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Haulotte Group HA12CJ, Maintenance Book

The Haulotte Group HA12CJ is an exceptional aerial work platform designed for both indoor and outdoor tasks. To ensure seamless operation and optimal performance, it is imperative to have the Maintenance Book at your disposal. Download the free manual now from manualshive.com and gain valuable insights for maintaining and maximizing the potential of this remarkable product.

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Maintenance book

HA

12

CJ

 - 

HA

32

CJ

 - 

HA

12

CJ

+ 

- H

A3

2C

J+

 

4000360350                   E12.14                   USA/GB

Maintenance book

E

HA12CJ - HA32CJ -  - 

4000358110

E12.14

USA

Summary of Contents for HA12CJ

Page 1: ...Maintenance book HA12CJ HA32CJ HA12CJ HA32CJ 4000360350 E12 14 USA GB Maintenance book E HA12CJ HA32CJ HA12CJ HA32CJ 4000358110 E12 14 USA ...

Page 2: ...2 4000360350 E12 14 USA GB HA12CJ HA32CJ HA12CJ HA32CJ ...

Page 3: ...Red labels 18 3 1 2 Orange labels 20 3 1 3 Yellow labels 22 3 1 4 Other labels 23 3 1 5 Green labels 24 3 1 6 Blue labels 24 3 2 Identification 25 C MAINTENANCE 1 General program 33 2 Detailed program 38 3 Maintenance sheets 88 3 1 Placingthemachineinmaintenanceconfiguration 88 3 2 Placinginoperatingconfiguration 88 3 3 Generalpoints 89 3 3 1 Recommendations on the conditions of maintenance 89 3 3...

Page 4: ...table rotation gearbox 115 E013 Pulleys and wear pads 117 E018 Battery 119 E022 Telescope 123 D DIAGNOSIS ASSISTANCE 1 Recommendations 125 2 Troubleshooting 126 E ELECTRIC CIRCUIT 1 Wiring diagram Main components 129 2 Fuses 131 3 Relays and terminals 131 F HYDRAULIC CIRCUIT 1 Hydraulic diagram Main components 133 2 Solenoid valves 133 G INTERVENTION REGISTER 1 Intervention register 135 ...

Page 5: ...roughout 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 ma...

Page 6: ...ns 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 i...

Page 7: ...rect 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 a...

Page 8: ...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 Recom...

Page 9: ...code For Russia and the Ukraine only The labels must be kept in good condition Additional decals can be ordered from HAULOTTE Services Labels 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 Labels Color Description Red Prohibitions Danger...

Page 10: ... 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 reco...

Page 11: ... 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 subsidia...

Page 12: ...y 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 ...

Page 13: ...ay 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 glowing burning cigarette Never expose the batteries or electrical components to...

Page 14: ...14 4000360350 E12 14 USA GB HA12CJ HA32CJ HA12CJ HA32CJ A Safety precautions ...

Page 15: ...A B C D E F G H I 15 4000360350 E12 14 USA GB HA12CJ HA32CJ HA12CJ HA32CJ B Recommendations Recommendations 1 Lubrication diagram Diagram HA12CJ HA32CJ HA12CJ HA32CJ 6 6 6 6 4 3 5 6 2 6 6 6 6 6 5 ...

Page 16: ...ption 4000010660 2 Gear box oil Can 20 l 5 3 gal US 2420801370 Gear box oil Barrel 209 l 55 2 gal US 2420801380 3 Hydraulic oil Standard Barrel 209 l 55 2 gal US 2420801310 Hydraulic oil Winter option 2505002640 4 Biological hydraulic oil Barrel 209 l 55 2 gal US 2820304310 5 Extreme pressure lithium grease 2820304320 6 Lead free grease Aerosol 0 4 l 0 1 gal US 2820304330 Lead free grease Can 5 l ...

Page 17: ... 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 Consumable HAULOTTE code Applicability Hydraulic filter cartridge 2427002910 HA12CJ HA32CJ HA12CJ HA32CJ Environmental conditions ISO Viscosity grade Ambient temperature between 15 C ...

Page 18: ...The red labels indicate a potentially fatal danger R7 R5 R3 R4 R8 R2 R6 R21 R17 R52 7814 518 b F GB D Composant spécifique à cette machine NE PAS INTERCHANGER Component specific to this machine DO NOT INTERCHANGE Komponenten nur für diese maschine geeignet NICHT AUSTAUSCHBAR N MACHINE COFFRET MACHINE ELECTRIC BOX N MASCHINE SCHALTKASTEN N ...

Page 19: ...ecific labels HA12CJ HA32CJ Specific labels HA12CJ HA32CJ R1 R9 Fmax 3550 daN Pmax 17 5 daN cm 307P228410 a kg kg kg Kg Kg 9 7 m 3 307P228510 a 250 Kg 307P229500 b 5 000 Kg R16 R1 R9 Fmax 3550 daN Pmax 17 5 daN cm 307P228410 a kg kg kg Kg Kg 9 7 m 3 307P228420 a 230 Kg 307P229500 b 5 000 Kg R16 ...

Page 20: ...20 4000360350 E12 14 USA GB HA12CJ HA32CJ HA12CJ HA32CJ B Recommendations 3 1 2 Orange labels Common decals CE Common decals AS The orange labels indicate a risk of serious injury O1 O1 ...

Page 21: ...Operate this machine with extreme caution STOP all operation if a malfunction occurs Test foot switch for proper operation RECOMMENDATIONS FOR USE DAILY INSPECTION INSTRUCTION BEFORE USE Test high engine and high drive cut out switches for proper operation DO NOT wash the electrical components with a washer pressure DO NOT use the machine as a welding earth DO NOT weld on the machine without first...

Page 22: ...B Recommendations 3 1 3 Yellow labels Common decals Specific HA12CJ HA32CJ and HA12CJ HA32CJ labels The yellow labels indicate a risk of material damage and or minor injury J1 J13 J6 J14 J2 J3 J4 a J10 J33 307P228450 a 1 3 2 307P228440 a J2 307P228780 a J34 ...

Page 23: ...i Kunden REF Customer REF REF Client 138P312120 Batterie Nr Battery no Batterie no 2901010690 Abdeckeng Nr Hood no Capot no 138P312000 Nennspannung Nominal voltage Tension nominale 48 Volt Kapazität Capacity Capacité 345 Ah Zellenanzahl Numbers of cells Nombre d éléments 8 Trog Nr Tray no Coffre no 138P311950 Total gewicht Total weight Masse total 650 Kg C5 Pb Pb A81 15 20 228 13 8 12 72 14 10 9 7...

Page 24: ...ATING PROPERLY DO NOT operate this machine unless you have been properly trained as described in the HAULOTTE Operation and Safety Manual by a qualified person and authorized to operate this machine Your training includes reading and understanding the safety operating and maintenance instructions in manufacturer s manuals knowing your employers work rules and applicable governmental regulations Fo...

Page 25: ...0360350 E12 14 USA GB HA12CJ HA32CJ HA12CJ HA32CJ B Recommendations 3 2 IDENTIFICATION CE and AS standards R7 J3 J4 R4 O1 A5 R17 R1 J1 R9 R9 A83 J33 A3 J4 A2 J6 R6 R6 A82 R3 R3 J34 R16 R54 A32 R16 R16 J3 A12 J3 A11 J2 R36 A87 ...

Page 26: ...6 4000360350 E12 14 USA GB HA12CJ HA32CJ HA12CJ HA32CJ B Recommendations A32 A81 R7 J3 R3 R4 R21 J13 J33 A8 J34 J4 R9 R9 R3 J4 R16 A15 A5 A16 J14 R5 R17 A7 R8 R52 R1 A1 R6 R6 A82 J10 A28 R17 R15 R20 R53 ...

Page 27: ...n french CE standard 307P220760 In english CE and AS standards 307P222750 In german CE standard 307P220850 In spanish CE standard 307P220710 In italian CE standard 307P221010 In dutch CE standard 307P221050 In latvian CE standard 307P225200 In polish CE standard 307P221260 In estonian CE standard 307P225180 In lithuanian CE standard 307P225220 In croatian CE standard 307P225240 In slovenian CE sta...

Page 28: ...078148890 30 Other Battery unit 1 For CE standard only 307P228000 For AS standard only 307P229480 31 Other Ground control box 1 307P227740 32 Other Platform control box 1 307P227720 33 Yellow Verification of tilt operation 1 3078144650 34 Red Do not interchange 4 3078145180 35 Other Plastic protection 2 307P228790 36 Yellow Lifting forbidden 2 307P228780 37 Other Emergency control box 1 For Italy ...

Page 29: ...A B C D E F G H I 29 4000360350 E12 14 USA GB HA12CJ HA32CJ HA12CJ HA32CJ B Recommendations ANSI and CSA standards 5 7 9 31 17 29 27 6 3 3 11 10 12 18 4 29 23 9 19 1 2 2 1 3 8 28 25 ...

Page 30: ...30 4000360350 E12 14 USA GB HA12CJ HA32CJ HA12CJ HA32CJ B Recommendations 6 31 31 1 2 2 3 21 9 9 31 18 28 13 5 30 24 15 7 14 32 29 27 22 1 16 15 29 26 ...

Page 31: ...105830 Other 10 Control of movements GREEN directional arrow 1 3078147970 Other 11 Control of movements RED directional arrow 1 3078147980 Red 12 Risk of crushing Collision hazard 1 In english 4000024830 In french 4000068080 In spanish 4000086510 Orange 13 Hand crushing hazard Battery 1 In english 4000025030 In french 4000068120 In spanish 4000086550 Other 14 Harness anchorage point 3 307P216290 O...

Page 32: ...n 2 307P228790 Yellow 28 Lifting forbidden 2 In english 307P228810 In french 4000106260 In spanish 4000106270 Red 29 Do not interchange 4 3078145180 Red 30 Operation instructions 1 In english 4000027580 In french 4000083200 In spanish 4000086650 Blue 31 Anchorage point Traction 4 4000027310 Blue 32 Option Notice 110 V 1 4000027590 Color Marking Description Qty HA32CJ HA32CJ ...

Page 33: ...me periods below are recommended for fuel powered machines in normal use 1 Increase in periodical inspections 2 For countries where machines are not subject to controlled periodic maintenance Symbol Description Symbol Description Visual inspections Systematic replacement Operation requiring HAULOTTE Services authorisation Check Test See user manual or machine maintenance book 1 Visual inspection w...

Page 34: ...ylinders No leaks Refer to the Maintenance manual No rust and abrasions on the cylinder rod No foreign objects on all surfaces Steering system Wheels Driving reducer Brake and Tires Tyres No cracks distortions damaged paint or other faults No missing or loose bolts Condition of the tires tyres cuts excessive wear etc State of the rotation systems Turntable rotation Turntable rotation selector in p...

Page 35: ...te guardrail Floor Platform rotation Rotary cylinder Harness anchorage point Boom assembly Structure parts Pulleys and wear pads 1 Bearings Cables and chains 1 Turntable assembly Structure parts Slew ring 3 Revolving joint and commutator Turntable rotation gearbox Turntable rotation locking pin Bearings Caps and covers Chassis assembly Structure parts Anchorage point Tires Tyres and rims Wheel nut...

Page 36: ...y lowering Indicators switches joysticks and selectors Tilt sensor Limit switch PV radius limit weighing Back to neutral for all joysticks selectors etc Power system Engine See manufacturer s guide Batteries terminals cleanliness attachment Hydraulic and electric assemblies Hydraulic pump Hydraulic tank cap and breather Hydraulic filter clogging indicator Hydraulic oil Electrical connections Commo...

Page 37: ... use and at least once a year Performance check for all functions and safety devices Greasing and lubrication according to the maintenance plan General condition of the machine paint no leaks cracks or excessive distortion etc Machine integrity no modifications without HAULOTTE Services authorisation Particular attention to be paid when checking the crown gear Visual appearence of the interior and...

Page 38: ...eck Test See user manual or machine maintenance book 1 Visual inspection with dismantling and exchange or replacement if necessary Operation requiring HAULOTTE Services authorisation Increase in periodical inspections Check level Tightening bolt etc Lubrication Lubrication Tolerance clearance lubrication Oil change 2 Static and dynamic tests For countries where machines are not subject to controll...

Page 39: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 40: ...d commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to the mainte...

Page 41: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 42: ...nd commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to the maint...

Page 43: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 44: ...nd commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to the maint...

Page 45: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 46: ...nd commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to the maint...

Page 47: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 48: ...nd commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to the maint...

Page 49: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 50: ...nd commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to the maint...

Page 51: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 52: ...nd commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to the maint...

Page 53: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 54: ...nd commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to the maint...

Page 55: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 56: ...nd commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to the maint...

Page 57: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 58: ...r Indicators switches joysticks and selectors Turntable rotation gearbox Tilt sensor Pins rings and pin stop Limit switch PV radius limit weighing Pulleys and wear pads Hydraulic and electric assemblies Bearings Cylinders welds leakproofness external leak excessive distortion Chassis assembly Rings Wheel nuts and bolts Hydraulic tank cap and breather Wheel reducer Hydraulic filter clogging indicat...

Page 59: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 60: ...nd commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to the maint...

Page 61: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 62: ...nd commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to the maint...

Page 63: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 64: ...nd commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to the maint...

Page 65: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 66: ...nd commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to the maint...

Page 67: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 68: ...nd commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to the maint...

Page 69: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 70: ...nd commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to the maint...

Page 71: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 72: ...nd commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to the maint...

Page 73: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 74: ...nd commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to the maint...

Page 75: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 76: ...nd commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to the maint...

Page 77: ...xcessive distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use...

Page 78: ...l Boom assembly E stop buttons on all control boxes Welds Circuit breaker and contactors Hoses and couplings Overload Pins rings and pin stop Horn Pulleys and wear pads Brakes Bearings Emergency lowering Cables and chains Indicators switches joysticks and selectors Cylinders welds leakproofness external leak excessive distortion Tilt sensor Turntable assembly Limit switch PV radius limit weighing ...

Page 79: ...tortion Bearings Rings Hydraulic tank cap and breather Hydraulic filter clogging indicator Hydraulic oil General points Mandatory inspection According to current legislation in the country of use and at least once a year Greasing and lubrication according to the maintenance plan Machine integrity no modifications without HAULOTTE authorisation Date Number of hours Intervenor HAULOTTE Services cont...

Page 80: ... distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at ...

Page 81: ...ng joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to...

Page 82: ... distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at ...

Page 83: ...ng joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to...

Page 84: ... distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at ...

Page 85: ...ng joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to...

Page 86: ... distortion Overload Turntable assembly Horn Slew ring Brakes Revolving joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at ...

Page 87: ...ng joint and commutator Emergency lowering Turntable rotation gearbox Indicators switches joysticks and selectors Pulleys and wear pads Tilt sensor Bearings Limit switch PV radius limit weighing Chassis assembly General points Wheel nuts and bolts Mandatory inspection According to current legislation in the country of use and at least once a year Wheel reducer Greasing and lubrication according to...

Page 88: ...ing maintenance is strictly forbidden Return the machine to operating configuration after maintenance has been completed N B For Russia and the Ukraine only All the fillings drain and lubrication points tanks caps engines drain plugs are red 3 1 PLACING THE MACHINE IN MAINTENANCE CONFIGURATION 3 2 PLACING IN OPERATING CONFIGURATION 1 Remove the turntable rotation locking pin 2 Pull the E stop butt...

Page 89: ...ged and need to be replaced must be replaced with bolts of identical specification Type Length Diameter Class Tighten to the torque indicated when reassembling If there are no specific requirements apply the normalized tightening torques Section C 3 Maintenance sheets E007 3 3 2 2 Pins and bearings Except maintenance schedule check pins and bearings in the following cases Abnormal noise during the...

Page 90: ...ring the bearing drift and the bearing housing must be correctly aligned during the assembly process The recommended values for the bearing drift are given on the diagram below Recommended Values After inserting the bearing lubricate and fit the pin Marking Description A At least 0 5 times the nominal diameter B Make a chamfer C Nominal diameter of the bearing 0 2 0 3 mm D Bearing drift E Diameter...

Page 91: ...g from external pollutants and potential damage Clean the bearing with a suitable solvent Replace the bearing in the following cases Presence of abrasions in the bearing housing and or inside the bearing itself Presence of abrasion wear oxidation deformations of the balls or rollers and the ring rollers Reassembly of the bearing pivot Clean the bearing housing or pin in order to remove all the for...

Page 92: ... of the front wheels and the reference mark on the ground If the distance is between 0 2 m 0 ft8 in and 1 5 m 4 ft11 in the test validates correct operation Otherwise contact HAULOTTE Services to repair the system Second test On ramp On non slipping loading ramp maximum slope 20 Draw a line on the slope to create a stopping reference Climb on the ramp at microspeed Release the joystick when the fr...

Page 93: ...d Fill the tank 1 Perform a complete cycle fully extend and retract of each cylinder 2 Fill the tank if necessary Never above of the maximum level Repeat the step 1 and 2 for each cylinder on the machine 3 3 3 2 Replacing damaged of hoses Replace hoses in the following circumstances Tears in the outer casing Cracks in the outer casing Apparent shielding Visible leak in the hose Damage to the outer...

Page 94: ... between two measurements does not exceed 4 cm the test validates correct operation If the difference between two measurements exceeds 4 cm contact HAULOTTE Services or carry out the additional tests described below Control cylinder by cylinder Position a load equal to the rated capacity on the cage or platform Perform the movement of the concern cylinder to half of its stroke After hose removal p...

Page 95: ... points of connection to ensure continuity of machine operation after the wire is replaced Note the cable path to facilitate reassembly Respect the order configuration of origin during the reassembly Type of cylinders Maximum drift authorised due to an internal leak of the cylinder Lift cylinder arm or boom Machine with working heights 26 m 85 ft4 in After 10 mn creep 0 2 mm After 60 mn creep 1 mm...

Page 96: ...96 4000360350 E12 14 USA GB HA12CJ HA32CJ HA12CJ HA32CJ C Maintenance ...

Page 97: ... 1 must be between the upper and lower markers 4 Filling up 5 Additional operation 1 Place the machine in its operating configuration 3 3 2 Placing in operating configuration Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area Check the oil level when cold before beginning a new period of work If the oil level 1 is not visible 1 Loosen and remove the ta...

Page 98: ...98 4000360350 E12 14 USA GB Control Filling up Oil tank E001 15 min ...

Page 99: ...lection pan Place barriers around the perimeter of the work area 1 Turn the wheel to obtain the following configuration 2 Plug 1 is on a horizontal line 3 Plug 2 is on a vertical line 4 Loosen and remove plug 1 5 Check the oil level 6 Top up the oil level to the hole if necessary 7 Refit and tighten plug 1 1 Turn the wheel until plug 2 is directed downwards 2 Loosen and remove plugs 1 and 2 3 Let ...

Page 100: ...100 4000360350 E12 14 USA GB Control Oil change Wheel reducer E002 15 mn ...

Page 101: ...HA32CJ HA12CJ HA32CJ 4 Additional operation 1 Place the machine in its operating configuration 3 3 2 Placing in operating configuration Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area Before dismantling ensure that the oil circuit is no longer under pressure and that the oil temperature is not too high 1 Loosen and remove the base nut 1 2 Loosen and...

Page 102: ...102 4000360350 E12 14 USA GB Replacement Hydraulic filter cartridge E003 15 min ...

Page 103: ...n 3 Filling up 4 Additional operation 1 Place the machine in its operating configuration 3 3 2 Placing in operating configuration Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area Touch the exterior of the filling hole with the pump spout before starting pouring to avoid any risk of static electricity causing sparks Make sure you are standing up wind ...

Page 104: ...104 4000360350 E12 14 USA GB Filling up Oil change Fuel tank E004 15 mn ...

Page 105: ...f greasing as indicated in the program Standard tool kit Steel shims Protective goggles Gloves Place barriers around the perimeter of the work area The illustrations in this paragraph do not necessarily correspond to the range of products designated in the manual 1 Check for the presence of all the locating bolts 2 Check that the accessible screws are not loosened If necessa ry tighten the screws ...

Page 106: ... 21 5 daN m 158 lbf ft HA20PX 21 5 daN m 158 lbf ft HA260PX 21 5 daN m 158 lbf ft HA32PX 21 5 daN m 158 lbf ft HA41PX NT 21 5 daN m 158 lbf ft H14TX 8 7 daN m 64 lbf ft H16TPX 8 7 daN m 64 lbf ft H21TX 21 5 daN m 158 lbf ft H23TPX 32 daN m 236 lbf ft H25TPX 21 5 daN m 158 lbf ft H28TJ 21 5 daN m 158 lbf ft H43TPX 21 5 daN m 158 lbf ft STAR 8 Ring on plate 13 5 daN m 100 lbf ft STAR 8 Plate on mast...

Page 107: ...l box align the turret at 90 to the chassis Lift the boom approximatively 30 from the ground Completely retract the boom Jib in horizontal position if fitted From the magnetic comparator note the clearance J1 between chassis or turret and the slew ring Clearance between chassis or turret and slew ring After having carried out the measurement Lower the boom at horizontal position Lift the arm if ex...

Page 108: ...hine in its operating configuration 3 3 2 Placing in operating configuration 2 Rotate the slew ring by one complete turn Consult the After Sales Service HAULOTTE Services A tight spot or grinding sound during rotation or the presence of metal particles escaping from the lip seal are signs of abnormal wear in the raceway Contact HAULOTTE Services ...

Page 109: ...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 Nonlinear wear of the ground contact surface greater than 10 Standard ...

Page 110: ...wheel nuts on the wheel to be removed 2 Raise the machine using a jack or a hoist 3 Remove the wheel nuts 4 Remove the wheel 5 Install the new wheel 6 Lower the machine to the ground 7 Tighten the wheel nuts to the recommended torque For safety reasons always use original HAULOTTE spare parts that are specific to this machine Refer to the spare parts catalog ...

Page 111: ...236 HA18PX Drive wheel 320 236 Steer wheel 320 236 HA20PX Drive wheel 320 236 Steer wheel 320 236 HA260PX Drive wheel 320 236 Steer wheel 320 236 HA32PX Drive wheel 650 479 Steer wheel 650 479 HA41PX NT Drive wheel 570 420 Steer wheel 570 420 H14TX Drive wheel 320 236 Steer wheel 320 236 H16TPX Drive wheel 320 236 Steer wheel 320 236 H21TX Drive wheel 320 236 Steer wheel 320 236 H23TPX Drive wheel...

Page 112: ...112 4000360350 E12 14 USA GB Replacement Tightening Wheel E006 15 min ...

Page 113: ...x3 630 790 464 66 582 67 890 990 656 43 730 19 1070 1180 789 19 870 32 M27x3 930 1150 685 93 848 2 1300 1400 958 83 1032 59 1560 1730 1150 6 1275 98 M30x3 5 1260 1570 929 33 1157 97 1770 1960 1305 49 1445 62 2200 2350 1622 64 1733 27 Nominal diameter Torque in N m lbf ft Class 8 8 Class 10 9 Class 12 9 M8x1 24 29 17 7 21 39 33 37 24 34 27 29 40 44 29 5 32 45 M10x1 25 46 57 33 93 42 04 64 71 47 2 5...

Page 114: ...114 4000360350 E12 14 USA GB Tightening Screws bolts and nuts E007 15 min ...

Page 115: ... Refit and tighten the drain out 2 5 Top up the oil level as indicated above 6 Refit the filling cap 1 5 Additional operation 1 Place the machine in its operating configuration 3 3 2 Placing in operating configuration Standard tool kit Protective goggles Gloves Oil collection pan Place barriers around the perimeter of the work area 1 Loosen and remove the filling cap 1 2 Check that the oil level i...

Page 116: ...116 4000360350 E12 14 USA GB Control Oil change Turntable rotation gearbox E008 15 mn ...

Page 117: ...chine in maintenance configuration 3 Control N B Packers of different thicknesses can be used for adjustment 4 Replacement Replace the friction pads 5 Additional operation 1 Place the machine in its operating configuration 3 3 2 Placing in operating configuration Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area Check the telescoping friction pad wear...

Page 118: ...118 4000360350 E12 14 USA GB Control Lubrication Replacement Pulleys and wear pads E013 15 mn ...

Page 119: ...n the caps located on the top of the battery The level of electrolyte in the battery must be approx 0 01 m 0 ft39 in above the plates 4 Filling up Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area The battery manufacturer s safety instructions must be followed Loosen the caps located on the top of the battery If the level of electrolyte is below the l...

Page 120: ...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 Open the bay Use the machine s on board charger The charger has a charge rate compatible to the battery capacity During charging The machine s electric system is automatically deactivated while the external power sup...

Page 121: ...he machine in its operating configuration 3 3 2 Placing in operating configuration To keep your batteries in good condition test the density of each element once a month using a batttery hydrometer according to the temperature indicated in the curves below Battery charge status according to density and temperature ...

Page 122: ...122 4000360350 E12 14 USA GB Control Filling up Battery charge Battery E018 10 min ...

Page 123: ... 3 3 1 Placing the machine in maintenance configuration 3 Lubrication Oil the parts of the telescope subject to friction with a spatula Oil the telescoping cable 4 Additional operation 1 Place the machine in its operating configuration 3 3 2 Placing in operating configuration Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area ...

Page 124: ...124 4000360350 E12 14 USA GB Lubrication Telescope E022 15 mn ...

Page 125: ...t hydraulic oil in the tank Batteries are charging Control box E stop push buttons are pulled out The control box selector key is set to platform or ground control box Control box relays are engaged Fuse status Ground control box solenoid valve status If the malfunction persists consult the troubleshooting table to identify the problem IF you cannot identify the problem contact HAULOTTE Services ...

Page 126: ...ontrol box power cable is damaged Repair or replace the cable Tilt or slope exceeding the authorised limit Lower the arm and boom Do not exceed the authorised limit Section G 1 Main characteristics Faulty speed variator Check the diagnosis LED or Contact HAULOTTE Services No power supply to brake release Check cables and brakes No power in horizontal drive mode Speed selector switch in the wrong p...

Page 127: ...heck the diagnosis LED or Contact HAULOTTE Services Lowering of the arm or the boom Lifting jack joints worn Replace the joint s Shut off valve clogged up Replace the valve and the oil filter No turntable rotation Turntable rotation locking pin is inserted in the chassis Remove the pin No steering Not enough hydraulic oil Top up the oil level Enable Switch control validation device is not enabled ...

Page 128: ...et side Repair tighten or replace the hoses or connectors The battery charger does not work No voltage in the selector Check the power supply connection Batteries discharged Charge the battery ies with another charger which does not have a regulator Faulty charger Repair or replace the charger Batteries wrongly connected to the charger Check the connection Faulty batteries Replace the batteries Th...

Page 129: ...m calculator coil power supply FU8 Protection fuse for controls sensors and displays FU9 Emergency electric pump option protection fuse FU10 Protection fuse for emergency stop and position selectors G1 Small chamber pressure sensor G2 Large chamber pressure sensor GB1 Left battery GB2 Right battery GC1 Converter 48V 12V H1 Hour meter H2 Work light Option HA1 Horn HA141 Buzzer Platform HA142 Buzzer...

Page 130: ... B Turntable left right Turntable SA140 Turntable emergency stop SA141 Platform emergency stop SB2 Manual brake release push button Option SB6 Enable Switch pedal SB105 Horn push button SB120 Speed button SB121 Speed button SB122 Emergency pump button SM1 Drive joystick SM2 Lifting and turntable rotation joystick SQ1 Tilt sensor SQ9 Telescope extended sensor SQ34 Arm boom unfolded sensor V1 Pump t...

Page 131: ...ection fuse FU6 Protection fuse for turntable calculator and turntable calculator coil power supply FU7 Protection fuse for platform calculator and platform calculator coil power supply FU8 Protection fuse for controls sensors and displays FU9 Emergency electric pump option protection fuse FU10 Protection fuse for emergency stop and position selectors Marking Description KAB Brake release relay KA...

Page 132: ...132 4000360350 E12 14 USA GB HA12CJ HA32CJ HA12CJ HA32CJ E Electric circuit ...

Page 133: ...CJ HA32CJ F Hydraulic circuit Hydraulic circuit 1 Hydraulic diagram Main components N B See end of manual 2 Solenoid valves Hydraulic unit HA12CJ HA32CJ HA12CJ HA32CJ YV6B YV7B YV5B YV2B YV1 YV0 YV8B YV4B YV9B YV10B YV3B YV6A YV7A YV5A YV2A YV8A YV4A YV9A YV10A YV3A ...

Page 134: ...ring control solenoid valve YV4A Turntable rotation left solenoid valve YV4B Turntable rotation right solenoid valve YV5A Arm lifting solenoid valve YV5B Arm lowering solenoid valve YV6A Boom lifting solenoid valve YV6B Boom lowering solenoid valve YV7A Telescope extension solenoid valve YV7B Telescope retraction solenoid valve YV8A Jib elevation control solenoid valve YV8B Jib lowering control so...

Page 135: ...e intervention register keeps a record of maintenance and repair work carried out inside or outside the maintenance programme N B In 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 ...

Page 136: ...136 4000360350 E12 14 USA GB HA12CJ HA32CJ HA12CJ HA32CJ G Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 137: ...A B C D E F G H I 137 4000360350 E12 14 USA GB HA12CJ HA32CJ HA12CJ HA32CJ G Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 138: ...138 4000360350 E12 14 USA GB HA12CJ HA32CJ HA12CJ HA32CJ G Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 139: ...A B C D E F G H I 139 4000360350 E12 14 USA GB HA12CJ HA32CJ HA12CJ HA32CJ G Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 140: ...140 4000360350 E12 14 USA GB HA12CJ HA32CJ HA12CJ HA32CJ G Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 141: ...1 4000360350_USA GB_E12 14 Electrical diagram Electric articulated lifts 1 HA12CJ HA32CJ HA12CJ HA32CJ 1 1 SUPPLY ...

Page 142: ...2 Electrical diagram Electric articulated lifts 1 2 VARIATOR ...

Page 143: ...3 Electrical diagram Electric articulated lifts 1 3 TURRET COMMAND ...

Page 144: ...4 Electrical diagram Electric articulated lifts 1 4 HIGH STATION COMMAND ...

Page 145: ...1 Hydraulic diagram Electric articulated lifts 1 HA12CJ HA32CJ HA12CJ HA32CJ 1 1 FOLIO 1 1 ...

Page 146: ...2 Hydraulic diagram Electric articulated lifts ...

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