Haulotte Group HA120PX Product guide

Maintenance book
HA120PX
4000599070 E11.16 USA / GB
Maintenance book
HA120PX

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HA120PX

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CONTENTS
Maintenance book
CONTENTS
1 - Maintenance book. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 - After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 - Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
A
SAFETY PRECAUTIONS
1 - Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 - Maintenance book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 - Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 - Decal colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 - Manufacturer's warranty . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 - Warranty acceptance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 - Warranty period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 - Conditions of warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 - Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 - Scope of intervention . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 - Instructions for intervention . . . . . . . . . . . . . . . . . . . . . . 13
B
RECOMMENDATIONS
1 - Lubrication diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 - Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 - Fuels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 - Motor oils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3 - Hydraulic oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 - Decals and markings locations HA120PX . . . . . . . . . . . 21
C
MAINTENANCE
1 - Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2 - Inspection program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3 - Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4 - Periodic inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5 - Reinforced inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6 - Major inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7 - Maintenance sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.1 - Placing the machine in maintenance configuration. . . . . . . . . . . . . . . . 41
7.2 - Placing in operating configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.3 - General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.3.1 - Recommendations on the conditions of maintenance . . . . . . . . 42
7.3.2 - Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.3.2.1 - Bolts and Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.3.2.2 - Pins and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.3.2.3 - Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.3.2.4 - Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.3.3 - Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.3.3.1 - Oil replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.3.3.2 - Replacing damaged of hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.3.3.3 - Evaluation of leaks on hydraulic cylinders . . . . . . . . . . . . . . . . . 48
7.3.4 - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.3.4.1 - Replacing damaged cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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Maintenance book
E002 - Wheel reducer. . . . . . . . . . . . . . . . . . . . . . . . 51
E003 -
Hydraulic filter cartridge . . . . . . . . . . . . . . . 53
E004 - Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
E005 - Slew ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
E006 -
Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
E007 - Screws, bolts and nuts . . . . . . . . . . . . . . . . 65
E013 - Pulleys and wear pads. . . . . . . . . . . . . . . . . 67
E018 -
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
E030 - Glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . 73
D
DIAGNOSIS ASSISTANCE
1 - Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
E
ELECTRIC CIRCUIT
1 - Wiring diagram-Main components . . . . . . . . . . . . . . . . . 79
2 - Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3 - Relays and terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4 - Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5 - Diagnosis assistance indicators. . . . . . . . . . . . . . . . . . . 87
6 - Locations and functions of the main safety features . . 88
7 - Buzzers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8 - Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
F
HYDRAULIC CIRCUIT
1 - Hydraulic diagram-Main components. . . . . . . . . . . . . . . 91
2 - Solenoid valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.1 - Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.2 - Steering unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.3 - Unit TOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.4 - Proportional unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
G
INTERVENTION REGISTER
1 - Intervention register. . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

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4000599070 E11.16 USA / GB
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You have just purchased a HAULOTTE® product
and we would like to thank you for your business.
1 - Maintenance book
As indicated on the delivery slip, this maintenance book is one of the documents in our on-board case
supplied on delivery of your machine.
Person using this product must do so in accordance with the instruction provided in this manual.
We would particularly like to draw your attention to 2 essential points :
• Compliance with safety instruction (machine, use, environment).
• Use of the equipment within the performance limits.
2 - 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..
• HAULOTTE® must be informed in the event of an incident that either involves one of these products
or has caused bodily injury or significant deterioration of property (personal property or the product);
contact HAULOTTE Services® immediately (See : HAULOTTE Services® contact details)

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3 - Compliance
We would like to remind you that HAULOTTE® complies with the provisions of any applicable
directives applicable to this type of machine.
HAULOTTE advises you that NO modifications carried out without the written permission
of HAULOTTE® will void the HAULOTTE warranty..
HAULOTTE® cannot be held liable for any changes to the technical characteristics/specifications
contained in this manual.
HAULOTTE® reserves the right to alter technical specifications and to make improvements or
modifications to the machine without modifying this manual.
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 options not require any particular precautions 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 decal compliance.

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Safety precautions
1 - Recommendations
1.1 - MAINTENANCE BOOK
The maintenance book is intended for the on-site maintenance technician.
It is the on-site maintenance technician's duty to carry out the regular maintenance work
recommended by HAULOTTE Services®.
This maintenance work is essential for correct machine operation.
If regular maintenance is not carried out, this may :
• Void the warranty.
• Cause machine malfunction.
• Reduce machine reliability and shorten its service life.
• Jeopardize operator safety.
To ensure that the regular maintenance requirements are fully satisfied, contact HAULOTTE
Services®.
HAULOTTE Services® technicians are specially trained to carry out extensive repairs,
interventions or adjustments on the safety systems or elements of HAULOTTE® machines.
They carry genuine HAULOTTE spare parts and tools as required, and also provide fully
documented reports on all work completed.

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A - Safety precautions
1.2 - SYMBOLS USED
Symbols are used to alert the operator to safety precautions or to highlight practical
information.
Symbol meanings
Symbol Description
Danger : Risk of injury or death
Caution : Risk of material damage
Prohibition relating to work safety and quality
Reminder : No identified risk, but a reminder of the need for common sense, good
practice or pre-action prerequisites
Cross-reference to another part of the manual (see section or sheet)
Cross-reference to another manual (see manual)
Cross-reference to repairs (contact HAULOTTE Services®)
Maintenance sheet
Time required for intervention
Recommended tools
Recommended part
Safety
N.B. : Additional technical information

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A - Safety precautions
1.3 - DECAL COLORS
The potential dangers and any specific regulations are indicated around the product by decals
and identification plates.
Familiarize yourself with the decals and their respective color codes.
Decal color code
Decal color code-For Russia and the Ukraine only
The decals must be kept in good condition. Additional decals can be ordered from HAULOTTE Services®.
Decals Color Description
Red Potentially fatal danger
Orange Risk of serious injury
Yellow Risk of material damage and/or minor injury
Other Additional technical information
Green Maintenance operation or information
Decals Color Description
Red Prohibitions - Danger
Yellow Warning : Risk of material damage and/or minor injury
Blue Precaution
Blue Information
Other Additional technical information

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A - Safety precautions
2 - Manufacturer's warranty
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.
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 personnel lifting machines and 12 months or up to a maximum of 1500 operating
hours for the other machines, including MJX or the Telescopic Handlers, starting from delivery
and terminating when the first limit is reached.
Spare parts are covered by a 6 month warranty.
2.3 - 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.
If no particular agreement has been made, any claims made after the previously established
warranty period has expired will be refused.

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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. On the other hand, in certain cases it is possible to contaminate fuel
and hydraulic circuits, especially when fuel and lubricants are stored on the work site. Moreover,
irregular or poor cleaning of the decanting device may also cause fuel/hydraulic circuit contamination
and therefore damage the parts in direct contact with these liquids. 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.
2.4 - WARRANTY 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 the only dealer
authorised to carry out work covered by the warranty) 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.

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A - Safety precautions
3 - Scope of intervention
The inspection and maintenance table below, identifies the role and the responsibilities of each party
in periodical machine maintenance..
Inspections and maintenance
If the machine is operated in a hostile environment or intensively, increase the frequency of maintenance.
Type of intervention Frequency Person-in-charge Intervenor Reference document
Pre-delivery inspection
Before each delivery of
sold, hired or resold
equipment
Owner (or hirer) Qualified HAULOTTE
Services® technician Operator's manual
Pre-operation
inspection
Before operation or
when the operator
changes
Operator Operator Operator's manual
Periodical preventive
maintenance
At the specified
intervals (250 hours
or 1 year)
Owner (or hirer)
On-site technician or
qualified HAULOTTE
Services® technician
Maintenance book
Periodical visit
2 times a year or at the
latest 6 months after
the last periodic visit,
and according to the
local regulations
Owner (or hirer)
Organization or
technician approved
by the employer or by
the intermediary
of HAULOTTE
Services® in
accordance with
the HAULOTTE
Services® contract
Maintenance book

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4 - Instructions for intervention
N.B.-:-Acid is neutralized with sodium bicarbonate and water.
Do not use the machine during while maintenance work is being completed on it.
For any intervention on the power sources, wear glasses and protective clothes (acid spray).
Do not operate the product in the following situations :
• Do not work in an explosive or flammable atmosphere (spark, flame, etc.).
• Do not touch the hot parts of the hydraulic power source (engine, filters, etc.).
• Do not bridge the battery terminals with metallic objects.
• Do not service the battery in proximity of spark, open flame, lit cigarettes.
• Never expose the batteries or electrical components to water (pressure cleaner, rain).
• Never disable the safety devices.
• Do not climb onto the covers.
• Do not fill up the fuel tank, when the engine is running and/or near a flame.
Use an oil collection pan to avoid polluting the environment.

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A - Safety precautions
Notes

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B - Recommendations
Recommendations
1 - Lubrication diagram
Diagram
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1
1

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B - Recommendations
List of ingredients
Marking Ingredient Symbol HAULOTTE® code
1Engine oil - Can 20 l(5,3 gal US) 2420801360
1Engine oil - Barrel 209 l(55,2 gal US) 2420801350
1Engine oil (+30° / - 20° ) 2820305670
1Engine oil (Winter option) 4000010660
2Gear box oil - Can 20 l(5,3 gal US) 2420801370
2Gear box oil - Barrel 209 l(55,2 gal US) 2420801380
3Hydraulic oil (Standard) - Barrel 209 l(55,2 gal US) 2420801310
3Hydraulic oil (Winter option) 2505002640
4Biological hydraulic oil - Barrel 209 l(55,2 gal US) 2820304310
5Extreme-pressure lithium grease 2820304320
6Lead-free grease - Aerosol 0,4 l(0.1 gal US) 2820304330
6Lead-free grease - Can 5 l(1,32 gal US) 2820304340
7Molybdenum grease
8 Oil
9High-pressure lubricant

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B - Recommendations
2 - Consumables
List of consumables
Consumable HAULOTTE® code
Hydraulic filter cartridge 2427002910
Air filter (system) 2175165000
Air filter (system) 2427003170
Diesel pre-filter 2324000620
Diesel filter 2427003140
Diesel filter 2427003150
Engine oil filter 2175131000
Engine oil filter 2324000610
Filter pack(1)
(1.) 1 hydraulic filter cartridge + 1 air filter + 1 diesel pre-filter + 1 diesel filter + 1 engine oil filter
KIT250H-LDW1
Filter pack(2)
(2.) 1 hydraulic filter cartridge + 1 air filter + 1 diesel pre-filter + 1 diesel filter + 1 engine oil filter
KKIT250H-DEUT1

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B - Recommendations
2.1 - FUELS
These fuels can be used on any type of mechanical injection engine. Please see machine
configuration.
N.B.-:-The fuel to be used is regulated by national laws; refer to these requirements and to the table
below to define the appropriate fuel.
Table of technically permitted fuels
Compliant
Not compliant
Engines Fuels
Hydraulic filter cartridge
European gas oil
according to
EN590
European fuel oil
according to
BS2869 class 2
American gas oil
according to
ASTMD975-07b
Japanese gas oil
according to NATO
F54
HATZ 41C
DEUTZ 2011/2012
PERKINS 403/804/1104
LOMBARDINI LDW 1404
KUBOTA D1105-W1
Other fuels :
• Biofuels : According to EN14214 (EU) and ASTM D6751-07a (USA) biofuels are allowed on some
engines and under certain conditions. For more information, please contact HAULOTTE Services®.
• Jet engine fuels (kerosene) : F34 and F35 types under OTAN designation are possible on some engines
and under certain conditions. For more information, please contact HAULOTTE Services®.
The use of vegetable oils is forbidden.

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B - Recommendations
2.2 - MOTOR OILS
In order to ensure that the engine will run properly, it is recommended to use the following oils
Viscosity table

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B - Recommendations
2.3 - HYDRAULIC OILS
Hydraulic oils must comply with the following requirements :
• Oil filterability must be compatible with absolute filters .
• Have properties such as :
• Antifoam and deaeration.
• Anti-wear, anti-shear and antioxydant.
• Rust and corrosion inhibitors (copper).
The recommended viscosity grades depending on the environmental conditions are as follows
:
Biodegradable oils may be used if they comply with the following requirements :
• Ambient operating temperature between -15 °C(-9 °F) and + 40 °C(+ 104 °F) .
• HEES type biodegradable oil only according to standards ISO 15380 and VDMA 24568.
• Necessary characteristics
Environmental conditions ISO Viscosity grade
Ambient temperature between - 15 °C(- 9 °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
Viscosity grade ISO Viscosity grade
Viscosity at + 40 °C(+ 104 °F) 46 +/- 3 mm² / s
Viscosity at + 100 °C(+ 260 °F) > 8 mm² / s
Viscosity index > 160
Flashpoint > 220° C (> 572° F)
Pour point < - 40° C (> - 104° F)