5] Arm Descent Deceleraon [tnecsed -5 ; +5] ANNEX 1 ON noitpircseDemaN & ]nim_leveL[seulaV Buzzer Choose for which movements the buzzer must be acvated 1 OFF Descent / Retract Movements All Movements Drive Drive + All Movements Flashing light 1 OFF All Movements Drive Drive + All Movements ON Tracking system 1 OFF ON Drive restricon when lied If opon is acve, it allows to cut drive and steering above a li height depending on the sengs 1 OFF ON if > 0.5m / 1.6 ON if > 1.5m / 5.0 User Idenficaon inhibited A llows to inhibit user idenficaon in case screen is not usable 3 OFF ANNEX 2 xxxxx.A Country Model 1 Zone Standard OPTIMUM 8 USA OPTIMUM 1931E North America Australia OPTIMUM 8 Russia/Ukraine OPTIMUM 8 Canada OPTIMUM 1931E North America ANNEX 4 Name Descripon & Values Unit Min Max Baeries type TROJAN 30XHS TROJAN T105 TROJAN GEL6V US BATTERY AGM 2000 US BATTERY 2200 Angle sensors type HONEYWELL ELOBAU ANNEX 3 Type: Name Diagnosticinstructions: ECU: [Ref] [Pin] [Wire] Type:2 DIGITALINPUTS SB801‐Emergencystop(turntable/frame) Ifbothemergencystopsarepulled,inputmustbeON(+VBAT).Ifnot: ‐checkframeemergencystopfunction(SB801) ‐checkplatformemergencystopfunction(SB802) ‐checkinputwirecontinuity CombiACX‐Frame m_I3 B.4 109 Digitalinput(HS) SQ800‐Tiltsensor Iftilt<3° (longitudinal)/1.5°(lateral),inputmustbeON(+VBAT).Ifnot: ‐checksensoradjustment ‐checksensorsupplyfuse(FU3‐10A) ‐checksensorsupply(wires0=0Vand109=+VBAT) ‐checkinputwirecontinuity CombiACX‐Frame m_I8 A.12 12 Digitalinput(HS) SA901TU‐Controlboxselector‐Turret Ifturretcontrolbox isselected,inputmustbeON(+VBAT).Ifnot: ‐checkswitchfunction ‐checkswitchsupplyfuse(FU3‐10A) ‐checkswitchsupply(wire98=+VBAT) ‐checkinputwirecontinuity CombiACX‐Frame m_I2 C.7 135 Digitalinput(HS) SA901PF‐Controlboxselector‐Platform Ifplatformcontrol boxisselected,inputmustbeON(+VBAT).Ifnot: ‐checkswitchfunction ‐checkswitchsupplyfuse(FU3‐10A) ‐checkswitchsupply(wire98=+VBAT) ‐checkinputwirecontinuity CombiACX‐Frame m_I1 C.2 133 Digitalinput(HS) SA907TU‐Hornswitch‐Turret Ifhornfunction isactivatedfromturretcontrolbox,inputmustbeON(+VBAT).Ifnot: ‐checkswitchfunction ‐checkswitchsupplyfuse(FU3‐10A) ‐checkswitchsupply(wire109=+VBAT) ‐checkinputwirecontinuity ACEX‐Frame s_I3 B.4 41(CN0.8) Digitalinput(HS) ST903‐Extremambianttemperaturesensor Ifambienttemperatureis insidenormalworkingconditions[‐20;+40]°C,inputmustbeON(+VBAT).Ifnot: ‐checksensor ‐checksensorsupplyfuse(FU3‐10A) ‐checksensorsupply(wires0=0Vand109=+VBAT) ‐checkinputwirecontinuity ACEX‐Frame s_I2 C.7 40(CNO.6) Digitalinput(HS) SA103‐Brakereleaseswitch Ifbrakerelease switchisactivated,inputmustbeON(+VBAT).Ifnot: ‐checkswitchfunction ‐checkswitchsupplyfuse(FU3‐10A) ‐checkswitchsupply(wire109=+VBAT) ‐checkinputwirecontinuity ACEX‐Frame s_I1 C.2 21 Digitalinput(HS) SQ144_145‐Potholesleft/rightpositionsensors Ifpotholesareextended, inputmustbeON(+VBAT).Ifnot: ‐checksensorsadjustment ‐checksensorssupplyfuse(FU3‐10A) ‐checkpowersupply(wire109=+VBAT) ‐checkinputwirecontinuity ACEX‐Frame s_I5 A.4 15 Digitalinput(HS) SM901EN‐Enableswitch‐Enable Ifplatformenableswitch isactivated,inputmustbeON(+VBAT).Ifnot: ‐checkswitchfunction ‐checkswitchsupplyfuse(FU3‐10A) ‐checkswitchsupply(wire109=+VBAT) ‐checkinputwirecontinuity CANTiller‐Platform ct_IN2 B.1 37 Digitalinput(HS) SM901L‐Joysticksteeringrocker‐Left Ifsteeringleft functionisactivatedfromjoystickrocker,inputmustbeON.Ifnot: ‐checkrockerfunction ‐checkrockersupplyfuse(FU3‐10A) ‐checkrockersupply(wire109=+VBAT) ‐checkinputwirecontinuity CANTiller‐Platform ct_IN10 B.11 35(pin6) Digitalinput(HS) SM901R‐Joysticksteeringrocker‐Right Ifsteering rightfunctionisactivatedfromjoystickrocker,inputmustbeON.Ifnot: ‐checkrockerfunction ‐checkrockersupplyfuse(FU3‐10A) ‐checkrockersupply(wire109=+VBAT) ‐checkinputwirecontinuity CANTiller‐Platform ct_IN3 B.2 36(pin3) Digitalinput(HS) SA907‐Hornswitch Ifhornfunctionis activatedfromplatformcontrolbox,inputmustbeON(+VBAT).Ifnot: ‐checkswitchfunction ‐checkswitchsupplyfuse(FU3‐10A) ‐checkswitchsupply(wire109=+VBAT) ‐checkinputwirecontinuity CANTiller‐Platform ct_IN5 B.4 34 Digitalinput(HS) ANNEX5A Type: Name Diagnosticinstructions: ECU: [Ref] [Pin] [Wire] Type:2 ANNEX5B SM901N‐Drive/Armjoystick‐OutofNeutral Ifdrivejoystickispulled,outofneutralinputmustbeON(+VBAT).Ifnot: ‐checkjoystickfunction ‐checkjoysticksupplyfuse(FU3‐10A) ‐checkjoysticksupply(wire109=+VBAT) ‐checkinputwirecontinuity CANTiller‐Platform ct_IN6 B.5 5 Digitalinput(HS) SA908a‐Drive/Armmovementselectionswitch‐ Directiona Ifdriveselectionswitchisactivatedfromplatformcontrolbox,inputmustbeON(+VBAT).Ifnot: ‐checkswitchfunction ‐checkswitchsupplyfuse(FU3‐10A) ‐checkswitchsupply(wire109=+VBAT) ‐checkinputwirecontinuity CANTiller‐Platform ct_IN11 B.12 76(pin1) Digitalinput(HS) SA908b‐Drive/Armmovementselectionswitch‐ Directionb Ifarm isselectedusingarmselectionswitchfromplatformcontrolbox,inputmustbeON(+VBAT).Ifnot: ‐checkswitchfunction ‐checkswitchsupplyfuse(FU3‐10A) ‐checkswitchsupply(wire109=+VBAT) ‐checkinputwirecontinuity CANTiller‐Platform ct_IN12 B.13 85(pin3) Digitalinput(HS) SWITCH1‐ArmUp IfActiv'Screenarm upswitchisactivated,inputmustbeON.Ifnot: ‐checkActiv'Screensupplyfuse(FU3‐10A) ‐checkActiv'Screensupply(wires0=0Vand02=+VBAT) Screen1‐Turret IN_1 Internal / Digitalinput SWITCH2‐ArmDown IfActiv'Screenarmdownswitchisactivated,inputmustbeON.Ifnot: ‐checkActiv'Screensupplyfuse(FU3‐10A) ‐checkActiv'Screensupply(wires0=0Vand02=+VBAT) Screen1‐Turret IN_2 Internal / Digitalinput SWITCH3‐Enableswitch IfActiv'Screenenableswitch isactivated,inputmustbeON.Ifnot: ‐checkActiv'Screensupplyfuse(Fu3‐10A) ‐checkActiv'Screensupply(wires0=0Vand02=+VBAT) Screen1‐Turret IN_3 Internal / LogicInput SWITCH5‐NavigationUp IfActiv'Screennavigationupswitch isactivated,inputmustbeON.Ifnot: ‐checkActiv'Screensupplyfuse(FU3‐10A) ‐checkActiv'Screensupply(wires0=0Vand02=+VBAT) Screen1‐Turret IN_UP Internal / LogicInput SWITCH6‐NavigationDown IfActiv'Screennavigationdownswitch isactivated,inputmustbeON.Ifnot: ‐checkActiv'Screensupplyfuse(FU3‐10A) ‐checkActiv'Screensupply(wires0=0Vand02=+VBAT) Screen1‐Turret IN_DOWN Internal / LogicInput SWITCH7‐NavigationConfirm IfActiv'Screennavigationconfirmswitch isactivated,inputmustbeON.Ifnot: ‐checkActiv'Screensupplyfuse(FU3‐10A) ‐checkActiv'Screensupply(wires0=0Vand02=+VBAT) Screen1‐Turret IN_OK Internal / LogicInput SWITCH8‐NavigationCancel IfActiv'Screennavigationcancel switchisactivated,inputmustbeON.Ifnot: ‐checkActiv'Screensupplyfuse(FU3‐10A) ‐checkActiv'Screensupply(wires0=0Vand02=+VBAT) Screen1‐Turret IN_BACK Internal / LogicInput [DIGITAL_OUTPUTS] KAH‐Supplyholdingrelay Ifmachineispoweredonwithkeyandnoemergencystopispressed,outputmustbeON(0V).Ifnot: ‐checksupplyfuses(FU3‐10A) ‐checkkeypositionselector(SA901) ‐checkoutputwirecontinuity CombiACX‐Frame m_O3 B.7 115 LogicOutput1.5A (LS)12APeak YV121‐Potholeretraction/steering rightvalve Ifsteeringrightorpotholesretractfunctionisrequested,outputmustbeON(0V).Ifnot,checkFunctionDiagnostic.Ifstatusis notOK: ‐checkvalvepowersupplyfuse(FU2‐10A) ‐checkvalvepowersupply(103=+VBAT) CombiACX‐Frame m_O0 A.1 54 Digitaloutput1.5A (LS) Type: Name Diagnosticinstructions: ECU: [Ref] [Pin] [Wire] Type:2 ANNEX5C YV122‐Potholeextension/steeringleftvalve Ifsteeringleftorpotholesextendfunctionisrequested,outputmustbeON(0V).Ifnot,checkFunctionDiagnostic.Ifstatusis notOK: ‐checkvalvepowersupplyfuse(FU2‐10A) ‐checkvalvepowersupply(103=+VBAT) CombiACX‐Frame m_O1 A.8 53 Digitaloutput1.5A (LS) HA901‐Buzzer(turret) Ifturretcontrolboxbuzzerfunctionisrequested outputmustbeON(0V).Ifnot,checkFunctionDiagnostic.IfstatusisnotOK: ‐checkpowersupplyfuse(FU2‐10A) ‐checkpowersupply(103=+VBAT) ‐checkoutputwirecontinuity CombiACX‐Frame m_O4 A.9 04 LogicOutput35mA (LS) KA1‐Hornrelay Ifhornfunctionis requested,outputmustbeON(0V).Ifnot,checkFunctionDiagnostic.IfstatusisnotOK: ‐checkrelay ‐checkpowersupplyfuse(FU2‐10A) ‐checkpowersupply(103=+VBAT) ‐checkoutputwirecontinuity ACEX‐Frame s_O3 B.7 70 LogicOutput1.5A (LS)12APeak YV903‐Pumpunloadingvalve Ifarm raise,potholesorsteeringmovementisrequested,outputmustbeON(0V).Ifnot,checkDiagnostic/Function.Ifstatus isnotOK: ‐checkpowersupplyfuse(FU2‐10A) ‐checkpowersupply(wire103=+VBAT) ACEX‐Frame s_O2 A.2 55 Digitaloutput1.5A (LS) KA2‐Flashinglightrelay Ifflashinglight functionisrequested,outputmustbeON(+VBAT).Ifnotcheckfunctiondiagnostic.IfstatusisnotOK: ‐checkpowersupplyfuse(103) ‐checkpowersupply(FU2‐10A=+VBAT) ‐checkoutputwirecontinuity ‐checkrelay ‐checkflashinglight ACEX‐Frame s_O6 B.6 31 Digitaloutput1.5A (LS) HL420‐Lightliftingmode Iflampisnotactive atpowerONorifstatusisnotOK: ‐checkLEDPCB ‐checkLEDsupplyfuse(Fu3‐10A) ‐checkLEDsupply(wire109=+VBAT) ‐checkoutputwirecontinuity CANTiller‐Platform ct_LED1 E.6 46 LogicOutput18mA (LS) HL100‐LightDriveselection Iflampisnotactive atpowerONorifstatusisnotOK: ‐checkLEDPCB ‐checkLEDsupplyfuse(FU3‐10A) ‐checkLEDsupply(wire109=+VBAT) ‐checkoutputwirecontinuity CANTiller‐Platform ct_LED2 E.7 94 LogicOutput18mA (LS) HL802‐Lightoverload‐platform Iflampisnotactive atpowerONorifstatusisnotOK: ‐checkLEDPCB ‐checkLEDsupplyfuse(FU3‐10A) ‐checkLEDsupply(wire109=+VBAT) ‐checkoutputwirecontinuity CANTiller‐Platform ct_LED4 F.1 44 LogicOutput18mA (LS) HL904‐LightLowBattery Iflampisnot activeatpowerONorifstatusisnotOK: ‐checkLEDPCB ‐checkLEDsupplyfuse(FU3‐10A) ‐checkLEDsupply(wire109=+VBAT) ‐checkoutputwirecontinuity CANTiller‐Platform ct_LED5 F.2 42 LogicOutput18mA (LS) HL800‐Lighttilt Iflampisnotactive atpowerONorifstatusisnotOK: ‐checkLEDPCB ‐checkLEDsupplyfuse(FU3‐10A) ‐checkLEDsupply(wire109=+VBAT) ‐checkoutputwirecontinuity CANTiller‐Platform ct_LED6 F.3 45 LogicOutput18mA (LS) HL903‐LightImpactingMachineBehaviourFailure(s) Iflampis notactiveatpowerONorifstatusisnotOK: ‐checkLEDPCB ‐checkLEDsupplyfuse(FU3‐10A) ‐checkLEDsupply(wire109=+VBAT) ‐checkoutputwirecontinuity CANTiller‐Platform ct_LED8 F.5 43 LogicOutput18mA (LS) Type: Name Diagnosticinstructions: ECU: [Ref] [Pin] [Wire] Type:2 ANNEX5D ANALOGINPUTS SR420‐Armanglesensor Armangleinputvoltagevalue: ‐mustincreasewhenarmisbeingraised ‐mustbearound1.0Vwhenarmisat0° ‐mustbearound4.0Vwhenboomisat57° Ifnot: ‐checksensormounting(ref.instructions) ‐checksensorsupplyfuse(FU3‐10A) ‐checksensorsupply(wires0=0Vand109=+VBAT) ‐checkinputwirecontinuit y CombiACX‐Frame m_AN1 C.4 13 Analoginput0‐10V SR420‐Armanglesensor Armangleinputvoltagevalue: ‐mustincreasewhenarmisbeingraised ‐ mustbearound1.0Vwhenarmisat0° ‐mustbearound4.0Vwhenboomisat57° Ifnot: ‐checksensormounting(ref.instructions) ‐checksensorsupplyfuse(FU3‐10A) ‐checksensorsupply(wires0=0Vand109=+VBAT) ‐checkinputwirecontinuit y CombiACX‐Frame m_AN1 C.4 13 Analoginput0‐10V SP400‐Armpressureloaddetector Overloadpressuresensorinputmustbe between[0;12]V,Ifnot: ‐checksensormounting(ref.instructions) ‐checkpowersupplyfuse(FU3‐10A) ‐checksensorsupply(wires0=0Vand109=+VBAT) ‐checkinputwirecontinuit y CombiACX‐Frame m_AN2 C.9 14(CN01.3) Analoginput0‐10V MOT_D_I‐Rightenginecurrent ECUCombiACXinternalsensor. CombiACX‐Frame I_mot_m Internal Internal motorcurrent SV300‐Motorspeedsensor1 Ifdriveforwardisongoing,valuemustbegreaterthan0Hz . Ifdrivereverse isongoing,value mustbelowerthan0Hz. Ifnomovementisongoing,valuemustbeequalto0Hz. CombiACX‐Frame V_mot_m D.1/4 63‐64 motorspeed ST302‐Motortemperaturesensor1 Motor1(M370)temperaturesensor.Temperaturemustbeclosetoambienttemperaturewhenmachinehasjustbeen CombiACX‐Frame T_mot_m D.3 26‐27 motortemperature ECU_TEMP‐ECUinternaltemperature ECUCombiACXinternalsensor.Temperaturemustbeclosetoambienttemperaturewhenmachinehasjustbeenstarted. CombiACX‐Frame T_var_m Internal Internal ECUtemperature(in PUMP_I‐Pumpcurrent CombiACXinternalvariablegivinghydraulicpumpcurrentconsumption . Variable mustbe equalto0mAwhennomovementisongoing. Variablemustbegreaterthan0mAwhenarmraise,steeringorpotholesmovementisongoing. CombiACX‐Frame I_Pump Internal Internal Pumpcurrent SR722‐Overloadanglesensor Platformpositioninputvoltagevalue: ‐mustdecreasewhenarm isbeingraised ‐mustbearound4.0Vwhenarmisat0° ‐mustbearound1.0Vwhenboomisat57° Ifnot: ‐checksensormounting(ref.instructions) ‐checksensorsupplyfuse(FU3‐10A) ‐checksensorsupply(wires0=0Vand109=+VBAT) ‐checkinputwirecontinuit y ACEX‐Frame s_AN2 C.9 20 Analoginput0‐ 10V SR722‐Overloadanglesensor Platformpositioninputvoltagevalue: ‐mustdecreasewhenarm isbeingraised ‐mustbearound4.0Vwhenarmisat0° ‐mustbearound1.0Vwhenboomisat57° Ifnot: ‐checksensormounting(ref.instructions) ‐checksensorsupplyfuse(FU3‐10A) ‐checksensorsupply(wires0=0Vand109=+VBAT) ‐checkinputwirecontinuit y ACEX‐Frame s_AN2 C.9 20 Analoginput0‐ 10V SR150‐Frontwheelsanglesensor Steeringanglesensorinputmustbebetween[0;12]Vandincreasewhen wheelsareturnedontheright.Ifnot: ‐checksensormounting(ref.instructions) ‐ checksensorsupply(wires49=0Vand48=+12V) ‐checkinputwirecontinuity ACEX‐Frame s_AN1 C.4 47 Analoginput0‐ 10V MOT_G_I‐Leftenginecurrent ECUACEXinternalsensor. ACEX‐Frame I_mot_s Internal Internal motorcurrent SV301‐Motorspeedsensor2 Ifdriveforwardisongoing,valuemustbegreaterthan0Hz . Ifdrivereverse isongoing,value mustbelowerthan0Hz. Ifnomovementisongoing,valuemustbeequalto0Hz. ACEX‐Frame V_mot_s D.1/4 67‐68 motorspeed ECU_TEMP‐ECUinternaltemperature ECUACEXinternalsensor.Temperaturemustbeclosetoambienttemperaturewhenmachinehasjustbeenstarted. ACEX‐Frame T_var_s Internal Internal ECUtemperature(in ST303‐Motor temperaturesensor2 Motor2(M371)temperaturesensor.Temperaturemustbeclosetoambienttemperaturewhenmachinehasjustbeen ACEX‐Frame T_mot_s D.3 71‐72 motortemperature Type: Name Diagnosticinstructions: ECU: [Ref] [Pin] [Wire] Type:2 ANNEX5E SM901‐Drive/Armjoystick IfdrivejoystickisOK,inputisvariablebetween[0.5;4.5]V.Ifnot: ‐checkjoystickfunction ‐checkjoystick5Vsupply(wires0=0Vand51=+5V) ‐checkjoystickcenterposition(approx.2.5V) ‐checkinputwirecontinuity CANTiller‐Platform ct_AN5 A.10 39 Analogueinput0‐5V AU_INFO‐Emergencystop(plateform)status Ifmachineispoweredandemergencystopsarenotpushed,inputmustbeequalto+VBAT.Ifnot: ‐checkinputsupplyfuse(FU3‐10A) ‐checkinputsupply(wire109) ‐checkinputdiode(D2) ‐checkinputwirecontinuity Screen1‐Turret AN_4 X2.3 109 Analoginput[0‐32V] ANALOGOUTPUTS YV120‐Potholes/steeringselection valve Ifpotholesmovementisrequested,outputmustbeON(0V).Ifnot: ‐checkvalvefunction ‐checkvalvesupplyfuse(FU2(10A)) ‐checkvalvesupply(wire103=+VBAT) ‐checkoutputwirecontinuity CombiACX‐Frame m_PWM B.3 56 PWMoutput YV420‐Armvalve Ifarmraisefunctionisrequested, outputmustaround1000mA. Ifarmdescentfunctionisrequested,outputmustincreasewitharmjoystickangleinrange[400‐1000]mA.Ifnot,check Diagnostic/Function.IfstatusisnotOK: ‐checkvalve ‐checkpowersupplyfuse(FU3‐10A) ‐checkpowersupply(109=+VBAT) ACEX‐Frame s_PWM B.3 19 PWMoutput Category Name Item Values Unit Description&References INTERNAL Powerpartstate Init Wait Alarm Alarm1 Alarm2 Alarm3 Powercontactorclosing Powercontactortest Electrovalve Ready Movement Movementselection None Drive/Steering Arm Dynamiccalibrationindex Staticcalibrationindex Movementselectionsetpoint None Drive/Steering [REF_IO]SA908a‐Drive/Armmovementselectionswitch‐Directiona Arm [REF_IO]SA908b‐Drive/Armmovementselectionswitch‐Directionb Movementselectioncontrol None Drive/Steering [REF_IO]SA908a‐Drive/Armmovementselectionswitch‐Directiona Arm [REF_IO]SA908b‐Drive/Armmovementselectionswitch‐Directionb ArmangleSR420 ° ArmangleSR722 ° Dynamicoverloadangle0 deg Dynamicoverloadpressure0 bar Dynamicoverloadangle1 deg Dynamicoverloadpressure1 bar Dynamicoverloadangle2 deg Dynamicoverloadpressure2 bar Dynamicoverloadangle3 deg Dynamicoverloadpressure3 bar Dynamicoverloadangle4 deg Dynamicoverloadpressure4 bar Dynamicoverloadangle5 deg Dynamicoverloadpressure5 bar Dynamicoverloadangle6 deg Dynamicoverloadpressure6 bar Dynamicoverloadangle7 deg Dynamicoverloadpressure7 bar Dynamicoverloadangle8 deg Dynamicoverloadpressure8 bar Dynamicoverloadangle9 deg Dynamicoverloadpressure9 bar Dynamicoverloadangle10 deg Dynamicoverloadpressure10 bar Dynamicoverloadangle11 deg Dynamicoverloadpressure11 bar Dynamicoverloadangle12 deg Dynamicoverloadpressure12 bar Dynamicoverloadangle13 deg Dynamicoverloadpressure13 bar Dynamicoverloadangle14 deg Dynamicoverloadpressure14 bar Dynamicoverloadangle15 deg ANNEX6A Category Name Item Values Unit Description&References ANNEX6B Dynamicoverloadpressure15 bar Dynamicoverloadangle16 deg Dynamicoverloadpressure16 bar Dynamicoverloadangle17 deg Dynamicoverloadpressure17 bar Dynamicoverloadangle18 deg Dynamicoverloadpressure18 bar Dynamicoverloadangle19 deg Dynamicoverloadpressure19 bar Staticoverloadangle0 deg Staticoverloadpressure0 bar Staticoverloadangle1 deg Staticoverloadpressure1 bar Staticoverloadangle2 deg Staticoverloadpressure2 bar Staticoverloadangle3 deg Staticoverloadpressure3 bar Staticoverloadangle4 deg Staticoverloadpressure4 bar Staticoverloadangle5 deg Staticoverloadpressure5 bar Staticoverloadangle6 deg Staticoverloadpressure6 bar Staticoverloadangle7 deg Staticoverloadpressure7 bar Staticoverloadangle8 deg Staticoverloadpressure8 bar Staticoverloadangle9 deg Staticoverloadpressure9 bar Staticoverloadangle10 deg Staticoverloadpressure10 bar Staticoverloadangle11 deg Staticoverloadpressure11 bar Staticoverloadangle12 deg Staticoverloadpressure12 bar Staticoverloadangle13 deg Staticoverloadpressure13 bar Staticoverloadangle14 deg Staticoverloadpressure14 bar Staticoverloadangle15 deg Staticoverloadpressure15 bar Staticoverloadangle16 deg Staticoverloadpressure16 bar Staticoverloadangle17 deg Staticoverloadpressure17 bar Staticoverloadangle18 deg Staticoverloadpressure18 bar Staticoverloadangle19 deg Staticoverloadpressure19 bar ArmCalibrationMinimumAngleSR420 pts ArmCalibrationMaximumAngleSR420 pts ArmCalibrationMinimumAngleSR722 pts ArmCalibrationMaximumAngleSR722 pts MaximumvalueofYV420electrovalvecontrolduring decompression % Category Name Item Values Unit Description&References ANNEX6C MinimumvalueofYV420electrovalvecontrolduring decompression % Machineunfolded ° Arminhighposition ° Overload OverloadAlarm Overloadalarmisactivatedifestimatedloadintotheplatformisgreaterthan230kgformore than0.8s.Itisthendeactivatedifestimatedloadintotheplatformislowerthan230kgformore OverloadCalibration Notdone Done [REF_FAIL]F06.01‐LoadManagementSystemnotcalibrated ArmAngle deg [REF_IO_MAIN]SR420‐Armanglesensor [REF_IO_MAIN]SR722 ‐Overloadanglesensor [REF_VARIABLE]ArmangleSR420 [REF_VARIABLE]ArmangleSR722 Pressure bar [REF_IO_MAIN]SP400‐Armpressureloaddetector Referencepressure b [REF_VARIABLE]ArmAngle Machine Activecontrolbox None Chassis [REF_IO]SA901TU‐Controlboxselector‐Turret Platform [REF_IO]SA901PF‐Controlboxselector‐Platform Chassiscontrolbox Inactive Active [REF_IO]SA907TU‐Hornswitch‐Turret [REF_IO]SA103‐Brakereleaseswitch [REF_IO]SWITCH3‐Enableswitch [REF_IO]SWITCH1‐ArmUp [REF_IO]SWITCH2‐ArmDown [REF_VARIABLE]Turretenableswitchstate Platformcontrolbox Inactive Active [REF_IO]SA901PF‐Controlboxselector‐Platform [REF_IO]SA907‐Hornswitch [REF_IO]SM901‐Drive/Armjoystick [REF_IO]SM901N‐Drive/Armjoystick‐OutofNeutral [REF_IO]SM901L‐Joysticksteeringrocker‐Left [REF_IO]SM901R‐Joysticksteeringrocker‐Right [REF_IO]SM901EN‐Enableswitch‐Enable [REF_VARIABLE]Platformenablepedalstate Machineunfolded Machineisconsideredasunfoldedif: ‐Armangleisnotcalibrated ‐orArmangleanalogsensorsareoutofrange ‐orArmanglevaluesareincoherent ‐orArmangleiscalibratedandarmanglevalueisabove10.2° [REF_VARIABLE]ArmAngle [REF_FAIL]F07.06‐ArmAnglesensor [REF_FAIL]F10.16‐Armanglecalibration Tilt [REF_IO]SQ800‐Tiltsensor Hourmeter h Platformenablepedalstate Inactive Activebutnotvalid(%s) Activeandvalid Turretenableswitchstate Inactive Activebutnotvalid(%s) Activeandvalid Batteryvoltage mV Batterylevel % Category Name Item Values Unit Description&References ANNEX6D Unbrakingenabled Useridentified Notidentified Identified Useridentification ECU MaxnumberofEEPROMqueries(R/W)intothestack CurrentnumberofEEPROMqueries(R/W)intothestack CurrentEEPROMstatus READY BUSY NumberofEEPROMstackerrors NumberofEEPROMstatuserrors Numberofinitializationtries Executiontimeof4mstask ms Executiontimeof8mstask ms Executiontimeof32mstask ms Executiontimeof128mstask ms Executiontimeof1000mstask ms CombiACXZapifailureCode ACEXZapifailureCode CANTillersoftwareversion Parametersfailureidentification Wrongconstantparametersfailureidentifier Parameterdefaultvaluefailureidenfier Currentvalueversusinitializedvaluefailureidentifier Master/slaveincoherencefailureidentifier Drive Drivemovementsetpoint Value % Internalsetpointsecuredcomingfromactivecontrolboxandformattedfrom0to100%fora givendirection Direction Neutral [REF_VARIABLE]Movementselection Forward [REF_VARIABLE]Platformcontrolbox Reverse [REF_IO]SM901‐Drive/Armjoystick Status OK [REF_IO]SM901N‐Drive/Armjoystick‐ OutofNeutral Functionnotactive [REF_IO]SM901EN‐Enableswitch‐Enable Neutralnotdetected afterpowerON Joystick/switchfailure Neutralnotdetected afterenginestart Joystick/switchmustbe released Enableswitch/pedalnot valid Drivemovementslowdown Value % Percentageoftheinternalsetpointreallyappliedfrom0(nomovement)to 100%(no slowdown) Number [REF_VARIABLE]Machineunfolded Driveforwardcuttings Cuttingnumber1 Acuttingnumbernonzero,meansthatthemovementinthisdirectionisprohibitedbythe cuttingconditionsoftheoperatinglogic: ‐0.00:nocutting ‐0.01to0.32:Enablecuttings ‐1.01to1.32:Generalcuttings ‐2.01to2.32:SimultaneousMovementcuttings ‐3.01to3.32:Overloadcuttings ‐4.01to4.32:Tiltcuttings ‐5.01to5.32:ReachLimitcuttings ‐6.01to6.32:Failurecuttings ‐7.01to7.32:Specificcuttings Category Name Item Values Unit Description&References ANNEX6E Cuttingnumber2 [REF_VARIABLE]Machineunfolded Cuttingnumber3 [REF_VARIABLE]Tilt [REF_VARIABLE]OverloadAlarm [REF_VARIABLE]OverloadCalibration Drivereversecuttings Cuttingnumber1 A cuttingnumbernonzero,meansthatthemovementinthisdirectionisprohibitedbythe cuttingconditionsoftheoperatinglogic: ‐0.00:nocutting ‐0.01to0.32:Enablecuttings ‐1.01to1.32:Generalcuttings ‐2.01to2.32:SimultaneousMovementcuttings ‐3.01to3.32:Overloadcuttings ‐4.01to4.32:Tiltcuttings ‐5.01to5.32:ReachLimitcuttings ‐6.01to6.32:Failurecuttings ‐7.01to7.32:Specificcuttings Cuttingnumber2 [REF_VARIABLE]Machineunfolded Cuttingnumber3 [REF_VARIABLE]Tilt [REF_VARIABLE]OverloadAlarm [REF_VARIABLE]OverloadCalibration Drive movementcontrol Value % Internalcontrolgeneratedfromtheinternalsetpoint(ifnocuttings)andformattedfrom0%to 100%foragivendirection,usingrampsandmin/maxspeeds. Thecontrolissenttotheactuatorsofthemachine Direction Neutral [REF_IO]MOT_G_I‐Leftenginecurrent Forward [REF_IO]SV300‐Motorspeedsensor 1 Reverse [REF_IO]ST302‐Motortemperaturesensor1 [REF_IO]MOT_D_I‐Rightenginecurrent [REF_IO]SV301‐Motorspeedsensor2 [REF_IO]ST303‐Motortemperaturesensor2 [REF_VARIABLE]Movementselectionsetpoint [REF_VARIABLE]Movementselectioncontrol Drivespeed Micro High [REF_VARIABLE]Movementselectionsetpoint [REF_VARIABLE]Movementselectioncontrol Speedreduction Rightmotorreduction % Leftmotor reduction Brakereleasecontrol(drive) Brakesopened OFF/ON Type Automaticcontrol [REF_VARIABLE]Drivemovementcontrol Automaticcontrolbut possibletoforcebrakes closure Manualcontrol Rightmotorspeedsetpoint Requestedspeed Realspeed [REF_IO]MOT_D_I‐Rightenginecurrent [REF_IO_MAIN]SV300‐Motorspeedsensor1 Leftmotorspeedsetpoint Requestedspeed Realspeed [REF_IO]MOT_G_I‐Leftenginecurrent [REF_IO]SV301‐Motorspeedsensor2 Steering Steeringmovementsetpoint Value % Internalsetpointsecuredcomingfromactivecontrolboxandformattedfrom0to100%fora givendirection Direction Neutral [REF_VARIABLE]Movementselection Left [REF_VARIABLE]Platformcontrolbox Right [REF_IO]SA102‐Driveselectionswitch Status OK [REF_IO]SM901L‐Joysticksteeringrocker‐Left Functionnotactive [REF_IO]SM901R‐Joysticksteeringrocker‐Right Category Name Item Values Unit Description&References ANNEX6F Neutralnotdetected afterpowerON Joystick/switchfailure Neutralnotdetected afterenginestart Joystick/switchmustbe released Enableswitch/pedalnot valid Steeringmovementslowdown Value % Percentageoftheinternalsetpointreallyappliedfrom0(nomovement)to100%(no slowdown) Number Steeringleftcuttings Cuttingnumber1 Acuttingnumbernonzero,meansthatthemovementinthisdirectionisprohibitedbythe cuttingconditionsoftheoperatinglogic: ‐0.00:nocutting ‐0.01to0.32:Enablecuttings ‐1.01to1.32:Generalcuttings ‐2.01to2.32:SimultaneousMovementcuttings ‐3.01to3.32:Overloadcuttings ‐4.01to4.32:Tiltcuttings ‐5.01to5.32:ReachLimitcuttings ‐6.01to6.32:Failurecuttings ‐7.01to7.32:Specificcuttings Cuttingnumber2 [REF_VARIABLE]Powerpartstate Cuttingnumber3 [REF_VARIABLE]Machineunfolded [REF_VARIABLE]OverloadCalibration [REF_VARIABLE] OverloadAlarm Steeringrightcuttings Cuttingnumber1 Acuttingnumbernonzero,meansthatthemovementinthisdirectionisprohibitedbythe cuttingconditionsoftheoperatinglogic: ‐0.00:nocutting ‐0.01to0.32:Enablecuttings ‐1.01to1.32:Generalcuttings ‐2.01to2.32:SimultaneousMovementcuttings ‐3.01to3.32:Overloadcuttings ‐4.01to4.32:Tiltcuttings ‐5.01to5.32:ReachLimitcuttings ‐6.01to6.32:Failurecuttings ‐7.01to7.32:Specificcuttings Cuttingnumber2 [REF_VARIABLE]Powerpartstate Cuttingnumber3 [REF_VARIABLE]Machineunfolded [REF_VARIABLE]OverloadCalibration [REF_VARIABLE]OverloadAlarm [REF_IO]SR150‐Frontwheelsanglesensor Steeringmovementcontrol Value % Internalcontrolgeneratedfromtheinternalsetpoint(ifnocuttings)andformattedfrom0%to 100%foragivendirection,usingrampsandmin/maxspeeds. Thecontrolissenttotheactuatorsofthemachine Direction Neutral [REF_IO]YV150L‐Steeringfrontleftvalve Left [REF_IO]YV150R‐Steeringfrontright valve Right [REF_IO]SR150‐Frontwheelsanglesensor Wheelssteeringangle ° [REF_IO]SR150‐Frontwheelsanglesensor Steeringleftlimit Steeringrightlimit Category Name Item Values Unit Description&References ANNEX6G Steeringanglecalibrationperformed Potholes Potholesmovementsetpoint Value % Direction Neutral Extend Retract Status OK Functionnotactive Neutralnotdetected afterpowerON Joystick/switchfailure Neutralnotdetected afterenginestart Joystick/switchmustbe released Enableswitch/pedalnot valid Potholesoutcuttings Cutting number1 Acuttingnumbernonzero,meansthatthemovementinthisdirectionisprohibitedbythe cuttingconditionsoftheoperatinglogic: ‐0.00:nocutting ‐0.01to0.32:Enablecuttings ‐1.01to1.32:Generalcuttings ‐2.01to2.32:SimultaneousMovementcuttings ‐3.01to3.32:Overloadcuttings ‐4.01to4.32:Tiltcuttings ‐5.01to5.32:ReachLimitcuttings ‐6.01to6.32:Failurecuttings ‐7.01to7.32:Specificcuttings Cuttingnumber2 Cuttingnumber3 Potholesincuttings Cuttingnumber1 Acuttingnumbernonzero,meansthatthemovementinthisdirectionisprohibitedbythe cuttingconditionsoftheoperatinglogic: ‐0.00:nocutting ‐0.01to0.32:Enablecuttings ‐1.01to1.32:Generalcuttings ‐2.01to2.32:SimultaneousMovementcuttings ‐3.01to3.32:Overloadcuttings ‐4.01to4.32:Tiltcuttings ‐5.01to5.32:ReachLimitcuttings ‐6.01to6.32:Failurecuttings ‐7.01to7.32:Specificcuttings Cuttingnumber2 Cuttingnumber3 Potholesmovementcontrol Value % Direction Neutral Extend Retract Arm Arm movement setpoint Value % Internalsetpointsecuredcomingfromactivecontrolboxandformattedfrom0to100%fora givendirection Direction Neutral [REF_VARIABLE]Chassiscontrolbox Raise [REF_VARIABLE]Platformcontrolbox Descent [REF_VARIABLE]Movementselection Status OK Functionnotactive Category Name Item Values Unit Description&References ANNEX6H Neutralnotdetected afterpowerON Joystick/switchfailure Neutralnotdetected afterenginestart Joystick/switchmustbe released Enableswitch/pedalnot valid Armmovementslowdown Value % Percentageoftheinternalsetpointreallyappliedfrom0(nomovement)to100%(no slowdown) Number [REF_VARIABLE]Chassiscontrolbox [REF_VARIABLE]Platformcontrolbox [REF_VARIABLE]Tilt [REF_VARIABLE]Machineunfolded [REF_VARIABLE]OverloadCalibration Armraisecuttings Cuttingnumber1 Acuttingnumbernonzero,meansthatthemovementinthisdirectionisprohibitedbythe cuttingconditionsoftheoperatinglogic: ‐0.00:nocutting ‐0.01to0.32:Enablecuttings ‐1.01to1.32:Generalcuttings ‐2.01to2.32:SimultaneousMovementcuttings ‐3.01to3.32:Overloadcuttings ‐4.01to4.32:Tiltcuttings ‐5.01to5.32:ReachLimitcuttings ‐6.01to6.32:Failurecuttings ‐7.01to7.32:Specificcuttings Cuttingnumber2 [REF_VARIABLE]Powerpartstate Cuttingnumber3 [REF_VARIABLE]OverloadCalibration [REF_VARIABLE]OverloadAlarm [REF_VARIABLE] Machineunfolded [REF_VARIABLE]Tilt [REF_IO]SQ534‐Mastextendeddetector Armdescentcuttings Cuttingnumber1 Acuttingnumbernonzero,meansthatthemovementinthisdirectionisprohibitedbythe cuttingconditionsoftheoperatinglogic: ‐0.00:nocutting ‐0.01to0.32:Enablecuttings ‐1.01to1.32:Generalcuttings ‐2.01to2.32:SimultaneousMovementcuttings ‐3.01to3.32:Overloadcuttings ‐4.01to4.32:Tiltcuttings ‐5.01to5.32:ReachLimitcuttings ‐6.01to6.32:Failurecuttings ‐7.01to7.32:Specificcuttings Cuttingnumber2 [REF_VARIABLE]OverloadCalibration Cuttingnumber3 [REF_VARIABLE]OverloadAlarm [REF_VARIABLE]Machineunfolded Armmovementcontrol Value % Internalcontrolgeneratedfromtheinternalsetpoint(ifnocuttings)andformattedfrom0%to 100%foragivendirection,usingrampsandmin/maxspeeds. Thecontrolissenttotheactuatorsofthemachine Direction Neutral [REF_IO]YV420‐Armvalve Raise [REF_IO]YV903‐Pumpunloadingvalve Descent [REF_IO]PUMP_I‐Pump current ELECTRIC SCHEMATIC- 1/3 24VDC 24 ELECTRIC SCHEMATIC- 2/3 RR RL ELECTRIC SCHEMATIC- 3/3 HYDRAULICHYDRAULIC‐‐ STEERINGSTEERING Discharge valveYV903=1 + Right steering YV121=1 Or Left steering YV122= 1 HYDRAULICHYDRAULIC‐‐ POTHOLEPOTHOLE Discharge valveYV903=1 + Pothole descent YV121=1 Or Pothole retract YV122=1 + Pthl / t lti YV120 1 P o th o l e / s t eer se l ec ti on YV120 = 1 HYDRAULICHYDRAULIC‐‐ LIFTINGLIFTING Discharge valveYV903=1 Raise/lower valveYV420=1 HYDRAULICHYDRAULIC‐‐ LOWERINGLOWERING Raise/lower valveYV420=1 4000361790.C 4000311260.F OPTIMUM 8 AC 01 4000361790.C 4000311260.F OPTIMUM 8 AC 02 4000361790.C 4000311260.F OPTIMUM 8 AC 03 4000361790.C 4000311260.F OPTIMUM 8 AC 04 4000349350.B Réservoir Tank M Direction Steering Ø40 Course 114 1/4’’ 1/4’’ 3/8’’ 1a 1b 4 M 1/4’’ 1/4’’ 1/4’’ YV121 180 bar 1,7b RV2 whithout pressure control USA version entrée Pression vérin Cylinder pressure input plug 1/4’’ 3/8’’ YV420 Ø1.2 5 Ø 1 . 2 3 / 8 ’ ’ P Y V 4 2 0 5 7 Capteur de pression Pressure sensor V é ri n d e l e v a g e L i f t i n g c y l i n d e r 1c 3/8’’ YV903 ’’4/1’’4/1 Potholes 1/4’’ 1/4’’ 1/4’’1/4’’ 1d 1 A B YV122 2 3 6 6 U YV120 : EV selecon potholes/dir YV121 : potholes up/dir droite YV122 : potholes down/dir gauche YV120 Ø0,8 24VDC / 2,2kW / 3,5cc/tr 4000246640.F 4000311490.E 4000313340.F 4000313380.B 4000313540.B 4000313760.D 4000421360.B 4000530650.B 100 4000595920 E 05.17 USA / GB G - Version summary OPTIMUM 8 - OPTIMUM 1931 E Notes
Operator's manual OPTIMUM 8 - OPTIMUM 1931 E 4000415480 E 01.18 USA / GB Operator's manual OPTIMUM 8 - OPTIMUM 1931 E OPTIMUM 8 - OPTIMUM 1931 E USA 2 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E 3 CONTENTS Operator's manual CONTENTS A FOREWORD 1 - User responsibility . . . . . . . . . . . . . . . . . . . . . . . 8 1.1 - Owner's responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.2 - Employer's responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.3 - Trainer's responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.4 - Operator's responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2 - Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.1 - Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.1.1 - Misuse Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.1.2 - Falling Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.1.3 - Overturning / Tip-over Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.1.4 - Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2.1.5 - Explosion / Fire Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2.1.6 - Crushing / Collision Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2.1.7 - Uncontrolled movement Hazards . . . . . . . . . . . . . . . . . . . . . . . . 18 3 - Safety inquiries. . . . . . . . . . . . . . . . . . . . . . . . . 18 4 - Incident notification . . . . . . . . . . . . . . . . . . . . . 19 5 - Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 5.1 - Product information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 5.1.1 - Change of Ownership Notification . . . . . . . . . . . . . . . . . . . . . . . 20 5.1.2 - Owner information update form . . . . . . . . . . . . . . . . . . . . . . . . . 21 5.2 - Product specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 B FAMILIARIZATION 1 - General safety. . . . . . . . . . . . . . . . . . . . . . . . . . 23 1.1 - Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1.2 - Decal content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 1.3 - Symbols and colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1.4 - Level of severity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1.5 - Symbols legend and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 2 - Models description. . . . . . . . . . . . . . . . . . . . . . 27 3 - Primary machine components . . . . . . . . . . . . 28 3.1 - Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 3.2 - Maintenance support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 3.3 - Extension deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 3.4 - Ground control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 3.4.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 3.4.2 - HAULOTTE Activ'Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 3.4.2.1 - LCD screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 3.5 - Platform control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 3.5.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 4 - Performance Specifications . . . . . . . . . . . . . . 39 4.1 - Technical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 4.2 - Working area / Range of motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 5 - Decals and markings locations. . . . . . . . . . . . 43 4 Operator's manual C PRE-OPERATION INSPECTION 1 - Recommendations . . . . . . . . . . . . . . . . . . . . . . 55 2 - Working area assessment . . . . . . . . . . . . . . . . 56 3 - Inspection and Functional test . . . . . . . . . . . . 57 3.1 - Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 4 - Safety functional checks . . . . . . . . . . . . . . . . . 61 4.1 - E-Stop button check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 4.2 - Activation of controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 4.3 - Fault detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 4.3.1 - Buzzers test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 4.4 - Overload sensing system (if fitted). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 4.5 - Slope warning device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 4.6 - Travel speed limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 4.7 - Electronic variable speed drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 4.8 - Operating temperature (For EAC standard only) . . . . . . . . . . . . . . . . . 64 4.9 - Machine braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 4.10 - Wheel motor brake release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 4.11 - Pothole protection system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 4.12 - On-board charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 4.12.1 - Battery charge level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 4.13 - Anti-crush system when lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 D OPERATION INSTRUCTIONS 1 - Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 1.1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 1.2 - Operation from the ground control box. . . . . . . . . . . . . . . . . . . . . . . . . . . 68 1.3 - Operation from the platform control box. . . . . . . . . . . . . . . . . . . . . . . . . . 69 2 - Ground control box . . . . . . . . . . . . . . . . . . . . . 70 2.1 - To start and stop the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 2.2 - Movement control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 2.3 - Additional controls from the ground control box . . . . . . . . . . . . . . . . . . . 71 3 - Platform control box . . . . . . . . . . . . . . . . . . . . 72 3.1 - To start and stop the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 3.2 - Drive and steer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 3.3 - Movement control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 4 - Emergency procedure . . . . . . . . . . . . . . . . . . . 75 4.1 - In case of power loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 4.2 - To rescue operator in platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 5 CONTENTS Operator's manual 5 - Transportation . . . . . . . . . . . . . . . . . . . . . . . . . 76 5.1 - Putting in transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 5.2 - Machine layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 5.3 - Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 5.4 - Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 5.4.1 - Free wheel mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 5.5 - Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 5.6 - Loading by ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 5.7 - Unloading by ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 5.8 - Lifting operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 5.9 - Loading and unloading with forklift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 6 - Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 7 - Battery care and maintenance . . . . . . . . . . . . 85 7.1 - Battery charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 E GENERAL SPECIFICATIONS 1 - Machine dimensions . . . . . . . . . . . . . . . . . . . . 90 2 - Major component masses . . . . . . . . . . . . . . . . 92 3 - Acoustics and vibrations. . . . . . . . . . . . . . . . . 92 4 - Wheel/Tire assembly . . . . . . . . . . . . . . . . . . . . 93 4.1 - Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 4.2 - Inspection and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 4.2.1 - Procedure of replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 5 - Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 5.1 - Plumber's kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 5.1.1 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 5.1.2 - Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 5.1.3 - Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 5.1.4 - Pre-operation inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 5.1.5 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 5.1.6 - Disassembly - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 5.1.7 - Specific decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 5.2 - Folding guardrails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 5.2.1 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 5.2.2 - Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 5.2.3 - Fold down operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 5.2.4 - Specific decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 5.2.5 - Raising guardrails to working position . . . . . . . . . . . . . . . . . . . 104 5.3 - Panel carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 5.3.1 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 5.3.2 - Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 5.3.3 - Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 5.3.4 - Pre-operation inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 5.3.5 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 5.3.6 - Disassembly - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 5.3.7 - Specific decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 5.4 - Swing gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 5.4.1 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 5.4.2 - Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 5.4.3 - Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 5.4.4 - Pre-operation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 6 Operator's manual F MAINTENANCE 1 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 2 - Maintenance Schedule. . . . . . . . . . . . . . . . . . 114 3 - Inspection program . . . . . . . . . . . . . . . . . . . . 115 3.1 - General program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 3.2 - Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 3.3 - Periodic inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 3.4 - Reinforced inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 3.5 - Major inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 4 - Repairs and adjustments. . . . . . . . . . . . . . . . 117 G OTHER INFORMATION 1 - Warranty disclosure . . . . . . . . . . . . . . . . . . . . 119 1.1 - After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 1.2 - Manufacturer's warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 1.2.1 - Warranty acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 1.2.2 - Warranty period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 1.2.3 - Procedure conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 1.2.4 - Conditions of warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 2 - Subsidiary contact information. . . . . . . . . . . 122 2.1 - California warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 A B C D E F G H I 7 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E A - Foreword 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/ modifications 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. 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 : Comply with safety instructions. Use the equipment within the specified/published 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 operator's manual is specific to the HAULOTTE® products listed on the cover page of this manual. The operator's manual does not replace the basic training required for equipment operators. HAULOTTE® has compiled this manual to assist in safe and efficient operation of the products covered in the manual. The manual must be available to all operators and must be kept in a legible condition. Additional copies can be ordered from HAULOTTE Services®. Stay Safe and keep working with HAULOTTE® ! Original language and version : Manuals in English and French are the original instructions. Manuals in other languages are translations of the original instructions. 8 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E A - Foreword 1 - User responsibility 1.1 - OWNER'S RESPONSIBILITY The owner (or hirer) has the obligation : • To inform operators of the instructions contained in the Operator's Manual. • For applying the local regulations regarding operation of the machine. • To replace all manuals or decals that are either missing or not legible. Additional copies can be ordered from HAULOTTE Services®. • To establish a preventive maintenance program in accordance with the manufacturer's recommendations, taking into account the environment and severity of use of the machine. • To perform periodic inspections in accordance with HAULOTTE® recommendations and local regulations. All malfunctions and problems identified during the inspection shall be corrected before the aerial work platform is returned to service. 1.2 - EMPLOYER'S RESPONSIBILITY The employer has the obligation : • To authorize the operator to use the machine. • To inform and familiarize the operator with the local regulations. Forbid anyone from operating the machine if : • Under the influence of drugs, alcohol, etc. • Subject to fits, loss of motor skills, dizziness, etc. 1.3 - TRAINER'S RESPONSIBILITY The trainer must be qualified to provide training to operators in accordance with applicable local regulations. The training must be given in an obstacle-free area until the trainee is considered competent as defined by the training program undertaken. A B C D E F G H I 9 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E A - Foreword 1.4 - OPERATOR'S RESPONSIBILITY The operator has the obligation to : • Read and understand the contents of this manual and familiarize himself with the decals affixed on the machine. • To inspect the machine before use according to HAULOTTE®'s recommendations.. • To inform the owner (or hirer) if the manual or any decals are missing or are not legible. • To inform of any malfunctioning of the machine. The operator shall ensure that frequent inspections were conducted by the owners and the operator may only operate the machine for the purpose intended by the manufacturer. Only authorized and qualified operators may operate HAULOTTE® machines. All operators must become familiar with and fully understand the emergency controls and be able to operate the machine in an emergency. The operator has the obligation to stop using the machine in the event of malfunction or safety problems on the machine or in the work area and report the problem immediately to his/her supervisor. 10 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E A - Foreword 2 - Safety 2.1 - SAFETY INSTRUCTIONS 2.1.1 - Misuse Hazards • Do not attach overhanging loads when raising or lowering the platform. • Do not tie the platform to an adjacent fixed or mobile structure. • Do not use/operate the machine when alone. A survey person or immediate Supervisor must be present on the ground in case of emergency. • Do not use a faulty or poorly maintained machine. Remove defective/damaged machine from service. • Do not climb onto the compartment covers of the machine. • Do not replace items critical to machine stability with items of different weight or specification. • Do not replace factory-installed tires with tires of different specifications or ply rating. • Do not alter or disable machine components that in any way affect safety and stability. • Do not disable the safety devices. • Do not deface, modify or obscure any decals or markings on the aerial work platform. • Do not use the machine for any other purpose than to position people, their tools and material to the overhead/elevated temporary work places. • Do not use the machine as a crane, material lift or elevator. Only use the machine as it was intended. A B C D E F G H I 11 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E A - Foreword 2.1.2 - Falling Hazards To enter or exit from the platform : • The machine must be completely stowed. • Face the machine to access the entry opening to the platform. • Keep 3 points of contact (both hands and a foot) on the steps and the guardrail. Before commencing operation : • Ensure that guard rails are correctly installed and secured. • Ensure that gate or sliding bar is in it’s proper closed position. • Remove oil or grease from the steps, floor, handrail and the guardrails. • Clear the platform floor free of debris. When in the platform : • Occupants must wear a fall restraint harness with lanyard and energy absorber, in accordance with applicable governmental regulations. Attach the lanyard to the designated fall restraint anchor provided in the platform. • The correct use of the harness requires the lanyard to be connected to an anchorage point designated by the decals. Refer to this decal located on the platform. • Hold on securely to the guardrails. • Always keep your feet firmly on the floor of the platform. • Do not sit, stand, or climb on the platform guard rails. • Work only within the platform guardrails area and do not lean over guardrails to perform work. • Do not exit the platform until it is in the completely stowed position. • Do not use the guardrail as a means of access to climb in or out of the platform. 307P216290 b x 1 12 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E A - Foreword 2.1.3 - Overturning / Tip-over Hazards Before positioning and operating the machine : • Ensure that the surface is capable of supporting the machine weight including the rated capacity. • Do not exceed the maximum rated capacity that includes the weight of both material and allowed number of occupants. Do not exceed the allowable number of occupants. • Place the loads uniformly distributed on the platform floor. • Do not increase the working height (using extensions, ladder, etc.). • Do not place ladders or scaffolds in the platform or against any part of this machine. • Do not use the machine in winds exceeding the permissible limit. • Do not increase the surface area of the platform exposed to wind. This includes adding panels, mesh, banners. Be aware when working with materials with a large surface area. This will add to the wind load on the machine. • Do not raise the platform or drive with platform elevated on an incline exceeding the rated slope for the machine. • Do not drive the machine on slopes or grades exceeding the specified limits. • Do not replace components critical to stability with components of different weight or specification. • Never use the machine with material or objects suspended from the guard-rail. • Do not pull or push towards any object outside of the platform. Do not exceed the maximum allowable side force stated in the performance specifications. • Do not use the machine to support any external structure. • Do not use the machine to tow other machines or to drag materials. A B C D E F G H I 13 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E A - Foreword Using a machine on a slope • If the tilt alarm sounds with the platform uphill : Stow the machine completely. • If the tilt alarm sounds with the platform facing downhill : Stow the machine completely. • While driving on a slope: • Always orientate the machine in the direction of the slope. • Stow the machine completely. • Do not travel down slopes in high speed. • Do not drive fast in narrow or cluttered areas. Keep speed under control while making turns or sharp bends. WIND : The aerial work platform can operate up to a maximum wind speed as indicated in the specifications. To identify the local wind speed, use the Beaufort scale below, use a wind gauge or an anemometer. Do not exceed the slope limit for each operation. Section B 4.1Technical specifications. Gradeability : • Driving UP or DOWN a slope in stowed position. Sideslope : • Driving in stowed position across a slope. Rated slope : • Operating with platform elevated. 14 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E A - Foreword N.B.-:-THE BEAUFORT SCALE OF WIND FORCE IS ACCEPTED INTERNATIONALLY AND IS USED WHEN COMMUNICATING WEATHER CONDITIONS. A WIND SPEED RANGE AT 10 M (32 FT 9 IN) ABOVE FLAT, CLEAR LAND IS ASSOCIATED WITH EACH DEGREE. Beaufort scale Force Meteorological description Observed effects m/s km/h mph 0 Calm Smoke rises vertically. 0 - 0,2 0 - 1 0 - 0,62 1 Very light breeze Smoke indicates the wind direction. 0,3 - 1,5 1 - 5 0,62 - 3,11 2 Light breeze Wind felt on the face. Leaves rustle. Weather vanes turn. 1,6 - 3,3 6 - 11 3,72 - 6,84 3 Slight breeze Leaves and small twigs in constant motion. Flags move slightly. 3,4 - 5,4 12 - 19 7,46 - 11,8 4 Nice breeze Raised dust and loose papers. Small branches are moved. 5,5 - 7,9 20 - 28 12,43 - 17,4 5 Nice breeze Small trees in leaf to sway. Crested wavelets form on inland waterways. 8,0 - 10,7 29 - 38 18,02 - 23,6 6 Cool wind Large branches in motion. Power lines and chimneys 'sing'. Umbrellas used with difficulty. 10,8 - 13,8 39 - 49 24,23 - 30,45 7 Near gale Whole trees in motion. Inconvenience felt when walking against wind. 13,9 - 17,1 50 - 61 31 - 37,9 8 Gale Some branches break. Generally we cannot walk against the wind. 17,2 - 20,7 62 - 74 38,53 - 45,98 9 Strong gale The wind causes slight damage to buildings. Tiles and chimney stacks are blown off. 20,8 - 24,4 75 - 88 46,60 - 54,68 A B C D E F G H I 15 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E A - Foreword 2.1.4 - Electrocution Hazards The machine is not electrically insulated and does not provide protection from contact or proximity to electrically charged conductors. Always position the lift at a safe distance from electrically charged conductors to ensure that no part of the machine is within an unsafe area. Respect the local rules and the minimum safety distance from power lines. Minimum safe approach distances N.B.-:-U SE THIS TABLE EXCEPT WHERE LOCAL REGULATIONS INDICATE OTHERWISE. Electric voltage Minimum safety distance Mètre Feet 0 - 300 V Avoid contact 300 V - 50 kV 3 10 50 - 200 kV 5 15 200 - 350 kV 6 20 350 - 500 kV 8 25 500 - 750 kV 11 35 750 - 1000 kV 14 45 • Do not operate the machine when close to live power lines, consider the movement of the machine and the sway of the electric power lines particularly in windy conditions. • Do not operate the machine during lightning, thunderstorms, snow/ice or any weather condition that could compromise operator safety. • Do not use the machine as a ground for welding. • Do not weld on the machine without first disconnecting the battery terminals. • Always disconnect ground cable first. • The machine must not be used while charging the batteries. • When using the platform AC power supply, ensure it is protected with a circuit breaker and residual current device. Keep away from the machine if it contacts energized power lines. Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut off. 16 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E A - Foreword 2.1.5 - Explosion / Fire Hazards 2.1.6 - Crushing / Collision Hazards • Always cordon off the area around the base of the machine to keep personnel and other equipment away from the machine while in use. • Warn personnel not to work, stand, or walk under a raised boom/platform. • Do not drive in reverse direction (opposite the field of vision). • Always ensure that the chassis is never driven any closer than 1 m (3 ft 3 in) to holes, bumps, slopes, obstructions, debris and ground coverings that may hide holes and other dangers. • Keep non-operating personnel at least 5 m (16 ft 5 in) away from the machine when driving. Always wear protective clothing and eye wear when working with batteries and power sources/systems. N.B.-:-A CID IS NEUTRALIZED WITH SODIUM BICARBONATE AND WATER. • Do not work on or operate a machine in an explosive or flammable atmosphere / environment. • Do not touch hot components. • Do not bridge the battery terminals with metallic objects. • Do not service the battery in proximity of spark, open flame, lit cigarettes. • ALWAYS avoid contact with battery acid. Battery acid causes serious burns and should be kept away from skin or eyes. If contact occurs, flush with water and consult a physician immediately. When in the platform : • Check the work area for overhead clearance, for any obstacles besides and below the platform when raising/lowering the platform and or before driving. • During movement, keep all the parts of the body inside the platform. Hold onto the guardrails on the opposite side to any surrounding structures. Take care to avoid trapping hands whilst holding the guardrails. • To position machine close to a building/structure, use extension deck feature, instead of driving machine closer to structure. A B C D E F G H I 17 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E A - Foreword • Be aware of driving direction. • Check the driving direction with the help of the red or green arrow on the chassis relative to the red and green arrows on the platform control box. • Also note that when changing the driving direction (Forward <> Reverse) the joysticks or switches must return to the neutral position before reversing the drive direction and for movement to occur. • When driving, position the platform so as to provide the best possible visibility and to avoid any blind spots. • Hold on securely to the guardrails. • Occupants must wear a fall restraint harness with lanyard and energy absorber, in accordance with applicable governmental regulations. Attach the lanyard to the designated fall restraint anchor provided in the platform. • Lanyard must be attached to the designated anchorage point. • Avoid contact with fixed or mobile obstacles (other machines). • Other machines (crane, aerial work platform, etc.) operating in the work area increase the risk of crushing or collision. Restrict the operation of machines moving within the aerial work platform work area. • Take into consideration the stopping distance, reduced visibility and blind spots of the machine. • Limit travel speed to suit the ground surface condition, slope (incline), and people in the vicinity. 18 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E A - Foreword 2.1.7 - Uncontrolled movement Hazards Do not use a damaged or malfunctioning machine. Be aware of uncontrolled movement and always respect the following : • Maintain clearance from high voltage lines. • Maintain clearance from generators, radar, electromagnetic fields. • Never expose the batteries or electrical components to water (high pressure washer, rain). • Never tow the machine over extended distances. • In case of a machine breakdown, it is possible to tow short distance to load it onto a trailer. • Never leave the hydraulic cylinders fully extended before switching off the machine, or when stationary for an extended period of time. • Lower the arms to the stowed position. • Select a safe parking location, on a firm level surface, clear of obstruction and traffic. • Ensure all compartments are closed and secured. • Chock the wheels. • Operator must remove the foot from the footswitch when any movement has ceased (For Japan only). 3 - Safety inquiries Inquiries relating to design criteria/specifications of a product, standards compliance, or overall machine safety should be sent to the HAULOTTE® PRODUCT SAFETY department. Each inquiry or request should include all relevant information; including contact name, telephone number, mailing address, email address, plus the machine model and serial number. The HAULOTTE® Product Safety department will evaluate each request/inquiry and will provide a written response. A B C D E F G H I 19 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E A - Foreword 4 - Incident notification Notify HAULOTTE® immediately when a HAULOTTE® product has been involved in an incident/ accident leading to personal injury or death, or when there is a major property damage. HAULOTTE Group - EUROPE Product Safety Department Address : La Péronnière - BP 9 - 42152 L'Horme - France Tel : +33 (0)4 77 29 24 24 Email : [email protected] HAULOTTE Group - Australia, India and Asia Product Safety Department Address : No.26 Changi North Way - Singapore 498812 - Singapore Tel : +65 6546 0123 Email : [email protected] HAULOTTE Group - North & South America Product Safety Department Address : 3409 Chandler Creek Rd. - Virginia Beach, VA 23453 - United States Tel : +1 757 689 2146 Email : [email protected] 20 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E A - Foreword 5 - Compliance 5.1 - PRODUCT INFORMATION Without the written permission from Haulotte, modifying a HAULOTTE® product is a Safety concern. Any modification may violate Haulotte design parameters, government regulations and industry standards. If you desire a modification to the product, submit a request in writing to HAULOTTE®. With the utmost care to ensure enhanced reliability and greater safety of the HAULOTTE® products, it is pertinent that when a "Service or Safety Bulletin" is issued, action is taken immediately. Once the bulletin has been addressed, make sure that the completed form is submitted to HAULOTTE®. Do not hesitate to contact HAULOTTE Services®, should you have any questions relating to the issued bulletin(s) or with questions on the policy itself. 5.1.1 - Change of Ownership Notification It is important and necessary to keep HAULOTTE Services® updated with current ownership of the machine. This way, HAULOTTE® will be able to provide the necessary support for the product. If you have sold or transferred this machine(s); it is your responsibility to notify HAULOTTE Services®. It is not required to include Lessees/Renters of Leased/Rented machines on this form. Use the HAULOTTE® Product Status Notification form to report scrapped, stolen, missing or recovered machine(s). A B C D E F G H I 21 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E A - Foreword 5.1.2 - Owner information update form Owner information update form Complete this form and mail or fax it to : HAULOTTE® subsidiary Name : Address 1 : Fax : Address 2 : e.mail address : Address 3 : Product information : Model : Machine serial number : Owner / Servicing information : Do not include leased or rented units in this form Current product owner 1 : Current product owner 2 : Name : Name : Company : Company : Address 1 : Address 1 : Address 2 : Address 2 : Country : Country : Phone : Phone : Date of ownership : Date of ownership : Signature : Signature : Date : Date : Company stamp is mandatory : Company stamp is mandatory : Tick here if the machine has been permanently removed from service (scrapped). The manufacturer's nameplate must be removed and returned to HAULOTTE Group when the unit is removed from service. Reason for removal : 22 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E A - Foreword 5.2 - PRODUCT SPECIFICATIONS HAULOTTE® cannot be held liable for any changes to the technical characteristics/ specifications contained in this manual. HAULOTTE® has a continuous improvement policy in place for its product range. Given this policy, the Company reserves the right to modify products technical characteristics / specifications without notice. Certain options can modify the machine's operating characteristics and its' associated safety. If your machine was originally delivered with options fitted, replacing a safety component associated with a particular option does not require any particular precaution other than those associated with the installation itself (static test). Otherwise, it is essential to follow the manufacturer's recommendations as stated below : • Installation by authorised HAULOTTE® personnel only. • Update the manufacturer's identification plate. • Have stability tests carried out by a certified agency/competent person. • Ensure decals are updated. A B C D E F G H I 23 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization Familiarization 1 - General safety 1.1 - INTENDED USE Do not operate the product in the following situations : • On soft, unstable or cluttered ground. • With wind blowing faster than the permissible limit. • Check the allowable wind speed specified in the performace specifications tabulation. • Consult the Beaufort scale. • Close to power lines. Keep a safe distance. • Outside of the temperature range -20°C / + 50°C (-4°F / +122°F). • In an explosive atmosphere / environment. • During storms. • In the presence of strong electromagnetic fields. N.B.-:-U SE THE MACHINE UNDER "NORMAL" CLIMATIC CONDITIONS. IF YOU NEED TO USE THE MACHINE IN CLIMATIC CONDITIONS LIKELY TO CAUSE DETERIORATION (EXTREME : HUMIDITY, TEMPERATURES, SALINITY, CORROSIVENESS, ATMOSPHERIC PRESSURE), CONTACT HAULOTTE S ERVICES®. REDUCE INTERVALS BETWEEN SERVICING. N.B.-:-W HILE THE MACHINE IS NOT IN USE, CARE MUST BE TAKEN TO BRING THE MACHINE TO THE FULLY STOWED POSITION. ENSURE THAT THE MACHINE IS LOCKED IN A SECURE LOCATION, AND THE CONTROL KEY IS REMOVED TO PREVENT UNAUTHORISED USE OF THE MACHINE. 24 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization 1.2 - DECAL CONTENT Decals are provided to alert the user of hazards inherent with the Aerial Work Platforms. Decals provide the following information : • The level of severity. • The specific hazard. • A method to avoid, suppress or reduce the hazard. • Descriptive text (where required). Familiarize yourself with the decals and the hazard severity levels. Decals must be kept in good legible condition. Familiarize yourself with the decals and their respective color codes. Additional decals can be ordered from HAULOTTE Services®. CE and AS standards ANSI and CSA standards Marking Description 1 Hazard symbol 2 Level of severity 3 Avoidance symbol pictorial 4 Avoidance text DANGER 1 2 3 DANGER CRUSH HAZARD Do not stand or walk behind or in front of the machine while in use. Stay clear from the path of boom rotation and platform lowering. Failure to comply will result in death or in serious injury 1 3 2 4 A B C D E F G H I 25 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization 1.3 - 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. 1.4 - LEVEL OF SEVERITY Symbol Description Danger : Risk of injury or death Caution : Risk of material damage Prohibited action 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®) N.B. : Additional technical information 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 recommended practices if not followed, may result in a malfunction or damage the machine or its components. Procedure : Indicates a maintenance operation. 26 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization 1.5 - SYMBOLS LEGEND AND DEFINITIONS Symbols are used throughout this manual to depict hazards, avoidance measures and indicate when information is required. Refer to the following table to familiarize yourself with these symbols. Symbol Description Symbol Description Symbol Description Body crushing hazard Foot crushing hazard High pressure fluid ejection hazard Hand crushing hazard Entanglement hazard Health/safety hazards related to chemicals Health-damaging effects from hot work environment Electrical contact or lightning strike Burns and scalds from contact with flames, explosion or radiation from heat sources Injury from Electric arcs - Energy supply disconnecting devices - Batteries fire, emissions, etc Risk of operator(s) falling Tip over due to excessive loading / wind load and excessive ground slope Relate and coordinate directional arrows on the chassis with those on the control box Do not put foot in this area Do not put your hand in this area Keep away from product working area Never expose batteries and electrical component to high pressure washer Ensure entry drop rail is down Flames prohibited Maintain safe clearance from high voltage electrically charged conductors as described in manual - Do not use in thunderstorms Overload Refer to operator manual Safety belt Use appropriate lanyard attached to dedicated anchor point. Wheel pressure Enable switch Use safety prop before attempting any maintenance work Tow point Tie down point Lift point Keep away from hot surfaces Wear protective equipment x 1 A B C D E F G H I 27 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization 2 - Models description Regulations Models ANSI and CSA standards OPTIMUM 1931 E CE, AS and EAC standards OPTIMUM 8 28 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization 3 - Primary machine components 3.1 - LAYOUT OPTIMUM 8 - OPTIMUM 1931 E C35 C171 C77 C168 C141 C7 C75 C78 C20 C2 C78 C58 C30 C42 C76 C81 C82 C6 C85 C1 C64 C20 C27 C20 C90 C107 C142 A B C D E F G H I 29 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization Universal plug 3.2 - MAINTENANCE SUPPORT Marking Description Marking Description C1 Chassis C77 Platform access ladder C2 Front drive wheels C78 Compartment locking latch C6 Platform C81 Sliding guardrail C7 Platform control box C82 Extension deck lock pin C20 Tie-down (and/or forklift loading) C85 Scissors C27 Ground control box + Universal plug C90 Battery bay (block) C30 Hydraulic oil tank C107 Pull T-handle for emergency lowering C35 Document holder C141 Rear wheel C42 Foot pedal switch (For Japan only) C142 Lanyard attachment points C58 Pothole protection C168 Maintenance support C64 Tilt sensor C169 Folding guardrails / Swing gate (Optional - Not shown) C75 Extension deck C171 Scissors lifting cylinder C76 Guardrail The maintenance stand must be in place before any maintenance operation is begun. Placing the machine in maintenance configuration : • Lift scissor arms to a sufficient height (floor of the platform at around 2,5 m / 8 ft 2 in from the ground). • Pull the plastic handle and put the stand in the vertical position. • Release the handle. The stand should remain in the vertical position. • Lower the scissor arms. • Scissor arm pivoting rod should rest on the V groove of the stand. Putting in use position : • To put back the machine into its normal operation, reverse the steps used above. 30 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization 3.3 - EXTENSION DECK N.B.-:-DO NOT LOAD THE EXTENSION DECK, FOR EASE OF MANOEUVRING. Ensure that gate or sliding bar is in it’s proper closed position. Perform the extending and retracting operations of the extension deck on flat, horizontal ground. To retract the extension deck : • Press pedal ( 1 ) and pull the extension deck rails ( 2 ) inwards to the locked position • Release the pedal. To extend the extension deck : • Press the pedal ( 1 ) to release the extension deck lock pin. • With pedal ( 1 ) pressed, push the extension deck guard rails ( 2 ) to the extended position. • Keep hands clear of pinch points. Make sure that the extension deck is in locked position. Be aware of the extended platform position when moving the machine. A B C D E F G H I 31 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization 3.4 - GROUND CONTROL BOX 3.4.1 - Layout General view Controls and indicators Marking Description Function 15 E-stop button Pulled out : Ground control box energized Pushed in : De-energizes control system 43 Horn button Not used 92 Control box activation key switch () Right : Ground control box energized Center : De-energizes control system Left : Platform control box energized 93 Battery charging indicator () Battery charger status 105 Beacon light (Optional) Move upwards : Flashing light turn ON Move downwards : Flashing light turn OFF 253 Diagnostic tool socket Connection to the diagnostic tool (HaulotteDiag) 92 253 ACTIV’ Screen 15 43 105 93 32 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization 3.4.2 - HAULOTTE Activ'Screen Upon starting and during operation of the machine, the LCD screen "Activ'Screen" located on the ground control box displays in real time the machine operating status. HAULOTTE Activ'Screen Controls and indicators Marking Description Function 1 Platform raising control Platform raises 2 LCD screen Display status of operation of the machine 3 Navigation button Navigation of menu to select function - Scroll up 4 Confirmation button Confirmation of the selected function 5 Cancellation button Go back 6 Platform overload indicator Platform overload indicator 7 Machine fault indicator Constantly lit in the event of an operation malfunction 8 Navigation button Navigation of menu to select function - Scroll down 9 'Enable Switch' selector Press in and hold : Enable switch 10 Platform lowering control Platform lowers A B C D E F G H I 33 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization 3.4.2.1 - LCD screen At startup : At startup with the ground or platform controls selected; system initiates a self check : • Bar gets filled up. • Home screen comes on with status icon of the machine - okay to proceed functioning the controls. Symbol Description 1 Information icons 2 Information text 3 Status icon of the machine Symbol Description Battery status Maintenance use Fault / alarms Hour meter 34 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization • After pressing on : • After again pressing on • Access code screen comes on - refer to maintenance manual for entering the access code • Validation by pressing on is active only if access code is known and entered - refer to maintenance manual for the procedure for the different level code useage Symbol Description 1 Software part number 2 Software version + Screen software version + Screen version 3 Screen identification + Screen software version 4 Machine serial number displayed A B C D E F G H I 35 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization Alarm status : Alarm status displayed as applicable - samples shown below Tilt : Overload : Low battery : 36 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization Present fault : Platform control box E-stop button pressed in (de-energized) : A B C D E F G H I 37 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization 3.5 - PLATFORM CONTROL BOX 3.5.1 - Layout General view Controls and indicators Marking Item Description Function 27 HL800 Tilt indicator Machine on excessive slope 30 HL802 Overload indicator Platform overloaded 43 SA907 Horn button Move upwards and hold to activate horn 46 SB802 E-stop button Pulled out : Platform control box power supply energized Pushed in : De-energizes control system 85 HL903 Fault indicator Fault indicator Faulty or tilting or overloaded machine 38 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization 91 HL904 Battery charging indicator Battery charged Flashing : Batteries have 40 % charge left Constantly on : Batteries have only 20 % charge left 108 SM901 Movement joystick Move forward : Forward drive or platform raising Move backwards : Reverse drive or platform lowering Front axle steering selector Press right side of button : Right-hand steering Press left side of button : Left-hand steering 110 HL420 Raising / lowering selector On : Raising / Lowering selection activated Off : Raising / Lowering movement is not selected 111 HL100 Driving selection indicator On : Driving function activated Off : Driving movement is not selected 112 SA908 2-position selector Move to the left : Platform raising / lowering Move to the right : Drive movements 123 SA905 'Enable Switch' selector Press in and hold : Associated command is validated Press in and hold : Enable switch Press in and hold : Enable switch Release : Associated command movement is halted 245 SB800 Foot pedal switch (For Japan only) Press in and hold : Enable switch Marking Item Description Function 100% 40% 20% A B C D E F G H I 39 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization 4 - Performance Specifications 4.1 - TECHNICAL CHARACTERISTICS Use the table to select the right Haulotte machine for the job. CE, AS and EAC standards Machine OPTIMUM 8 Characteristics - Dimensions SI Imp. Maximum working height 7,77 m 25 ft 6 in Maximum platform height 5,77 m 18 ft 11 in Total weight 1520 kg 3350 lbs Maximum platform capacity 230 kg 500 lbs Maximum number of occupants allowed Indoor use : 2 Outdoor use : 1 Maximum wind speed allowed Indoor use : 0 km/h Outdoor use : 45 km/h Indoor use : 0 mph Outdoor use : 28 mph Manual force - CE - AS Indoor use : 400 N (90 lbf) Outdoor use : 200 N (45 lbf) Gradeability 25 % Maximum side rated slope allowed - CE - AS 1,5° Maximum longitudinal rated slope allowed - CE - AS 3° Maximum load on wheel 963 kg 2,125 lbs Maximum ground pressure of wheel on paved ground 14 kgf/ cm2 200 lbf/in2 Drive speed : • Folded machine maximum speed • Unfolded machine maximum speed 4,5 km/h 0,5 km/h 2.79 mph 0.3 mph Maximum freewheel speed during towed operation 4,5 km/h 2.79 mph Outside turning radius 1,5 m 4 ft 11 in Inside turning radius 1 m 3 ft 3 in Power source - Electric HAULOTTE® code Standard Option Quantity System voltage Capacity 2440207960 X 4 6V 180Ah (C5) 2901011640 X 4 6V 195Ah (C5) 4000564910 X 4 6V 182Ah (C5) 2901012540 X 4 6V 154Ah (C5) For Japan only 4000558700 X 4 6V 170Ah (C5) 4000090820 X 2 12V 115Ah (C5) Hydraulic tank capacity 6 l 1.6 gal US 40 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization ANSI and CSA standards Machine OPTIMUM 1931 E Characteristics - Dimensions SI Imp. Maximum working height 7,77 m 25 ft 6 in Maximum platform height 5,77 m 18 ft 11 in Total weight 1440 kg 3,175 lbs Maximum platform capacity 230 kg 500 lbs Maximum number of occupants allowed Indoor use : 2 Outdoor use : 2 Maximum wind speed allowed Indoor use : 0 km/h Outdoor use : 45 km/h Indoor use : 0 mph Outdoor use : 28 mph Manual force - ANSI - CSA 445 N 100 lbf Gradeability 25 % Rated slope - ANSI - CSA 0° Maximum load on wheel 963 kg 2,125 lbs Maximum ground pressure of wheel on paved ground 15 kgf/cm2 208 lbf/cm2 Drive speed : • Folded machine maximum speed • Unfolded machine maximum speed 4,5 km/h 0,5 km/h 2.79 mph 0.3 mph Maximum freewheel speed during towed operation 4,5 km/h 2.79 mph Outside turning radius 1,5 m 4 ft 11 in Inside turning radius 1 m 3 ft 3 in Power source - Electric HAULOTTE® code Standard Option Quantity System voltage Capacity 2440207960 X 4 6V 180Ah (C5) 2901011640 X 4 6V 195Ah (C5) 4000564910 X 4 6V 182Ah (C5) 2901012540 X 4 6V 154Ah (C5) For Japan only 4000558700 X 4 6V 170Ah (C5) 4000090820 X 2 12V 115Ah (C5) Hydraulic tank capacity 6 l 1.6 gal US A B C D E F G H I 41 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization 4.2 - WORKING AREA / RANGE OF MOTION OPTIMUM 8 - OPTIMUM 1931 E 42 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization Notes A B C D E F G H I 43 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization 5 - Decals and markings locations CE and AS standards - OPTIMUM 8 - 1/2 44 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization CE and AS standards - OPTIMUM 8 - 2/2 A B C D E F G H I 45 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization CE and AS standards - OPTIMUM 8 Marking Color Description Quantity OPTIMUM 8 1 Red Height of the floor and load 2 4000422970 2Blue Maximum Pressure per Tire - Floor Loading 4 4000417260 3 Other Commercial name - Bright machine 2 3078146730 3 Other Commercial name - Dark machine 2 307P222270 4 Other Decal HAULOTTE® - 500 x 100 - Bright machine 2 307P217080 4 Other Decal HAULOTTE® - 500 x 100 - Dark machine 2 307P224740 4 Other Decal HAULOTTE® - 500 x 100 - Red machine 2 307P220360 6 Other Identification plate 1 3078146180 7 Other Rivet 4 2421803570 11 Other Lanyard attachment points 3 307P216290 12 Other Material risk - Yellow and black adhesive tape 1 2421808660 16 Other Max and min oil level 1 307P221060 17 Red Risk of crushing 2 4000244370 18 Orange Hand crushing hazard - Risk of crushed hands 4 4000024890 19 Red Operation instructions 1 4000025140 20 Red Operation instructions 1 In german ( CE standard) : 307P222730 In english ( CE and AS standards) : 307P222740 In chineese ( CE standard) : 4000698920In korean ( CE standard) : 4000618590 In croatian ( CE standard) : 4000360810 In danish ( CE standard) : 307P222760 In spanish ( CE standard) : 307P222770 In estonian ( CE standard) : 4000360870 In finish ( CE standard) : 307P222780 In french ( CE standard) : 3078149030 In greek ( CE standard) : 4000561810 In dutch ( CE standard) : 307P222790 In hungarian ( CE standard) : 4000360890 In italian ( CE standard) : 307P222800 In japanese ( CE standard) : 4000359830 In latvian ( CE standard) : 4000359840 In lithuanian ( CE standard) : 4000359850 In norwegian ( CE standard) : 4000359900 In polish ( CE standard) : 4000359860 In portuguese ( CE standard) : 307P222810 In romanian ( CE standard) : 4000359870 In slovakian ( CE standard) : 4000359880 In slovenian ( CE standard) : 4000359890 In swedish ( CE standard) : 307P222820 22 Orange Wound foot - Do not place foot 2 4000027090 23 Red Risk of crushing - Driving direction 1 3078145100 24 Red Danger of electrocution 2 For CE standard only : 4000244350 For AS standard only : 4000227500 25 Red Risk of crushing - Closing drop rail 1 4000025080 26 Red Danger of electrocution - Ground for welding 2 4000027100 27 Red Verification of tilt operation 1 4000244380 28 Red Do not interchange 1 4000504670 31 Red Brake release 1 4000361570 46 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization 32 Blue Anchorage point - Traction 4 4000027310 34 Red Risk of electrocution - Water projection 1 4000025130 36 Red Risk of crushing - Platform 1 4000244340 53 Green Emergency lowering location 1 4000227200 55 Yellow Risk of electrocution - Charger - 240 V 1 For CE standard only : 4000273940 For AS standard only : 4000307410 57 Other Position of the lift truck forks 4 3078143830 58 Other Battery compartment locking 2 4000310170 59 Red Scissors safety 1 4000027550 61 Blue Risk of crushing 2 4000025060 62 Red Stop time during descent 1 4000271010 64 Green Battery verification 1 4000274040 65 Orange Hand crushing hazard - Battery 1 4000027440 68 Other Transport height 1 4000417380 69 Other Battery isolation switch 1 4000420660 70 Other Electric traction AC 2 4000425350 200 Other "Made in Europe" 1 For CE standard only : 4000137690 201 Red Wearing of a safety harness is essential 1 AS standard only : 4000275670 Marking Color Description Quantity OPTIMUM 8 A B C D E F G H I 47 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization EAC standard - OPTIMUM 8 - 1/2 48 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization EAC standard - OPTIMUM 8 - 2/2 A B C D E F G H I 49 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization EAC standard Marking Color Description Quantity OPTIMUM 8 1 Red Height of the floor and load 2 4000426450 2Blue Maximum Pressure per Tire - Floor Loading 4 4000417260 3 Other Commercial name - Bright machine 2 3078146730 3 Other Commercial name - Dark machine 2 307P222270 6 Other Identification plate 1 For Russia : 4000388680 For Ukraine : 4000054150 7 Other Rivet 4 2421803570 11 Other Lanyard attachment points 3 307P226710 12 Other Material risk - Yellow and black adhesive tape 1 2421808660 16 Other Max and min oil level 1 307P221060 18 Orange Hand crushing hazard - Risk of crushed hands 4 307P227660 19 Red Operation instructions 1 For Russia : 307P227190 For Ukraine : 307P227840 20 Blue Operation instructions 1 For Russia : 4000359920 For Ukraine : 4000359910 22 Orange Wound foot - Do not place foot 2 307P227010 23 Red Risk of crushing - Driving direction 1 For Russia : 4000010890 For Ukraine : 4000011390 24 Red Danger of electrocution 2 4000010920 25 Red Risk of crushing - Closing drop rail 1 307P226950 26 Red Danger of electrocution - Ground for welding 2 307P226970 27 Red Verification of tilt operation 1 For Russia : 307P227060 For Ukraine : 307P227870 28 Red Do not interchange 1 4000504670 31 Red Brake release 1 4000361570 32 Blue Anchorage point - Traction 4 4000135970 34 Red Risk of electrocution - Water projection 1 307P226780 36 Red Risk of crushing - Platform 1 4000244340 53 Green Emergency lowering location 1 4000227200 55 Yellow Risk of electrocution - Charger - 240 V 1 307P227520 57 Other Position of the lift truck forks 4 4000013830 58 Other Battery compartment locking 2 4000310170 59 Red Scissors safety 1 4000270960 61 Blue Risk of crushing 2 4000270970 62 Other Stop time during descent 1 For Russia : 4000011400 For Ukraine : 4000011430 64 Green Battery verification 1 For Russia : 307P227180 For Ukraine : 307P227860 65 Orange Hand crushing hazard - Battery 1 4000027440 68 Other Transport height 1 4000417380 69 Other Folding guardrails 1 4000420660 70 Other Electric traction AC 2 4000425350 204 Red Lubrication point 2 307P219370 207 Red Smoking forbidden 1 307P226760 209 Yellow Battery danger 1 307P226790 50 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization 210 Yellow Fire Hazard 1 307P226800 211 Red Electrical danger 2 307P226810 213 Yellow Corrosion hazard 1 307P226830 214 Yellow Danger unstable side 1 307P226930 216 Other Tamper-proof 6 307P227450 218 Blue Caution helmet compulsory 1 307P226680 221 Blue Obligatory routing 1 307P227510 229 Red Do not travel down the ramp at a fast speed 1 307P226990 230 Red No admittance to unauthorized persons 2 307P227560 231 Red Do not park in the work area 2 4000010910 235 Yellow Vertical crushing of the body 2 4000014270 236 Blue Wearing eye protection mandatory 1 307P226670 237 Yellow Risk of crushing 2 307P227670 Marking Color Description Quantity OPTIMUM 8 A B C D E F G H I 51 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization ANSI and CSA standards - OPTIMUM 1931 E - 1/2 52 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization ANSI and CSA standards - OPTIMUM 1931 E - 2/2 A B C D E F G H I 53 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization ANSI and CSA standards Marking Color Description Quantity OPTIMUM 1931 E 1 Red Height of the floor and load 3 In english : 4000427710 In french : 4000427720 In spanish : 4000427730 2Blue Maximum Pressure per Tire - Floor Loading 4 4000417260 3 Other Commercial name - Bright machine 2 4000504010 3 Other Commercial name - Dark machine 2 4000504020 4Other Decal HAULOTTE® - 500 x 100 - Bright machine 2 307P217080 4Other Decal HAULOTTE® - 500 x 100 - Dark machine 2 307P224740 4Other Decal HAULOTTE® - 500 x 100 - Red machine 2 307P220360 6 Other Identification plate 1 307P218930 7 Other Rivet 4 2421803570 11 Other Lanyard attachment points 3 307P216290 12 Other Material risk - Yellow and black adhesive tape 1 2421808660 16 Other Max and min oil level 1 307P221060 17 Red Risk of crushing 2 In english : 4000130190 In french : 4000130200 In spanish : 4000130210 18 Orange Hand crushing hazard - Risk of crushed hands 4 In english : 4000024770 In french : 4000067710 In spanish : 4000086490 19 Red Operation instructions 1 4000025140 20 Red Operation instructions 2 In english : 4000243670 In french : 4000243680 In spanish : 4000243690 22 Orange Wound foot - Do not place foot 2 In english : 4000024840 In french : 4000068180 In spanish : 4000086610 27 Red Verification of tilt operation 1 In english : 4000130300 In french : 4000130310 In spanish : 4000130320 28 Red Do not interchange 1 4000504670 31 Red Brake release 1 4000361570 32 Blue Anchorage point - Traction 4 4000027310 36 Red Risk of crushing - Platform 1 4000244340 53 Green Emergency lowering 1 4000227200 56 Yellow Risk of electrocution - Charger - 110 V 1 4000419150 57 Other Position of the lift truck forks 4 3078143830 58 Other Battery compartment locking 2 4000310170 59 Red Scissors safety 1 In english : 4000024850 In french : 4000068070 In spanish : 4000086500 61 Blue Risk of crushing 2 In english : 4000024780 In french : 4000067700 In spanish : 4000086480 64 Green Battery verification 1 4000274040 54 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E B - Familiarization 65 Orange Hand crushing hazard - Battery 1 In english : 4000025030 In french : 4000068120 In spanish : 4000086550 68 Other Transport height 1 4000417380 69 Other Folding guardrails 1 4000420660 70 Other Electric traction AC 2 4000425350 Marking Color Description Quantity OPTIMUM 1931 E A B C D E F G H I 55 4000415480 E 01.18 USA / GB C - Pre-operation inspection OPTIMUM 8 - OPTIMUM 1931 E Pre-operation inspection 1 - Recommendations The owner, the site manager, the supervisor and the operator are all responsible to ensure the machine is fit for the work it is to perform; i.e. that the machine is suitable to carry out the work in complete safety and in compliance with this Operator's Manual. All managers who are responsible for persons operating the machine must be familiar with the local regulations currently applicable in the country of use and ensure that they are adhered to. Before using the machine, read the previous chapters in this manual. Ensure that you have understood the following points : • Safety precautions. • Operator's responsibilities. • Conditions and the operating principles of the machine. 56 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E C - Pre-operation inspection 2 - Working area assessment To ensure safety during operation, the following should be considered : • Segregate other site traffic (delivery vehicles, dumpers, etc) from the work area. • Check the work area for localized features, e.g. manholes, service ducts, potholes, etc. • Check ground covers (temporary and permanent) are strong enough to withstand the applied pressure. • Check ground covers are secured and monitor them. Take similar action for permanent covers. • Check the load bearing capacity (distributed load and point loading) when working inside a building, or on a structure. • Check the load bearing capacity (distributed load and point loading) of the supporting ground. • Provide supervision to ensure safe systems of work are appropriate and being used. • Check for overhead crushing and contact hazards. • Check weather conditions have not altered ground conditions (e.g. heavy or prolonged rain). • Establish limits for safe operation (e.g. maximum wind speed). Remember conditions can change internally (e.g. if roller doors are opened). • Comply with permit to work systems where sites have them (e.g. chemical plants). • Provide a rescue plan for all risks, including falls and crush hazards. Ensure personnel understand and are appropriately trained in the rescuing procedures. Site based personnel trained in operation of functions and in the emergency lowering systems from the ground control box should be present. Ensure that access to the ground controls is available. • Assess other alternative work methods or equipment before operating near a steep slope. If the machine must be placed near an edge or steep slope, ensure barriers are available to support the weight of the machine. Take into consideration the machine's stopping distance. If this is not possible, evaluate and establish the placement of machine and sequence of operations so that the aerial work platform can operate in a safe manner (e.g. machine is in line with the edge rather than towards the edge). Extra care must be taken if aerial work platforms are used to manoeuvre up through several levels of steelwork. There is a risk of the operator being trapped should the basket strike the steelwork. This risk increases with the number of steelwork levels and if material is piled up on lower level reducing the spacing between levels. A B C D E F G H I 57 4000415480 E 01.18 USA / GB C - Pre-operation inspection OPTIMUM 8 - OPTIMUM 1931 E 3 - Inspection and Functional test 3.1 - DAILY INSPECTION Each day before the beginning of a new work session and with each change of operator, the machine must be subjected to a visual inspection and a complete functional test. In case of loose fasteners, refer to torque table value in maintenance book. In case of leaks, replace the damaged part before use. In case of structural part deformation, cracks, broken weld, paint chips, replace the part before use. Sample of broken welds Inspection Forms are provided to assist your inspection process. We recommend these forms to be completed daily and stored to assist with your maintenance schedule. Each action is depicted in the daily inspection sheet using the following symbols. • Never use a defective or a malfunctioning aerial work platform. • If any item on the check list is marked "No" during the inspection; machine must be tagged and placed out of service. • Do not operate the machine until all identified items are corrected and it has been declared safe for operation. Visual inspection without disassembly Lubrication-Grease Functional adjustments Drain Test and validate Tighten Check levels Systematic replacement Visual inspection with small disassembly or movement needed to reach the part. Replacement is necessary. Proof tests : Need HAULOTTE Services® authorization. For countries where machines are not subject to controlled periodic maintenance. 58 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E C - Pre-operation inspection Daily inspection Visual inspection without disassembly Check level To check by test Yes No Corrected Not applicable Manuals and displays. Clean or replace if necessary. Presence, cleanliness and legibility of the manufacturer's plate Presence, cleanliness and legibility of operator's and maintenance manuals Presence and cleanliness of load chart of the machine Control box (Ground and Platform) Presence and cleanliness of the control box No visible damage All decals at the control boxes are clean and legible Operation of start / stop device Operation of E-stop button device Operation of enable switch Operation of horn from platform control box Operation of movement from platform control box Test warning alarm lights and buzzer No abnormal noise and jerky movements from platform control box Joysticks and movement switches return to neutral Presence of the turret pin and its locking device Presence of end stops and their locking system Work Platform. Floor, guardrails, access and extensions Absence of cracks, broken parts, damaged paint No deterioration and visible damage Harness anchor points are not cracked or damaged, with the decal attached and legible No screws missing / loose parts A B C D E F G H I 59 4000415480 E 01.18 USA / GB C - Pre-operation inspection OPTIMUM 8 - OPTIMUM 1931 E Entry bar/gate closes automatically and is not prevented from closing. Folding guard-rail (if fitted) is fixed securely in position Extending structure (scissors) Absence of cracks, broken parts, damaged paint No deterioration and visible damage No screws missing / loose parts No foreign body in joints or slides Presence of securely fitted maintenance devices (safety stand) Frame, axle, steering system, scissors, pot hole mechanism Check the system for damage and to ensure that it deploys when the platform is raised Absence of cracks, broken parts, damaged paint No deterioration and visible damage No screws missing / loose parts No foreign body in joints or slides No rust and abrasions on welds Condition of tires/tyres (wear, cutting, damage ...) Wheel reducer is undamaged and operates smoothly Correct opening and locking of covers Pin, pin stop, bearing ... Presence of the turret pin and its locking device Presence of end stops and their locking system No bent, cracked or broken pins, pin stops, bushes or bearings Cylinder and hydraulic component : pumps, filters, manifold No leaks on the pump, tank or fittings No deformation, visible damage, broken weld or leaks on hydraulic cylinder Presence and good condition of hydraulic hose No screws missing / loose parts Check hydraulic oil level is above the minimum level (Machine folded) 60 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E C - Pre-operation inspection Energy storage : Batteries Battery electrolyte level No screws missing / loose parts Presence and good condition of the batteries: terminations and clamps, electrolyte level ... Electric cables No torn or split wire sheaths No evidence of chemical damage or corrosion on all cables No oxidation or corrosion on terminals Sensors and safety device Slope limiting device operates properly Test of load sensing system (visual warning at control box) Serial number : Hours of operation : HAULOTTE Services® contract reference : Intervention record number : Date : Name : Model : Signature : A B C D E F G H I 61 4000415480 E 01.18 USA / GB C - Pre-operation inspection OPTIMUM 8 - OPTIMUM 1931 E 4 - Safety functional checks To protect the user and the machine, safety systems prevent the movement of the machine beyond its operating limits. These safety systems when activated immobilize the machine and prevent further movement. The operator must be familiar with this technology and understand that is not a malfunction but an indication that the machine has reached an operation limit. Aerial Work platforms are equipped with two control boxes which allow operators to safely use the machine. An auxiliary device (T-handle) is available on the chassis to assist with the emergency lowering of the machine. Each control box is equipped with an E-Stop button, which cuts all movements when pushed in. The following checks describe the operation of the machine and the specific controls required. The speed selector buttons at the ground control box and the platform control box act as the enable switch. For the location and description of these controls : refer to section B 3.3 and D 2 Ground control box and B 3.4 and D 3 Platform control box. 4.1 - E-STOP BUTTON CHECK Ground control box E-stop button Platform control box E-stop button Step Action 1 Pull the E-stop button ( 15 ) at ground. 2 Turn the control box activation key switch ( 92 ) to the right to energize the ground control box. The indicators light up. 3 Push the E-stop button ( 15 ). The indicator goes out. Step Action 1 Pull the E-stop push-button ( 46 ). 2 Turn the control box activation key switch ( 92 ) to the left to energize the platform control box. The indicators light up. 3 Push the E-stop button ( 46 ). The indicator goes out. 62 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E C - Pre-operation inspection 4.2 - ACTIVATION OF CONTROLS The deadman foot pedal (enable switch) must be activated to allow any movement. The "Enable Switch" system depends on the machine configuration and will consist of one of the following : • Enable trigger on platform control joystick. • Foot pedal (enable switch) in the platform (Optional). • Enable switch on the ACTIV'Screen on ground control box. 4.3 - FAULT DETECTOR The machine is equipped with an on-board fault detection system, which indicates the type of fault to the operator. The fault is identified by a default code. The default code is displayed at the ground control box. According to the type of fault, the machine MAY switch into DOWNGRADEMODE mode and certain movements are prevented to maintain Operator's safety. Do not use the machine until the fault has been corrected. 4.3.1 - Buzzers test From the ground control box 4.4 - OVERLOAD SENSING SYSTEM (IF FITTED) If the platform load exceeds the maximum allowed load, no movement is possible from the 2 control boxes. At ground and platform control boxes a buzzer sounds and an indicator light warns the operator. To return the machine to normal operation remove weight from the platform until the load is below the maximum allowed load. Daily check that the LED's illuminate when the machine is switched on : • Verify that the Overload system is active : Refer to Indicators ( 6 ) at ground and ( 30 ) at platform. • Verify that the buzzers are functioning : Refer to Buzzers test A periodic inspection of this device must be performed according to the recommendation in Maintenance Schedule. Step Action 1 Pull the E-Stop buttons ( 15 ) at ground control box and ( 46 ) on the platform control box 2 Turn the control box activation selector key ( 92 ) to the left or right to activate a control box. An audible signal (beep) sounds. A B C D E F G H I 63 4000415480 E 01.18 USA / GB C - Pre-operation inspection OPTIMUM 8 - OPTIMUM 1931 E 4.5 - SLOPE WARNING DEVICE From each control box, a buzzer alerts the operator that the machine is not folded/stowed and is positioned on a slope exceeding the slope allowed. N.B.-:-T HE SLOPE SENSOR IS ONLY ACTIVE WHEN THE PLATFORM IS NOT IN THE STOWED POSITION. When the unfolded machine is on a slope greater than the rated slope, out of the stowed position, DRIVE and LIFT functions are disabled(For CE, AS and CSA only). All speeds are reduced In this case, fully lower the platform and reposition the machine on level ground before raising the platform again. N.B.-:-D EPENDING ON YOUR MACHINE CONFIGURATION, OUTSIDE ASSISTANCE MAY BE NECESSARY IN ORDER TO CARRY OUT THIS OPERATION. To check the tilt sensor at ground control box 4.6 - TRAVEL SPEED LIMITATION Drive speed is proportional to control, without restriction, until the maximum speed is reached (machine in fully stowed position). The only speed allowed when not in stowed position is microspeed (This speed is a default speed programed into the machine). 4.7 - ELECTRONIC VARIABLE SPEED DRIVE The machines are equipped with 2 electronic variable speed regulators configured for each function and manages the required power needed for each motor. Step Action 1 Pull the E-stop push-buttons on the platform and ground control boxes (46, 15). 2 Switch on the machine from the ground control box (92). 3 Lower the platform completely. 3 Locate the tilt sensor next to the ground control box. 4 Manually tilt and maintain the tilt sensor towards the front for a few seconds ( Section B 3.1 - Layout) : 5 The audible beep sounds. 6 For machines fitted with : The slope sensor prevents lifting and driving movements (For CE, AS and CSA only). Do not interchange the speed controllers/regulators between machines even if they are the same model. 64 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E C - Pre-operation inspection 4.8 - OPERATING TEMPERATURE (FOR EAC STANDARD ONLY) Hydraulic energy to perform machine movements is provided by an electric motor driven hydraulic pump.The operating speed of the pump is governed by a speed regulator. If the temperature limits are reached, an audible alarm alerts the operator. All movements are cut off except getting back to transport position. Temperature limits : • from 0° C / 32° F to + 40° C / 104° F Location of operating temperature thermostat 4.9 - MACHINE BRAKING When electric power is cut off, the machine stops automatically. Performance levels may be reduced in the following situations : • Descending a bumpy ramp. • Worn tires/tyres. • Damp or muddy ground conditions. Check that the brakes are applied automatically when the Drive joystick is released to the neutral position. 4.10 - WHEEL MOTOR BRAKE RELEASE Each time a drive command is activated, electric power releases the brakes. 4.11 - POTHOLE PROTECTION SYSTEM The machine is equipped with a pothole mechanism under the chassis that is deployed automatically when the platform is out of the stowed position. Check the system for damage and ensure that it deploys when the platform is raised. A B C D E F G H I 65 4000415480 E 01.18 USA / GB C - Pre-operation inspection OPTIMUM 8 - OPTIMUM 1931 E 4.12 - ON-BOARD CHARGER Battery charging starts as soon as an external supply is connected to the battery charger. 4.12.1 - Battery charge level The indicator (93) shows the charge status of the battery whilst charging : 4.13 - ANTI-CRUSH SYSTEM WHEN LOWERING A device alerts people on the ground of a risk of crushing : • Between the lifting systems. • Under platform extension. This device automatically operates between the transport height position limit and the lower position (Refer to Driving speed) All versions, lowering control from the platform and ground control boxes : • Slows the downward movement and emits an audible signal. Standard CE, lowering movement from platform control box : • At the end of the lowering operation, a 3 (second) automatic delay is initiated before resuming lowering, to avoid the risk of crushing. When the battery pack is being charged with an external power supply, the machine's electric system is automatically deactivated. • Green indicator : Battery charged 100 %. • Yellow LED : Battery charged 80 %. • Red LED : Battery in initial charging phase. 66 4000415480 E 01.18 USA / GB OPTIMUM 8 - OPTIMUM 1931 E C - Pre-operation inspection Notes A B C D E F G H I 67 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E Operation instructions 1 - Operation 1.1 - INTRODUCTION Only trained and authorized personnel shall be permitted to operate this aerial work platform. 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 and emergency systems. 68 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E 1.2 - OPERATION FROM THE GROUND CONTROL BOX • Turning "ON" and "OFF" of the machine is performed with selector key switch (92). • Activation of a desired control box is achieved by turning the control box energizing selector switch ( 92 ) to the desired position. • The ground control box is energized and is active ONLY when : • The E-stop buttons on both ground and platform control boxes are not pressed in. • The machine is switched on. • Ground control box is selected. • An E-stop button at each control box stops all movements when pressed in (deactivated). N.B.-:-A N E-STOP BUTTON PRESSED IN DOES NOT TURN OFF THE MAIN POWER SUPPLY TO THE MACHINE . • An enable switch ( 9 ) provided must be activated and maintained to authorize one or more function movements. If enable switch ( 9 ) is kept engaged without selecting a function movement for more than 8 s; enable switch is automatically de-activated. • The release of "Enable switch" ( 9 ) while performing a movement stops all the movements. The stop of movements is progressive. If the "Enable switch" system is re-pressed, the movement doesn't restart. It could restart only when the selected function switch/joystick is released to neutral position. • All switches and joystick operating a movement, return automatically to neutral when released. • At power up, a switch in it's neutral position will be taken into account to authorize movement. • The ground control box is designed for maintenance and emergency rescue operations only. Refer to Section D 4.2 To rescue operator in platform. • The status of the switches is tested automatically when the machine is switched on, and checked at every starting. A switch will be active only after it has been detected to be in neutral position. The following switches are not controlled : • Beacon light (if fitted) A buzzer beeps in the following conditions : • Overload (if fitted). • Machine out of stowed position and on a slope greater than allowable slope. • Movements option. • Indicators / Cluster : All indicators are checked after powering on the machine A B C D E F G H I 69 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E 1.3 - OPERATION FROM THE PLATFORM CONTROL BOX • The platform control box can only be used if : • The E-stop buttons on both ground and platform control boxes are not pressed in (Energized). • Machine switched on at ground control box. • Platform control box selected from ground control box. • A faulty joystick is not taken into account to control a movement. If this fault disappears, the movement is authorised again. • An E-Stop button is present at each control box. When pushed in, it stops all functions movements and will shut off the engine (if equipped). • An "Enable switch" ( 123 ) or Foot pedal switch in the basket ( 245 ) is present and should be activated to authorize one or more function movements. If the enable switch is kept active for more than 8 seconds without selecting a function movement, then movement is disallowed. The enable switch must be released (reset) before movement can occur. • The release of "Enable switch" ( 123 ) or Foot pedal switch in the basket ( 245 ) while performing a movement stops all the movements. The stop of movements is progressive. If the "Enable switch" is pressed again quickly within 0,5 s the movement restarts. If the "Enable switch" is not pressed again quickly enough within + 0,5 s the movement will not restart. It could restart only when the selected function switch/joystick is released to neutral position. • All switches and joystick operating a movement, return automatically to neutral when released. • At power up, a switch in it's neutral position will be taken into account to authorize movement. • The status of the switches is tested automatically when the machine is switched on, and checked at every starting. A switch or joystick will be active only after it has been detected in neutral position. A buzzer beeps in the following conditions : • Overload (if fitted). • Machine out of stowed position and on a slope greater than allowable slope. • Indicators - All the indicators are tested • When the machine is switched on. 70 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E 2 - Ground control box 2.1 - TO START AND STOP THE MACHINE • Ensure that the E-Stop buttons ( 15 ) and ( 46 ) at the ground and platform control boxes are pulled out. • Turn the key of the control box activation switch ( 92 ) to the right to energize the ground control box. To shut-down the machine from the ground control box : • Turn the control box activation selector ( 92 ) key to the center. • Push in the E-stop button ( 15 ). 2.2 - MOVEMENT CONTROL N.B.-:-RELEASING THE ENABLE SWITCH WILL STOP ALL MOVEMENTS. Ground box controls (emergency station) Even at low movement speeds, use the controls with caution. Control Action Platform raising / lowering Push the platform raising / lowering selector ( 106 ) upwards to raise the platform. Press the platform raising / lowering selector ( 106 ) downwards to lower the platform. Emergency lowering / Emergency platform lowering halted Pull the T-handle ( C107 ) to lower the platform. Release the T-handle ( C107 ) to stop platform lowering. Once rescue operations are complete, write an incident report. A B C D E F G H I 71 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E Pull T-handle for emergency lowering N.B.-:-P ULLING ON TO THE T-HANDLE, IMMEDIATELY ACTIVATES THE EMERGENCY LOWERING OF THE PLATFORM. 2.3 - ADDITIONAL CONTROLS FROM THE GROUND CONTROL BOX For the machines equipped with beacon light : • Push the beacon light selector switch ( 105 ) upwards to turn ON the beacon light. • Push the beacon light selector switch ( 105 ) downwards to turn OFF the beacon light. ALWAYS keep personnel and obstructions clear of the aerial work platform that might block the lowering. 72 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E 3 - Platform control box 3.1 - TO START AND STOP THE MACHINE To start the machine : At the ground control box : • The E-stop button on the ground control box must be in ON position (pulled out / activated). • Turn the key on the control box activation selector switch ( 92 ) to the left to energize the platform control box. At the platform control box : • Pull the E-stop button (46). To stop the machine : • Push in the E-stop button (46). A B C D E F G H I 73 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E 3.2 - DRIVE AND STEER CONTROL To control the direction and drive : • Move the 2-position selector ( 112 ) to the right. • The drive indicator ( 111 ) lights up. • Simultaneously operate drive joystick ( 108 ) with joystick trigger (Enable switch ( 123 )) pressed in and maintained. N.B.-:-F OR JAPAN ONLY - BOTH THE ENABLE SWITCH ( 123 ) AND FOOT PEDAL SWITCH ( 245 ) MUST BE PRESSED TO ACTIVATE A FUNCTION. N.B.-:-F OR JAPAN ONLY - DRIVE AND STEER RESTRICTION WHEN ELEVATED, DEPENDING ON THE OPTION SELECTED AS SHOWN BELOW : OFF-D RIVE AND STEERING FUNCTIONS ARE ALLOWED AT FULL HEIGHT. ON IF > 0.5 M (1.6 FT) - DRIVE AND STEER FUNCTIONS ARE CUT OFF ON IF > 1.5 M (5.0 FT) - DRIVE AND STEER FUNCTIONS ARE CUT OFF N.B.-:-THE DRIVE AND LIFT SPEEDS ARE PROPORTIONAL TO THE POSITION OF THE JOYSTICK. PUSHING THE JOYSTICK COMPLETELY FORWARD OR BACKWARD, WILL RESULT IN MAXIMUM SPEED. Control Action Driving Move the drive joystick ( 108 ) forwards to drive the machine forwards. Move the drive joystick ( 108 ) backwards to drive in reverse. Front-axle steering Push the front-axle steering selector thumb switch ( 108 ) to the right to steer to the right. Push the front-axle steering selector thumb switch ( 108 ) to the left to steer to the left. 74 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E 3.3 - MOVEMENT CONTROL To operate raising/lowering function, move 2 position selector switch ( 112 ) to the left. Activate raising/lowering selector ( 110 ). Simultaneously operate joystick ( 108 ) with joystick trigger (Enable switch ( 123 )) pressed in and maintained. N.B.-:-F OR JAPAN ONLY - BOTH THE ENABLE SWITCH ( 123 ) AND FOOT PEDAL SWITCH ( 245 ) MUST BE PRESSED TO ACTIVATE A FUNCTION. Control Action Platform raising / lowering Push the movement joystick ( 108 ) forwards to raise the platform. Push the movement joystick ( 108 ) backwards to lower the platform. 1 . 2 . 3 . . 1. When the platform is lowered to a height of 1,50 m(4 ft11 in) from the ground; a time delay is automatically activated for a few seconds, before any further lowering of the platform can commence 2. This is to avoid any risk of crushing 3. The alarm sounds A B C D E F G H I 75 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E 4 - Emergency procedure 4.1 - IN CASE OF POWER LOSS In case of loss of the main power source, the secondary (back-up) power unit, powered by the starting battery, allows movements to be controlled from both the ground and platform control boxes. In an emergency, if the operator has to exit the platform while it is elevated, the transfer of the operator must respect the following recommendations. : • Exit onto a sturdy and safe structure. • The occupant(s) must ensure that 2 lanyards are used for security/safety. One must be attached to the designated anchorage point on platform the occupant(s) is in and the other attached to the structure intended to get on. • Occupant(s) must exit the current platform through the normal access. N.B.-:-D O NOT DETACH THE LANYARD FROM THE CURRENT PLATFORM IF THE TRANSFER TO THE NEW STRUCTURE POSES ANY DANGER OR UNTIL THE TRANSFER IS SAFELY COMPLETED. DO NOT ATTEMPT TO CLIMB DOWN FROM THE PLATFORM. WAIT FOR ASSISTANCE TO LEAVE THE CRADLE SAFELY . 4.2 - TO RESCUE OPERATOR IN PLATFORM In a situation where an operator located in the platform needs to be rescued (for example in case of illness, injury or trapped against a structure making the control box inaccessible), the rescue personel at ground level needs to obtain rapid and direct access to operating functions. HAULOTTE® provides a ground control emergency system that should be used to safely bring the operator into such a position that appropriate medical attention could be provided. Lower the platform using the T-handle on the chassis. Or : 1. Turn the key of the control box activation switch ( 92 ) to the right to energize the ground control box. The platform box controls are de-energized. 2. Lower the platform from the ground control box. 3. Lower the platform using the platform raising/lowering selector ( 1 ) while simultaneously press- ing and maintaining the "Enable switch" ( 9 ). 4. Release it to halt lowering. Once rescue operations are complete, write an incident report. 76 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E 5 - Transportation 5.1 - PUTTING IN TRANSPORT POSITION During loading, ensure that : • The loading ramp can support the machine weight. • The loading ramp is correctly attached to transport vehicle. • The loading ramp has sufficient grip surface. • The transport vehicle must be parked on a level surface and must be secured to prevent rolling away while machine is being loaded or unloaded. To climb the slope, move progressively the drive joystick ( 108 ). If the slope is too steep, use a winch in addition to traction. Do not place yourself below or too close to the machine during loading. The machine must be completely in the stowed configuration : • Check the platform is completely empty. • Platform extension must be retracted in the locked position. • Drive the machine onto the truck bed. • Secure the machine to the tie down points provided (See picture). A wrong move can lead to machine tipping over and may cause serious injuries and material damage. The manual extension (if fitted) must be retracted and locked during transport or towing. A B C D E F G H I 77 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E 5.2 - MACHINE LAYOUT 5.3 - UNLOADING Before unloading, check that the machine is in good condition. • Remove the tie downs. • At ground control box turn control box activation switch ( 92 ) to the left to energize platform box. • At the platform controls, with 2 position selector ( 112 ) turned to the right, carefully and progressively move drive joystick ( 108 ) with Enable switch ( 123 ) pressed and maintained. To reinstate the system, lift the platform a few centimetres (inches) from the ground control box. Warning : Upon starting a machine that has been secured and transported, the safety system may detect a false overload preventing all movement from the platform control box. 78 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E 5.4 - TOWING To tow a broken-down machine, release brake (Refer to Section D 5.4.1 Brake release). Perform this operation on flat ground with wheels chocked. In the towing configuration, the machine braking system is inactive. Use of a drawbar is recommended : • Do not exceed the maximum freewheel speed (Refer to Section B 4 Technical specifications). • Do not exceed a grade of 25%. In the event of a machine breakdown, the machine can be towed a short distance to load it onto a transport vehicle : • Ensure that no one is in the platform during towing. • Before towing, ensure that the platform is fully lowered. • The platform must be empty. • ALWAYS keep personnel and obstructions clear of the aerial work platform when brakes are released. A B C D E F G H I 79 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E 5.4.1 - Free wheel mode To tow a broken-down machine, release brake. If the machine is towed, the brakes on the drive wheels can be released using the switch located in the motor pump unit compartment. To release the machine's brakes, the following conditions must be met : • The platform control box or the ground control box must be selected. • The machine must be completely stowed. • No movement selected. • The machine must not be tilted. Push the brake release button for at least 3 s. An audible signal (beep) sounds. Releasing the button disengages the brakes. The brake release procedure stops automatically if the brake release button is pushed again, any actions are taken at the control boxes, the machine is turned off, or the control box in use is changed. Perform these operations on flat, horizontal ground. Failing that, block the wheels to immobilize the machine. During brake release operation, the machine is in free wheel mode and the brake system no longer functions. In the towing configuration, the machine is no longer slowed down. Use a drawbar to avoid any risk of accident. Do not exceed 4.5 km/h (2.79 mph) . 80 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E 5.5 - STORAGE When the machine is stored with platform raised, it is necessary to regularly switch "ON" the power to ensure that the security systems are active.. It is recommended that the machine is not stored or immobilized unfolded. Ensure all access panels, doors and side compartment covers are shut and secured. Turn the energizing key selector switch ( 92 ) at the ground control box to the "center" position to shut OFF the power. Remove the energizing key to prevent unauthorized operation of the machine. The machine can be stored in a designated area when not in use. If it has been stored for longer than 3 months without use then a periodic inspection must be conducted. Storing of the machine with an obstacle under the extended platform is forbidden. When machine is stored and not used for more than 1 week, check the battery's state of charge, recharge if necessary. To avoid any risk of corrosion on rods of cylinders during a storage period of for more than 1 month : • In a normal atmospheric environment : perform a complete cycle for the cylinders every 2 months while they are in storage. • In harsh environments (high levels of salinity in the atmosphere: close to the sea, industrial environment with chloride emissions and/or humidity >70%), we recommend applying the following protection process : • Wash and rinse the entire machine with plenty of clean water. • Dry all the cylinder rods using an air gun. • Apply a solvent-based oil leaving an oily film after evaporation of the solvent directly to all rods left exposed when the machine is in storage position. • Re-apply the product every month. After washing the machine, make sure it is fully air-dry and does not contain moisture on corrosive parts (cylinders rods for example). Do not wash any electrical components, particularly with high pressure washer. Wipe away dirt from around electrical components with a dry cloth. A B C D E F G H I 81 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E 5.6 - LOADING BY RAMP 5.7 - UNLOADING BY RAMP 1. Remove the tie downs. 2. Start the machine. 3. The ramp is in good condition and of sufficient capacity. The lifting equipment ie. slings, shackles, hooks, lifting beam etc. are in good condition and of sufficient capacity. To avoid any risk of sliding during loading, ensure that : • The loading ramp can bear the load. • The loading ramp is correctly attached. • The loading ramp has sufficient grip. If the slope exceeds 25% grade, use a winch to assist in loading on to the ramp. Never place yourself below or too close to the machine during loading. A wrong move can lead to the tipping over of the machine and cause serious bodily and material accidents. Before operating, check that the machine is in good condition. If the machine has been damaged during transportation, contact the transporter in writing 82 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E 5.8 - LIFTING OPERATION During loading / unloading operation, if it becomes necessary to lift the machine using an overhead crane, it is important to respect the following : • Put the machine in stowed position (Extension retracted). • Ensure the platform is empty. • Verify that lifting accessories are in good operation and match the technical specifications listed below. It is important that the lifting devices are attached only to the designated lifting eyes. • Each of the slings used for lifting the machine must be adjusted to keep the machine level and to minimize the risk of damage to the machine. • Anchorage point for lifting are identified / labeled by the following symbol . • ONLY trained and authorized personnel should attempt to lift the machine. Procedure for the use of slings Never lift the machine with slings attached to counterweight. Number of shackles Number of slings Length Maximum load per sling and shackle 4 4 2 m / 6 ft 7 in 1000 kg/ 2,205 lbs A B C D E F G H I 83 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E 5.9 - LOADING AND UNLOADING WITH FORKLIFT Unloading • Carefully lift the machine and make sure that the machine weight is properly balanced. • Slowly lower the machine and place it on the ground. • Lower the platform. The machine must be in the fully stowed transport position. • Ensure that the machine controls are in the OFF position. • Forklift used to load and unload must have adequate capacity (Refer to Section B 4 Technical specifications). • Adjust the forklift forks spread to match with the machine fork pockets. • Carefully insert the forklift forks in the designated machine fork pockets. Never place yourself below or too close to the machine during loading. A wrong move can lead to machine tipping over and may cause serious injuries and material damage. 84 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E 6 - Hydraulic oil External environmental conditions can reduce performance of the machine if the hydraulic oil temperature does not reach its optimum range. It is recommended to use the hydraulic oil according to weather condition. Refer to the table below. N.B.-:-I T IS RECOMMENDED TO REPLACE LOW TEMPERATURE OIL AS THE AMBIENT TEMPERATURE REACHES + 15°C (59°F). IT IS NOT ADVISABLE TO MIX OILS OF DIFFERENT BRANDS OR TYPES. Environmental conditions SAE Viscosity grade Ambient temperature between - 15°C (5°F) and + 40°C (+ 104°F) HV 46 Ambient temperature between - 35°C (- 31°F) and + 35°C (+ 95°F) HV 32 Ambient temperature between 0°C (+ 32°F) and + 45°C (+ 113°F) HV 68 A B C D E F G H I 85 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E 7 - Battery care and maintenance 7.1 - BATTERY CHARGING Recharge aerial work platform batteries after each 8 hour work shift or as needed. When the aerial work platform is not in use, batteries should be recharged at least once per week. Under normal circumstances, battery recharge should take approximately 8-10 hours. However, a full recharge may take up to 24 hours, if the battery charge is extremely low. Battery charger status Ground control box : The indicator (93) indicates charge status. Platform control box : The indicator (91) indicates charge status. • Green indicator : Battery charged 100 %. • Yellow LED : Battery charged 80 %. • Red LED : Battery in initial charging phase. • Battery charged : • Flashing : Batteries have 40% charge left : • Constantly on : Batteries have only 20% charge left : 100% 40% 20% 86 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E When should the batteries be charged ? : • Do not let the battery discharge to below 20 %. • When the batteries are discharged to between 35 % and 80 % of their nominal capacity. • If installing new batteries, recharge them after 3 or 4 hours of use 3 to 5 times. • After a long period of non-use. • Never leave the batteries discharged. • Do not put off recharging the batteries in cold weather as the electrolyte may freeze. How to charge the batteries ? : • Use the machine's on-board charger. The charger has a charge rate compatible to the battery capacity. • Ensure that the mains supply is compatible to the charger's consumption. • Top up the batteries with distilled water to the minimum electrolyte level if any of the elements are below this minimum level. • Work in a clean and well-ventilated area away from naked flames. • Move the aerial work platform to a well-ventilated area with direct access to a AC electrical outlet. • Do not recharge the batteries if the temperature of the electrolyte exceeds 40 °C(104 °F) . Allow to cool down. • Keep the top of the batteries clean and dry. Incorrect connection or corrosion may cause a high loss of power. • The charger settings are adjusted in the factory using its own cable. If the cable needs changing, the HAULOTTE® factory must be contacted to obtain authorisation. Before charging the batteries, switch the machine off. Charger type 24 V - 20 Ah Electric power supply 220 V single phase 50 Hz 120 V single phase 60 Hz 80 V single phase 50 - 60 Hz System voltage 24 V Charging time Approximately 10 h for batteries discharged to 80 % A B C D E F G H I 87 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E To recharge the aerial work platform batteries : Attach a 12 AWG multi-strand, grounded extension cord with a maximum length of 15 m (50 ft) to the receptacle located on the charger. Plug the extension cord into outlet. Start-up is automatic as soon as the mains connection is established. The charger is fitted with a LED indicator placed near the special holding frame : • Green indicator : Battery charged 100 % • Yellow LED : Battery charged 80 % • Red LED : Charger in the intitial charge phase The CHARGING indicator LED remains lit continuously during the first stage of the charge cycle. The charge current will be displayed on the BATTERY CHARGER FACEPLATE. To display the Battery Voltage, press (push) in and hold the BATTERY VOLTAGE button. How to maintain battery autonomy ? : • Do not charge the batteries in cold temperatures. • The battery life is reduced when the machine is used in cold temperatures (< 0 °C(32 °F) ). • If the machine is not going to be used for a length of time, shut-off the power with battery isolation switch(E-stop button ( 15 )). • Do not let the battery discharge to below 20 %. • If batteries are deeply discharged (<10%); standard battery charger may not be enough to recharge battery. 88 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E When the battery charge reaches 80% of capacity, the yellow 80% CHARGED indicator LED will become lit and the green CHARGING indicator LED will begin to flash. Unplug the extension cord from the outlet and the charger receptacle on the aerial work platform. Store the extension cord for next use. N.B.-:-A LWAYS UNPLUG THE BATTERY CHARGER POWER CORD BEFORE MOVING THE AERIAL WORK PLATFORM . FAILURE TO DISCONNECT POWER CORD COULD CAUSE DAMAGE TO THE EQUIPMENT. Do not disconnect any output leads or connectors between the batteries and the charger when the charger is on. To stop a charge in progress, always unplug the extension cord from the AC power source. Recharge batteries in a well-ventilated area only. Do not charge batteries near fire, spark or other potential ignition sources. Batteries may emit highly explosive hydrogen gas while charging. Failure to properly ventilate the charge gasses could result in death or serious injury. Always charge aerial work platform batteries away from flammable materials. ALWAYS avoid contact with battery acid. Battery acid causes serious burns and should be kept away from skin or eyes. If contact occurs, flush with water and consult a physician immediately. A B C D E F G H I 89 4000415480 E 01.18 USA / GB D - Operation instructions OPTIMUM 8 - OPTIMUM 1931 E Notes 90 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E General Specifications 1 - Machine dimensions Stowed / Transport position : Configuration that takes the minimum floor space necessary for storage and / or delivery of the machine - Access position. A B C D E F G H I 91 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E CE, AS and EAC standards ANSI and CSA standards Machine OPTIMUM 8 Marking Specifications - Dimensions SI Imp. A Overall length of machine 1,89 m 6 ft 2 in B Overall width of machine 0,79 m 2 ft 7 in C Overall height of machine 1,99 m 6 ft 6 in D Wheel base 1,38 m 4 ft 6 in E Ground clearance - Pothole mechanism deployed with platform raised 2,2 cm 1 in Ground clearance - Pothole mechanism retracted with platform fully lowered 6 cm 3 in F X G Platform dimensions 1,73 m x 0,74 m 5 ft 8 in x 2 ft 5 in H Storage length 1,89 m 6 ft 2 in J Storage height 1,99 m 6 ft 6 in Machine OPTIMUM 1931 E Marking Specifications - Dimensions SI Imp. A Overall length of machine 1,89 m 6 ft 2 in B Overall width of machine 0,79 m 2 ft 7 in C Overall height of machine 1,99 m 6 ft 6 in D Wheel base 1,38 m 4 ft 6 in E Ground clearance - Pothole mechanism deployed with platform raised 2,2 cm 1 in Ground clearance - Pothole mechanism retracted with platform fully lowered 6 cm 3 in F X G Platform dimensions 1,73 m x 0,74 m 5 ft 8 in x 2 ft 5 in H Storage length 1,89 m 6 ft 2 in J Storage height 1,99 m 6 ft 6 in 92 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E 2 - Major component masses 3 - Acoustics and vibrations The acoustics and vibrations specifications are based upon the following conditions : • The airborne noise emissions at workstation are determined per European Directive 2006/42/CE. • The guaranteed sound power level LWA (displayed on the product) is determined per European Directive 2000/14/CE. • The vibrations transmitted by the machinery to the hand/arm system and to the whole body are determined per European Directive 2006/42/CE. Specifications OPTIMUM 8 OPTIMUM 1931 E SI Imp. Frame assembly mass 948 kg 2090 lbs Scissors assembly mass 430 kg 950 lbs Platform assembly mass 125 kg 275 lbs Drive wheel mass 19 kg 40 lbs Steer wheel mass 19 kg 40 lbs Central counterweight mass 248 kg 550 lbs Moulded (Steps) counterweight mass 244 kg 540 lbs Specifications Sound pressure level at workstation 63 dBA Vibrations hand/arm Vibration transmitted by this MEWP to the hand-arm does not exceed 2,5 m/s²(98,4 in/s²) Vibrations whole body Vibration transmitted by this MEWP to the whole body does not exceed 0,5 m/s²(19,6 in/s²) A B C D E F G H I 93 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E 4 - Wheel/Tire assembly 4.1 - TECHNICAL SPECIFICATIONS 4.2 - INSPECTION AND MAINTENANCE Component Standard wheel Reference number Solideal Typ e Solid tires/tyres Size 316 mm / 108 mm (12,5 in/ 4,25 in) Tor qu e 115 Nm (84.81 ft lbs) Replace the wheels and the tires if any of the following conditions exist : • Presence of cracks, damage, deformation or other faults on the hub • Damage to the tire : • Cut or hole > 3 cm (2 in) in the rubber side wall. • Blister or pronounced lump on the external and lateral wall. • Damaged wheel stud. • Damage or wear on the side wall to the extent that the reinforcing wire is visible. • Consistent wear of the ground contact surface greater than 25% Tires and rims are critical components for the stability of the machine. For safety reasons : • Use only HAULOTTE® spare parts according to the technical characteristics of the machine. Refer to the spare parts catalog. • Do not replace factory-installed tires with tires of different specifications or ply rating. 94 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E 4.2.1 - Procedure of replacement • Slightly lift the machine using the lifting points of the frame. • Place a wooden spacer under the frame to support the machine after lifting off the ground. • Straighten the bent tooth of the washer which restricts the nut rotation. Use a screwdriver and a hammer. • Use the locknut socket TMFS5 to loosen the nut. • Remove the nut and the washer. • Remove the wheel (use an extractor if necessary). A B C D E F G H I 95 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E Reassembly of the wheel • Use a new locking washer MB5 (4000505880). Marking Description 1 Wheel 2 Motor shaft 3 Washer 4 Nut 96 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E • Use a new nut KM5 (2454131050). 1. Check that the shaft key is well positioned in the motor shaft. 2. Mount the wheel on the motor shaft. 3. Install the washer first then the nut. 4. Tighten the nut with a calibrated torque wrench and locknut socket FMFS5 to preset torque of 8 kgf. m (58 lbsf. ft). 5. If no washer tooth lined up with any notch in the nut, continue to tighten the nut until it is aligned. 6. Bend the aligned washer tooth in the notch to stop rotation. A B C D E F G H I 97 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E 5 - Options 5.1 - PLUMBER'S KIT 5.1.1 - Description This attachment is an assembly designed to transport pipes and tubes. The assembly comprises of 2 cradles securely attached to the platform. The load (material) should be placed in both the cradles and secured with a strap (not supplied). 5.1.2 - Characteristics 5.1.3 - Safety precautions Specifications OPTIMUM 8 OPTIMUM 1931 E SI Imp. Weight of the carrier 9 kg 20 lbs Weight of the equipment on the carrier 50 kg 110 lbs Maximum load surface 0,3 m² (Ø 0,2 m x 1,5 m) 3.3 sq.ft (Ø 8 in x 4 ft 11 in) Maximum wind speed allowed 0 m/s - 0 km/h 0 mph • Please read and assimilate the instructions before using the attachment. • This attachment is designed for transporting pipes and tubes. Do not use this attachment for transporting other types of load. . • Do not suspend loads. • Do not overload the attachment and ensure that the material is correctly attached by straps (not supplied). • Do not exceed the maximum allowable platform capacity. The combined weight of the attachment, load, the occupants, the tools and any other equipment must not exceed the maximum allowable platform capacity. • Do not load tubes whose surface area exceeds the maximum authorized surface area. Exposing an additional surface area to the wind reduces machine stability. Do not install any other attachments that increase the surface area exposed to the wind. • Do not use the machine if the wind speed exceeds the authorized limit of the attachment. • The cradles should always be positioned such that they are within the platform. Position the bottom end of the cradles such that they are resting on the platform floor. • When maneuvring, ensure you maintain a safe distance between the load and the obstacles in the work environment. 98 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E 5.1.4 - Pre-operation inspection 5.1.5 - Operation • Position and centre the load to rest on the 2 cradles. • Securely attach the load to each cradle with supplied straps. Strapping example(s) • Check that the cradle has no cracks or other damage. • Check that the cradle is correctly installed and secured to the platform(Ensure fastening screws are tightened and pins correctly positioned). • Check that the information decal is present on the cradle and is legible. • Check that the strap(s) is(are)not twisted or torn. • Check that the position of the load and attachment is not obstructing access to the platform or the controls. • Check that the position of the attachment and the load is not reducing visibility during maneuvers in the work environment. A B C D E F G H I 99 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E 5.1.6 - Disassembly - Assembly OPTIMUM 8 / 1931E • Straddle the support pipes (1, 1A, 1B) and (1C) on the structure of the fixed or folding guard rails (7). • Lock in place with the pin ( 5 ). • Tighten the 3 screws ( 3 ) and 3 washers ( 2 ) to the recommended torque N.B.-:-T ORQUE REQUIREMENTS : 22 NM (16 FT LBS) • Pre-operation test : Place and secure the load of 50 kg (110 lbs) max. on the cradle. Ensure that the cradle can support the load and that there is no visual structural damage. Marking Description 1 - 1A - 1B - 1C Carrier 2 Spring washer 3 Fastening screw 4 Strap 5 Dowel pin 6 Adjustment screw 7 Guardrail 8 Platform 4 17 5 6 1A 1B 8 2 3 1C 100 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E 5.1.7 - Specific decals Location of the decals OPTIMUM 8 / 1931E Marking Description Quantity Part number 1 Risk of overturning 1 In english - ANSI : 4000426070 In french - ANSI : 4000415300 In spanish - ANSI: 4000426060 1 A B C D E F G H I 101 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E 5.2 - FOLDING GUARDRAILS 5.2.1 - Description Folding guardrails system is designed to allow guardrails to be lowered to reduce the overall height of the machine. This system facilitates moving the machine through low height doorways/passages. 5.2.2 - Safety precautions 5.2.3 - Fold down operation • Extension deck must be fully retracted and in locked position. • The intermediate sliding entrance bar must be at its lowest position. • Fully lower the platform to the stowed position. • Take care to avoid trapping the hands while folding the guardrails. • User must wear gloves. • Keep hands clear of pinch points. • Perform the folding of the guardrails from outside of the platform. 102 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E Remove platform control box from its designated position and place it on platform floor Remove the 2 pins ( G2 ) from the platform front guardrails. Tip element ( 2 ) inwards onto the platform floor. Remove pin ( G3 ) from the right hand extension guardrail. Lift the guardrail and slowly tip it inwards until it contacts element ( 3 ). Remove pin ( G4 ) from the left hand extension guardrail. Lift the guardrail and slowly tip it inwards until it contacts element ( 4 ). A B C D E F G H I 103 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E Remove the 2 pins ( G5 ). Lift and tip inwards and down until it contacts the element ( 6 ). Remove the pin ( G6 ). Lift and tip left hand main railing inwards until it contacts the element ( 3 ). Do not release the element ( 5 ). Remove the pin ( G7 ). Lift and tip right hand main railing inwards until it contacts the element ( 6 ). 104 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E 5.2.4 - Specific decals 5.2.5 - Raising guardrails to working position To raise the folded guardrails to the vertical working position : • Follow the fold down operational sequence in the reverse order. • Ensure all pins are installed and secured. Marking Description Quantity Part number 8 Explanation work and transport positions 1 4000557230 A B C D E F G H I 105 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E 5.3 - PANEL CARRIER 5.3.1 - Description This attachment is an assembly designed to transport panels. The assembly comprises of a tray that extends along the length of the floor. The panel(s) should be placed in the tray and secured to the guard rail with a strap (not supplied). 5.3.2 - Characteristics 5.3.3 - Safety precautions Specifications OPTIMUM 8 OPTIMUM 1931E SI Imp. Weight of the carrier 7 kg 15 lbs Maximum allowable weight of the panels on the carrier 50 kg 110 lbs Maximum load surface 3 m² (L 2,5 m x H 1,2 m) 32 sq.ft (L 8 ft x H 4 ft) Maximum wind speed allowed 0 m/s - 0 km/h 0 mph • Please read and assimilate the instructions before using the attachment. • This attachment is designed for transporting panels. Do not use this attachment for transporting other types of load. • Do not suspend loads. • Position the panel(s) centrally on cradle with deck extended. • Secure the panel in place with the use of strap. • Do not overload the attachment and ensure that the panels are secured with straps. • Do not exceed the maximum allowable platform capacity. The combined weight of the attachment, load, the occupants, the tools and any other equipment must not exceed the maximum allowable platform capacity. • Do not load panels whose surface area exceeds the maximum authorized surface area. Exposing an additional surface area to the wind reduces machine stability. Do not install any other attachments that increase the surface area exposed to the wind. • Do not use the machine if the wind speed exceeds the authorized limit of the attachment. • When maneuvring, ensure you maintain a safe distance between the load and the obstacles in the work environment. 106 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E 5.3.4 - Pre-operation inspection 5.3.5 - Operation • Position and center the load to rest on the cradle. • Securely attach the load on the cradle with straps. Strapping example(s) • Check that the cradle has no cracks or other damage. • Check that the cradle is correctly installed and secured to the platform (Ensure fastening screws are tightened and pins correctly positioned). • Check that the information decal is present on the cradle and is legible. • Check that the strap(s) is(are)not twisted or torn. • Check that the position of the load and attachment is not obstructing access to the platform or the controls. • Check that the position of the attachment and the load is not reducing visibility during maneuvers in the work environment. A B C D E F G H I 107 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E 5.3.6 - Disassembly - Assembly OPTIMUM 8 - OPTIMUM 1931E 108 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E A B C D E F G H I 109 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E 1. Position the sheet metal support ( 2 ) against the sheet metal support ( 1 ). Tighten the screws ( 4 ) and the nuts ( 5 ) to the recommended torque. 2. Place the protection pads ( 7 ), the rivets ( 6 ) and the stops ( 3 ). 3. After checking that the decal is on the cradle, position the sheet metal support ( 1 ) on the outside of the guardrail on the side of the control box. 4. Tighten the screw ( 4 ) and the nut ( 5 ) to the recommended torque. Tighten the screws ( 8 ) to the recommended torque. 5. Position the bumpers ( 9 ) and fasten with clamps ( 10 ). N.B.-:-TORQUE REQUIREMENTS : 10 NM (7 LBS/FT) FOR M6 AND 22 NM (16 LBS/FT) FOR M8. • Pre-operation test : Place and secure the load of 50 kg (110 lbs) max. on the cradle. Ensure that the cradle can support the load and that there is no visual structural damage. Marking Description 1 Sheet metal support 2 Sheet metal support 3 Stop 4 Screw 5 Nut 6 Rivet 7 Protection pad 8 Screw 9 Bumper 10 Clamp 110 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E 5.3.7 - Specific decals Location of the decals OPTIMUM 8 - OPTIMUM 1931E Marking Description Quantity Part number 1Danger 1 In french : 4000676050 In english : 4000676060 In spanish : 4000676070 A B C D E F G H I 111 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E 5.4 - SWING GATE 5.4.1 - Description "SWING GATE" consists of a laterally mounted pivoting ½ gate with closing latch, which enables a better access to platform. Spring loaded hinges and a latching mechanism allows the gate to swing inwards only. Swing gate 5.4.2 - Characteristics Width of the gate : 600 mm / 24 in 5.4.3 - Safety precautions 5.4.4 - Pre-operation instructions • Inspect that the latching mechanism is securely fastened. • Check the hinges and latch operate correctly and are not deformed. • Ensure that the gate returns automatically to the closed and fastened position after entering or exiting the platform. • The gate is part of the guardrail system and must be securely fastened after entering the platform. • Pay attention to the toe board when entering or exiting the platform. 112 4000415480 E 01.18 USA / GB E - General Specifications OPTIMUM 8 - OPTIMUM 1931 E Notes A B C D E F G H I 113 4000415480 E 01.18 USA / GB F - Maintenance OPTIMUM 8 - OPTIMUM 1931 E Maintenance 1 - General As an owner and/or operator of Haulotte equipment, your Safety is of utmost importance to HAULOTTE® , which is why HAULOTTE® places such a high priority on product safety. INSPECTIONS are not only required by HAULOTTE®, but may also be required by industry standards and/or governmental regulations. To ensure that your equipment continues to perform to the factory set performance levels, it is important that you regularly maintain your equipment and avoid making any modifications that are not approved by HAULOTTE®. Regular and timely inspections will reduce equipment down time as well as prevent possible injury. N.B.-:-DO NOT OPERATE UNLESS YOU ARE FAMILIAR AND TRAINED IN THE PRINCIPLES OF SAFE MACHINE OPERATION. Overview : • Walk-around inspections take only a few minutes at the beginning and end of each shift – one of the best ways to prevent mechanical problems and safety hazards. What to Do : • Use your senses: sight, smell, hearing and touch. Frequency : • Check your machine periodically during your entire workday. • Make sure to do your inspection the same way every time. • Complete one of these inspections at the start and end of each shift. N.B.-:-I F DAMAGE OR UNAUTHORIZED MODIFICATIONS ARE DISCOVERED, THE MACHINE MUST BE REMOVED FROM SERVICE UNTIL REPAIRS ARE MADE BY A QUALIFIED SERVICE TECHNICIAN. It is the owner's responsibility to ensure the required maintenance as recommended by Haulotte is completed prior to the operation of the machine. 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. 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. The inspection and maintenance table, identifies the role and the responsibilities of each party in periodical machine maintenance. Section C 3 - Inspection and Functional test. 114 4000415480 E 01.18 USA / GB F - Maintenance OPTIMUM 8 - OPTIMUM 1931 E 2 - Maintenance Schedule This section provides the necessary information needed to place the machine in safe operation. According to the current regulations, this machine has been designed for a minimum service life of 10 years. The life may be extended or reduced dependent on the severity of operating conditions, the machine condition itself and by conducting effective inspections and maintenance in addition to other external factors. There are a number of factors which can affect the design life including but not limited to, severity of operating conditions/routine maintenance which should be carried out in accordance with this manual. Severity of operating conditions may require a reduction in time between maintenance periods. Machines that have been out of service or have not been in use for more than 3 months must undergo a periodic inspection before the machine is put back into service. Maintenance must be carried out by a competent company or person familiar with mechanicalprocedures. Maintenance operations performed must be recorded in a register / log book of the machine. A B C D E F G H I 115 4000415480 E 01.18 USA / GB F - Maintenance OPTIMUM 8 - OPTIMUM 1931 E 3 - Inspection program 3.1 - GENERAL PROGRAM The machine must be inspected on a regular basis at intervals of no less than once 1 per year. The purpose of the inspection is to detect any defect which could lead to an accident during routine use of the machine. Local standards and regulations may require more frequent inspections. HAULOTTE® requires Reinforced and Major Inspections to be carried out on the product to extend its service life. Inspections must be carried out by a competent company or person. The inspection results must be recorded in the safety register or machine log book controlled and overseen by the company manager. This register or machine log book and the list of competent repair persons must be made available to the government work inspector and HAULOTTE Services®. 3.2 - DAILY INSPECTION The Daily inspection includes a visual inspection, operational checks and testing of the safety systems. This must be conducted by the operator before using the machine. This inspection is the responsibility of the user. Refer to Section C 3.1 - Daily inspection. When Responsible Stakeholder What Before sale Owner (or renter) Competent technician or qualified technician HAULOTTE Services® Periodic inspection Before rent Owner (or renter) Competent technician or qualified technician HAULOTTE Services® Daily inspection Before use or every change of user User User Annually ( 1 year) Owner (or renter) Competent technician or qualified technician HAULOTTE Services® Periodic inspection 5 years Owner (or renter) Qualified technician HAULOTTE Services® Reinforced inspection 10 years Owner (or renter) Qualified technician HAULOTTE Services® Major inspection 116 4000415480 E 01.18 USA / GB F - Maintenance OPTIMUM 8 - OPTIMUM 1931 E 3.3 - PERIODIC INSPECTION The Periodic inspection is a thorough evaluation of the operation and safety features of the machine. It must be conducted before the sale / resale of the machine and/or at least once every year. Local regulations may have specific requirements on frequency, and content of inspections. The severity of operating conditions may require frequent inspections. This inspection is the responsibility of the owner, and inspections must be carried out by a competent company or person. This inspection is in addition to the daily inspection. This inspection should also be conducted after : • Extensive dismantling and reassembly of major components. • Repairs involving the machine's essential components. • Any accident causing stress to the machine. 3.4 - REINFORCED INSPECTION The Reinforced inspection is a thorough evaluation of the machine's structural components, to ensure proper functionality of the machine. This evaluation must occur at a frequency of 5000 hours or every 5 years. This inspection is the responsibility of the owner, and it must be conducted by a HAULOTTE Services® technician or by a competent company or person. This inspection includes : • Daily inspection • Periodic inspection N.B.-:-R EFER TO THE MAINTENANCE MANUAL FOR DETAILS. 3.5 - MAJOR INSPECTION The Major inspection is a thorough evaluation of the machine's integrity and proper functioning; after a normal service life of 10 years. This evaluation must take place after 10 years of operation and then repeated every 5 years thereafter. The severity of operating conditions may require frequent inspections. This inspection is the responsibility of the owner, and it must be conducted by a HAULOTTE Services® technician. This inspection includes : • Daily inspection • Periodic inspection • Reinforced inspection N.B.-:-R EFER TO THE MAINTENANCE MANUAL FOR DETAILS. A B C D E F G H I 117 4000415480 E 01.18 USA / GB F - Maintenance OPTIMUM 8 - OPTIMUM 1931 E 4 - Repairs and adjustments Extensive repairs, interventions or adjustments on the safety systems or components must be performed by a HAULOTTE Services® technician. Use original spare parts and components only. N.B.-:-HAULOTTE S ERVICES® TECHNICIANS ARE TRAINED PROFESSIONALS TO PERFORM EXTENSIVE REPAIRS, INTERVENTIONS AND ADJUSTMENTS ON THE SAFETY SYSTEMS OR COMPONENTS OF HAULOTTE® MACHINES. THE TECHNICIAN CARRIES GENUINE HAULOTTE® SPARE PARTS AND TOOLS AS REQUIRED, AND ALSO PROVIDES FULLY DOCUMENTED REPORTS ON ALL WORK COMPLETED. HAULOTTE Services® will not take responsibility for any outcomes resulting from inferior services or repairs performed by other unauthorised personnel. HAULOTTE® reminds that NO modifications SHALL be carried out without the written permission of HAULOTTE®. Any unauthorised repairs/modifications will void HAULOTTE® warranty. With the utmost care to ensure enhanced reliability and greater safety of the HAULOTTE® products, it is pertinent that when a "Service or Safety Bulletin" is issued, action is taken immediately. Once the bulletin has been addressed, make sure that the completed form is submitted to HAULOTTE®. N.B.-:-W HEN DISPOSING OR SCRAPPING THIS MACHINE, PLEASE CONSIDER APPROPRIATE METHODS OF RECYCLING. ANY ITEMS THAT REQUIRE SPECIFIC DISPOSAL ARE LISTED WITH INSTRUCTIONS IN THE MAINTENANCE MANUAL. 118 4000415480 E 01.18 USA / GB F - Maintenance OPTIMUM 8 - OPTIMUM 1931 E Notes A B C D E F G H I 119 4000415480 E 01.18 USA / GB G - Other information OPTIMUM 8 - OPTIMUM 1931 E Other information 1 - Warranty disclosure 1.1 - AFTER SALES SERVICE Our HAULOTTE Services® After Sales Service is at your disposal throughout your machine's service life to ensure the optimum use of your HAULOTTE product : • When contacting our After Sales Service, ensure that you provide the machine model and serial number. • When ordering any consumables or spare parts, please use this manual and the HAULOTTE® Essential catalogue to receive your genuine HAULOTTE® spare parts, your only guarantee of parts interchangeability and correct machine operation. • If there is an equipment malfunction involving a HAULOTTE® product, then contact HAULOTTE Services® immediately even if the malfunction does not involve material and/or bodily damage. 1.2 - MANUFACTURER'S WARRANTY 1.2.1 - Warranty acceptance On reception of his machine, the owner or rental company must check the machine's condition and fill out the machine reception slip provided. 1.2.2 - Warranty period The present warranty is valid for a period of 12 months or up to a maximum of 1000 operating hours for lifting and handling equipment and 2000 operating hours for public works machinery, starting from delivery and terminating when the first limit is reached. Spare parts are covered by a 6 month warranty. 1.2.3 - Procedure conditions To benefit from the warranty, the owner or rental company must inform the nearest HAULOTTE® subsidiary or the subsidiary that delivered the machine (the only dealer authorised to carry out an intervention under the manufacturer's warranty agreement) of the defect in writing as quickly as possible. The subsidiary will decide whether to repair or replace the part that proves to be faulty. The owner or rental company must present the duly completed maintenance book supplied with the machine as proof that the maintenance operations recommended by the manufacturer have been carried out. The owner or rental company must ensure that the defect covered by the HAULOTTE® warranty is reported to and acknowledged by the HAULOTTE® subsidiary as rapidly as possible or must report the defect in writing. Work carried out under the HAULOTTE® warranty will be performed by the subsidiary which delivered the machine, wherever possible. 120 4000415480 E 01.18 USA / GB G - Other information OPTIMUM 8 - OPTIMUM 1931 E 1.2.4 - Conditions of warranty HAULOTTE® guarantees its products against defects, faults or manufacturing defects when the owner or rental company has informed HAULOTTE® of the defect. The warranty does not cover the consequences of normal wear, nor any defects, failure or damage resulting from poor maintenance or abnormal usage, in particular overloading, impact by an external source, faulty installation or any modification made to products marketed by HAULOTTE® and performed by the owner or rental company. In the event of operation or use which does not comply with the instructions or recommendations in the maintenance book, warranty claims will not be accepted. The machine utilisation period must be recorded by reading the engine hour meter whenever an intervention is made. The engine hour meter must be maintained in good working order to guarantee maximum working life and to justify maintenance at the recommended time. Warranty obligations for the time period stated above will cease immediately in situations where the defect is due to the following reasons : • Use of spare parts that are not HAULOTTE® originals. • If elements or products other than those recommended by the manufacturer are used. • If the HAULOTTE® name, serial numbers or identification marks are removed or altered. • After an unreasonably long delay before reporting a manufacturing problem. • If the owner or rental company continues to use the machine despite problems. • If damage is caused by modifications that do not comply with HAULOTTE® specifications. • If lubricants, hydraulic oils or fuels that do not comply with HAULOTTE® recommendations are used. • If the machine is incorrectly repaired or used by the customer. • In case of an accident caused by a third party. If no particular agreement has been made, any claims made after the previously established warranty period has expired will be refused. A B C D E F G H I 121 4000415480 E 01.18 USA / GB G - Other information OPTIMUM 8 - OPTIMUM 1931 E The present warranty does not cover damage that may result directly or indirectly from any flaws or defects covered by the latter : • Consumables : No claims will be accepted for objects or parts replaced in the context of normal machine usage. • Settings : Adjustments of all sorts may become necessary at any time. Therefore adjustments are considered a part of normal machine usage conditions and are not covered by the warranty. • Hydraulic and fuel circuit contamination : Every possible precaution is taken to ensure that fuel and hydraulic liquid delivered is clean. HAULOTTE® will not accept any claims concerning cleaning of the fuel circuit, filter, injection pump or any other equipment in direct contact with fuel or lubricants. • Wearing parts (pads, bearings, tires/tyres, connections, etc.) : These parts are, by definition, subject to deterioration during the period of operation. Wearing parts will therefore not be covered by the warranty agreement. 122 4000415480 E 01.18 USA / GB G - Other information OPTIMUM 8 - OPTIMUM 1931 E 2 - Subsidiary contact information HAULOTTE FRANCE PARC DES LUMIERES 601 RUE NICEPHORE NIEPCE 69800 SAINT-PRIEST TECHNICAL Department: +33 (0)820 200 089 SPARE PARTS : +33 (0)820 205 344 FAX : +33 (0)4 72 88 01 43 E -mail : [email protected] www.haulotte.fr HAULOTTE ITALIA VIA LOMBARDIA 15 20098 SAN GIULIANO MILANESE (MI) TEL: +39 02 98 97 01 FAX: +39 02 9897 01 25 E-mail : [email protected] www.haulotte.it HAULOTTE HUBARBEITSBÜHNEN GmbH Ehrenkirchener Strasse 2 D-79427 ESCHBACH TEL : +49 (0) 7634 50 67 - 0 FAX : +49 (0) 7634 50 67 - 119 E.mail : [email protected] www.haulotte.de HAULOTTE VOSTOK 61A, RYABINOVAYA STREET Bldg. 3 121471 MOSCOW RUSSIA TEL/FAX : +7 495 221 53 02 / 03 E.mail : [email protected] www.haulotte-international.com HAULOTTE DO BRASIL AV. Tucunaré, 790 CEP: 06460 - 020 – TAMBORE BARUERI – SAO PAULO – BRASIL TEL : +55 11 4196 4300 FAX : +55 11 4196 4316 E.mail : [email protected] www.haulotte .com.br HAULOTTE IBERICA C/ARGENTINA N° 13 - P.I. LA GARENA 28806 ALCALA DE HENARES MADRID TEL : +34 902 886 455 TEL SAT : +34 902 886 444 FAX : +34 911 341 844 E.mail : [email protected] www.haulotte.es HAULOTTE POLSKA Sp. Z.o.o. UL. GRANICZNA 22 05-090 RASZYN - JANKI- TEL : +48 22 720 08 80 FAX : +48 22 720 35 06 E-mail : [email protected] www.haulotte.pl HAULOTTE MÉXICO, Sa de Cv Calle 9 Este, Lote 18, Civac, Jiutepec, Morelos CP 62500 Cuernavaca México TEL : +52 77 7321 7923 FAX : +52 77 7516 8234 E-mail : [email protected] www.haulotte-international.com HAULOTTE PORTUGAL ESTRADA NACIONAL NUM. 10 KM. 140 - LETRA K 2695 - 066 BOBADELA LRS TEL : + 351 21 995 98 10 FAX : + 351 21 995 98 19 E.mail : [email protected] www.haulotte.es HAULOTTE SINGAPORE Pte Ltd. No.26 CHANGI NORTH WAY, SINGAPORE 498812 Parts and service Hotline: +65 6546 6150 FAX : +65 6536 3969 E-mail: [email protected] www.haulotte.sg HAULOTTE MIDDLE EAST FZE PO BOX 293881 Dubaï Airport Free Zone DUBAÏ United Arab Emirates TEL : +971 (0)4 299 77 35 FAX : +971 (0) 4 299 60 28 E-mail : haulottemiddle- [email protected] www.haulotte-international.com HAULOTTE SCANDINAVIA AB Taljegårdsgatan 12 431 53 Mölndal SWEDEN TEL : +46 31 744 32 90 FAX : +46 31 744 32 99 E-mail : [email protected] [email protected] www.haulotte.se HAULOTTE TRADING (SHANGHAI) Co. Ltd. #7 WORKSHOP No 191 HUA JIN ROAD MIN HANG DISTRICT SHANGHAI 201108 CHINA TEL : +86 21 6442 6610 FAX : +86 21 6442 6619 E-mail : [email protected] www.haulotte.cn HAULOTTE ARGENTINA Ruta Panamericana Km. 34,300 (Ramal A Escobar) 1615 Gran Bourg (Provincia de Buenos Aires) Argentina TEL.: +54 33 27 445991 FAX. +54 33 27 452191 E-mail : [email protected] www.haulotte-international.com HAULOTTE UK Ltd STAFFORD PARK 6 TELFORD - SHROPSHIRE TF3 3AT TEL : +44 (0)1952 292753 FAX : + 44 (0)1952 292758 E.mail : [email protected] www.haulotte.co.uk HAULOTTE GROUP / BILJAX 125 TAYLOR PARKWAY ARCHBOLD, OH 43502 – USA TEL : +1 419 445 8915 FAX :+1 419 445 0367 Toll free : +1 800 537 0540 E.mail : [email protected] www.haulotte-usa.com HAULOTTE NORTH AMERICA 3409 Chandler Creek Rd. VIRGINIA BEACH, VA 23453 – USA TEL : +1 757 689 2146 FAX :+1 757 689 2175 Toll free : +1 800 537 0540 E.mail : [email protected] www.haulotte HAULOTTE CHILE El Arroyo 840 Lampa (9380000) Santiago (RM) TEL : + 562 2 3727630 E.mail : [email protected] www.haulotte-chile.com -usa.com HAULOTTE NETHERLANDS BV Koopvaardijweg 26 4906 CV OOSTERHOUT - Nederland TEL : +31 (0) 162 670 707 FAX : +31 (0) 162 670 710 E.mail : [email protected] HAULOTTE AUSTRALIA PTY Ltd 46 GREENS ROAD DANDENONG – VIC – 3175 TEL : 1 300 207 683 FAX : +61 (0)3 9792 1011 E.mail : l [email protected] hl HAULOTTE INDIA Unit No. 1205, 12th foor,Bhumiraj Costarica, Plot No. 1&2, Sector 18, Palm Beach Road, Sanpada, Navi Mumbai- 400 705 Maharashtra, INDIA Tel. : +91 22 66739531 to 35 E-mail : [email protected] www.haulotte.in A B C D E F G H I 123 4000415480 E 01.18 USA / GB G - Other information OPTIMUM 8 - OPTIMUM 1931 E 2.1 - CALIFORNIA WARNING For electric (battery operated) machines CALIFORNIA PROPOSITION 65 BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Batteries also contain other chemicals known to the State of California to cause cancer. WASH HANDS AFTER HANDLING. 124 4000415480 E 01.18 USA / GB G - Other information OPTIMUM 8 - OPTIMUM 1931 E Notes
OPTIMUM 8 — OPTIMUM 1931 E
E
— Adjustments
• For any type A (ACTIVE) failure code, it will appear on display in lower control and the warning light will flicker
on upper controls (see below).
• For any type D (DETECTED) failure code, it will also appear on display in lower control and the warning light
will flicker on upper controls.
• For any type N failure code, it means that this alarm will never appear on display.
• An internal code (column C) with 5 digits, visible only on the console, allows specifying the trigger conditions of
the failure.
Each trigger condition is associated with a single code number (16 possible single codes in decimal format
corresponding to a single bit in binary format) :
• If several conditions are active at the same time, single codes are added to form the resulting code displayed.
For example, il conditions 1 and 4 of single code are active, then the resulting code displayed will be 5 (1+4=5).
All alarms codes are gathered per category (ex F02xxx contactors)
4000595920
E 05.17
USA
71
A
B
C
D
E
F
G
H
I
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Training manual
Training manual
OPTIMUM 8 —
OPTIMUM 1931 E
USA
4000595920
E 05.17
USA /
Related Manuals for Haulotte OPTIMUM 8
Summary of Contents for Haulotte OPTIMUM 8
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Page 1
Training manual Training manual OPTIMUM 8 — OPTIMUM 1931 E 4000595920 E 05.17 USA /… -
Page 2
OPTIMUM 8 — OPTIMUM 1931 E 4000595920 E 05.17 USA /… -
Page 3: Table Of Contents
Layout ……….2.3.2 — HAULOTTE Activ’Screen ……2.3.2.1 — LCD screen .
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Page 4
Training manual 2 — List of actuators and sensors … . . 2.1 — Sensors and actuators……… 2.2 — Sensors detail. -
Page 5
Training manual STUDY OF THE HYDRAULIC SCHEMA 1 — Hydraulic units ……1.1 — General overview ……….1.1.1 — The hydraulic components . -
Page 6
Training manual SIMPLIFIED BREAKDOWN GUIDE 1 — No start ……. 2 — No lift . -
Page 7: Foreword
MAINTENANCE AND REPAIR OPERATIONS ON YOUR HAULOTTE® MACHINE MAY ONLY BE PERFORMED BY TRAINED AND EXPERIENCED TECHNICIANS You are in possession of the summary document provided during the HAULOTTE® technical training programme. It will allow you to find the information necessary for performing maintenance and repairs on your HAULOTTE®…
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Page 8: Revision
OPTIMUM 8 — OPTIMUM 1931 E — Foreword Section E : The adjustments It will include the following elements : • The way to use/connect the console of diagnostic. • The list of main menus and its architecture. • The list of alarms with their explanation.
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Page 9: Main Features And Functions
OPTIMUM 8 — OPTIMUM 1931 E — Main features and functions Main features and functions 1 — Models description REGULATION MODELS ANSI and CSA standards OPTIMUM 1931 E CE, AS and EAC standards OPTIMUM 8 4000595920 E 05.17 USA /…
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Page 10: Primary Machine Components
OPTIMUM 8 — OPTIMUM 1931 E — Main features and functions 2 — Primary machine components 2.1 — WORKING AREA / RANGE OF MOTION OPTIMUM 8 — OPTIMUM 1931 E 4000595920 E 05.17 USA /…
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Page 11: Transportation
OPTIMUM 8 — OPTIMUM 1931 E — Main features and functions 2.2 — TRANSPORTATION 2.2.1 — Machine layout 4000595920 E 05.17 USA /…
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Page 12: Ground Control Box
OPTIMUM 8 — OPTIMUM 1931 E — Main features and functions 2.3 — GROUND CONTROL BOX 2.3.1 — Layout General view ACTIV’ Screen Controls and indicators MARKING DESCRIPTION FUNCTION Pulled out : Ground control box energized E-stop button Pushed in : De-energizes control system…
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Page 13: Haulotte Activ’screen
OPTIMUM 8 — OPTIMUM 1931 E — Main features and functions 2.3.2 — HAULOTTE Activ’Screen Upon starting and during operation of the machine, the LCD screen «Activ’Screen» located on the ground control box displays in real time the machine operating status.
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Page 14: Lcd Screen
OPTIMUM 8 — OPTIMUM 1931 E — Main features and functions 2.3.2.1 — LCD screen At startup At startup with the ground or platform controls selected; system initiates a self check : • Bar gets filled up. • Home screen comes on with status icon of the machine — okay to proceed functioning the controls.
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Page 15
OPTIMUM 8 — OPTIMUM 1931 E — Main features and functions • After pressing on SYMBOL DESCRIPTION Software part number Software version + Screen software version + Screen version Screen identification + Screen software version Machine serial number displayed • After again pressing on •… -
Page 16
OPTIMUM 8 — OPTIMUM 1931 E — Main features and functions Alarm status Alarm status displayed as applicable — samples shown below • Tilt • Overload • Low battery 4000595920 E 05.17 USA /… -
Page 17
OPTIMUM 8 — OPTIMUM 1931 E — Main features and functions • Present fault • Platform control box E-stop button pressed in (de-energized) 4000595920 E 05.17 USA /… -
Page 18: Platform Control Box
OPTIMUM 8 — OPTIMUM 1931 E — Main features and functions 2.4 — PLATFORM CONTROL BOX 2.4.1 — Layout General view 4000595920 E 05.17 USA /…
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Page 19
OPTIMUM 8 — OPTIMUM 1931 E — Main features and functions Controls and indicators MARKING NAME DESCRIPTION FUNCTION HL800 Tilt indicator Machine on excessive slope HL802 Overload indicator Platform overloaded SA907 Horn button Move upwards and hold to activate horn… -
Page 20
OPTIMUM 8 — OPTIMUM 1931 E — Main features and functions Notes 4000595920 E 05.17 USA /… -
Page 21: Study Of The Wiring Diagram
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram Study of the wiring diagram 1 — System architecture 4000595920 E 05.17 USA /…
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Page 22: Power Circuit
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 1.1 — POWER CIRCUIT 4000595920 E 05.17 USA /…
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Page 23: Logic Circuit
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 1.2 — LOGIC CIRCUIT 4000595920 E 05.17 USA /…
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Page 24: Drive Circuit
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 1.3 — DRIVE CIRCUIT The traction is controlled by 2 asynchronous 3 phases motors (24VAC — 1KW). Each motor is piloted by one variator ( COMBIACX master for RR motor and ACEX slave for RL motor) through CAN — BUS network.
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Page 25
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram The whole unit is located in the chassis (rear side as shown below) 4000595920 E 05.17 USA /… -
Page 26: Function Of The Variators
I/O too. • The software upload process is done by connecting the DIAG PAD console or HAULOTTE DIAG application. • The ACEX variator (slave) controls the traction of RL motor (no need to upload software on it).
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Page 27: Control Of The Traction
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 1.3.1.1 — Control of the traction 1.3.1.2 — Control of the pump (other movements) 4000595920 E 05.17 USA /…
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Page 28: Details Of Sensors
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 1.3.1.3 — Details of sensors • The speed rotation of each motor is controlled through an encoder with 2 signals shifted at 90° each and 48 impulses per round.
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Page 29: Detail Of The Connections
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 1.3.1.5 — Detail of the connections 4000595920 E 05.17 USA /…
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Page 30
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram Detail of the connectors on variators. For any connector, the pin 1 always starts at the lower right corner as shown below. Connector are labelled as follow : •… -
Page 31: Scissors Arm
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 1.3.2 — Scissors arm The arms stack are independent and equipped with standards axles secured by clips and ring (see below). 4000595920 E 05.17 USA /…
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Page 32: List Of Actuators And Sensors
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 2 — List of actuators and sensors 2.1 — SENSORS AND ACTUATORS Sensors and actuators 4000595920 E 05.17 USA /…
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Page 33
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram NAME DESCRIPTION SP400 Pressure sensor SQ144 Pothole limit sensor SQ145 Pothole limit sensor SQ800 Tilt sensor SR150 Steering potentiometer SR420 Tilt sensor low position SR722 Arm angle sensor… -
Page 34: Sensors Detail
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 2.2 — SENSORS DETAIL 2.2.1 — Limit switchs for potholes MARKING FUNCTION DESCRIPTION SQ144 Sensors = 1 when potholes are retracted SQ145 4000595920 E 05.17 USA /…
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Page 35: Steering Potentiometer
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 2.2.2 — Steering potentiometer MARKING FUNCTION DESCRIPTION Value 2.5 kΏ, supply in 12 VDC (coming from ACEX variator) Before to launch the calibration, the pre-setting has to be done at mid-…
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Page 36: Angle Transducers
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 2.2.3 — Angle transducers MARKING FUNCTION DESCRIPTION Analogic sensor (0.5/4.5VDC), detection of low position SR420 Value adjustable according to scissors angle (~ 74 – 535 pts) Calibration system angle/pressure through consoles or active screen…
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Page 37: Pressure Transducer
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 2.2.4 — Pressure transducer MARKING FUNCTION DESCRIPTION Analogic transducer (4-20mA), value variable depends of the pressure on SP400 big chamber of the lifting cylinder Calibration system angle/pressure through consoles or active screen 4000595920 E 05.17…
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Page 38: Slope Sensor
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 2.2.5 — Slope sensor MARKING FUNCTION DESCRIPTION Tilt Y = 1.5° / X =3° (wire 12 = Vbat if machine on flat surface) SQ800 1=red=+Batt / 2=white=signal / 3=black=GND 2.2.6 — Battery charger…
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Page 39: Fuses And Relays
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 2.2.7 — Fuses and relays MARKING FUNCTION DESCRIPTION Protection electrovalve circuit (10A) Protection main circuit (10A) Protection accessories circuit (10A) SA103 Toggle switch for manual brake release function…
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Page 40: Actuators And Their Location
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 2.3 — ACTUATORS AND THEIR LOCATION 2.3.1 — List of actuators In the following tables : • The column n°2 indicates the position on the connector on modules (if required).
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Page 41: Fuses
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 2.3.3 — Fuses FUSES NAME LOCATION CONNECTOR FUNCTION FU1A 01 — 03 Protection ACEX variator (125 A) FU1C 01 — 07 Protection COMBIACX variator (300 A) 01 — 08…
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Page 42
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram SENSORS NAME LOCATION CONNECTOR FUNCTION Pressure transducer 4 — 20 mA located in large SP400 02 — 06 CXC.9 chamber of lifting cylinder (14) SQ144 / SQ145 02 — 18 AXA.4… -
Page 43: Outputs
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 2.3.5 — Outputs RELAYS-MOTORS NAME LOCATION CONNECTOR FUNCTION 01 — 07 Main relay for commands (115) 02 — 17 AXB.7 Horn command (70) 02 — 20 AXA.8 Flashing light command (89) 02 — 10 CXB.1/5…
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Page 44
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram BUZZER AND LIGHTS NAME LOCATION CONNECTOR FUNCTION HA901 05 — 13 CXA.9 Buzzer (04) HA907 03 — 13 Horn (184) EL901/B 06 — 05 Option flashing light (32) -
Page 45: Cut Out Conditions Of Every Function
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 2.4 — CUT OUT CONDITIONS OF EVERY FUNCTION 2.4.1 — Glossary MARKING DESIGNATION Down Left Right F/FWD Forward REV/B Reverse/backward SETP Setpoint A IN Analogic input D IN…
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Page 46: Power Supply/Commands
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 2.4.2 — Power supply/commands N.B.-:- • The diagnostic menu is very important on this model as it will permit to the technician to focuse only on the dysfunction encountered and then save time to repair the machine.
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Page 47
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram Explanation of the cinematic Explanation of the Cuttings function This is valid for every movement including drive mode. CUT-OFF CONDITIONS DESCRIPTION Enable General movement deactivation General General Inhibition… -
Page 48
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram REQUIREMENTS DEFINITION Machine is powered ON with key SA901 of lower control box if no emergency stop is pushed (EMSTOP=ON and PowerON=1). At power on, the relays close : SB801=ON & KAH=ON •… -
Page 49: Drive
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 2.4.3 — Drive 2.4.3.1 — Validation REQUIREMENTS DEFINITION The drive movement happens relative to the activated panel, in the specified direction and set point and DSV01 regarding to validation and slowdown conditions : SETP[Drive]=FWD|N|REV:[0-100]%…
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Page 50
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram REQUIREMENTS DEFINITION CUT-OFF TILT CUT-OFF CONDITIONS Tilt activated with unfolded machine and tilt cut-off DSV03 Tilt activated (some countries or tilt safety configuration) out of production mode REQUIREMENTS… -
Page 51
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram REQUIREMENTS DEFINITION Following limits are applied on the set point (SETP[Drive]): DIRECTIONS MOVEMENT SET POINT LIMIT CONDITIONS Unfolded machine (micro speed) and not SPEED[uS Drive Fwd] SPEED[uS Drive Rev] masked DSV04.2… -
Page 52: Steering
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 2.4.4 — Steering 2.4.4.1 — Validation REQUIREMENTS DEFINITION The steering movement happens in the specified direction and set point, regarding to validation and slow STV01 down conditions : SETP[Steering]=LEFT|N|RIGHT:[0-100]%…
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Page 53
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram REQUIREMENTS DEFINITION CUT-OFF TILT CUT-OFF CONDITIONS Tilt activated with unfolded machine and tilt cut-off STV03 Tilt activated (some countries or tilt safety configuration) out of production mode REQUIREMENTS… -
Page 54: Actuators
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram REQUIREMENTS DEFINITION STV04 There is not limitation of steering set point 2.4.4.2 — Actuators REQUIREMENTS DEFINITION The formatted control (CTRL[Steering]) is applied on the actuators driving the movement…
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Page 55: Arm
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 2.4.5 — Arm 2.4.5.1 — Validation REQUIREMENTS DEFINITION Steering movements happen in the specified direction and set point regarding to validation and slowdown AMV01 conditions : SETP[Arm]=UP|N|DOWN:[0-100]% REQUIREMENTS…
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Page 56
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram REQUIREMENTS DEFINITION CUT-OFF TILT CUT-OFF CONDITIONS Tilt activated with unfolded machine and tilt cut-off AMV03 Tilt activated (some countries or movement tilt safety option) REQUIREMENTS DEFINITION CUT-OFF REACH LIMIT CUT-OFF CONDITIONS… -
Page 57
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram REQUIREMENTS DEFINITION Following limits are applied on the set point ((SETP[Arm])) DIRECTIONS MOVEMENT SET POINT LIMIT CONDITIONS Tilt and machine unfolded AMV04 Chassis control box active and load management calibration not in… -
Page 58: Actuators
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 2.4.5.2 — Actuators REQUIREMENTS DEFINITION The formatted control (CTRL[Arm]) is applied on the actuators driving the movement Raise movement : • Hydraulic pump guarantees the proportionality of raise movement: control pump value (CTRL[PumpArm]) is computed from the arm raise value (CTRL[Arm]).
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Page 59
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram REQUIREMENTS DEFINITION After a movement of raise or descent, if the country is not USA, the arm cylinder valve YV420 is controlled at low values to suppress the pressure due to dynamics and then enable a reliable and repetitive measure of pressure for load management system. -
Page 60: Brake Release
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 2.4.6 — Brake release REQUIREMENTS DEFINITION The release of brake is controlled : • Automatically during the normal operating mode. • Or on special conditions during test mode.
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Page 61: Potholes
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 2.4.7 — Potholes 2.4.7.1 — Validation REQUIREMENTS DEFINITION Steering movements happen in the specified direction and set point regarding to validation and slowdown conditions. The potholes set point is automatically computed based on the control of drive movement or arm movement : CTRL[Drive]≠N:0 &…
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Page 62
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram REQUIREMENTS DEFINITION CUT-OFF TILT CUT-OFF CONDITIONS POV03.1 Tilt REQUIREMENTS DEFINITION CUT-OFF REACH LIMIT CUT-OFF CONDITIONS POV03.1 Reach limit REQUIREMENTS DEFINITION CUT-OFF FAILURE CUT-OFF CONDITIONS POV03.1 Power contactor stuck… -
Page 63: Actuators
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram 2.4.7.2 — Actuators REQUIREMENTS DEFINITION The formatted control (CTRL[Steering]) is applied on the actuators driving the movement CTRL Pump YV121 YV122 YV903 CTRL[PumpSteering] NEUTRAL CTRL[PumpSteering] Potholes extension :…
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Page 64
OPTIMUM 8 — OPTIMUM 1931 E — Study of the wiring diagram Notes 4000595920 E 05.17 USA /… -
Page 65: Study Of The Hydraulic Schema
OPTIMUM 8 — OPTIMUM 1931 E — Study of the hydraulic schema Study of the hydraulic schema 1 — Hydraulic units 1.1 — GENERAL OVERVIEW 1.1.1 — The hydraulic components 1.1.1.1 — Pump unit MARKING FUNCTION DESCRIPTION YV903 By-pass valve (pump is in pressure)
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Page 66: Selection Valve Potholes/Steering
OPTIMUM 8 — OPTIMUM 1931 E — Study of the hydraulic schema 1.1.1.2 — Selection valve potholes/steering MARKING FUNCTION DESCRIPTION Valve 6 ways / 2 positions for selection potholes or steering (priority for YV120 potholes) 4000595920 E 05.17 USA /…
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Page 67: Lifting Cylinder Valve
OPTIMUM 8 — OPTIMUM 1931 E — Study of the hydraulic schema 1.1.1.3 — Lifting cylinder valve MARKING FUNCTION DESCRIPTION Valve PWM (Pulse Width Modulation) lift/descent of platform (Slow YV420 descent when PF < 3 meters. Information coming from angle sensor…
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Page 68
OPTIMUM 8 — OPTIMUM 1931 E — Study of the hydraulic schema Notes 4000595920 E 05.17 USA /… -
Page 69: Adjustments With Diag Pad Console
The adjustments/parameters settings /list of alarms, calibration of the machine are accessible on on-board activ screen console, as well as this console below or Haulotte Diag application installed in laptop. The VCI (Vehicle Computer Interface) adapter could be connected from any controls (turret or in platform) using wireless or cable connection.
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Page 70: List Of Menus
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments 2 — List of menus See end of manual 2.1 — MACHINE SETTINGS 2.1.1 — Speeds and ramps See end of manual : Annex 1 2.1.2 — Options See end of manual : Annex 2 2.1.3 — Configurations…
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Page 71: Failures List
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments 3 — Failures list • For any type A (ACTIVE) failure code, it will appear on display in lower control and the warning light will flicker on upper controls (see below). • For any type D (DETECTED) failure code, it will also appear on display in lower control and the warning light will flicker on upper controls.
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Page 72: List Of Failures Per Category
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments 3.1 — LIST OF FAILURES PER CATEGORY FAILURES DESCRIPTION INVERTER COMBIACX: Failure in the high current hardware protection circuit. • Internal fault. • Replace the inverter. COMBIACX: When no current is applied to the traction motor, the current feedbacks are out of permitted standby range.
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Page 73
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments FAILURES DESCRIPTION COMBIACX: The controller has reached thermal cutout (temperature of the controller base plate is higher than 85°C). • Power down and allow to cool. • Do not operate in ambient temperatures over to 60°C. -
Page 74
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments FAILURES DESCRIPTION ACEX: Short circuit detected on electromechanical brake or main contactor output (overcurrent). • Main contactor drive coil : Check connections and wiring for interruptions between controller and coil. • Motor brake coil : Check connections and wiring for interruptions between controller coil. -
Page 75
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments FAILURES DESCRIPTION CONTACTOR The driver of main contactor drive coil is shorted, or its coil is disconnected. • Ensure there is no short or low-impedance pull-down between MC and -Vbatt. • Check connections and wiring for interruptions of MC DRIVE coil. -
Page 76
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments FAILURES DESCRIPTION JOYSTICKS Analog signal SM901 is out of allowed range : F05.01 —> SM901 < 0.2V | SM901 > 4.8V Arm/Drive Incoherence between analog signal and out of neutral signals for SM901 joystick : joystick —>… -
Page 77
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments FAILURES DESCRIPTION SENSORS COMBIACX: The motor temperature sensor is not correctly connected or damaged. F07.05 • Key OFF/ON. • Check wiring. Motor temperature ACEX: The motor temperature sensor is not correctly connected or damaged. -
Page 78
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments FAILURES DESCRIPTION ELECTRIC CIRCUIT COMBIACX: Power capacitors voltage does not increase at start-up. • Ensure that no external device is connected to the batteries. • Check battery, power cables and connections. COMBIACX: The controller detects an overvoltage or under voltage condition. -
Page 79
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments FAILURES DESCRIPTION Two panels are selected : Check selector key : F08.07 —> SA901T=ON & S0901PF=ON Circuit No panel is selected : Check selector key : selector —> SA901T=OFF & S0901PF=OFF COMBI ACX: The PEV connector (B2) is not connected to the battery or the voltage is different. -
Page 80
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments FAILURES DESCRIPTION FUNCTIONS F10.14 Steering Steer angle is not calibrated. angle not Perform steer angle calibration. calibrated F10.16 Arm angle is not calibrated. Arm angle not Perform arm angle calibration. calibrated FAILURES… -
Page 81
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments FAILURES DESCRIPTION INTERNAL FAULTS For all failure details : • Check wiring. • Check the Can Bus connections. • Ensure that all the connectors pins are properly in place and the connectors are free of moisture or oxidation. -
Page 82
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments FAILURES DESCRIPTION Model not set (not possible => always Optimum8) Model = Not Set Country not set : Set country Country = Not Set Serial number = 0: set serial number F12.05 SerialNumber = «000000»… -
Page 83
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments FAILURES DESCRIPTION ACEX: Software watchdog active. • Key OFF/ON. ACEX: Problem on the Analog/Digitial conversion of micro controller. • Key OFF/ON. ACEX: Watchdog circuit output became high due to hardware or software problem (WDG1). -
Page 84
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments FAILURES DESCRIPTION SWITCHES Incoherence between the 2 signals of front steering switch of platform box (both active) : F13.02 —> SM901L = 1 & SM901R = 1 Platform switches Incoherence between the 2 signals of movement selection : Check switches —>… -
Page 85
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments FAILURES DESCRIPTION ENGINE COMBIACX: Motor maximum temperature reached. • Check the thermal sensor wiring and ohm value. • Improve the air cooling of the motor. F16.01 • If the warning is present when the motor is cool, then the problem is inside the controller : Replace it. -
Page 86
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments FAILURES DESCRIPTION COMBIACX: During drive, motor output voltage is lower than expected. • Check the motor power wiring and connections. • Check the motor phases for proper insulation with the chassis. • Check that MC DRIVE power contact close properly, with a good contact. -
Page 87: Maximum Height Adjustment
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments 4 — Maximum height adjustment 4000595920 E 05.17…
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Page 88: Cutback Speed Position Height Adjustment
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments 5 — Cutback speed position height adjustment 4000595920 E 05.17 USA /…
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Page 89: Load Management System
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments 6 — Load management system 6.1 — CALIBRATION PROCEDURES N.B.-:- Before starting the calibration, check that the sensors are well mounted mechanically (Lift the scissors in order to get access to theses sensors).
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Page 90
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments Pre setting of the transducers MARKING SENSORS LOW POSITION UPPER POSITION SR420 ~ 74 pts ~ 530 pts SR722 ~ 420 pts ~ 530 pts 4000595920 E 05.17 USA /… -
Page 91: Steering
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments 6.2 — STEERING The calibration is required for multiple reasons : • When the variator COMBIACX or one component linked to the steering has been changed. • When the pump doesn’t stop when steering at full lock (left or right).
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Page 92: Steering Calibration Procedure
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments 6.2.1 — Steering calibration procedure Preadjust the potentiometer so as to obtain the «steer angle» parameter at 0° to Activ’ Screen display ANGLE SENSORS CALIBRATION VALID RANGE V (approx.) Left (-75.19°) SR150 [150 ;…
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Page 93: Calibration Arm Angle Sensors (Honeywell Sensors)
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments 6.3 — CALIBRATION ARM ANGLE SENSORS (HONEYWELL SENSORS) ANGLE SENSORS CALIBRATION VALID RANGE V (approx.) SR420 Low (0°) [60 ; 160] [0.615 ; 1.641] SR722 Low (0°) [320 ; 420] [3.283 ; 4.309] SR420 High (57°)
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Page 94: Calibration Arm Angle Sensors (Elobau Sensors)
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments 6.4 — CALIBRATION ARM ANGLE SENSORS (ELOBAU SENSORS) ANGLE SENSORS CALIBRATION VALID RANGE V (approx.) SR420 Low (0°) [60 ; 160] [0.615 ; 1.641] SR722 Low (0°) [320 ; 420] [3.283 ; 4.309] SR420 High (57°)
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Page 95: Adjustment Of Pressures
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments 7 — Adjustment of pressures 7.1 — MAIN PRESSURE The setting and minimess plug is unique for all movements. MARKING DESIGNATION VALUE Main pressure 180bar +-5b 7.2 — THE SPEEDS MARKING DESIGNATION…
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Page 96
OPTIMUM 8 — OPTIMUM 1931 E — Adjustments Notes 4000595920 E 05.17 USA /… -
Page 97: Simplified Breakdown Guide
OPTIMUM 8 — OPTIMUM 1931 E — Simplified breakdown guide Simplified breakdown guide This guide does not replace the cut out conditions described previously in this manual. It allows the technician to have a logical step of breakdown service, detailing the successive steps to be followed starting from general tips until the details.
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Page 98: No Drive
OPTIMUM 8 — OPTIMUM 1931 E — Simplified breakdown guide 3 — No drive • Toggle switch SA908. • Joystick SM901. • Foot pedal switch SB800( US only). • AC motor M370 — M371. • Brakes YB100 — YB101. • Temperature probes ST301 — ST302.
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Page 99: Version Summary
OPTIMUM 8 — OPTIMUM 1931 E — Version summary Version summary 1 — Version summary OPTIMUM 8 — STANDARDS WIRING DIAGRAM HYDRAULIC DIAGRAM OPTIMUM 1931E Standard version All countries 4000311260 4000349350 2 — List of schematics See end of manual…
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Page 100
OPTIMUM 8 — OPTIMUM 1931 E — Version summary Notes USA / EN 4000595920 E 05.17… -
Page 136
OPTIMUM 8 — OPTIMUM 1931 E — Version summary Notes 4000595920 E 05.17 USA / GB…
Table of Contents for Haulotte Group OPTIMUM 8:
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77 4000429690 E 11.15 US / GB Chassis Removal / replacement of steering pivot assembly MS0090 Chassis Removal / replac ement of steeri ng pivot assembly 1 — You will need 2 — Plan of the assembly Plan of the assembly • Standard tool kit • Protective goggles • Gloves • Overhead crane or equivalent, 1 T / 1,205 lb capacity minimum • Torque wrench for 10 Nm , 80 Nm and 250 Nm • Grease gun • Place barriers around the perimeter of the work area 60 min Exclusively use tools and auxiliar
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101 4000429690 E 11.15 US / GB Chassis Calibration steering MS0097 5 — Checks Turn on the machine and test the steer function- the pump motor should stop when the steering is at mechanical limit and the steering switch is held on : • When wheels steer to the left the steer angle decreases : Its limit is set to + 47,6° • When wheels steer to the right the steer angle increases : Its limit is set to — 75,2 °
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119 4000429690 E 11.15 US / GB OPTIMUM 8 — OPTIMUM 1931 E E — Trouble shooting and diagram Failure Code C Description F01 : Inverter Low Battery F01.08 (A) 1 Low battery voltage (estimated value < 10%). Check for damaged batteries, battery cables or connections. Recharge batteries. Measure batteries voltage and compare it with the value BATTERY VOLTAGE parameter in the TESTER menu. If they are different, adjust the v
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64 4000429690 E 11.15 US / GB General data Breaking test procedure MS0004 Notes
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83 4000429690 E 11.15 US / GB Platform Removal / replacement of platform assembly MS0095 Platform Removal / re placemen t of platfor m assembly 1 — You will need 2 — Level of knowledge required 3 — Preliminary operation The operations of disassembling if they exist should be carried out only on the installations completely disconnected and must be entrusted only to people having the necessary technical training. Respect, in addition to th
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80 4000429690 E 11.15 US / GB Chassis Removal / replacement of steering pivot assembly MS0090 Removing the steering pivot : • Place a block under the pivot (or wheel) so the assembly does not fall out on the ground when the upper plate is unscrewed. • Unscrew the 2 cap head bolts on the top of the pivot. Attention, the pivot is no longer fixed in the chassis. • Slide the assembly down and out of the chassis. • Re
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134 4000429690 E 11.15 US / GB OPTIMUM 8 — OPTIMUM 1931 E E — Trouble shooting and diagram 3 — Electric diagram
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128 4000429690 E 11.15 US / GB OPTIMUM 8 — OPTIMUM 1931 E E — Trouble shooting and diagram Failure Code C Description F13 : Switches Lower Box Switches Check switches F13.01 (D) 1 Incoherence between the 2 signals of front steering switch of platform box (both active) —> SM901L = 1 & SM901R = 1 2 Incoherence between the 2 signals of movement selection —> SM903A = 1 & SM903B = 1 Neutral switch Check chassis switches F13.10 (A) 1 Neut
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139 4000429690 E 11.15 US / GB OPTIMUM 8 — OPTIMUM 1931 E F — Records Records 1 — Intervention register The intervention register keeps a record of maintenance and repair work carried out inside or outside the maintenance programme. N.B.-:-I N THE CASE OF A HAULOTTE SERVICES® INTERVENTION, THE QUALIFIED TECHNICIAN MUST INDICATE THE HAULOTTE SERVICES® INTERVENTION NUMBER. Date Type of intervention Number of hours Intervenor HAULOTTE Services® intervention number
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98 4000429690 E 11.15 US / GB Scissors Removal / replacement of Scissor pack MS0096 Notes
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137 4000429690 E 11.15 US / GB OPTIMUM 8 — OPTIMUM 1931 E E — Trouble shooting and diagram 4 — Hydraulic diagram
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22 4000429690 E 11.15 US / GB OPTIMUM 8 — OPTIMUM 1931 E C — Familiarization 1.3 — GROUND CONTROL BOX 1.3.1 — Layout General view Controls and indicators Marking Description Function 15 E-stop button Pulled out : Ground control box energized Pushed in : De-energizes control system 43 Horn button Not used 92 Control box activation key selector Right : Ground control box energized Center : De-energizes control system Left : Platform control box energized 93 Battery charging indicator Battery charger status 105 Beacon light (Optional) Move upwards : Flashing l
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Specifications:2113/2113419-optimum_8.pdf file (15 Jan 2023) |
Accompanying Data:
Haulotte Group OPTIMUM 8 Boom Lifts PDF Maintenance Book (Updated: Sunday 15th of January 2023 11:12:52 AM)
Rating: 4.8 (rated by 72 users)
Compatible devices: 3522A, 3632T, H12SX, HT21RT O, xlb-4725a, HA20RTJ O, H14T, HA33JE.
Recommended Documentation:
Text Version of Haulotte Group OPTIMUM 8 Maintenance Book
(Ocr-Read Summary of Contents, UPD: 15 January 2023)
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106, 106 4000429690 E 11.15 US / GB Scissors Calibration arm angle sensors MS0099 In the ACTIV’Screen (or using HaulotteDiag) navigate to the calibration menu and enter Arm angle calibration 5 — Checks • Turn the machine off then on, and test the li…
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142, 142 4000429690 E 11.15 US / GB OPTIMUM 8 — OPTIMUM 1931 E F — Records Date Type of intervention Number of hours Intervenor HAULOTTE Services® intervention number
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66, 66 4000429690 E 11.15 US / GB General data Torque Values MS0005 Metric fastener torque chart This charts is to be used as a guide only unless noted elsewhere in this manual Siz e (m m) Class 4.6 Class 8.8 Class 12.9 Dull dry (A) Lubed (B) Yellow dry (C) Dull dry (A) Lubed (B) Yel l ow dry (C) Dull d…
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41, Haulotte Group OPTIMUM 8 41 4000429690 E 11.15 US / GB OPTIMUM 8 — OPTIMUM 1931 E D — Inspection and maintenance schedule The circuit breaker is working correctly Slope limiting device operates properly Axle locking device operate properly Pothole safety device operate properly (if equipped) Test of load sensing system (…
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77, 77 4000429690 E 11.15 US / GB Chassis Removal / replacement of steering pivot assembly MS0090 Chassis Removal / replac ement of steeri ng pivot assembly 1 — You will need 2 — Plan of the assembly Plan of the assembly • Standard tool kit • Protective goggles • Gloves • Overhead crane o…
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43, 43 4000429690 E 11.15 US / GB OPTIMUM 8 — OPTIMUM 1931 E D — Inspection and maintenance schedule Periodic inspection In addition to the daily inspection program Visual inspection without disassembly To check by test Visual inspection with small disassembly or movement needed to reach the …
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62, Haulotte Group OPTIMUM 8 62 4000429690 E 11.15 US / GB General data Cylinder inspection MS0003 3.3 — MAJOR INSPECTION A thorough inspection of the structural parts must be realized all the 5000 h or 10 years with disassembling of the element to check the entirety of the welding. Each Cylinder must be disassembled and must be …
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15, Haulotte Group OPTIMUM 8 15 4000429690 E 11.15 US / GB OPTIMUM 8 — OPTIMUM 1931 E B — Safety 2 — Maintenance and repair training 2.1 — OWNER’S RESPONSABILITY The owner (or hirer) has the obligation to inform technician of the instructions contained in the Operator Manual and Maintenance Book. The owner (or…
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38, 38 4000429690 E 11.15 US / GB OPTIMUM 8 — OPTIMUM 1931 E D — Inspection and maintenance schedule 3 — Daily inspection The content and method of inspection must be conducted by operators before using the machine, it includes a visual inspection and functional and …
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118, 118 4000429690 E 11.15 US / GB OPTIMUM 8 — OPTIMUM 1931 E E — Trouble shooting and diagram Failure Code C Description F01 : Inverter Inverter Master F01.01 (A) 1 COMBIACX : Failure in the high current hardware protection circuit. Internal fault. Replace the inverter. 2 COMBIACX : When no cu…
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Haulotte Group OPTIMUM 8 User Manual
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Haulotte Group OPTIMUM 8 User Guide
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Haulotte Group OPTIMUM 8 PDF Manual
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Haulotte Group OPTIMUM 8 Owner’s Manuals
Recommended Instructions: USGENERAL 97071, 19D, CNRFGWA
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Terex Genie S-80 J
Service and Repair Manual Serial Number Range S®-80 J from S80JH-101 from S80JD-101 This manual includes: Repair procedures Fault Codes Electrical and Hydraulic Schematics S®-80 J TraX™ For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. …
Genie S-80 J 135
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Terex Genie S-80 J
Operator’s Manual Serial Number Range S®-80 J from S80JH-101 ANSI/CSA North America South America Asia S®-80 J TraX™ with Maintenance Information Original Instructions First Edition First Printing Part No. 1306265GT …
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DINGLI AMWP-8100
浙 江 鼎 力 机 械 股 份 有 限 公 司 Zhejiang Dingli Machinery Co.,Ltd 邮箱/Mailbox：[email protected]网址/Website：www.cndingli.com1/48 培训资料 （Training Files） AMWP-8100 …
AMWP-8100 48
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Terex Genie ZX-135/70
Service Manual Serial Number Range ZX-135/70 From ZX13513-2001 to ZX13514-2532 (does not include ZX13514-2463, ZX13514-2469 and ZX13514-2531) Part No. 218700 Rev F September 2015 …
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Operating Impressions, Questions and Answers: