Haulotte HA120PX User manual

Operator's manual
HA120PX
4000327280 E09.16 USA / GB
Operator's manual
HA120PX

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HA120PX

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CONTENTS
Operator's manual
CONTENTS
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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......................................... 8
2 - Safety ..........................................9
2.1 - Safety instructions.............................................. 9
2.1.1 - Misuse Hazards ......................................9
2.1.2 - Falling Hazards......................................10
2.1.3 - Overturning / Tip-over Hazards .........................11
2.1.4 - Electrocution Hazards.................................14
2.1.5 - Explosion / Fire Hazards...............................15
2.1.6 - Crushing / Collision Hazards ...........................15
2.1.7 - Uncontrolled movement Hazards ........................16
3 - Safety inquiries .................................17
4 - Incident notification .............................17
5 - Compliance ....................................18
5.1 - Product information ...........................................18
5.1.1 - Change of Ownership Notification .......................18
5.1.2 - Owner information update form .........................19
5.2 - Product specifications .........................................20
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FAMILIARIZATION
1 - General safety ..................................21
1.1 - Intended use .................................................21
1.2 - Decal content................................................. 22
1.3 - Symbols and colors ...........................................23
1.4 - Level of severity............................................... 23
1.5 - Symbols legend and definitions.................................24
2 - Models description ..............................25
3 - Primary machine components.....................26
3.1 - Layout .......................................................26
3.2 - Ground control box............................................28
3.2.1 - Layout .............................................28
3.3 - Platform control box ...........................................30
3.3.1 - Layout .............................................30
4 - Performance Specifications.......................32
4.1 - Technical characteristics ....................................... 32
4.2 - Working area / Range of motion ................................33
5 - Decals and markings locations HA120PX ...........34

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Operator's manual
C
PRE-OPERATION INSPECTION
1 - Recommendations ..............................39
2 - Working area assessment ........................40
3 - Inspection and Functional test ....................41
3.1 - Daily inspection ...............................................41
4 - Safety functional checks .........................45
4.1 - E-Stop button check ...........................................45
4.2 - Activation of controls ...........................................45
4.3 - Fault detector .................................................46
4.3.1 - Buzzers test ........................................ 46
4.4 - Automatic engine cut-out.......................................46
4.5 - Overload sensing system (if fitted)...............................46
4.6 - Slope warning device ..........................................47
4.7 - Travel speed limitation .........................................48
4.8 - Drive buzzer ..................................................48
D
OPERATION INSTRUCTIONS
1 - Operation......................................49
1.1 - Introduction ...................................................49
1.2 - Operation from the ground control box...........................49
1.3 - Operation from the platform control box..........................51
2 - Ground control box .............................52
2.1 - To start the machine from the ground control box .................52
2.2 - Boom and arm controls ........................................53
2.3 - Additional controls from the ground control box ...................54
3 - Platform control box.............................55
3.1 - To start and stop the machine ..................................55
3.2 - Drive and steer control .........................................56
3.3 - Boom and arm controls ........................................57
3.4 - Additional controls .............................................58
4 - Emergency procedure ...........................59
4.1 - In case of power loss ..........................................59
4.2 - To rescue operator in platform ..................................60
4.3 - No power available ............................................61
5 - Transportation .................................62
5.1 - Putting in transport position .....................................62
5.2 - Machine layout................................................63
5.3 - Unloading ....................................................64
5.4 - Towing .......................................................65
5.4.1 - Disengaging the drive hubs ............................ 65
5.4.2 - Re-engaging the drive hubs ............................ 65
5.5 - Storage ......................................................66
5.6 - Lifting operation ...............................................67

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CONTENTS
Operator's manual
6 - Cold Weather Recommendations ..................68
6.1 - Engine oil ....................................................68
6.2 - Hydraulic oil ..................................................69
6.3 - Preheating operation ..........................................69
E
GENERAL SPECIFICATIONS
1 - Machine dimensions.............................72
2 - Major component masses ........................73
3 - Acoustics and vibrations .........................73
4 - Wheel/Tire assembly ............................74
4.1 - Technical specifications........................................ 74
4.2 - Inspection and maintenance ...................................74
5 - Options .......................................76
5.1 - On-board generator ...........................................76
5.1.1 - Principle ...........................................76
5.1.2 - Procedure ..........................................76
5.2 - Activ' Shield Bar - SECONDARY GUARDING SYSTEM ........77
5.2.1 - Description .........................................77
5.2.2 - Characteristics ......................................78
5.2.3 - Safety precautions ...................................79
5.2.4 - Pre-operation inspection...............................80
5.2.5 - Operation ..........................................82
5.2.6 - Specific decals ......................................83
F
MAINTENANCE
1 - General........................................85
2 - Maintenance Schedule ...........................86
3 - Inspection program .............................87
3.1 - General program .............................................87
3.2 - Daily inspection ............................................... 88
3.3 - Periodic inspection ............................................88
3.4 - Reinforced inspection .........................................88
3.5 - Major inspection .............................................. 88
4 - Repairs and adjustments .........................89
G
OTHER INFORMATION
1 - Warranty disclosure .............................91
1.1 - After Sales Service ............................................91
1.2 - Manufacturer's warranty .......................................91
1.2.1 - Warranty acceptance .................................91
1.2.2 - Warranty period .....................................91
1.2.3 - Procedure conditions .................................91
1.2.4 - Conditions of warranty ................................92
2 - Subsidiary contact information ....................93

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Operator's manual

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4000327280 E09.16 USA / GB
HA120PX
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/modifi-
cations to the aerial work platform must be approved by HAULOTTE®.
This manual shall be considered a permanent component of the machine and shall be kept with the aerial work platform
in the designated Manual Holder, at all times.
Safe operation of this product can only be assured if you follow the operating instructions contained in this manual. 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 con-
fused 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.

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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.
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.

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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 boom or 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 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.

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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 arrest harness with lanyard and energy
absorber, in accordance with applicable governmental regulations.
Attach the lanyard to the designated fall arrest 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

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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.
• Do not use the machine with material or objects hanging from the
guardrail or the boom.
• 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.

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A- Foreword
Using a machine on a slope
If the tilt alarm sounds with the platform uphill : First lower the boom and then retract the boom.
• If the tilt alarm sounds with the platform facing downhill : First retract the boom and then lower the
boom.
• While driving, always place the boom above the rear axle, in the direction of movement.
• While driving on a slope:
• Always orientate the machine in the direction of the slope.
• Always place the boom and the arms in fully retracted and in stowed position.
• 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 in stowed position UP or DOWN a slope.
Rated slope :
• Operating with platform elevated.

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A- Foreword
N.B.-:-The Beaufortscaleofwindforceisacceptedinternationallyandisusedwhencommunicating
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
2Light 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 Squall Some branches break. Generally we
cannot walk against the wind. 17,2 - 20,7 62-74 38,53 - 45,98
9 Strong squall
The wind causes slight damage to
buildings. Tiles and chimney stacks are
blown off.
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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.-:-Use this table except where local regulations indicate otherwise.
Electric voltage Minimum safety distance
Mètre Feet
0 - 300 V Avoid contact
300V-50kV 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.

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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).
• Be aware of the boom position and tail swing when rotating the turret (turntable).
• 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 and
slewing.
• Be aware of driving direction.
• When turret is slewed/rotated 180°, the platform is now facing the rear of the machine.
• 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.
Always wear protective clothing and eye wear when working with
batteries and power sources/systems.
N.B.-:-Acid is neutralized with sodium bicarbonate and water.
• Do not start the engine if you smell or detect liquid propane gas (LPG),
gasoline, diesel fuel or other explosive substances.
• 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.
• Do not fill up the fuel tank, when the engine is running and/or near a
flame.
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, it is recommended
using the upper boom and or arms movement control functions to
position, rather than driving machine closer to structure.

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A- Foreword
• 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 restraint harness in accordance with applicable governmental regulations.
Attach the lanyard to the designated fall restraint anchor provided in the platform. Fall restraint system
: Protection system that restrains or prevents a worker from being exposed to a fall.
• 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.
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.
• Retract the boom and lower the arms to the stowed position.
• Rotate the turntable so that the boom is between the non-steering wheels.
• 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.

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A- Foreword
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.
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 : [phone]
Email : [email protected]
HAULOTTE Group - Australia, India and
Asia Product Safety Department
Address : No.26 Changi North Way -
Sinpapore 498812 - Singapore
Tel : [phone]
Email : [email protected]
HAULOTTE Group - North & South
America Product Safety Department
Address : 3409 Chandler Creek Rd. -
Virginia Beach, VA 23453 - United States
Tel : [phone]
Email : [email protected]

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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).

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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 :

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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 their
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.