Haulotte Group HT21RT O Maintenance Book Download Page 260 | Manualshive

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260

4000511390

E03.16

USA / GB

HT21RT O - HT21RT O SW - HT61RT O - HT21RT PRO - HT21RT PRO SW - HT61RT PRO -
HT23RTJ O - HT23RTJ O SW - HT67RTJ O - HT23RTJ PRO - HT23RTJ PRO SW - HT67RTJ PRO

E

Trouble shooting and diagram

Marking

Description

FU1

Fuse -10 A - Engine shutdown

FU2

Fuse - 20A - Starter

FU3

Not used

FU4

Fuse - 25A - Generator

FU5

Fuse - 30A - General

FU6

Not used

FU7

Fuse - 15A - ECU

FU8

Fuse - 20A - Option

FU9

Fuse - 20A - Attachments

FU10

Not used

FU11

Fuse - 7.5A - + Permanent

FU12

Not used

FU13

Fuse - 20A - Power

FU14

Not used

FU15

Not used

FU16

Not used

FU17

Not used

FU18

Not used

FU19

Fuse - 5A - Emergency stop and selectors

KA1

Relay - 1RT - 12V - Engine shutdown

KA2

Relay - 1RT - 12V

KA3

Solenoid valve

KA4

General

KA5

Relay - 1RT - 12V - Engine speed

KA9

Relay - 1RT - 12V - Horn

KMG

Relay - 1T - 12V/70A - Main relay

KMP

Relay - 1T - 12V/70A - Power

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Summary of Contents for HT21RT O

Page 1: ...SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO 4000511390 E03 16 USA GB Maintenance Book HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RT...

Page 2: ...2 4000511390 E03 16 USA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO...

Page 3: ...utionHazards 13 1 4 Explosion FireHazards 14 2 Maintenance and repair training 15 2 1 Owner sresponsability 15 2 2 Technician sresponsability 15 2 3 HAULOTTEServices 15 2 4 Training 15 2 5 Productmodi...

Page 4: ...neralsafetyandspecificinterventionsonmotor 44 3 2 GeneralSpecifications 45 3 3 Consumables 45 3 4 Ingredient 45 4 Lubrication diagram 46 4 1 Greasingpointslocalization 47 5 Consumables Oils Fuels Engi...

Page 5: ...ng wheels reducer143 MS0012 Condition of the cables inspection Criteria of replacement 161 MS0013 Check and replacing the pads 167 MS0014 Procedure of dismantling reassembling telescope cylinder 175 M...

Page 6: ...e shooting and diagram 1 Trouble shooting 249 1 1 Recommendations 249 1 2 Description 249 1 3 Requirements 249 2 Legend 256 2 1 PCBTurret 256 3 Electric diagram 261 4 Hydraulic diagram 270 F Records 1...

Page 7: ...mpliance with safety instruction machine use environment Use of the equipment within the performance limits With regard to the designation of our equipment we stress that this is purely for commercial...

Page 8: ...nual to indicate specific hazards and the hazard severity level when operating or maintaining the Aerial Work Platform S y m b o l Symbol Description Danger Risk of injury or death Caution Risk of mat...

Page 9: ...TO INDICATE SPECIFIC HAZARDS WHEN OPERATING OR MAINTAINING THE MACHINE Color Title Description Danger Indicates a hazardous situation which if not avoided WILL result in death or serious injury Warnin...

Page 10: ...10 4000511390 E03 16 USA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO A Preface Foreword Notes...

Page 11: ...MENTATION Your safety and the safety of the people around are essential Make sure the work area is clean in order to not to pollute the system of the machine Before performing any maintenance interven...

Page 12: ...e Return the machine to operating configuration after maintenance has been completed 1 Remove the turntable rotation locking pin 2 Pull the E stop button 1 2 UNCONTROLLED MOVEMENT HAZARD Be aware of u...

Page 13: ...00 kV 14 45 Do not operate the machine 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 con...

Page 14: ...es 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 wor...

Page 15: ...derstand the contents of this manual operators manuals and the decals affixed on the machine The technician must inform the owner or hirer if the manual or any decals are missing or in poor condition...

Page 16: ...acting 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 r...

Page 17: ...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...

Page 18: ...ation during the period of operation Wearing parts will therefore not be covered by the warranty agreement 3 4 WARRANTY CONDITIONS To benefit from the warranty the owner or rental company must inform...

Page 19: ...TJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization Familiarization 1 Primary machine components 1 1 LAYOUT H T 2 1 R T O H T 2 1 R T O S W H T 6 1 R T O H T 2 1 R T P R O H T 2 1 R T P R O...

Page 20: ...latform control box C35 Document holder C8 Input jib compensation cylinder C42 Enable Switch pedal C9 Upper boom C72 Output jib compensation cylinder C10 Slew ring C113 Beacon light C11 Turntable asse...

Page 21: ...21 4000511390 E03 16 USA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization Notes...

Page 22: ...USA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization 1 2 GROUND CONTROL BOX 1 2 1 Layout G...

Page 23: ...ing on Validation of controls when engine started automatic switching of emergency electropump if the engine is stopped 7 Turntable rotation switch By pressing on Counter clockwise CCW rotation By pre...

Page 24: ...Gas supply2 By pressing on Propane Gas supply selection 18 Petrol Gasoline or diesel supply3 By pressing on Fuel supply selection 19 Engine warning indicator Engine pre heating Alarm icon Is ON at pow...

Page 25: ...achine operating status C o n t r o l s a n d i n d i c a t o r s Icon Description Function Machine power up Start up screen Navigation buttons Above Activ Screen display Home Button Allows return to...

Page 26: ...present Cancel Button Used to refuse or cancel a selection within the menu Validation Button Used to confirm selection within the menus Home screen dashboard Will be visible depending on the machine...

Page 27: ...enance schedules has been exceeded Stop motor Icon is ON if an engine failure is detected coolant pressure alternator etc Or if the Engine shuts down after 3 seconds of running Or after 1 second when...

Page 28: ...nges from GREEN to RED when the engine is overheating coolant temperature is higher than 110 C Displays machine Information Will be visible depending on the machine Displays the applicable number soft...

Page 29: ...pe greater than the permitted slope Depending on the machine configuration machine raise and extend functions may be slowed or prevented Overload The platform is overloaded Remove the excessive load t...

Page 30: ...HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization Machine fault Will be visible depending on the machine Machine fault icons Failure code F02 xx Fault power contactor Fa...

Page 31: ...J PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization Failure code F05 xx Fault joystick Failure code F06 xx Fault weight management system Failure code F07 xx Fault limit switch or sensor Failure code F...

Page 32: ...TJ PRO SW HT67RTJ PRO C Familiarization Failure code F12 xx Fault electronic control unit ECU Failure code F15 xx Fault data communication system CAN Operator PIN code Will be visible depending on the...

Page 33: ...23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization Emergency Mode Will be visible depending on the machine Access code not yet entered Access code entered is correct Level 1...

Page 34: ...on is Enabled when The E Stop at platform control box is pushed in de energized The machine is in overload state Ground control box is selected energized The emergency overriding button is activated T...

Page 35: ...35 4000511390 E03 16 USA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization Notes...

Page 36: ...SA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization 1 3 PLATFORM CONTROL BOX 1 3 1 Layout...

Page 37: ...ed Pressed in De energizes control system Engine stopped 78 Not used 79 Generator selector2 2 For machines fitted with Move to the left Generator deactivated Move to the right Generator activated 823...

Page 38: ...pre heating LED 111 Fault LED 103 Low fuel level LED 112 Tilt LED 104 Engine warning LED 113 Radius limit LED 105 Engine shutdown LED 114 Overload LED 106 DPF disable LED 115 Turret at 180 LED 107 DP...

Page 39: ...off 450 kg load selected Permanently lighted machine in the 450 kg zone and the 450 kg load is validated otherwise off1 United States Canada 500 lbs load selected Permanently lighted position of the m...

Page 40: ...f engine quipped with Particulate Filter Regeneration 5 If engine quipped with Particulate Filter Regeneration Filter status Level of clogging DPF cannot be recovered 250 ON ON Manual regeneration req...

Page 41: ...41 4000511390 E03 16 USA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization Notes...

Page 42: ...RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization 2 Device layout 2 1 SENSORS AND ACTUATORS S e n...

Page 43: ...R380 Sensor Boom 1000 lbs angle limit zone SR381 Sensor Cable break 1 SQ990 Sensor Engine overheating ST160 Sensor Engine oil pressure SP162 Sensor Engine temperature ST161 Valve Translation forwards...

Page 44: ...ape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system Place a do not operate tag at the s...

Page 45: ...TED ON YOUR HAULOTTE PLEASE REFER TO THE ENGINE MANUFACTURER S MANUAL THE ENGINE MAY NOT BE COVERED BY THE WARRANTY IN CASE OF DAMAGE CAUSED BY USING UNSUITABLE FUEL 3 3 CONSUMABLES 3 4 INGREDIENT Con...

Page 46: ...LOTTE code 1 Engine oil 30 20 2820305720 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 Hyd...

Page 47: ...RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization 4 1 GREASING POINTS LOCALIZATION Slew ring 1 on the planetary gear dr...

Page 48: ...SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization 1 on the boom lift cylinder 4 on the steering cylinder if 2WS...

Page 49: ...6 USA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization 2 on the jib lift cylinder 1 on the...

Page 50: ...ording 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 F3...

Page 51: ...the following components heat exchanger and piping Refer to the QEM specifications Enter the value for the capacity of the external system in this row C l a s s i f i c a t i o n A P I EMA LGR 1 API C...

Page 52: ...ng 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...

Page 53: ...ement from the ground control box HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO Micro drive speed 0 5 km h 0...

Page 54: ...54 4000511390 E03 16 USA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization Notes...

Page 55: ...factors are amongst a number which may extend or shorten the Design Life of the product Maintenance operations must be carried out by a competent technician whose selection is under the responsibility...

Page 56: ...status MS0029 Slew ring replacement MS0029 Cooling system MS0029 Battery Check of battery electrolyte level MS0110 Check of density battery electrolyte MS0110 Slew ring Lubrication endless screw rolli...

Page 57: ...PRO D Inspection and maintenance schedule Wear pads MS0013 Pins and bushes Work platform floor guardrails access and extensions Fixing platform on support Fixing platform ground on platform Fixing sli...

Page 58: ...ded in the safety register or machine log book controlled and overseen by the company manager This register or machine log book and the list of competent repair persons must be made available to the G...

Page 59: ...ghten loosened hardware refer to recommended torque value table in maintenance book In case of leaks tighten or replace the damaged part before placing the machine in service In case of structural par...

Page 60: ...e control box No deterioration All decals at the control boxes are clean and legible Operation of start stop device Operation of E stop button device Operation of enable switch Operation of horn from...

Page 61: ...aged and operates smoothly All compartments covers open and lock properly Rotation system orientation turret basket and jib No cracks broken weld paint chipped No deterioration and visible damage No s...

Page 62: ...r split wire sheaths No evidence of chemical damage or corrosion on all cables No oxidation or corrosion on terminals Sensors and safety device Stabilizers operate correctly and lock securely in posit...

Page 63: ...have specific requirements on frequency and content of inspections Otherwise or in addition use the detailed program below This inspection is the responsibility of the owner and must be conducted by...

Page 64: ...if necessary Presence cleanliness and legibility of the manufacturer s plate Control box Operation of emergency lowering device Work Platform Floor guardrails access and extensions No cracks broken w...

Page 65: ...wear cutting damage Anchor points for handling fixed undamaged and signalized if equipped Wheel reducer Rotation systems orientation turret basket and jib No cracks broken weld paint chipped No foreig...

Page 66: ...or missing loose parts Absence of cylinder leakage Energy storage and motorisation tanks batteries and engine No screw or missing loose parts Absence of leaks battery acid engine oil etc Presence and...

Page 67: ...and if needed adjustment of work area limitation device if equipped Presence and good operation of sensors Sensors and safety device Static tests on horizontal ground Dynamic test on horizontal groun...

Page 68: ...reach the part Replacement is necessary Proof tests Need HAULOTTE Services authorization For countries where machines are not subject to controlled periodic maintenance Yes No Correcte d Not applicab...

Page 69: ...lters manifold No torn or split wire sheaths Shielding is not apparent No evidence of chemical damage or corrosion on all cables Energy storage and motorisation tanks batteries and engine No screws mi...

Page 70: ...n Major inspection allow determining the suitability integrity and proper functioning of the machine It must take place when the machine is 10 years or 5000 h after renewed every 5 years This inspecti...

Page 71: ...chines are not subject to controlled periodic maintenance Yes No Corrected Not applicable Frame axle steering system stabilizers arms No deterioration and visible damage Pin pin stop bearing Bushes an...

Page 72: ...00511390 E03 16 USA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO D Inspection and maintenance schedule N...

Page 73: ...generally applicable for safety accident prevention All the precautions must be done in work before intervening on and near the machine After completion of work all the covers and safety devices must...

Page 74: ...tion If anomalies are noted according to the list below a reinforced control will have to be carried out to judge conformity of the part Absence of foreign body to the articulations and slides Absence...

Page 75: ...tive checks The criteria quoted above are applicable The main items to be inspected are Boss welds on chassis turret arms booms and jib Booms and arms welds E x a m p l e In the event of suspicion of...

Page 76: ...ts without jolts while supporting the load All the security device function correctly Authorized maximum speeds of operation are not exceeded Refer to the user manual for the description of the safety...

Page 77: ...ions Every day before use Fast visual inspection without disassembling Check the presence of the pins and visible stops pins without disassembling Check the presence of the screws Check absence of def...

Page 78: ...ence of shaving in the housing of the bearing and or the bearing Check the absence of heavy abrasion wear oxidation deformations of the balls or rollers and the ball races The periodicity can evolve u...

Page 79: ...housing must be correctly aligned during the assembly process The recommended values for the bearing drift are given on the diagram below R e c o m m e n d e d V a l u e s After inserting the bearing...

Page 80: ...espect the following stages Clean boring and or the pins to remove all the foreign bodies Slightly lubricate boring and or pins Lubricate the ring of the bearing slightly To fit bearing in a boring ta...

Page 81: ...ndencies generally applicable for safety accident prevention All the precautions must be done in work before intervening on and near the machine After completion of work all the covers and safety devi...

Page 82: ...using the ground control box To activate the cylinder to be tested proceed as follows Lift Arm hydraulic cylinder Lift the arm to approximately half full height The telescopic boom should be fully ext...

Page 83: ...f the cylinder Lift cylinder arm or boom Machine with working heights 26 m 85 ft4 in After 10 mn creep 0 2 mm 7874 in After 60 mn creep 1 mm 0 039 in Outriggers cylinder Oscillating axle locking Lift...

Page 84: ...ears with disassembling of the element to check the entirety of the welding Each Cylinder must be disassembled and must be review using non destructive checks The criteria quoted above are applicable...

Page 85: ...rs or every 6 months High speed On a flat ground or slightly inclined always lower than the authorized slope see plate manufacturer Trace on the ground a line being used as reference mark of stop Roll...

Page 86: ...86 4000511390 E03 16 USA GB General data Breaking test procedure MS0004 Notes...

Page 87: ...ellow dry Dull dry Lubed Dry Dull dry Lubed Dry Dull dry Lubed Dry ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm 8 5 9 8 5 4 7...

Page 88: ...7 61 62 7 20 41 55 5 55 74 5 60 81 3 80 108 4 68 92 1 1 2 13 57 77 3 75 101 6 80 108 4 110 149 93 126 20 64 86 7 85 115 90 122 120 162 105 142 9 16 12 80 108 4 110 149 120 162 150 203 130 176 18 90 12...

Page 89: ...m Slew ring Slew ring Chassis 215 Nm Turntable Slew ring 215 Nm Hydraulic motor Slew ring 105 Nm ECU ECU Carrier 6 Nm Engine Hydraulic pump Engine housing 125 Nm Exhaust 95 Nm Engine Carrier side pump...

Page 90: ...OBA Mounting on platform support and link piece Apply torque in 3 times 1 123 Nm 2 246 Nm 3 370 Nm Tightening crosswise in the order below 370 Nm Platform control box 16 Nm Silentbloc fastening platfo...

Page 91: ...usted only to people having the necessary technical training Respect in addition to the instructions appearing in the present instructions the legal tendencies generally applicable for safety accident...

Page 92: ...in the rubber side wall Blister or pronounced lump on the external and lateral wall Damaged wheel stud Damage or wear on the side wall to the extent that the reinforcing wire is visible Consistent wea...

Page 93: ...d Tighten the wheel nuts to the recommended torque Refer to maintenance and repair manuals Component Standard wheel Reference number 385 65 22 5 Filled foam or inflated wheel pressure Standard foam Wh...

Page 94: ...94 4000511390 E03 16 USA GB Chassis and turntable Tires Tyres and pressures Wheel replacement MS0006 Notes...

Page 95: ...xist should be carried out only on the installations completely disconnected and must be entrusted only to people having the necessary technical training Respect in addition to the instructions appear...

Page 96: ...on 5 With boom in this position place drive control lever to reverse and carefully drive machine off of block and ramp 6 Have an assistant check to see that left front or right rear wheel remains elev...

Page 97: ...egal tendencies generally applicable for safety accident prevention All the precautions must be done in work before intervening on and near the machine After completion of work all the covers and safe...

Page 98: ...ng hole with the pump spout before starting pouring to avoid any risk of static electricity causing sparks Make sure you are standing up wind to avoid being splashed by the fuel 1 Loosen and remove th...

Page 99: ...n the present instructions the legal tendencies generally applicable for safety accident prevention All the precautions must be done in work before intervening on and near the machine After completion...

Page 100: ...achine and to guarantee its service life Whatever the type of system installed on the machine interior or external teeth follow the recommendations of greasing as indicated in the program Grease the i...

Page 101: ...B Chassis and turntable Slew ring inspection MS0010 3 1 FOR HA16RTJ HA16RTJ O HA16RTJ PRO HA46RTJ O HA46RTJ PRO ONLY 1 on screw drive system Slew ring 2 nipples on the raceways inside the slew ring 3...

Page 102: ...21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO 215 Nm 158 6 lb ft HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO 215 Nm 158 6 lb ft HA16RTJ 215 Nm 158 6 lb ft HA32PX H...

Page 103: ...ightening torque table Visually check the presence of the teeth and gear if possible Check the appearance of the teeth A tight spot or grinding sound during rotation or the presence of metal particles...

Page 104: ...J1 between chassis or turret and the slew ring C l e a r a n c e b e t w e e n c h a s s i s o r t u r r e t a n d s l e w r i n g After having carried out the measurement Lower the boom at horizonta...

Page 105: ...s and safety devices must be positioned back completely and operational 3 Gearbox inspection 4 Oil gearbox replacement 1 Remove the filling cap 1 2 Loosen the drain plug 2 3 Let the oil drain out 4 Re...

Page 106: ...106 4000511390 E03 16 USA GB Chassis and turntable Gearbox inspection Oil replacement MS0011 Notes...

Page 107: ...M E 3 V 2 0 0 3 M E 3 V 2 4 0 3 M E 3 V 2 0 0 4 M T E 3 D 1 8 0 3 M D I E 3 V 2 4 0 3 M D I E 3 V 3 6 0 0 E 3 V 6 0 0 T E 3 V 3 3 0 0 E 3 B G V 3 6 0 0 T E 3 B G 1 Intake manifold 2 Speed control lev...

Page 108: ...machine while under the influence of alcohol or drugs Do not wear loose torn or bulky clothing around the machine It may catch on moving parts or controls leading to the risk of accidents Use additio...

Page 109: ...f exhaust remains colorless If the output slightly exceeds the rated level exhaust may become a littele colored with the output level kept constant If the engine is run continuously with dark exhaust...

Page 110: ...versed the sound of the engine changes and exhaust gas will come out of the air cleaner 3 A louder knocking sound will be heard when the engine starts running backwards 2 3 2 Remedies 1 Immediately se...

Page 111: ...operation When cleaning any parts do not use gasoline but use regular cleanser Always use proper tools that are in good condition Make sure you understand how to use them before performing any service...

Page 112: ...rtridge depending on the oil pan Check of intake air line Every 400 hours Replacement of fuel filter cartridge Cleaning of water separator Every 500 hours Removal of sediment in fuel tank Cleaning of...

Page 113: ...ur fuel is mandatory for these engines when operated in US EPA regulated areas Therefore please use No 2 D S15 diesel fuel as an alternative to No 2 D and use No 1 D S15 diesel fuel as an alternative...

Page 114: ...fuels specified to EN 590 or ASTM D975 are recommended No 2 D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service To avoid personal injury Do not mix gasoline...

Page 115: ...he fuel system Air bleeding of the fuel system is required if After the fuel filter and pipes have been detached and refitted After the fuel tank has become empty Or before the engine is to be used af...

Page 116: ...y 1 Fuel tank below injection pump 4 Electric or Mechanical pump 2 5 Main Filter 3 Pre filter 6 Injection pump To avoid personal injury Check or replace the fuel pipes after stopping the engine Broken...

Page 117: ...er lever A OFF 2 Fuel filter pot B ON Remove the top cap and rinse the inside with diesel fuel Take out the element and rinse it with diesel fuel After cleaning reinstall the fuel filter keeping out o...

Page 118: ...ducting inspections maintenance or for a cleaning procedure Contact with engine oil can damage your skin Put on gloves when using engine oil If you come in contact with engine oil wash it off immediat...

Page 119: ...personal injury Be sure to stop the engine before changing the oil filter cartridge Allow engine to cool down sufficiently oil can be hot and cause burns 1 Replace the oil filter cartridge 2 Remove t...

Page 120: ...than 30 minutes after it has been stopped Do not remove the radiator cap while coolant is hot When cool to the touch rotate cap to the first stop to allow excess pressure to escape Then remove cap com...

Page 121: ...ns loss of coolant 5 Coolant Radiator cleaner and anti freeze All seasons Pure water and anti freeze 4 3 3 Remedies for quick decrease of coolant 1 Check any dust and dirt between the radiator fins an...

Page 122: ...f the coolant temperature warning lamp lights up or if steam or coolant does not stop squirting from the radiator overflow pipe turn off the load and keep the engine idling COOLING DOWN for at least 5...

Page 123: ...f mixed with the cleaning agent sludge may build up adversely affecting the engine parts 7 Kubota genuine long life coolant has a service life of 2 years Be sure to change the coolant every 2 years N...

Page 124: ...inspect inside of the element with a light and check if it is damaged or not 7 Replace the primary element every year or every 6 cleanings If the primary element is stained heavily replace it soon At...

Page 125: ...ting will be more difficult if the battery charge is low Be careful to recharge it at an early occasion before it is too late If the red signal on the dust indicator attached to the air cleaner is vis...

Page 126: ...ll times especially when charging the battery When charging the battery remove the battery vent plugs When disconnecting the cable from the battery start with the negative terminal and when connecting...

Page 127: ...charges while it is stored Recharge it once a month in summer and every 2 months in winter 5 When exchanging an old battery for a new one use batte ry of equal specification 1 Plug A Highest level B L...

Page 128: ...eld after maintenance or checking 1 Stop the engine and remove the key 2 Apply moderate thumb pressure to belt between the pul leys 3 If tension is incorrect loosen the alternator mounting bolts and u...

Page 129: ...place 5 When the engine is not used for a long period of time run it for about 10 minutes under no load every 2 to 3 months to keep it free from rust If the engine is stored without any running moistu...

Page 130: ...ery In winter always remove battery from machine charge fully and keep indoors Install in machine at time of use When output is insufficient Compression is insufficient Bad valve and excessive wear of...

Page 131: ...ng system Oil lamp lights up during operation Check the lubricating system Check if the engine bearing clearances are within factory specs Check the function of the relieve valve in the lubricating sy...

Page 132: ...132 4000511390 E03 16 USA GB Chassis and turntable KUBOTA diesel engine MS0029 Notes...

Page 133: ...before intervening on and near the machine After completion of work all the covers and safety devices must be positioned back completely and operational 3 Periodic inspection To test the function Put...

Page 134: ...cell means calibration is required when the system values become out of correct range or when any of the platform sub assembly components cage support flooring etc are replaced The system can be recal...

Page 135: ...135 4000511390 E03 16 USA GB Chassis and turntable Overload system MS0017 4 1 RESET OF THE ZERO EMPTY CAGE VALUE 1 2 3 4 5...

Page 136: ...f the ECU has a valid calibration already stored or not Press to start calibration Press to quit menu 3 Ensure cage is empty and free of load not Press to start calibration 4 reset is complete Display...

Page 137: ...16 USA GB Chassis and turntable Overload system MS0017 4 2 CALIBRATION USING A FIXED KNOWN WEIGHT OF 250 KG 551 LB With the console access menu 3 4 Calibration and scroll down to arrive at the screen...

Page 138: ...ed or not Press to start calibration Press to quit menu 3 Place 250 kg 550 lb load centrally positioned in cage Press OK to confirm 250 kg 550 lb load is in the cage 4 Press to start calibration 5 250...

Page 139: ...is and turntable Overload system MS0017 4 3 CALIBRATION WITH A KNOWN WEIGHT OF ANY VALUE BETWEEN 50 KG 110 LB AND 300 KG 662 LB With the console access menu 3 5 Calibration and scroll down to arrive a...

Page 140: ...Place load centrally positioned in cage Press OK to confirm load is in the cage 4 Press OK adjust the load value Use to decrease value Use to increase value 5 Once the display value is adjusted to ma...

Page 141: ...the load used for calibration in the platform and verify that the estimated load displayed corresponds to the actual load Correct the basket level exceed 10 10 Internal error EEPROM read write access...

Page 142: ...142 4000511390 E03 16 USA GB Chassis and turntable Overload system MS0017 Notes...

Page 143: ...y Assorted hydraulic fittings System for recovery oils Drive reducer Oil Hydraulic hand pump 0 250 psi Pressure gauge 0 300 psi Special tools refer plans at end of document Place barriers around the p...

Page 144: ...d torque The following steps describe how to tighten and torque bolts or socket head cap screws in a bolt circle Tighten but do not torque bolt A until snug Go to the opposite side of the bolt circle...

Page 145: ...e unit 2 Drain oil from unit Note the condition and volume of the oil 3 Remove retaining Ring 6G by prying the open end of Retaining Ring out of the groove in the Ring Gear 1E with a screwdriver then...

Page 146: ...un Gear 11 if necessary 9 Loosen and remove the 3 Flat Heat Bolts 19 that retain the Ring Gear 1E to the Housing 1G 10 Lift the Ring Gear 1E off the Housing 1D 11 Remove the O ring 18 from between the...

Page 147: ...Spindle 1A being careful to not drop the Needle Bearings 4C in the process 16 Remove 4 Thrust Washers 4B 28 Needle Rollers 4C and the Thrust Spacer 4D from the Second Stage Planet Gear 4F 17 Repeat S...

Page 148: ...rrier 3A 2 Using a soft face hammer tap the Planet Shaft 3E out of the Carrier 3A 3 Using a 1 8 diameter punch drive the Roll Pin 4G out of the Planet Shaft 3E N B THE ROLL PINS 4G SHOULD NOT BE REUSE...

Page 149: ...S 1G THE HOLES WILL NEED TO BE CLEANED UP PRIOR TO REMOVING THE SET SCREWS 3 While supporting the unit on Hub 1D flange press Spindle 1A out of Hub 1D 4 Remove outbound position Bearing Cone 1C from B...

Page 150: ...urize the brake port in the Spindle 1A until the Piston 8A comes out of piston bore of Spindle 1A then pull the Piston 8A out of the Spindle 1A by hand 4 Remove Backup Ring 8H and O ring 8F from groov...

Page 151: ...pockets if necessary 3 Unscrew 2 Hex Head Bolts 6C and remove Disengage Cap 6B from Cover 6A 4 Pull Disengage Rod 6D out from Cover 6A 5 Use appropriate tool to remove O ring 6E from internal groove i...

Page 152: ...r place one more Thrust Washer 3B onto Planet Shaft 3E Align the Thrust Washer 3B Make sure the flat faces towards the inside of the carrier and make sure the button fits in the pocket on the inside o...

Page 153: ...m of the small O Ring 8F 11 Set the Piston 8A so that the large diameter end id down Install large Backup Ring 8E in the large diameter groove at the bottom of the Piston 8A 12 Install large O Ring 8D...

Page 154: ...e Bearing Nut N B FINAL TORQUE IS INITIAL ROLLING TORQUE PLUS 40 50 IN LBS E G IF THE INITIAL ROLLING TORQUE IS 30 IN LBS THE FINAL ROLLING TORQUE IS BETWEEN 70 80 IN LBS BE SURE TO ROTATE HUB AS THE...

Page 155: ...ECEIVE A GENEROUS AMOUNT OF LUBRICANT OIL AS THEY ARE BEING ASSEMBLED 1 Place Hub Spindle Subassembly on the bench 2 Grease O Ring 18 and place it into groove of Hub 1D 3 Place Ring Gear 1E onto Hub 1...

Page 156: ...for 20 minutes 15 2 THE LEAK TEST MAIN UNIT The purpose of a leak test is to make sure the unit is air tight You can tell if your unit has a leak if the pressure gauge reading on your leak checking fi...

Page 157: ...ure torque 1 Screw 1 bolt down into the hub and rotate the hub so that the bolt is at twelve o clock 2 Position the torque wrench so that it is perpendicular to the vertical centerline as shown 3 The...

Page 158: ...s and turntable Dismantling Reassembling wheels reducer MS0026 18 Assembly drawing Item Description 1A Spindle 1B Lip seal 1C Tapered bearing assembly 1D Housing 1E Ring gear 1F Bearing nut 1G Socket...

Page 159: ...t 4F Planet gear 4G Roll pin 4H Thrust washer 5 Retaining ring internal 6A Cover 6B Disengage cap 6C Bolt 6D Dowel pin 6E O ring 6F Pipe plug 6G Retaining ring internal 7 Coupling 8A Brake piston 8B B...

Page 160: ...160 4000511390 E03 16 USA GB Chassis and turntable Dismantling Reassembling wheels reducer MS0026 Notes...

Page 161: ...ommends respecting the following inspections 3 1 DAILY CHECK 3 1 1 Articulated and telescopic machines To position the machine on a flat and firm ground To put the machine under tension and select the...

Page 162: ...he tightening of the fastenings of the cables on the visible points of fixing To extend the structure to obtain an access to the wire rope To extend the boom at least 3 m 9 ft 10 in for the telescopic...

Page 163: ...length of the cable Replacement is compulsory when 1 strand is broken near the ends No deformed folds or frayed strands must be observed No signs of corrosion must be observed Machine Original diamet...

Page 164: ...ts of fixing To raise the masts unit to the doors inspection To extend the structure to obtain an access to the wire rope Using a flash light perform a visual inspection of the following items Check t...

Page 165: ...2 No broken strands must be observed in particular at the ends Replacement is compulsory when 3 strands or more are broken along the length of the cable Replacement is compulsory when 1 strand is brok...

Page 166: ...ntact HAULOTTE Services MS0018Boom adjustment procedure 5 Criteria of replacement Cables with a diameter measuring less than 6 mm must be replaced every 5 years All other cables must imperatively be r...

Page 167: ...uctions the legal tendencies generally applicable for safety accident prevention All the precautions must be done in work before intervening on and near the machine After completion of work all the co...

Page 168: ...4000511390 E03 16 USA GB Upper boom Check and replacing the pads MS0013 4 Check the worn of friction pads Check the telescoping friction pad wear indicators Change the pad if the indicator is not visi...

Page 169: ...e and telescope upper and side pads without removing the boom Machine stowed boom retracted and in horizontal position Insert a pin to lock the tubes Attach the platform with slings Put the platform o...

Page 170: ...seals are in perfect condition Protect the telescoping cylinder orifices Dismantling the lifting beam assembly extension cables Undo the nuts to remove the cables from the lifting beam Use a caliper t...

Page 171: ...pads MS0013 Remove the lifting beam cables Remove the lifting beam Removing the cylinder guide cross member Remove the 2 pads 1 from the top of the cross member Undo the 6 screws 2 First pull then rem...

Page 172: ...16 USA GB Upper boom Check and replacing the pads MS0013 N B THE FINAL CONFIGURATION IS AS FOLLOWS The final configuration is as follows Remove the top right pad 1 Remove the top right side pad 2 Rem...

Page 173: ...is as follows Remove the telescope extension cable support plate 1 screw 2 Pull the cable support plate 1 back to the rear of the telescope cylinder N B GENTLY PULL THE CABLE SUPPORT PLATE 1 ON THE BA...

Page 174: ...cing the pads MS0013 N B REPLACING THE PADS AND REASSEMBLING ARE DONE IN REVERSE ORDER TO REMOVING THEM THE HOUSINGS HAVE GUIDES SO THAT THE PADS CAN BE PUT IN POSITION BLIND MAKING REASSEMBLY EASIER...

Page 175: ...towed position The operations of disassembling if they exist should be carried out only on the installations completely disconnected and must be entrusted only to people having the necessary technical...

Page 176: ...ng Reassembling the telescope cylinder Machine stowed boom retracted and in horizontal position Insert a pin to lock the tubes Attach the platform with slings Put the platform on a flat horizontal sur...

Page 177: ...mbly extension cables Undo the nuts to remove the cables from the lifting beam Use a caliper to measure the compression of the spring washers and adjust to the same compression when reassembling the u...

Page 178: ...d by removing the 1 flanged nuts Remove the 4 screws that hold the 2 the boom base return cables Remove the 2 boom base return cables Remove the lifting beam cables N B DO NOT DISCONNECT THE LIFTING B...

Page 179: ...then remove the cross member 3 N B THE FINAL CONFIGURATION IS AS FOLLOWS Removing the 2 flanges Undo the screws holding the left and right hand side flanges Remove the left and right hand side flanges...

Page 180: ...ove the telescope extension cable support plate 1 screw 2 Pull the cable support plate 1 back to the rear of the telescope cylinder N B GENTLY PULL THE CABLE SUPPORT PLATE 1 ON THE BACK SO THAT YOU CA...

Page 181: ...reassembling telescope cylinder MS0014 Pull the cylinder up to the opening at the back of the turntable N B BEFORE COMPLETELY FREEING THE CYLINDER YOU MUST FIRST ATTACH ALL THE CABLES UNDERNEATH AND...

Page 182: ...the wooden prop to prop up the cylinder so that you can position the cylinder retaining strap on the other side of the opening Pull the cylinder out to approximately 2500 mm 8 ft 2 in from the pulley...

Page 183: ...000511390 E03 16 USA GB Upper boom Procedure of dismantling reassembling telescope cylinder MS0014 N B REASSEMBLE IN THE REVERSE ORDER OF DISMANTLING Remove the cylinder Replace the cables and the pul...

Page 184: ...184 4000511390 E03 16 USA GB Upper boom Procedure of dismantling reassembling telescope cylinder MS0014 Notes...

Page 185: ...embling if they exist should be carried out only on the installations completely disconnected and must be entrusted only to people having the necessary technical training Respect in addition to the in...

Page 186: ...screw see the following picture Tight the lock nut Check that the 7 lock washers are present in the position shown on the diagram 2 On the front of the machine Tight the chain until having a length of...

Page 187: ...ide Tight the chain for having a length of 20 mm 0 1 mm between the last washer and the plan of the boom See the following picture 5 Extend the telescopic boom to 1 meter approximately Retract the tel...

Page 188: ...188 4000511390 E03 16 USA GB Upper boom Boom adjustment procedure MS0015 Notes...

Page 189: ...ly disconnected and must be entrusted only to people having the necessary technical training Respect in addition to the instructions appearing in the present instructions the legal tendencies generall...

Page 190: ...front of magnet in the middle Loosen the nuts 1 to adjust the sensor Sensor adjustment Set the mechanical cam sensor to change state at this position passage from ON to OFF having previously set the...

Page 191: ...platform control box Raise the boom at 75 Extend the telescope to its maximum From the ground or platform control box lower the boom until the cut of abacus of the machine Check the boom angle include...

Page 192: ...192 4000511390 E03 16 USA GB Upper boom Boom angle sensor adjustment MS0018 Notes...

Page 193: ...protective equipment suitable for the job and the particular conditions of environment in witch the material can be found see safety information specific to the operation site Position the machine on...

Page 194: ...s feature an innovative modular cage design which allows for the replacement of different components individually without the need to replace the complete cage The cage assembly consists of the follow...

Page 195: ...ir connectors either side of the control box not shown Unscrew and remove the 2 x 8mm bolts nuts reference A and B that fasten the control box support to the handrail assembly Unscrew and remove the 4...

Page 196: ...2 2 REMOVAL REPLACEMENT OF FLOOR SECTION N B THE FLOOR PANELS ARE IN 2 OR 3 SECTIONS DEPENDING ON THE PLATFORM SIZE N B THERE ARE DIFFERENT OPTIONS FOR THE FLOOR MATERIAL BUT THE PROCEDURE REMAINS UN...

Page 197: ...IS RECOMMENDED TO FIRST REMOVE THE FLOOR PANELS TO ALLOW EASIER ACCESS 2 3 1 Removal D visser la p dale pied du panneau de plancher et la sortir du panier non illustr Remove the 2 bolts nuts ref A an...

Page 198: ...n the jib section Remove the circlip ref 2 from the security pin ref 13 and remove the pin Support the weight of the cage assembly from above with a crane or underneath using a forklift or equivalent...

Page 199: ...free from all rust paint and any other foreign materials The load cell mounting bolts ref 5 must be replaced after every demounting The load cell mounting bolts ref 5 need to be correctly tensioned to...

Page 200: ...000511390 E03 16 USA GB Upper boom Procedure of dismantling reassembling cage MS0027 3 Complementary operations Calibrate the overload system as required 4 Checks Complete a full test of machine funct...

Page 201: ...the job and the particular conditions of environment in witch the material can be found see safety information specific to the operation site Position the machine on a flat ground stabilized and in a...

Page 202: ...ntity 1 Housing 1 2 Shaft 1 3 Piston sleeve 1 4 End cap 1 103 1 Screw 1 103 2 Washer 1 106 1 Port plug 1 106 2 Port plug 1 109 Lock pin 2 113 Set screw 6 200 T Seal 1 202 T Seal 1 204 O Ring 1 205 Cup...

Page 203: ...rmly secured to the work bench A pipe vise or mounting fixture work well Avoid personal injury and machinery damage Read the Service and Repair Manual for proper installation maintenance and repair pr...

Page 204: ...a size 2 is shown If the pin cannot be removed with the screw extractor use a 5 16 bit to drill out the entire pin Do not drill deeper than 1 2 12 7 mm 5 Install the end cap removal tools provided wit...

Page 205: ...ween models One set indicates the timing between the piston sleeve 3 and the housing 1 photo at left the second set between the piston and the shaft lower photo To ensure correct rotation and accurate...

Page 206: ...aft with a rubber mallet 12 As in step 9 above before removing the piston 3 mark the housing 1 ring gear in relation to the piston outside diameter gear There should now be timing marks on the housing...

Page 207: ...emove the O ring 204 and backup ring 207 from end cap 4 N B TO AVOID DAMAGE TO MACHINED PARTS CAREFULLY REMOVE SEALS USING REMOVAL TOOLS WITH ROUNDED EDGES 16 Remove the wear guide 302 from the end ca...

Page 208: ...ure of dismantling reassembling hydraulic rotary actuators MS0028 19 Remove the O ring 304 1 from its groove in the end cap 4 and shaft 2 20 Remove the outside diameter piston seal 202 from the piston...

Page 209: ...T BE CLOSELY FOLLOWED TO INSURE PROPER OPERATION OF THE ACTUATOR 1 Clean all parts in a solvent tank and dry with compressed air prior to inspecting 2 Carefully inspect all critical areas for any surf...

Page 210: ...ntents under pressure Use caution when removing port plugs and fittings N B TO AVOID CONTAMINATION TO MACHINED PARTS MAKE SURE WORK AREA IS CLEAN 1 Gather all the components and tools into one locatio...

Page 211: ...ar motion 5 Install the wear guide 302 on the end cap 4 and shaft 2 6 Install the O ring 204 and back up ring 207 into the inner seal groove on the end cap 4 7 Install the inner T seal 200 into the ap...

Page 212: ...n until the outer piston seal 202 contacts the inside housing bore 12 Looking into the housing bore from the shaft flange end rotate the piston 3 until the marks you put on the piston and the housing...

Page 213: ...haft 2 with the gear teeth on the inside of the piston 3 When the marks align gently tap the flan ge end of the shaft with a rubber mallet until the gear teeth engage 16 Install two bolts in the threa...

Page 214: ...19 Thread the end cap 4 onto the shaft 2 Make sure the wear guide remains in place on the end cap as it is threaded into the housing 1 20 Tighten the end cap 4 using a metal bar In most cases the ori...

Page 215: ...ith cap screws 113 or set screws Remove the grease port screws from the shaft flange and end cap See exploded view N B IF A HYDRAULIC TEST BENCH IS NOT AVAILABLE THE ACTUATOR CAN BE ROTATED BY HAND OP...

Page 216: ...r is equipped with with a counterbalance valve plug the valve ports Connect the hydraulic lines to the housing ports Bleed all air from the actuator Rotate the shaft to the end of rotation at 3000 psi...

Page 217: ...liters is purged Avoid personal injury and machinery damage Read the Service and Repair Manual for proper installation maintenance and repair procedure To avoid injury or damage to product Secure pro...

Page 218: ...laced if a steady flow of fluid is seen coming from the valve ports 4 Piston and or shaft seal leak Remove the plug and the housing s valve ports Operate the actuator through the housing ports Conduct...

Page 219: ...ons completely disconnected and must be entrusted only to people having the necessary technical training Respect in addition to the instructions appearing in the present instructions the legal tendenc...

Page 220: ...ic oil level to ensure safety operation N B CHECK THE OIL LEVEL WHEN COLD AND WHEN THE MACHINE IS STOWED BEFORE BEGINNING A NEW PERIOD OF WORK The oil level 1 must be between the upper and lower marke...

Page 221: ...shaving 4 1 CONSUMABLE Use only oils whose features correspond to HAULOTTE recommendations Section C Familiarization Consumable or contact HAULOTTE Services Not mix two different characteristics oils...

Page 222: ...222 4000511390 E03 16 USA GB Hydraulics Hydraulic oil Level Replacement MS0019 Notes...

Page 223: ...all the hoses are correctly tightened Check the absence of tear and crack of the external hoses Check that the shielding of the hose is not apparent Check the absence of chemical aggression of the me...

Page 224: ...bly For safety reasons respect imperatively the following conditions of reassembly Using the reference marks carried out previously carry out the courses of hoses During the fixing of the hoses respec...

Page 225: ...sence of deformations damage crack on tanks pump and block hydraulics Absence of foreign body on all surfaces Absence of missing or loosened part bolt nut connection flexible device etc Hydraulic oil...

Page 226: ...oil 2 Loosen and remove the base nut 3 3 Loosen and remove the cartridge 1 4 Screw in a new cartridge 5 Refit and tighten the base nut 3 6 Reset the clogging indicator 2 by pressing it until it becom...

Page 227: ...rimeter of the work area Exclusively use tools and auxiliary average adapted Always wear necessary safety clothing Description In Bar In PSI General 240 5 3481 72 Pressure LS 30 5 435 72 Emergency pum...

Page 228: ...28 4000511390 E03 16 USA GB Hydraulics Pressure adjustment MS0022 3 Pressure plug location D r i v i n g p r e s s u r e c o n n e c t i o n P r e s s u r e i n l e t f o r o t h e r m o v e m e n t s...

Page 229: ...ulic ways MS0023 Hydraulics Hydraulic ways 1 You will need Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area Exclusively use tools and auxiliary average...

Page 230: ...230 4000511390 E03 16 USA GB Hydraulics Hydraulic ways MS0023 2 Turntable HT21RT O HT21RT O SW HT61RT O HT23RTJ O HT23RTJ O SW HT67RTJ O F o l i o 1 2...

Page 231: ...231 4000511390 E03 16 USA GB Hydraulics Hydraulic ways MS0023 F o l i o 2 2...

Page 232: ...232 4000511390 E03 16 USA GB Hydraulics Hydraulic ways MS0023 3 Turntable HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO F o l i o 1 2...

Page 233: ...233 4000511390 E03 16 USA GB Hydraulics Hydraulic ways MS0023 F o l i o 2 2...

Page 234: ...234 4000511390 E03 16 USA GB Hydraulics Hydraulic ways MS0023 4 Chassis HT21RT O HT21RT O SW HT61RT O HT23RTJ O HT23RTJ O SW HT67RTJ O F o l i o 1 2...

Page 235: ...235 4000511390 E03 16 USA GB Hydraulics Hydraulic ways MS0023 F o l i o 2 2...

Page 236: ...236 4000511390 E03 16 USA GB Hydraulics Hydraulic ways MS0023 5 Chassis HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO F o l i o 1 2...

Page 237: ...237 4000511390 E03 16 USA GB Hydraulics Hydraulic ways MS0023 F o l i o 2 2...

Page 238: ...HOLDER 158P344440 GUIDE CHAINE et FLEXIBLES CABLE and CHAIN HOLDER 158P344440 GUIDE CHAINE et FLEXIBLES CABLE and CHAIN HOLDER 158P344440 C 2 1 2 3 4 L gende des d trompages couleur par collier plast...

Page 239: ...239 4000511390 E03 16 USA GB Hydraulics Hydraulic ways MS0023 7 Jib...

Page 240: ...240 4000511390 E03 16 USA GB Hydraulics Hydraulic ways MS0023 Notes...

Page 241: ...Hydraulic manifold wiring Hydraulic manifold wiringInspect for a liberal coating of dielectric grease at the following location All wire harnesses connectors to the ground control box Start the engine...

Page 242: ...242 4000511390 E03 16 USA GB Electric Electrical wiring MS0025 Notes...

Page 243: ...st be entrusted only to people having the necessary technical training Respect in addition to the instructions appearing in the present instructions the legal tendencies generally applicable for safet...

Page 244: ...ach maturity 0 hour If the display shows and maintenance alert it is possible to erase this alert after performing maintenance on the machine by doing the procedure below On the lower control panel pr...

Page 245: ...ill need 2 Technical specifications Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area Exclusively use tools and auxiliary average adapted Always wear nec...

Page 246: ...emove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 6 Check the ambient air temperature and adjust the specific gravity reading for each...

Page 247: ...R T P R O H T 2 3 R T J O H T 2 3 R T J O S W H T 6 7 R T J O H T 2 3 R T J P R O H T 2 3 R T J P R O S W H T 6 7 R T J P R O P h o t o 2 B B H T 2 1 R T O H T 2 1 R T O S W H T 6 1 R T O H T 2 1 R T...

Page 248: ...n d t e m p e r a t u r e 4 Battery Never leave the batteries discharged Do not put off recharging the batteries in cold weather as the electrolyte may freeze Top up the electrolyte level if necessary...

Page 249: ...hooting table to identify the problem IF you cannot identify the problem contact HAULOTTE Services 1 2 DESCRIPTION The FAILURES function describes the requirements relative to failures monitoring info...

Page 250: ...on to ground Check connection to U100 ECU Check connection on PCB F03 Relay Horn relay Chk KA9 F03 06 D Horn relay failure Open circuit or short circuit KA9 Check relay Check connection to ground Chec...

Page 251: ...t to GND or to 12V 2 YV401 Compensation ON OFF electrovalve failure open circuit or short circuit while compensation movement 4 YV421 Compensation ON OFF electrovalve failure open circuit or short cir...

Page 252: ...al electrovalve failure while boom telescoping movement YV382 short circuit to GND or to 12V 2 YV392 Boom telescoping safety valves failure open circuit or short circuit while boom telescoping out mov...

Page 253: ...YV620 electrovalves connection to ground to U106 ECU Principal movements Chk YV101 F04 11 D LS valve failure detected Open circuit or short circuit Check connection to LSD1 x output Drive Speed Chk YV...

Page 254: ...nd SM120XYON digital value are incoherent SM120Y Check 5V supply Check connection to ground Check joystick Turret Joystick Chk SM10X F05 04 D Turret rotation joystick failure 1 SM120X Analogue value o...

Page 255: ...ANSI and Load Measurement option Active VAR LoadGaugesIncoherent 1 Check SP480 and SP481 connections to ground to U104 ECU analogue inputs Redo calibration Low Power Chk gauges supply F06 05 D Lower...

Page 256: ...21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram 2 Legend 2 1 PCB TURRET L o c a t...

Page 257: ...0511390 E03 16 USA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram L o c a t...

Page 258: ...A D6 3mm verte R4 1K 1 4W 5 1 2 E4 104 1 2 E5 105 1 2 E6 106 1 2 E7 107 1 2 E9 109 1 2 E10 110 1 2 E11 111 1 2 E12 112 1 2 E8 108 K A D7 1N4004 J1 13 J1 12 J1 6 X_FU4 4450715 K A D8 3mm verte R5 1K 1...

Page 259: ...J1 19 X_FU9 4450715 K A D20 3mm verte R15 1K 1 4W 5 K A D21 1N4004 X_FU8 4450715 K A D22 3mm verte R16 1K 1 4W 5 X_FU18 4450715 K A D23 3mm verte R17 1K 1 4W 5 1 2 E13 113 1 2 E14 114 1 2 E15 115 1 2...

Page 260: ...25A Generator FU5 Fuse 30A General FU6 Not used FU7 Fuse 15A ECU FU8 Fuse 20A Option FU9 Fuse 20A Attachments FU10 Not used FU11 Fuse 7 5A Permanent FU12 Not used FU13 Fuse 20A Power FU14 Not used FU1...

Page 261: ...A GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram 3 Electric diagram E n g i...

Page 262: ...E03 16 USA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram E n g i n e p a r...

Page 263: ...E03 16 USA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram T u r n t a b l e...

Page 264: ...USA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram T u r n t a b l e p a r...

Page 265: ...GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram T u r n t a b l e p a r t N...

Page 266: ...GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram T u r n t a b l e p a r t N...

Page 267: ...6 USA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram C a g e p a r t N o e...

Page 268: ...6 USA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram C a g e p a r t N o e...

Page 269: ...00511390 E03 16 USA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram O p t i...

Page 270: ...1RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram 4 Hydraulic diagram T u r n t a b l e j i b...

Page 271: ...21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram T u r n t a b l e j i b b o o m P...

Page 272: ...RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram C h a s s i s 4 b r a k e s 1 2 1 3...

Page 273: ...RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram C h a s s i s 4 b r a k e s 2 2 15...

Page 274: ...E03 16 USA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram D i r e c t i o n...

Page 275: ...000511390 E03 16 USA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram O p t i...

Page 276: ...6 4000511390 E03 16 USA GB HT21RT O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Note...

Page 277: ...ords 1 Intervention register The 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 INTE...

Page 278: ...T O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO F Records Date Type of intervention Number of hours Intervenor HAUL...

Page 279: ...T O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO F Records Date Type of intervention Number of hours Intervenor HAUL...

Page 280: ...T O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO F Records Date Type of intervention Number of hours Intervenor HAUL...

Page 281: ...T O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO F Records Date Type of intervention Number of hours Intervenor HAUL...

Page 282: ...T O HT21RT O SW HT61RT O HT21RT PRO HT21RT PRO SW HT61RT PRO HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO F Records Date Type of intervention Number of hours Intervenor HAUL...

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