Haulotte HA26 RTJ PRO SW Maintenance Book Download Page 407 | Manualshive

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407

4001055180

E 06.21

USA / GB

HA26 RTJ O - HA26 RTJ O SW - HA26 RTJ PRO - HA26 RTJ PRO SW -
HA80 RTJ O - HA80 RTJ PRO

E

- Trouble shooting and diagram

Failures

N

Dec

Description

Supplies

F08.04
ECU Input Supply

U104 / U106

D

1

Detected  ECU voltage difference : Difference between  U106 (SPU) and  U104 (basket  B2)
:  2V for  2s
--> 12VB – 12VBSLAVE > 2.00V
• Check  U100,  U104 and  U106 supply voltage
• Check fuses
• Check supply voltage coherence between all  ECU (more than 2000 V far during the first 4
seconds after start)

2

Overvoltage of U106 supply
--> 12VB > 17.00V

3

Overvoltage of U104 supply
--> 12VBSLAVE > 17.00V

F08.05
ECU Output Supply

U106 5V regul

D

1

Failure on regulated 5V output of U106 ECU (SPU 70-66) supplying position sensors
--> 5VSUPPLY = FAIL
• Check fuses
• Check the harness (check short circuit to power supply, to ground supply, open circuit…)

2

Failure on regulated 5V output of U104 ECU (basket slave node) supplying the joysticks
--> 5 V output is measured out the range [4.5;5.5] V and 5 V output not failing
• Check fuses
• Check the harness (check short circuit to power supply, to ground supply, open circuit…)

4

Failure on regulated  5V output of  U104 ECU (basket slave node) supplying the joysticks
--> Detected failure on  5V output
Switch  OFF/ON the machine, check the failure has gone (probable cause: internal failure of
the  ECU)

F08.07
Circuit Selector

D

Incoherence on control box selector SA900 :
--> Check contactor output status

F08.08
Unplugged
connector

Connectors/Fuses

D

1

Supplies’ input detected as unplugged on connectors : Check the CN1.B connectors for
U106 ECU :
--> 12VD1<5.00V & 12VF1<5.00V

2

Supplies’ input detected as unplugged on connectors : Check the CN2.A connectors for
U106 ECU :
--> 12VD2<5.00V & 12VF2<5.00V

4

Supplies’ input detected as unplugged on connectors : Check the CN2.B connectors for
U106 ECU :
--> 12VD3<5.00V & 12VF3<5.00V

8

Supplies’ input detected as unplugged on connectors : Check the CN3.A connectors for
U106 ECU :
--> 12VD4<5.00V & 12VF4<5.00V

16

Supplies’ input detected as unplugged on connectors : Check the CN3.B connectors for
U106 ECU :
--> 12VD5<5.00V

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Summary of Contents for HA26 RTJ PRO SW

Page 1: ...ce Book HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO 4001055180 E 06 21 USA GB MAINTENANCE BOOK HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO USA ...

Page 2: ...2 24203 4001055180 0 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO ...

Page 3: ...nce and repair training 17 2 1 Owner sresponsability 17 2 2 Technician sresponsability 17 2 3 HAULOTTEServices 17 2 4 Training 17 2 5 Productmodification 18 2 6 AfterSalesService 18 2 7 Productinformation 18 3 Conditions of warranty 18 C Familiarization 1 Primary machine components 20 1 1 Layout 20 1 2 Groundcontrolbox 22 1 2 1 Layout 22 1 2 2 HAULOTTE Activ Screen 2 26 1 3 Platformcontrolbox 48 1...

Page 4: ... of actuators 86 2 3 2 Modules 87 2 3 3 Fuses 87 2 3 4 Inputs 89 2 3 5 Outputs 92 3 Power source Engine specifications 95 3 1 Generalsafetyandspecificinterventionsonmotor 95 3 2 GeneralSpecifications 95 3 3 Consumables 96 4 Consumables Oils Fuels Engine oil Coolant level 97 4 1 Fuel 97 4 1 1 Other fuels 97 4 2 Engineoil 98 4 3 Hydraulicoil 99 4 4 Gearmotoroil 99 4 5 Coolant 100 4 6 Cylinderstorage...

Page 5: ... MS0140 Remove Replace boom assembly 179 MS0141 Removing Replacing the pads 193 MS0142 Remove Replace Boom cylinder 201 MS0143 Remove Re install output compensation cylinder 207 MS0144 Remove Re install input compensation cylinder 215 MS0145 Remove Replace arm cylinder 223 MS0146 Remove Replace telescope cylinder 231 MS0149 Battery ies 241 MS0151 Remove re install the covers 245 MS0152 Remove Re i...

Page 6: ...latform 331 MP0018 Slew ring clearance check 335 MP0019 Torque tightening of the slew ring 343 MP0020 Emptying the diesel tank 347 MP0021 Draining the cooling circuit 351 MP0021 Draining the cooling circuit Kohler engine 351 MP0023 Starter battery inspection 359 MP0024 Checking the bushings and pins 363 MP0025 Checking the condition of belts 365 MP0026 Checking and cleaning the fuel filter 367 MP0...

Page 7: ...Trouble shooting 397 1 1 Recommendations 397 1 2 Description 397 1 3 Requirements 397 1 4 Failureslist 398 1 4 1 List of failures per category 398 2 Legend 414 2 1 PCBTurret 414 3 Electric diagram 420 4 Hydraulic diagram 432 F Records 1 Intervention register 441 ...

Page 8: ...8 Maintenance Book ...

Page 9: ...ion 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 purposes and not to be con fused with the technical specifications Only the specifications in this manual should be used to study the suitability of the equipment for the intended use This maintenance and repairs book is specifi...

Page 10: ...dicate specific hazards and the hazard severity level when operating or maintaining the Aerial Work Platform Symbol Symbol Description Danger Risk of injury or death Caution Risk of material damage Prohibition relating to work safety and quality Reminder to use good practice or follow pre operation checks Cross reference to another part of the manual Cross reference to another manual Cross referen...

Page 11: ...N OPERATING OR MAINTAINING THE TELEHANDLER Color Title Description Danger Indicates a hazardous situation which if not avoided WILL result in death or serious injury Warning Indicates a hazardous situation which if not avoided COULD result in death or serious injury Caution Failure to comply could result in minor or moderate injury Notice Indicates practices not related to personal injury Procedur...

Page 12: ...12 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO A Preface Foreword Notes ...

Page 13: ...ce interventions place the machine in maintenance configuration Never leave the hydraulic cylinders fully extended before switching off the machine or when stationary for an extended period of time Keep the elements of the machine in configuration of maintenance thanks to mechanics devices Report that the machine is under maintenance by tagging the platform and ground control boxes 1 Place the mac...

Page 14: ... aware of uncontrolled movement and always respect the following Maintain clearance from high voltage lines Maintain clearance from generators radar electromagnetic fields Never expose the batteries or electrical components to water high pressure washer rain Never tow the machine over extended distances In case of a machine breakdown it is possible to tow short distance to load it onto a trailer N...

Page 15: ...o not operate the machine when close to live power lines consider the movement of the machine and the sway of the electric power lines particularly in windy conditions Do not operate the machine during lightning thunderstorms snow ice or any weather condition that could compromise operator safety Do not operate the machine during lightning or storms Do not use the machine as a welding earth Do not...

Page 16: ...LIZED WITH SODIUM BICARBONATE AND WATER Do not start the engine if you smell or detect liquid propane gas LPG gasoline diesel fuel or other explosive substances Do not work in an explosive or flammable atmosphere environment Do not touch hot components Do not bridge the battery terminals with metallic objects Do not service the battery in proximity of spark open flame lit cigarettes Do not fill up...

Page 17: ...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 and of any malfunction of the machine 2 3 HAULOTTE SERVICES The HAULOTTE is at your service in all 5 continents of the world via an extensive network of its own factory trained technicians who are ready to respond to your eve...

Page 18: ...dering any consumables or spare parts please use this manual and the HAULOTTE Essential catalogue to receive your genuine HAULOTTE spare parts your only guarantee of parts interchangeability and correct machine operation If there is an equipment malfunction involving a HAULOTTE product then contact HAULOTTE Services immediately even if the malfunction does not involve material and or bodily damage...

Page 19: ...19 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization Familiarization Notes ...

Page 20: ...1 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization 1 Primary machine components 1 1 LAYOUT HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO ...

Page 21: ...3 Counterweight C7 Platform control box C35 Document holder C8 Input jib leveling cylinder C36 Top arm C9 Upper boom C38 Bottom arm C10 Slew ring C42 Foot Switch C11 Turntable assembly C72 Output jib compensation cylinder C13 Arm Boom link piece C113 Beacon light C14 Hydraulic drive motor and reducer C140 Propane bottles C15 Right side compartment hydraulic oil tank and fuel tank C150 Jib lifting ...

Page 22: ...22 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization 1 2 GROUND CONTROL BOX 1 2 1 Layout General view ...

Page 23: ...By pressing on Boom raising SA520D By pressing on Boom lowering 5 SA420U Arm raising lowering switch By pressing on Arm raising SA420D By pressing on Arm lowering 6 SB800 Enable Switch Back up unit selector By pressing on Validation of controls when engine started automatic switching of emergency electropump if the engine is stopped 7 SA250L Turntable rotation switch By pressing on Counter clockwi...

Page 24: ...r Hydraulic oil temperature icon is active on the Activ Screen Or Engine pressure icon is active on the Activ Screen Or Engine stop icon is active on the Activ Screen Or Overload machine status is active on the Activ Screen 16 SA303 Engine start up selector By pressing on Engine start stop 17 SA300 Propane Gas supply2 By pressing on Propane Gas supply selection 18 SA305 Petrol Gasoline or diesel s...

Page 25: ...red5 By pressing on Regeneration start up 22 SA900 Control box activation key switch De energizes control system Platform control box energized Ground control box energized 23 Activ Screen 2 1 For machines fitted with 2 For machines fitted with 3 For machines fitted with 4 For machines fitted with 5 For machines fitted with Marking Name Description Function ...

Page 26: ...2 Navigation buttons Above Activ Screen display Home Button Allows return to the home screen at any time Up Navigation Permits scrolling up through the screen if present Left navigation Permits navigation to screens to the left if present Down Navigation Permits allows scrolling down through the screen and onto the following screen if present Right Navigation Permits navigation to screens to the r...

Page 27: ...6 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization On initial start up of the machine or after 3 day of inactivity the following screens are displayed in order Controls and indicators Icon Description Function Icon Description Function Machine power up Start up screen ...

Page 28: ...authorization of technician Access code entered is incorrect Access code NIV 1 Will be visible depending on the machine The machine can be personalized with a user identification code Personalization is only possible with level 1 access Machine properties display Soft version machine serial number adjustment parameters Possible change of parameters Language fault display format brightness setting ...

Page 29: ...escription Function Icon Description Function Operator PIN code Will be visible depending on the machine The machine can be personalized with a user identification code Personalization is only possible with level 2 access Contact HAULOTTE Services Operator PIN code not yet entered Operator PIN code entered is correct Operator PIN code entered is incorrect ...

Page 30: ...machine is in overload state Ground control box is selected energized The emergency overriding button is activated Emergency mode is deactivated when The E Stop at platform control box is pulled out energized The machine is NOT in overload state Ground control box is NOT selected energized The Emergency mode is out of service non functional Emergency mode has been used and activation of its functi...

Page 31: ...one Machine Model Machine model display Hour meter next maintenance zone Hourmeter The timer flashes if the engine is switched on and the hourmeter increases Maintenance use The Maintenance Tool icon and the number of hours remaining until the next maintenance are displayed for 5 seconds when the machine is started up Maintenance Tool icon blinks if maintenance is due The maintenance tool icon tur...

Page 32: ...il temperature Icon is ON when the temperature in the hydraulic reservoir has exceeded the maximum required temperature Stop using the machine and allow the oil to cool down Engine oil pressure Icon is ON if engine oil pressure is lower than required limit while engine is running The Engine must be switched OFF immediately to avoid damaging the motor Engine oil level The engine oil level is under ...

Page 33: ...Description Function Home screen dashboard Will be visible depending on the machine Warning icons zone Engine warning Icon is ON if Engine warning is detected Or one of the engine maintenance schedules has been exceeded Warning icons zone Engine decontamination fault If fitted Engine decontamination system fault In this case you must contact HAULOTTE Services as soon as possible ...

Page 34: ...Description Function Icon Description Function Home screen dashboard Will be visible depending on the machine Warning icons zone DPF regeneration required If fitted Permanently lighted if the particle filter requires regeneration with a high clogging level Warning icons zone DPF regeneration inhibited If fitted Light stays on if regeneration is inhibited ...

Page 35: ...26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization Warning icons zone DPF regeneration in progress high temperature in the exhaust system HEST If fitted Light stays on during regeneration Icon Description Function Icon Description Function ...

Page 36: ...nction Home screen dashboard Will be visible depending on the machine Functional information zone Power mode used Diesel GPL LPG Electrical Bargraph Digital Gauge Fuel reserve indicator ON OFF The indicator changes from GREEN to RED when the fuel level is low and indicator is activated Analog Gauge Fuel level gauge The fuel level indicator switches from GREEN to RED when the fuel level is low ...

Page 37: ...age The indicator switches to RED if the voltage is low Engine Speed rpm Engine speed display Temperature motor Displays Engine coolant temperature The indicator switches from GREEN to RED when the engine overheats Additional functions Beacon The icon is ON when the flashing light is switched on Working light The icon is ON when the work light is switched on Activ Lighting System The icon is ON wh...

Page 38: ...achine status zone Pictogram and title Displays the pictogram and machine status Ready Machine ready displayed when no failures and no other machine state icons is active Alarm Alarm icon is flashing slowly If there is either an active or detected machine failure or if the machine is in an overload or tilt is active When the Alarm symbol is displayed there will also be a symbol displayed to show e...

Page 39: ...elector switch is in platform control box position Ground control selected Selector switch is in ground control box position Tilt The machine is elevated and is on a slope greater than the permitted slope Depending on the machine configuration the lifting and extension functions are slowed or stopped Overload The platform is overloaded Remove the excessive load to or below the rated capacity to re...

Page 40: ...ion Function Home screen dashboard Will be visible depending on the machine Layout Pre heating Engine s automatic preheat system is active The time to pre heat will vary according to engine and ambient temperature The machine can be started as soon as the indicator goes out Radius limitation Icon is ON if the range limit is active Machine is charging The machine is charging by the engine ...

Page 41: ... the machine Low fuel level Fuel level is low Refill the fuel tank to the marked level Attention Lack of fuel may damage the motor engine and will not be covered under warranty Stop Emission System Icon is ON when the function cuts the engine Activ Lighting System The function is off To switch it on go to the Settings menu DPF regeneration required If fitted Permanently lighted if the particle fil...

Page 42: ...iarization Controls and indicators Icon Description Function Icon Description Function Home screen dashboard Will be visible depending on the machine Layout Diagnostic in progress The HaulotteDiag console is connected to the machine Screen software obsolete Screen software update essential Contact HAULOTTE Services ...

Page 43: ...the machine Activ Shield Bar disable The secondary safety system is switched off Activ Shield Bar triggered The secondary safety system is triggered An operator may be trapped on the platform In this situation supervisor s at ground level must turn the control box key selector 22 to the ground control box position to take control The platform box controls are now de energized Check that the E Stop...

Page 44: ...s and indicators Icon Description Function Icon Description Function Home screen dashboard Will be visible depending on the machine General information zone Machine software version and code Displays the reference and version of the software installed on the machine Machine date and time Displays the date and time of the machine ECU ...

Page 45: ...n Machine fault Will be visible depending on the machine Machine fault icons Failure code F01 xx Fault Variator Failure code F09 xx Fault IC Engine Failure code F02 xx Fault power contactor Failure code F10 xx Fault Functions Failure code F03 xx Fault command relay Failure code F11 xx Fault machine safety Failure code F04 xx Fault electro valve Failure code F12 xx Fault electronic control unit ECU...

Page 46: ...lt Will be visible depending on the machine Machine fault icons Failure code F05 xx Fault joystick Failure code F13 xx Fault Switches Failure code F06 xx Fault weight management system Failure code F14 xx Fault Driving pump Failure code F07 xx Fault limit switch or sensor Failure code F15 xx Fault data communication system CAN Failure code F08 xx Fault electrical circuit Failure code F16 xx Fault ...

Page 47: ...47 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization Notes ...

Page 48: ...48 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization 1 3 PLATFORM CONTROL BOX 1 3 1 Layout General view ...

Page 49: ...ctor to the right to sound the horn The horn stops when the selector switch is released 44 SA304 Fuel selector1 Push switch to the right for LPG liquid propane gas supply Push switch to the left for gasoline petrol or diesel fuel supply 45 SA110 Drive speed selector High speed drive Low speed drive 46 SB802 E stop button Pulled out Platform control box energized Pressed in De energizes control sys...

Page 50: ...Crab mode 230 SA303 Engine start up stop selector Start or stop the engine depending on the machine s operating status by moving the toggle switch upwards 259 SA910 Activ Lighting System selector ON OFF Automatic lighting 1 For machines fitted with 2 For machines fitted with 3 If machine equipped with dual load 4 For machines fitted with 5 For machines fitted with Marking Name Description Function...

Page 51: ... 102 HL300 Combustion engine pre heating LED 103 HL307 Low fuel level LED 104 HL304 Engine warning LED 105 HL305 Engine shutdown LED 106 HL301 DPF regeneration required If equipped LED 107 HL302 DPF regeneration in progress high temperature in the exhaust system HEST If equipped LED 108 HL303 DPF regeneration inhibited If equipped LED 1091 HL805 Load selection 250 kg 550 lbs LED 110 HL807 Foot Swi...

Page 52: ... RTJ O HA80 RTJ PRO C Familiarization LED 113 HL804 Radius limit LED 114 HL802 Overload LED 115 Turret at 180 LED 116 HL720 Platform leveling LED 1172 HL806 Load selection 350 kg 770 lbs 1 If machine equipped with dual load 2 If machine equipped with dual load Marking Name Symbol Function ...

Page 53: ...hing Reach limitation system fault Slow flashing The machine is in the 250 kg 550 lbs low load zone the low load is validated and 350 kg 770 lbs heavy load is selected by the selector 82 Illuminated Limit of work zone with movement cut off or machine in 250 kg 550 lbs low load zone and load not validated 250 kg 550 lbs load selected LED LED 109 will be lit on display panel 350 kg 770 lbs load sele...

Page 54: ... in the diesel clogged air filter etc Lighted or flashing in case of fault managed by the engine ECU Engine shutdown Lighted in case of major engine fault e g engine overheating oil pressure alternator fault etc Lighted in case of faults managed by the engine ECU DPF regeneration required Permanently lighted if the particle filter requires regeneration with a high clogging level1 1 If engine equip...

Page 55: ...55 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization Notes ...

Page 56: ...6 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization 2 List of actuators and sensors 2 1 SENSORS AND ACTUATORS Sensors and actuators ...

Page 57: ...m raised SQ421 Sensor Arm s position sensor SQ421 1 if arm folded SQ423 Sensor Arm s position sensor SQ423 1 if arm folded SQ520 Sensor Boom s position sensor SQ520 1 if boom folded SQ521 Sensor Boom s position sensor Dual load SQ522 Sensor Boom s position sensor SQ522 1 if boom folded SQ523 Sensor Proximity sensor for boom angle SQ524 Sensor Boom s position sensor SQ524 1 if boom raised SQ530 Sen...

Page 58: ...ng YV520 D Valve Boom descent YV530 PWM Boom telescoping YV530 O Valve Telescope extension YV530 I Valve Telescope retracted YV620 U Valve Jib raising YV620 D Valve Jib lowering YV720 U Valve Hydraulic compensation up YV720 D Valve Hydraulic compensation down YV750 R Valve Basket rotation to the right YV750 L Valve Basket rotation to the left YV800 Valve LS Valve YV801 Valve Boom extension safety ...

Page 59: ... O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization 2 2 SENSORS DETAIL 2 2 1 Turret Marking Item Description 1 SQ800 Tilt sensor 2 ST900 Hydraulic oil temperature sensor 3 SL300 Fuel level detection if level 5 liters SL300 0 ...

Page 60: ...HA80 RTJ O HA80 RTJ PRO C Familiarization 2 2 2 Kubota Engine Assembly Detail on pumps Marking Item Description 1 Diesel engine EGV KUBOTA V2403 36 5 KW 2 Drive pump 3 Equipment pump 4 EGV D6 EGV Electronic Governor Module D6 KUBOTA 5 KM160 Preheating relay 6 Air filter 7 Fuel filter ...

Page 61: ...61 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization 2 2 2 1 Diesel engine Tier 3 V2403 36 5KW ...

Page 62: ...ine variable speed control solenoid including stop function 3 SV300 Engine speed sensor 4 ST302 Engine water temperature detection 5 SP160F Pressure transducer Forward drive 6 SP160B Pressure transducer Reverse drive 7 YV160B PWM valve for REV drive mode 8 YV160F PWM valve for FWD drive mode 9 M300 Starter motor 10 Alternator 60A 11 EGV D6 EGV Electronic Governor Module D6 KUBOTA 12 KM160 Preheati...

Page 63: ...63 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization Detail on EDC Kubota module ...

Page 64: ...6 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization Marking Item Description 1 EDC71CV45 ECU KUBOTA module 2 KM160 Preheating relay feed pump 3 KM3 Main relay 4 FU50 Fuse 20A 5 FU51 Fuse 5A 6 FU52 Fuse 5A 7 FU53 Fuse 5A 8 MAF Mass flow sensor ...

Page 65: ... SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization 2 2 3 Kohler Engine Assembly Detail on pumps Marking Item Description 1 Diesel engine Kohler KDI1903 2 Drive pump 3 Equipment pump 4 Module ECU Kohler 5 Air filter 6 Fuel filter ...

Page 66: ...66 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization 2 2 3 1 Diesel engine Kohler STAGE V KDI 1903 TC 36 5 kW 50hp Overview ...

Page 67: ...67 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization ...

Page 68: ...tor 2 SP160B Pressure transducer Reverse drive 3 SP160F Pressure transducer Forward drive 4 SP300 Oil pressure 5 SP301 Clogged filter sensor 6 SQ163 Sensor Detection water in the fuel circuit 7 SV300 Engine speed sensor 8 ST302 Water temperature sensor 9 ST901 Engine temperature sensor 10 YV160B PWM valve for REV drive mode 11 YV160F PWM valve for FWD drive mode ...

Page 69: ...69 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization Ambient air temperature sensor ST901 EGR valve ...

Page 70: ... USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization Marking Description 1 T MAP sensor Input pressure detection 2 Delta P sensor Detection of clogging level of DPF filter ...

Page 71: ...71 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization Marking Description 1 EGTS sensor Controls the DPF regeneration strategy ...

Page 72: ...72 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization Fuel pressure sensor in common rail ...

Page 73: ... RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization Detail on ECU and relay Marking Item Description 1 ECU Kohler module 2 KM4 Start relay 3 KM3 Main relay 4 KM5 Electric pump relay 5 KM160 Preheating relay feed pump ...

Page 74: ...0 RTJ O HA80 RTJ PRO C Familiarization Fuses box Marking Item Description 1 FU400 60A Protection main supply 2 FU406 15A Protection starter 3 FU401 20A Protection KM3 4 FU402 5A Protection supply 5 FU403 5A Protection ignition 6 FU404 5A Protection EGR valve 7 FU405 5A Protection option ...

Page 75: ...A26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization 2 2 4 Arm sensors Marking Item Description 1 SQ420 ILS sensor Arm up 2 SQ421 ILS sensor Arm stowed 3 SQ423 Proximity sensor in redundancy with SQ421 Arm stowed ...

Page 76: ...0 RTJ PRO C Familiarization 2 2 5 Boom sensors Marking Item Description 1 SQ520 ILS sensor Boom stowed 2 SQ522 ILS sensor boom stowed in redundancy with SQ520 3 SQ524 Limit switch detection boom up 4 SQ530 ILS sensor Telescopic boom IN 5 SQ531 ILS sensor telescopic boom IN in redundancy with SQ530 ...

Page 77: ...rization For dual load option only Marking Item Description 1 SQ521 Proximity sensor for dual load option Boom stowed 2 SQ523 ILS sensor in redundancy with ILS for dual load option Boom stowed 3 SQ532 ILS sensor for telescopic boom length detection OFF if retracted 4 SQ533 Boom length inductive sensor ON if retracted ...

Page 78: ...78 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization State of telescopic length sensors State of boom angle sensors ...

Page 79: ...SW HA80 RTJ O HA80 RTJ PRO C Familiarization 2 2 6 Upper controls N B THE STRAIN GAUGES IS PROTECTED BY A FUSE FU34 1A LOCATED INSIDE THE UPPER CONTROL BOX Marking Item Description 1 SP800 Strain gauges for load detection on basket 2 SP801 Strain gauges for load detection on basket ...

Page 80: ...6 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization Upper controls Marking Item Description 1 SR720 Detection basket angle 10 must be adjusted in parallel to the side of the metal sheet 2 SR721 Detection basket angle 10 must be adjusted fully at the bottom of the hole ...

Page 81: ...B HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization Upper controls with Activ Shield Bar device This anti entrapement device prevents the operator to be trapped when using the machine ...

Page 82: ... 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization Marking Item Description 1 SQ902 Proximity sensor for ASB bar detection Reset done by pressing foot switch SB800 ...

Page 83: ...load the AWP on truck in total safety and also keeps working on site when daylight is too dark When the luminosity is lower than 50 lumens night the auto mode logic is as follow Machine state Light zone Turret light zone Basket light zone Movement light zone Lower control box selected ON Upper control box selected ON ON Upper control box selected with engine running and movement in process ON ON O...

Page 84: ...84 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization 2 2 7 1 Architecture of the system Upper controls ...

Page 85: ...lection Activ lighting system AUTO ON OFF 2 HL912A Light on upper controls 3 HL912B Light on upper controls 4 HL912C Platform light 5 HL912D Platform light 6 HL913 Light under basket 7 SN900 Twilight sensor for luminosity detection ON if 50 lumens 8 EL907 Light under boom 9 EL906 Light on Counterweight 10 HL911 Light above LCB 11 HL910A Light under turret engine side 12 HL910B Light under turret L...

Page 86: ...ate noted 0 corresponds to 0 V opened contact or not activated The state noted 1 corresponds to the tension of the circuit closed or activated contact Glossary Marking Description FWD Forward drive REV Reverse drive FL Front left FR Front right RL Rear left RR Rear right PF Platform LS Low speed drive LS valve adj Load sensing valve adjustment MS Medium speed drive HS High speed drive ILS Magnet r...

Page 87: ...2 Generator 20 A FU3 03 03 Start stop engine 15 A FU4 03 04 Engine start 25 A FU5 03 08 Main supply Vbat 30 A FU6 03 08 Option ignition overspeed 20 A FU7 03 15 Power supply V ECU node B2 15 A FU8 03 10 Option flashing light 20 A FU9 03 13 Power supply for accessories 20 A FU11 03 09 Power supply on Activ Screen display 7 5 A FU13 03 11 Power supply V for SPU7066 module 20 A FU23 02 19 Overspeed r...

Page 88: ...055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO C Familiarization N B THE STRAIN GAUGES ARE PROTECTED BY A FUSE FU34 1 A LOCATED INSIDE THE UPPER CONTROL BOX ...

Page 89: ...105 4 Emergency pump B129 SA802 07 11 CN105 14 Dual load B143 SA900 03 06 Main power switch key ON OFF 106 SA904 08 18 Working light option 183 SA906 07 09 CN104 11 Generator B116 SA907 07 07 CN104 1 Horn B106 SA907b 11 10 Horn lower controls for RUS UKR option 184 SA910 11 15 Activ Lighting System option 913 914 SB800 08 16 CN105 12 Foot Switch 1 for any movement B141 SB801 03 06 Main emergency s...

Page 90: ... 2B 14 ILS detection arm in stowed position 281 SQ423 06 11 1B 13 Proximity detection for arm in stowed position in redundancy with SQ421 222 SQ520 06 18 2B 12 ILS detection for boom in stowed position 384 SQ521 06 12 2A 17 Proximity sensor for boom angle position dual load only 521 SQ522 06 07 3B 30 ILS detection for boom in stowed position in redundancy with SQ520 223 SQ523 06 15 1B 14 Boom posi...

Page 91: ...ization SR721 08 13 CN105 16 Basket inclination 1 if at 10 B145 ST302 02 11 Water temperature detection in engine 130 ST900 06 10 3B 23 Hydraulic oil overheating detection 1 if OK 125 ST902 02 02 Temperature switch detection oil cooler 191 SV300 02 13 Engine speed detection 133 Sensors Name Location Connector Function ...

Page 92: ...Tier 4 engine only 138 KA8 05 13 1B 28 Option flashing light 194 KA9 05 14 1B 2 Horn command 187 KA10 11 19 CN105 24 Command for Activ Lighting System option 915 KAC 08 12 CN105 30 Activ Shield Bar command B510 KA140 10 18 Selection Petrol gas mode KMG 03 15 Main line contactor 143 KMP 03 14 Power relay Keeps power a few seconds after KMG 143 SD85 02 19 Option overspeed relay Option KM3 09 13 10 7...

Page 93: ...50R 06 16 2B 27 Front right steering 602 YV160B 05 05 3A 19 PWM REV drive valve 619 YV160F 05 06 3A 26 PWM FWD drive valve 620 YV250 05 06 3A 4 PVG valve for turret rotation 880 YV420 05 10 2A 20 PWM valve for am lift descent 282 YV520 05 11 2A 4 PWM valve for boom lift descent 381 YV530 05 12 2A 3 PWM valve for telescope extension retraction 387 YV620D 08 14 CN105 32 Jib descent B604 YV620U 08 14...

Page 94: ...ption working light 183 EL905 09 11 CN105 29 Activ Shield Bar detection B608 EL906 11 14 3B 1 Light on Counterweight Activ Lighting System option EL907 11 15 3B 25 Light on main boom Activ Lighting System option HL901 08 09 CN106 19 Activ Shield Bar activated B609 HL902 08 10 CN105 29 Activ Shield Bar detection B608 HL910A B 11 13 3B 4 Lights under turret L R Activ Lighting System option 906 HL911...

Page 95: ...h location to inform personnel that the equipment is being worked on The hot engine parts can cause injury and burns Before performing maintenance on the engine cool the engine and parts By touching a functioning engine there is a risk of burns from contact with hot parts and injuries by the rotating parts To avoid any risk of accident using compressed air example blowing air filter always wear a ...

Page 96: ...000531300 20 l 5 3 gal US Engine oil 15W40 4000530600 5 l 1 32 gal US 2420801360 20 l 5 3 gal US 2820305720 209 l 55 2 gal US Hydraulic oil HV32 4000096350 20 l 5 3 gal US Hydraulic oil HV46 4000530620 5 l 1 32 gal US 2420801320 20 l 5 3 gal US 2420801310 209 l 55 2 gal US Biological hydraulic oil HV46 2505003830 209 l 55 2 gal US Transmission oil 80W90 4000530610 1 l 0 22 gal US 2420801370 20 l 5...

Page 97: ...in conditions For more information please contact HAULOTTE Services Jet engine fuels kerosene F34 and F35 types under OTAN designation are possible on some engines and under certain conditions For more information please contact HAULOTTE Services The use of vegetable oils is forbidden Engines Fuels Hydraulic filter cartridge European gas oil according to EN590 European fuel oil according to BS2869...

Page 98: ...for engine operation at the highest ambient temperature that is anticipated Generally use the highest viscosity oil that is available to meet the requirement for the temperature at start up Engine oil viscosity Classification API EMA LGR 1 API CF CF 4 CG 4 CH 4 CI 4 Viscosity grade Ambient temperature Minimum Maximum SAE 0W20 40 C 40 F 10 C 50 F SAE 0W30 40 C 40 F 30 C 86 F SAE 0W40 40 C 40 F 40 C...

Page 99: ...OTOR OIL The recommended oil is EP type the characteristics of which comply with standards MIL L 2105 and API GL5 N B REFER TO CONSOMMABLES Viscosity grade HV46 HV46 Biodegradable HV32 HV68 Ambient temperature Between 15 C 9 F and 40 C 104 F Between 15 C 9 F and 40 C 104 F Between 35 C 31 F and 35 C 95 F Between 0 C 32 F and 45 C 113 F Hydraulic oil temperature Between 15 C 9 F and 80 C 176 F Betw...

Page 100: ...achine completely to remove any trace of harsh environmental pollution Clean the cylinder rods which are sensitive to corrosion using clean water Perform a dynamic test For each cylinder perform a movement from stop to stop 3 times each movement Dry the cylinder rods Grease the cylinder rods with protective oil See recommendations Verify absence of any oil leaks N B REFER TO CONSOMMABLES The coola...

Page 101: ...olyplex Bardahl grease Nature of the lubricating oil Semi synthetic Mineral oil Semi synthetic Appearance Viscous grease Semi solid Semi solid Thickening nature Lithium Lithium Calcium Complex lithium Color Ivory Red Blue Grade NLGI 1 2 2 Operating temperature C 40 at 140 20 at 120 20 at 160 Viscosity of the basic oil at 40 C 104 F mm s ISO 3104 25 220 140 Viscosity of the basic oil at 100 C 212 F...

Page 102: ... RTJ O HA80 RTJ O HA26 RTJ PRO HA80 RTJ PRO Low drive speed 1 2 km h 0 7 mph High drive speed 5 km h 3 1 mph Maximum towing speed 5 km h 3 1 mph Time for telescopic boom extension 60 s 5 Time for telescopic boom retraction 60 s 5 Time for raising boom 44 s 4 Time for descent boom 44 s 4 Time for continue turntable rotation 33 s 3 per 1 2 rotation Time for complete left right cage rotation 22 s 3 T...

Page 103: ...before the start of a new work shift and at every change of user This inspection is performed by and under the responsibility of the user and includes the visual and functional inspection of the machine as well as the testing of its safety systems A description of the daily inspection can be found in the machine s user manual We recommend these forms to be completed daily and stored to assist with...

Page 104: ...tion contained in our manual is to be complemented by the information found in the engine manufacturer s maintenance manual which can be found on the link in the associated maintenance sheet MS0238 Oil change To check by test Tightening Levelling Visual inspection Functional adjustments Checks Cleaning Lubrication Lubrication Systematic replacement First 50H Page or associated procedure First 50H ...

Page 105: ...the steering system MP0027 Grease the bushings and pins Slew ring Grease the turntable slew ring MP0044 KUBOTA WG2503 engine Drain the engine oil MP0036 Replace the oil filter MP0004 Clean the air filter MP0030 Check the belt tension and condition MP0007 MP0025 KUBOTA V2403M V2403CR T4B V2403CR T5B engine Clean the fuel filter MP0026 Clean the air filter MP0030 Check the belt tension and condition...

Page 106: ... wheel reducer level MP0002 Tighten the steering system MS0005 Slew ring Tighten the slew ring MP0019 KUBOTA WG2503 engine Replace the belt MP0032 KUBOTA V2403M V2403CR T4B V2403CR T5B engine Drain the engine oil MP0036 Replace the oil filter MP0004 Replace the fuel filter MP0005 Replace the belt MP0032 KOLHER KDI1903 engine Drain the engine oil Replace the oil filter Replace the fuel filter Repla...

Page 107: ...ry 1 year or 1000H OK NOK Corrected Comments Chassis assembly Wheel reducer steering wheel pivot Drain the wheel reducer MP0043 KUBOTA WG2503 engine Replace the fuel filter MP0005 Replace the air filter MP0010 KUBOTA V2403M V2403CR T4B V2403CR T5B engine Replace the air filter MP0010 KOLHER KDI1903 engine Replace the air filter Hydraulic oils filters and hoses Replace the hydraulic filter MP0006 A...

Page 108: ...OK Corrected Comments Chassis assembly Wheel reducer steering wheel pivot Check the bushings and pins Replacement if necessary MS0002 MP0024 Slew ring Check the slew ring clearance MP0018 KUBOTA WG2503 engine Drain the oil tank MP0020 Drain the cooling circuit MP0021 KUBOTA V2403M V2403CR T4B V2403CR T5B engine Drain the oil tank MP0020 Drain the cooling circuit MP0021 KOLHER KDI1903 engine Drain ...

Page 109: ...ance Level 2 Every 6000H Every 3000H Page or associated procedure Every 3000H OK NOK Corrected Comments KUBOTA V2403CR T4B V2403CR T5B engine Clean the diesel particulate filter Every 5000H Page or associated procedure Every 5000H OK NOK Corrected Comments KOLHER KDI1903 engine Drain the cooling circuit Every 6000H Page or associated procedure Every 6000H OK NOK Corrected Comments KUBOTA V2403CR T...

Page 110: ... a qualified technician Under no circumstances may this inspection replace the control required by local regulations Use the detailed program below Periodic Page or associated procedure Periodic OK NOK Corrected Comments Chassis assembly Wheel reducer steering wheel pivot Check state of tires tyres and inflations Motor Check that there are no leaks from the engine s components engine hose radiator...

Page 111: ...s broken welds and chipped paintwork on the structure Check for the absence of missing or loose screws and bolts Check for the absence of deformation cracking and breakage of axis stops bushing and axes Check for the absence of foreign bodies in joints and sliding parts Safety devices Test the operation of the upper and lower control boxes manipulators switches buttons horn emergency stops screens...

Page 112: ...s fully functional It must be carried out after 10 years then every 5 years This inspection is the responsibility of the owner and must be carried out by a technician HAULOTTE Services or an authorized and qualified person In order to carry it out contact the subsidiary HAULOTTE or the authorized distributor Machine sheet N B THE LIST OF MAINTENANCE SHEETS IS NOT EXHAUSTIVE OTHER SHEETS MAY BE SEN...

Page 113: ...s familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire permit etc and comply with the specific safety instructions at the intervention s...

Page 114: ... are Boss welds on chassis turret arms booms and jib Booms and arms welds All the accessible structural part without disassembling must be subjected to a fast visual inspection 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 of deformation and visible ...

Page 115: ...if needed 4 3 FUNCTIONAL TESTS The following tests must be performed periodically Section D Inspection and maintenance schedule An important technical intervention An accident resulting from a failure of a major component The following tests must be realized by a qualified staff under secure conditions The results of the tests must be entirely documented To avoid the swing of the machine during th...

Page 116: ...acteristics to be reached 4 5 STRUCTURAL TEST The following test shows that the structure of the machine is in conformity with the safety requirements The machine must be place on level and firm ground With 100 of the maximum allowed load operate from ground control box or emergency control box all the movements the platform floor must reach a height of about 1 above the ground Measure the distanc...

Page 117: ...oxidation of the pins stops pins Only an authorised and qualified technician is permitted to work on the machines HAULOTTE The use of this form implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obli...

Page 118: ...s Clean the bearing with a suitable solvent Check the absence 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 under the following conditions Section D Inspection and maintenance schedule Abnormal noise during movements of the structure Prolonged storage ...

Page 119: ...ightly lubricate boring and or pins Lubricate the ring of the bearing slightly To fit bearing in a boring take support on the external ring of the bearing To fit bearing on an axis take support on the interior ring of the bearing 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 7874 µ in 11810 µ in D Bearing drift E Diamete...

Page 120: ...120 4001055180 E 06 21 USA GB General data Pins and bearing inspection MS0002 Notes ...

Page 121: ...ligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire permit etc and comply with the specific safety instructions at the intervention site Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE are described in th...

Page 122: ...ity of the air Generic Control Position a load equal to the rated capacity on the cage or platform Raise the cage or the platform 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 extended and in the horizontal position For machines fitted with Boom lif...

Page 123: ... 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 Absence of deformation and visible damage Absence of crack broken welding oxidation glare of painting Type of cylinders Maximum drift authorised due to an internal leak of the cylinder Lift cylinder arm or boom Machine with working height...

Page 124: ...124 4001055180 E 06 21 USA GB General data Cylinder inspection MS0003 Check 1 Pipe weld connection 2 Rod weld connection 3 Ring 4 Rod 5 Piston ...

Page 125: ...miliar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire permit etc and comply with the specific safety instructions at the intervention site ...

Page 126: ...pe see plate manufacturer Trace on the ground a line being used as reference mark of stop Roll moving front until reaching maximum speed Between 3 km h 1 9 mph and 6 5 km h 4 039 mph according to the machines Release the manipulator as soon as the wheels axles are on the level of the traced reference mark Stopped machine measure the distance between the wheel axles and traced reference mark on the...

Page 127: ...Yellow 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 41 7 2 9 88 16 2 22 14 19 1 18 8 25 5 23 6 32 20 1 27 3 26 9 36 5 28 38 23 6 32 31 4 42 6 10 12 17 16 5 10 8 14 7 14 4 19 6 32 45 44 27 9 37 8 37 2 50 5 47 2 64 39 9 54 1 53 2 72 2 55 75 46 7 63 3 6...

Page 128: ... 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 90 122 120 162 130 176 170 230 140 189 5 8 11 110 149 150 203 160 217 210 284 180 244 18 130 176 170 230 180 244 240 325 200 271 3 4 10 200 271 270 366 280 379 380 515 320 433 16 220 298 300 406 310 420 4...

Page 129: ...nce 0 10 BSPP threads according to ISO1179 Thread Torque ft lbs Nm G1 4 26 35 G3 8 52 70 G1 2 66 90 G3 4 133 180 G1 229 310 G1 1 4 332 450 G1 1 2 398 540 UNF threads according to ISO11926 2 3 Thread Torque ft lbs Nm 7 16 20 15 20 1 2 20 30 40 9 16 18 33 45 3 4 16 59 80 7 8 14 100 135 1 1 16 12 136 185 1 5 16 12 199 270 1 5 8 12 251 340 1 7 8 12 306 415 ...

Page 130: ... 92 125 59 80 M22x1 5 100 135 74 100 M26x1 5 133 180 125 170 M33x2 0 229 310 229 310 M42x2 0 332 450 243 330 Hose size JIC thread JIC torque ORFS thread ORFS torque ft lbs Nm ft lbs Nm DN06 1 4 7 16 20 11 15 15 21 9 16 18 18 21 25 28 DN10 3 8 9 16 18 22 31 30 42 11 16 16 30 33 40 45 DN12 1 2 3 4 16 37 52 50 70 13 16 16 41 44 55 60 DN16 5 8 7 8 14 51 69 69 94 1 14 59 66 80 90 DN19 3 4 1 1 16 12 72 ...

Page 131: ... Drive pump Engine housing 160 Nm Equipment pump Drive pump 160 Nm Screw fastening elastic coupling Flywheel 44 Nm Counterweight Counterweight Turntable 500 Nm Telescope Pads rear telescope Screws 10 Nm Nuts 45 Nm Platform rotation cylinder Cylinder Link piece 44 Nm Medium threadlocker Screw connecting cylinder link piece 800 Nm Strain gauge MOBA Mounting on platform support and link piece Apply t...

Page 132: ...132 4001055180 E 06 21 USA GB General data Torque Values MS0005 Notes ...

Page 133: ...es that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits au...

Page 134: ...ing 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 the tank cap 2 Fill up the tank 3 Refit and tighten the tank cap 4 Clean up any fuel that may have escaped from the tank ...

Page 135: ...ope The boom is horizontal Put the turret if equipped in the axis Carry out a beaconing of the sector maximum risk zone machine height Locate the hoses and their connections points to guarantee the good performance of the machine after intervention Locate the hoses course to facilitate the reassembly To recover oil use an oils container in order not to pollute the environment After disassembling C...

Page 136: ...machine in operational configuration Carry out some movements implementing the hoses concerned in order to purge the hydraulic system Check the absence of leakage Control the level of hydraulic oil tank Check the pressures Description Torque JIC Torque ORFS Hose 1 4 diameter 6mm 1 5 daN m 11 08 lbf ft 2 6 daN m 19 22 lbf ft Hose 3 8 diameter 10mm 3 5 daN m 25 86 lbf ft 4 2 daN m 31 04 lbf ft Hose ...

Page 137: ...d technician can work on HAULOTTE machines The technician should take all steps to protect themselves or others against all risks of injury related to this intervention The technician should ensure that suitable PPE personal protective equipment for the job is used and check the particular conditions of environment in which the material can be found see safety information specific to the operation...

Page 138: ...el load cell type weight management system mounted between the platform and the boom assembly The location of the load 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 recalibrated in 3 ways depending on the software version Reset of the Zero empty cage ...

Page 139: ... 1 CONFIGURING THE MACHINE BEFORE START CALIBRATION The machine must be completely stowed Tilt inactive Weight sensors not out of range Platform tilt in 10 10 Ground control box selected 5 2 CONNECTION AND USE CONSOLE N B CONTACT HAULOTTE SERVICES Cellule de charge Load cell ...

Page 140: ...CESS CODE Main menu Access code Level 2 or 3 In the main menu select Main menu Machine settings Calibration Then select the calibration you will do RESET 0KG calibration of the offset or RESET 250KG calibration of the gain with fixed weight of 250 kg 551 lbs or 75 kg 165 lbs calibration of the gain with adjustable weight between 300 kg 662 lbs and 75 kg 165 lbs ...

Page 141: ... CAGE VALUE N B ACCESS CODE LEVEL 2 Before any calibration procedure make sure to remove from the basket platform all options weighing more than 15 kg 33 lbs Welding machine support Basket mesh For calibration with a fixed or adjustable weight the load must integrate the weight of all basket options ...

Page 142: ...IGHT OF 250 KG 551 LBS N B ACCESS CODE LEVEL 2 Before any calibration procedure make sure to remove from the basket platform all options weighing more than 15 kg 33 lbs Welding machine support Basket mesh For calibration with a fixed or adjustable weight the load must integrate the weight of all basket options ...

Page 143: ...65 LBS AND 300 KG 662 LBS N B AVEC CODE D ACCÈS NIVEAU 3 CODE JOURNALIER Before any calibration procedure make sure to remove from the basket platform all options weighing more than 15 kg 33 lbs Welding machine support Basket mesh For calibration with a fixed or adjustable weight the load must integrate the weight of all basket options ...

Page 144: ...F06 04 Incoh Gauges SP800 SP801 SP800 measured weight and SP801 measured weight are more than 50 kg far and gauges are not out of range and gauges are calibrated Check SP800 and SP801 connections to ground to U104 ECU analog inputs Redo calibration F06 05 Low Power Gauges supply Low power for strain gauges is detected low VbattB2 basket is under 8500mV Check gauges power supply F06 09 Negative loa...

Page 145: ... equipment is located see safety information specific to the work site Position the machine on a flat and firm surface clear of obstructions beware of power lines Mark out the work area Switch off the ignition and remove the ignition key Put a DO NOT USE decal near the start stop button to inform personnel that work is currently in progress on the equipment Beware of the risk of burns the hydrauli...

Page 146: ... machine on a flat and firm surface clear of obstructions beware of power lines Mark out the work area Machine stowed Switch off the ignition and remove the ignition key Mark and disconnect the hoses from the hydraulic motor 1 Plug the hoses to avoid pollution Undo the 2 screws 2 Remove the hydraulic motor ...

Page 147: ...ction and check that the displacement of the hoses is correct Carry out a driving test Check for any oil leaks Top up the oil level if necessary If the motor has been replaced remove and retain its traceability number Check state and presence of the seals on hydraulic motor Replace and tighten the 2 screws to a torque of 57 Nm Check for the presence of seal on connections Maintain hoses so they do...

Page 148: ...148 4001055180 E 06 21 USA GB Chassis Remove re install the hydraulic motor MS0119 Notes ...

Page 149: ...eople having the necessary technical training Respect in addition to the instructions appearing in 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 of work all the covers and safety devices must be positioned back completely and operational 3 Technic...

Page 150: ...de wall Blister or pronounced lump on the external and lateral wall Damaged wheel stud Damage or wear on the side wall to the extent that the reinforcing wire is visible Consistent wear of the ground contact surface greater than 25 Tires and rims are critical components for the stability of the machine For safety reasons Use only HAULOTTE spare parts according to the technical characteristics of t...

Page 151: ...ine to the ground Tighten the wheel nuts to the recommended torque Refer to maintenance and repair manuals Component Standard wheel Reference number Solideal 1025 x 365 Type Solid tires tyres Wheel mass 278 kg 6 kg 613 lbs 13 lbs Size 1025 365 mm 3 ft 4 in 1 ft 2 in Torque 450 Nm 332 ft lbs Machine type Wheel type Metric torque value Imperial torque value HT26 RT O HT80 RT O Drive wheel 450 N m 33...

Page 152: ...152 4001055180 E 06 21 USA GB Chassis and turret Wheel replacement MS0123 6 Bronze washer replacement Replace the bronze washer 3 if its thickness is below 2 5 mm ...

Page 153: ...A clamp to crimp the wires Place barriers around the perimeter of the work area 1 person Step 1 Disconnect the plug 2 Remove the caps on the plug Step 2 Pick up the pins in the plastic bag Strip the wires of the tracker Crimp the wires with the pins with a crimping clamp Step 3 Take the wedgelock off the plug Thread the wires in the positions regarding the information ...

Page 154: ... back on the plug to fix the pins Step 5 Reconnect the plugs Mount the tracker The tracking device is operational C1 Universal connector Pin 1 permanent battery Pin 2 GND 0 V Pin 3 battery voltage Pin 4 Machine with engine Engine ON information Electrical machine Movement and driving information Pin 5 Power ON information Pin 6 Pin 7 Movement information Flashing light option activation Pin 8 Driv...

Page 155: ... this form implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have al...

Page 156: ...surface clear of obstructions beware of power lines Mark out the work area Remove the counterweight Refer to MS0138 Remove re install the main counterweights Standard tool kit Collars COLSON Needle thread Wooden block Place barriers around the perimeter of the work area 1 Switch off the ignition and remove the ignition key Place a block under the boom ...

Page 157: ...SA GB Turntable Remove re install the harness BUS CAN MS0137 On the turntable behind the main block disconnect the CN06 1 and CN06 2 plugs Remove the connectors Protect the wires with a plastic bag Identification of connectors ...

Page 158: ... GB Turntable Remove re install the harness BUS CAN MS0137 Unscrew the STAUFF clamp through which the wiring harnesses run Cut the collars and pull the basket side cable bundle Remove the collar STAUFF from the cable bundle CAN ...

Page 159: ...ness BUS CAN MS0137 Remove the 6 fixing screws from the panel to enable access to the cylinder Then pull the wiring harness on the output compensation cylinder side Cut the collars in the link piece Bring the wiring harness on the outside right hand side of the boom ...

Page 160: ...e re install the harness BUS CAN MS0137 Remove the protective panels and cut the collars that fix the cable bundle to the rails conduits Attach the hoses to the boom Remove the cable bundle from the cable chain Bring the cable bundle up to the jib ...

Page 161: ... E 06 21 USA GB Turntable Remove re install the harness BUS CAN MS0137 Remove the panel from the arm assembly Remove the cable bundle from the sheath at the basket level Disconnect the connector located on the basket ...

Page 162: ...achine stopped Check the absence of leakage Check oil level Test all of the functions from the ground station and platform station Perform a static test by putting 290 kg 639 lbs on the platform Machine unfolded 15 mn after checking the performance of its parts Arm cylinder boom cylinder telescope cylinder compensation receiver cylinder jib cylinder In compliance with the country s laws have the m...

Page 163: ...n this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire ...

Page 164: ...ench and 46 mm 2 in socket Torque wrench Tap M30 1 hoisting strap s for 3000 kg 6614 lbs at a length of 2 m 6 ft 7 in 2 hoisting rings M30 3000 kg 6614 lbs minimum Grease Place barriers around the perimeter of the work area Counterweight mass 51200 kg 11 243 lbs 1 Switch off the ignition and remove the ignition key Take off the plastic caps that protect the threads on the counterweight If the thre...

Page 165: ...tall the main counterweights MS0138 Secure the counterweight with rings using 2 lyre shackles of at least 3000 kg and 2 lifting straps of 3000 kg length 2000 mm Apply a small amount of tension on the bridge crane Unscrew the engine casing fastening screws ...

Page 166: ...ights MS0138 Lock the engine tray in the open position Disconnect the twilight sensor Remove the collars COLSONS from the fasteners to remove the cable bundle from the length of the counterweight Remove the 5 screws that fix the panel to the counterweight and put it to one side ...

Page 167: ...r of dismantling 7 Additional operations Clean off any residual oil or grease Clean the work area Machine stopped Check the absence of leakage Check oil level Perform a static test by putting 290 kg 639 lbs on the platform Machine unfolded 15 mn after checking the performance of its parts Counterweight tightening torque 500 N m In compliance with the country s laws have the machine approved by an ...

Page 168: ...168 4001055180 E 06 21 USA GB Turntable Remove re install the main counterweights MS0138 Notes ...

Page 169: ... implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the perm...

Page 170: ...in minimum for extracting the arm hinge pin ORFS plug kit 2505001600 3 hoisting strap s for 3000 kg 6 615 lbs at a length of 3000 mm 9 ft 10 in 2 ratcheting straps that support 2000 kg 4 41 lbs at a length of 4000 mm 13 ft 1 in 1 ratcheting straps that support 1000 kg 2 205 lbs at a length of 4000 mm 13 ft 1 in 2 shackles 4500 kg 9 921 lbs 1 axis of handling arm 800 070 010 A bridge or handling de...

Page 171: ... Remove Replace arm assembly MS0139 Raise the arm to clear access to the tie rod s axes Unscrew the 2 the fastening strap screws on the fuel tank To access the the lower arm hinge pin unscrew the 2 fastening screws on the strap support plate ...

Page 172: ... 21 USA GB Lower arm Remove Replace arm assembly MS0139 On the turntable behind the main block disconnect the CN06 1 and CN06 2 plugs Remove the connectors Protect the wires with a plastic bag Identification of connectors ...

Page 173: ...MS0139 Mark the passage of the hoses through the collars STAUFF Make a mark on each hose at the entrance or exit of the collars This will allow them to be easily repositioned during reassembly Locate disconnect and seal all designated hoses from the main hydraulic block ...

Page 174: ... the fastening screws from the collars Bring the hoses to the back of the arm Disconnect the arm sensor plug SQ421 Strap the tie rods to the link piece using a ratcheting strap supporting 1000 kg 2 205 lbs at a length of 4000 mm 13 ft 1 in Put a small amount of tension on the strap ...

Page 175: ...the arms and the tie rods and tension the strap Tie down the basket side using the holes in the connecting part and a suitable axis On the counterweight side raise the axis of the boom with the smooth clevis circlip Make a slip knot on the axle with the lifting strap of 3000 kg 6 615 lbs length 3000 mm 9 ft 10 in Make a slip knot on the axle with the lifting strap of 3000 kg 6 615 lbs length 3000 ...

Page 176: ...139 For safety place a block under the arm Align the bridge and add tension to it In the test center we use a 1 strap of 4000 kg 8819 lbs and the position here black line Loosen the screws that hold the locking pins Remove the circlips Remove the pins on the lower tie rods ...

Page 177: ...ace arm assembly MS0139 Place the assembly on a flat surface while ensuring the assembly s stability Take out the screw that holds the locking pin Extract the pin by knocking it out to the fuel tank side connecting the lower arm casing to the turntable ...

Page 178: ...ling a new cylinder note the traceability number Lubricate the cylinder s axes and rings 7 Additional operations Clean off any residual oil or grease Clean the work area Move the cylinders several times to empty them Machine stopped Check the absence of leakage Check oil level Perform a static test by putting 290 kg 639 lbs on the platform Machine unfolded 15 mn after checking the performance of i...

Page 179: ...rm implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the pe...

Page 180: ...m capacity of 2000 kg 4 410 lbs Axle capacity 3000 kg 6 615 lbs Grease for pins ORFS plug kit 2505001600 Hydraulic oil Collars RILSAN Place barriers around the perimeter of the work area Boom assembly mass 1700 kg 3 748 lbs 2 Position the machine on a flat and firm surface clear of obstructions beware of power lines Mark out the work area Retract the telescope arm place the jib in the horizontal p...

Page 181: ...ssembly MS0140 Remove the counterweight Refer to MS0138 Remove re install the main counterweights On the turntable behind the main block disconnect the CN06 1 and CN06 2 plugs Remove the connectors Protect the wires with a plastic bag Identification of connectors ...

Page 182: ...per boom Remove Replace boom assembly MS0140 Remove the collars STAUFF at the front of the arm Remove the protective panel on the basket side so that you can pull the cable bundle Remove the collar STAUFF located at the top of the arm ...

Page 183: ...GB Upper boom Remove Replace boom assembly MS0140 Remove the 6 fixing screws from the panel to enable access to the cylinder Then pull the wiring harness on the output compensation cylinder side Cut the collars in the link piece ...

Page 184: ...bly MS0140 Attach a sling to the cylinder Place a container underneath the connections Carefully and gradually loosen the fastenings Disconnect the hoses and plug them Remove the fixing screw from pin on the rod side and push the pin Remove the axle from the cylinder ...

Page 185: ...Place the cylinder on the wooden wedge Locate the 2 hoses leading to the compensation receiver cylinder Place a container underneath the connections Carefully and gradually loosen the fittings until there is a trickle of oil Re tighten the fittings when the pressure has dropped ...

Page 186: ...A GB Upper boom Remove Replace boom assembly MS0140 Remove the fixing screw from the pin on the shaft side of the cylinder and then push the pin Pull out the pin Spread the hoses and cable bundle to tilt the cylinder backwards ...

Page 187: ...ace boom assembly MS0140 Disconnect the supply hoses from the telescope cylinder Seal the holes using the plug kit Remove the sensors SQ520 and SQ522 If there is a double load option also disconnect SQ523 and SQ521 Disconnect the sensors SQ530 and SQ531 ...

Page 188: ...boom Remove Replace boom assembly MS0140 Mark and disconnect at the bulkheads the 2 block supply hoses ON OFF Plug the openings after disassembly Disconnect the sensors from the top of the connecting part Remove the bolt for lifting rings ...

Page 189: ...he boom assembly Place the 2 articulated lifting rings onto the boom Sling it with 2 straps of 4 m 13 ft 1 in with a capacity of 3000 kg 6 615 lbs Place the articulated lifting ring and lyre shackle at the end of the telescope Sling using a strap of 4 m 13 ft 1 in with a capacity of 3000 kg 6 615 lbs ...

Page 190: ...190 4001055180 E 06 21 USA GB Upper boom Remove Replace boom assembly MS0140 Apply a small amount of tension on the bridge crane Remove the locking pin from the boom s hinge Pull out the pin ...

Page 191: ...the connections risk of seal damage This will avoid the hoses twisting when they are connected to the rigid tubes 7 Additional operations Clean off any residual oil or grease Clean the work area Move the cylinder several times to empty it Machine stopped Check the absence of leakage Check oil level Perform a static test by putting 290 kg 639 lbs on the platform Machine unfolded 15 mn after checkin...

Page 192: ...192 4001055180 E 06 21 USA GB Upper boom Remove Replace boom assembly MS0140 Notes ...

Page 193: ...m implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the per...

Page 194: ...punch diameter 35 mm 4 in Torque wrench for 10 Nm Torque wrench for 44 Nm Normal threadlocker 1 strap length 3 m 9 ft 10 in capacity 1000 kg 2 205 lbs 1 hoisting strap s for 3000 kg 6 615 lbs at a length of 2 m 6 ft 7 in A bridge or handling device Palettes for placement under the platform about 300 mm 12 in Place barriers around the perimeter of the work area 1 Raise the arm above the counterweig...

Page 195: ...scope about 100 mm 4 in to disassemble the front pads located on the boom shaft Place blocks under the basket Switch off the ignition and remove the ignition key Mark the adjustment pallets and disassemble the pads on the boom shaft The 2 upper pads on the jib side and then the 4 lateral pads ...

Page 196: ... the telescope by using a hoisting strap that supports 3000 kg 6 65 lbs at a length of 2 m 6 ft 7 in Tension the bridge to raise the telescope box so that the pads can be pulled out Mark the adjustment pallets then disassemble the 2 lower front pads Remove the 6 fixing screws from the panel to enable access to the cylinder ...

Page 197: ...SA GB Upper boom Removing Replacing the pads MS0141 Remove the fixing screw from the pin on the shaft side of the cylinder and then push the pin Pull out the pin Spread the hoses and cable bundle to tilt the cylinder backwards ...

Page 198: ...ing Replacing the pads MS0141 Mark the adjustment pallets and remove the 2 lateral pads Remove the 2 lower pads For the upper pads mark the adjustment pallets and take out the screws Put a small amount of tension on the telescope to remove the pads ...

Page 199: ...at the seals are on the connections before reconnecting the hoses Install the back lower pads Install the back lower lateral pads Install the output compensation cylinder Grease the pin Install the pin s stopper clevis Install the front lower pads Install the front lateral pads Install the front upper pads 7 Additional operations Clean the work area Perform a static test by putting 290 kg 639 lbs ...

Page 200: ...200 4001055180 E 06 21 USA GB Upper boom Removing Replacing the pads MS0141 Notes ...

Page 201: ...rm implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the pe...

Page 202: ...llet Pin punch diameter 30 mm 1 18 in 1 strap length 3 m 9 ft capacity 1000 kg 2 205 lbs Ratchet strap Boom cylinder 4000471480 Grease for pins ORFS plug kit 2505001600 Hydraulic oil Place barriers around the perimeter of the work area Major component masses Boom cylinder 208 kg 459 lbs Upper boom 1700 kg 3 748 lbs 2 Lift the arm to release the boom cylinder s axis Remove the panel from the cable ...

Page 203: ...203 4001055180 E 06 21 USA GB Upper boom Remove Replace Boom cylinder MS0142 Lower the boom on the wedging Secure the arm and sling the rear side Switch off the ignition and remove the ignition key ...

Page 204: ...ve Replace Boom cylinder MS0142 Sling the rod side of the cylinder Place a container underneath the connections Disconnect the hoses and plug them Remove the fixing screw from pin on the rod side and push the pin Remove the axle from the cylinder ...

Page 205: ...f gravity Middle of the cylinder Remove the fixing screw from pin on the rod side and push the pin Do not remove completely the axis as it maintains the upper arm and link part Use a shaft diameter 35 mm 2 in and length 800 mm 32 in Remove the axis from the body side of the cylinder Take out the axis of maximum length 400 mm 16 in in order to be able to release the cylinder ...

Page 206: ...sk of seal damage This will avoid the hoses twisting when they are connected to the rigid tubes 7 Additional operations Clean off any residual oil or grease Clean the work area Move the cylinder several times to empty it Machine stopped Check the absence of leakage Check oil level Perform a static test by putting 290 kg 639 lbs on the platform Machine unfolded 15 mn after checking the performance ...

Page 207: ...The use of this form implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user mu...

Page 208: ... sign Remove the covers Refer to MS0132 Remove replace covers Standard tool kit Height wedge 300 mm 12 in Tray Mallet Pin punch diameter 30 mm 1 18 in 1 strap length 3 m 9 ft 8 in Handling equipment Seal pouch Grease for pins ORFS plug kit 2505001600 Hydraulic oil Place barriers around the perimeter of the work area Major component masses Output compensation cylinder 40 kg 896 lbs 1 Machine stowed...

Page 209: ...compensation cylinder MS0143 Locate the 2 hoses leading to the compensation receiver cylinder Place a container underneath the connections Carefully and gradually loosen the fittings until there is a trickle of oil Re tighten the fittings when the pressure has dropped ...

Page 210: ... Re install output compensation cylinder MS0143 Remove the 6 plate s fastening screws that give access to the output compensation cylinder Remove the fixing screw from the pin on the shaft side of the cylinder and then push the pin Pull out the pin ...

Page 211: ...stall output compensation cylinder MS0143 Spread the hoses and the cable bundle to tilt the transmitter cylinder backwards Carefully and gradually loosen the hoses to decrease the pressure Disconnect the hoses and plug them Attach a sling to the cylinder ...

Page 212: ...ve Re install output compensation cylinder MS0143 Remove the cylinder and place it on blocks Removal operation is complete Remove the fixing screw from the pin on the body side of the cylinder and push the pin Pull out the pin Extract the cylinder ...

Page 213: ... the connections risk of seal damage This will avoid the hoses twisting when they are connected to the rigid tubes 7 Additional operations Clean off any residual oil or grease Clean the work area Move the cylinder several times to empty it Machine stopped Check the absence of leakage Check oil level Perform a static test by putting 290 kg 639 lbs on the platform Machine unfolded 15 mn after checki...

Page 214: ...214 4001055180 E 06 21 USA GB Upper boom Remove Re install output compensation cylinder MS0143 Notes ...

Page 215: ...he use of this form implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user mus...

Page 216: ...et Pin punch diameter 30 mm 1 18 in Tray Circlips pliers 1 strap length 3 m 9 ft capacity 1000 kg 2 205 lbs Handling device Receiver compensation cylinder Seal pouch Grease for pins ORFS plug kit 2505001600 Hydraulic oil Place barriers around the perimeter of the work area Major component masses Compensation cylinder 30 kg 67 lbs 2 ...

Page 217: ...4 5 Removal Position the machine on a flat and firm surface clear of obstructions beware of power lines Mark out the work area With the arm and boom folded and the telescope extended to access the pin on the side at the bottom of the output compensation cylinder support the platform on pallets ...

Page 218: ...input compensation cylinder MS0144 Switch off the ignition and remove the ignition key Strap the cylinder s rod to the boom Place a wooden wwdge underneath the cylinder Remove the fixing screw from the pin on the shaft side of the cylinder and then push the pin ...

Page 219: ... Pull out the pin Lower the cylinder onto the block and remove the strap Start the ignition and retract the cylinder rod Place a container underneath the connections Carefully and gradually loosen the fittings until there is a trickle of oil Re tighten the fittings when the pressure has dropped ...

Page 220: ...linder s axes and rings Check that the seals are on the connections before reconnecting the hoses Hold the hoses to ensure that they don t turn while tightening the connections risk of seal damage This will avoid the hoses twisting when they are connected to the rigid tubes Bring the hoses to the cylinder side Remove the circlip from the body side axis Secure the cylinder before pushing out the ax...

Page 221: ...eral times to empty it Machine stopped Check the absence of leakage Check oil level Perform a static test by putting 290 kg 639 lbs on the platform Machine unfolded 15 mn after checking the performance of its parts Arm cylinder boom cylinder telescope cylinder compensation receiver cylinder jib cylinder In compliance with the country s laws have the machine approved by an accredited organization ...

Page 222: ...222 4001055180 E 06 21 USA GB Upper boom Remove Re install input compensation cylinder MS0144 Notes ...

Page 223: ... that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits auth...

Page 224: ...ool kit Tray Collars RILSAN or straps Mallet Pin punch diameter 30 mm 1 18 in plug kit 1 straps length 3 m 9 ft 8 in capacity 1000 kg 2 205 lbs 1 straps length 2 m 6 ft 7 in capacity 1000 kg 2 205 lbs Ratchet strap Place barriers around the perimeter of the work area Lift the boom to clear access to the arm cylinder Secure the boom For safety secure the lower tie rods ...

Page 225: ... GB Lower arm Remove Replace arm cylinder MS0145 Switch off the ignition and remove the ignition key Remove the collars STAUFF Remove the collars from the hoses and cables and fix them to the arm to enable access to the cylinder ...

Page 226: ...m cylinder MS0145 Place a strap on the cylinder s rod Empty the arm s cylinder Plug the hoses and the cylinder Remove the fixing screw from the pin on the shaft side of the cylinder and then push the pin Pull out the pin Put the cylinder on the wooden pallet ...

Page 227: ... USA GB Lower arm Remove Replace arm cylinder MS0145 Strap the body side of the cylinder Remove the fixing screw from the pin on the body side of the cylinder and push the pin Pull out the pin Extract the cylinder diagonally ...

Page 228: ...bricate the cylinder s axes and rings Check that the seals are on the connections before reconnecting the hoses Hold the hoses to ensure that they don t turn while tightening the connections risk of seal damage This will avoid the hoses twisting when they are connected to the rigid tubes Remove the cylinder and place it on blocks Removal operation is complete Use a ratchet strap to slide the cylin...

Page 229: ... to empty it Machine stopped Check the absence of leakage Check oil level Perform a static test by putting 290 kg 639 lbs on the platform Machine unfolded 15 mn after checking the performance of its parts Arm cylinder boom cylinder telescope cylinder compensation receiver cylinder jib cylinder In compliance with the country s laws have the machine approved by an accredited organization ...

Page 230: ...230 4001055180 E 06 21 USA GB Lower arm Remove Replace arm cylinder MS0145 Notes ...

Page 231: ...The use of this form implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user mu...

Page 232: ... in a horizontal position take out the telescope to access the shaft side pin Pin the telescope barrel and boom to prevent the barrel from coming out Height wedge 700 mm 28 in Wooden block 1 prong diameter 22 mm 0 87 in Standard tool kit Tray Lamp 2 straps length 2 m 6 ft 7 in capacity 1000 kg 2 205 lbs Bridge A second handling device Grease for pins ORFS plug kit 2505001600 Hydraulic oil Place ba...

Page 233: ...6 21 USA GB Upper boom Remove Replace telescope cylinder MS0146 Prepare a stable block of around 700 mm 28 in and place the basket on top of it using the tilt function Switch off the ignition and remove the ignition key ...

Page 234: ...scope cylinder MS0146 Locate the 2 hoses leading to the compensation receiver cylinder Place a container underneath the connections Carefully and gradually loosen the fittings until there is a trickle of oil Re tighten the fittings when the pressure has dropped ...

Page 235: ...per boom Remove Replace telescope cylinder MS0146 Remove the 6 fixing screws from the panel to enable access to the cylinder Remove the fixing screw from the pin on the shaft side of the cylinder and then push the pin Pull out the pin ...

Page 236: ...r MS0146 Move the hoses and cables aside so that you can tilt the transmitter cylinder Disconnect the supply hoses from the telescope cylinder Plug the hoses and the cylinder Remove the sensors SQ520 and SQ522 If there is a double load option also disconnect SQ523 and SQ521 ...

Page 237: ...Replace telescope cylinder MS0146 Disconnect the sensors Take off the circlips and extract the shaft side pin Place a strap under the cylinder through the opening Remove the fixing screw from the pin on the body side of the cylinder and push the pin ...

Page 238: ...inder in order to extract the body side axis Place a wooden wwdge underneath the cylinder Position the cylinder on the bottom part of the telescope s barrel Sling the body side of the cylinder passing it through the rear door Pull the cylinder lightly Be careful not to hang anything onto the outlet of the anti buckling plate ...

Page 239: ...ons before reconnecting the hoses Hold the hoses to ensure that they don t turn while tightening the connections risk of seal damage This will avoid the hoses twisting when they are connected to the rigid tubes Take hold of the rod side of the cylinder with the second handling device Lay down the cylinder on wooden blocks In order to make it easier for the guidance part to enter the telescope posi...

Page 240: ...imes to empty it Machine stopped Check the absence of leakage Check oil level Perform a static test by putting 290 kg 639 lbs on the platform Machine unfolded 15 mn after checking the performance of its parts Arm cylinder boom cylinder telescope cylinder compensation receiver cylinder jib cylinder In compliance with the country s laws have the machine approved by an accredited organization ...

Page 241: ...will 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 necessary safety clothing Type 12 V DC Group 34 78 Quantity 1 Cold cranking ampere 830 A ...

Page 242: ...move the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the re sults 6 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to Step 9 Result One or more battery cells display a specific grav...

Page 243: ... 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 Avoid overflowing Wash the top of the batteries without removing the caps Dry with compressed air or clean cloths Oil the terminals ...

Page 244: ...244 4001055180 E 06 21 USA GB Electric Battery ies MS0149 Notes ...

Page 245: ...ent is located see safety information specific to the work site Position the machine on a flat and firm surface clear of obstructions beware of power lines Mark out the work area Switch off the ignition and remove the ignition key Put a DO NOT USE decal near the start stop button to inform personnel that work is currently in progress on the equipment Beware of the risk of burns the hydraulic syste...

Page 246: ... MS0151 3 Removal 3 1 MOVABLE COVER ON THE MOTOR SIDE Open the engine cover Position the machine on a flat and firm surface clear of obstructions beware of power lines Mark out the work area Machine in stowed position Switch off the ignition and remove the ignition key ...

Page 247: ...Remove re install the covers MS0151 Sling each side of the cover Apply a small amount of tension on the bridge crane Loosen the screw that the fixes the engine casing to the turret Open and lock the engine casing to access the casing s screws ...

Page 248: ...248 4001055180 E 06 21 USA GB Turntable Remove re install the covers MS0151 Loosen the screws that fix the cover support plate to the turret ...

Page 249: ...249 4001055180 E 06 21 USA GB Turntable Remove re install the covers MS0151 Lift the cover slightly with the bridge Remove the cover ...

Page 250: ...250 4001055180 E 06 21 USA GB Turntable Remove re install the covers MS0151 3 2 MOVABLE COVER ON THE CONTROL BOX SIDE Open the cover on the control box side Sling each side of the cover ...

Page 251: ...5180 E 06 21 USA GB Turntable Remove re install the covers MS0151 Disconnect the beacon switch Apply a small amount of tension on the bridge crane Loosen the screws that fix the cover support plate to the turret ...

Page 252: ... re install the covers MS0151 Remove the cover 4 Re installation Perform the operations in the reverse order of dismantling 5 Additional operations Clean off any residual oil or grease Ensure that the locks on the movable covers are locked properly ...

Page 253: ...op button to inform personnel that work is currently in progress on the equipment Beware of the risk of burns the hydraulic system operates at high temperatures The pressure in the hydraulic system is very important It can cause accidents Relieve the pressure before beginning any work and never search for oil leaks using your hands Engine exhaust gases contain harmful products of combustion Always...

Page 254: ...ware of power lines Mark out the work area Machine stowed Switch off the ignition and remove the ignition key Make a stable pallet stack about 400 mm 16 in tall Loosen the screws without removing them from the wheel Lift the machine with the jack to raise the wheel off the ground Place wedges under the chassis and lower the jack slowly Sling the wheel with the strap ...

Page 255: ...on gear MS0152 Remove the wheel and lay it down flat on a pallet with the outer side downwards Loosen the screw and remove the clevis pin Remove the pin that connects the steering cylinder to the wheel pivot Put the cylinder to one side Mark disconnect and plug the hoses ...

Page 256: ...ane Remove the locking pin screws and withdraw the pins connecting the steering pivot to the chassis Remove the steering pivot reduction gear assembly Set aside the bronze washers Place the assembly on the ground Sling the assembly by the holes in the wheel steering pivot Position the assembly on the wheel with the reduction gear studs inserted into the rim ...

Page 257: ...tling Remove the hydraulic motor Undo the 2 screws Loosen the 12 screws connecting the reduction gear to the wheel steering pivot Mark the position of the reducer on the wheel pivot before removal Sling the steering pivot Remove the wheel steering pivot If the reduction gear has been replaced note its traceability number Remember to refit the bronze rings ...

Page 258: ...01055180 E 06 21 USA GB Chassis Remove Re install wheel reduction gear MS0152 Grease the pins when re installing and comply with the tightening torque Check state and presence of the seals on hydraulic motor ...

Page 259: ...ness of 2 5 mm for fixing the wheel to the gear unit If the reduction gear has been replaced check the oil level Fill the reduction gear if it is empty If the machine is still on wedges disengage the reducer in order to turn it manually Position the plugs correctly to fill up or top up with oil Manually release the reduction gear Loosen the 2 screws from the central plate and turn it over to disen...

Page 260: ... the reduction gear is disengaged from the brake Turn the reduction gear to position the oil top up filling and drain plugs The level can only be established when the plug is positioned in the horizontal axis of the reduction gear Remove the plug The oil should be just level with the hole Top up using the syringe if necessary ...

Page 261: ...position once the operation is finished Grease the wheel steering pivot pins Clean off any residual oil or grease Move the steering and check that the hose movement range is correct Perform a travel test and check the stopping distance At high speed the machine must stop between 1 2 m 3 9 ft and 1 6 m 5 2 ft Check for any oil leaks ...

Page 262: ...262 4001055180 E 06 21 USA GB Chassis Remove Re install wheel reduction gear MS0152 Notes ...

Page 263: ...ch Manuel d atelier 9Y111 14251 In english Workshop manual 9Y111 07841 V2403 CR Engine In french Manuel d atelier 9Y111 10985 In english Workshop manual 9Y111 07825 V2403M Engine In french Manuel d atelier 9Y111 02584 In english Workshop manual 9Y111 02574 V2607 CR E4 Engine In french Manuel d atelier 9Y111 11034 In english Workshop manual 9Y111 06744 V2607 MT E3 Engine In french Manuel d atelier ...

Page 264: ...s manual PERKINS engine type 1104D 44T 4 DEUTZ TCD 2 9 L4 Engine In french Manuel de l opérateur 03124630_10_2013 In english Operator s manual 03124628 en 5 KOHLER KDI 3404 TCR Engine In french ED0053030060 UM_KDI_3404TCR_REV_00_FR_HD In english ED0053030050 UM_KDI_3404TCR_REV_00_EN_HD KDI 1903 TC STAGE V Engine In english ED0053029490_UM_KDI_1903_2504TCR_REV_19_1_EN In french ED0053029710_UM_KDI_...

Page 265: ...is form implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all t...

Page 266: ...ork area barriers cones marking tape Restrict access to the area restricted access sign DO NOT OPERATE tag Personal protective equipment Standard tool kit Torque wrench Place barriers around the perimeter of the work area 1 person Switch off the ignition and remove the ignition key Place a do not operate tag at the start stop switch location to inform personnel that the equipment is being worked o...

Page 267: ...dure MP0001 7 Additional operations Clean the work area Chassis Reduction gear Non steering wheels Check the tightening torque of the 8 studs 260 N m 192 lbf ft wheel pivot Reduction gear Steer wheels Check the tightening torque of the 8 studs 280 N m 206 lbf ft ...

Page 268: ...268 4001055180 E 06 21 USA GB Chassis Wheel tightening procedure MP0001 Notes ...

Page 269: ...ained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to wor...

Page 270: ...ground Place wedges under the chassis and lower the jack slowly Disconnect the gear system Loosen the 2 screws from the central plate and turn it over to disengage the reduction gear Manually turn the wheel to position the filler cap to the top of the vertical axis 3 Open the caps 2 3 If the level is correct oil should drain from the orifice 2 If not add oil via the cap 3 using the syringe until o...

Page 271: ...s Clean any oil traces Clean the work area Rotate the wheel moving it slowly to place a filler cap at the top of the vertical axis 1 Open the caps 1 2 It is level when the oil overflows from the hole 2 If not add oil via the cap 1 using the syringe until oil flows through the hole 2 Close the caps and wipe up any oil that has spilled on the floor ...

Page 272: ...272 4001055180 E 06 21 USA GB Chassis Wheel reducer level procedure MP0002 Notes ...

Page 273: ...y and manual load handling The user must have all the permits authorizations required to work fire permit etc and comply with the specific safety instructions at the intervention site Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE are described in this sheet Beware of the risk of burns the hydraulic system operates at high temperatures...

Page 274: ...tions beware of power lines Put the machine in stowed position boom and arm fully retracted and lowered Appropriate workwear Gloves Safety shoes Safety goggles DO NOT OPERATE tag Personal protective equipment Rags Standard tool kit Place barriers around the perimeter of the work area 1 person Switch off the ignition and remove the ignition key Place a do not operate tag at the start stop switch lo...

Page 275: ...gine Remove the oil level gauge wipe it clean and reinstall it 4 Remove the gauge again If the oil level is between the marks 1 and 2 the oil level is correct If the oil level is lower than the minimum mark 1 Remove the oil filling cap 3 and top up with new oil until it reaches the correct level After adding oil wait more than 5 minutes and check the oil level again If the level is still below the...

Page 276: ...276 4001055180 E 06 21 USA GB Turntable Procedure for checking the level of engine oil MP0003 Notes ...

Page 277: ... etc and comply with the specific safety instructions at the intervention site Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE are described in this sheet Beware of the risk of burns the hydraulic system operates at high temperatures The pressure in the hydraulic system is very important It can cause accidents Relieve the pressure befor...

Page 278: ...engine MP0003 4 Risk prevention Means of protection to be used when implementing the range 5 You will need Appropriate workwear Gloves Safety shoes Safety goggles DO NOT OPERATE tag Personal protective equipment Rags Standard tool kit Place barriers around the perimeter of the work area 1 person ...

Page 279: ... and arm fully retracted and lowered Switch off the ignition and remove the ignition key Place a do not operate tag at the start stop switch location to inform personnel that the equipment is being worked on Check the engine oil level before starting or more than 5 minutes after stopping the engine Remove the oil level gauge wipe it clean and reinstall it 4 Remove the gauge again If the oil level ...

Page 280: ... Additional operations Clean the work area If the oil level is lower than the minimum mark 1 Remove the oil filling cap 3 and top up with new oil until it reaches the correct level After adding oil wait more than 5 minutes and check the oil level again If the level is still below the limit repeat the operation ...

Page 281: ...c and comply with the specific safety instructions at the intervention site Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE are described in this sheet Beware of the risk of burns the hydraulic system operates at high temperatures The pressure in the hydraulic system is very important It can cause accidents Relieve the pressure before b...

Page 282: ...otection to be used when implementing the range 5 You will need Appropriate workwear Gloves Safety shoes Safety goggles DO NOT OPERATE tag Personal protective equipment Standard tool kit Oil filter wrench Rags Engine oil filter 4000076270 Container Place barriers around the perimeter of the work area 1 person ...

Page 283: ...ignition key Place a do not operate tag at the start stop switch location to inform personnel that the equipment is being worked on The oil cartridge is at the rear of the engine To access it swivel the engine by removing the screw 1 Remove the oil filter 2 using a filter wrench Apply a layer of clean oil to the seal of the new cartridge Tighen the new cartridge by hand until it comes into contact...

Page 284: ...284 4001055180 E 06 21 USA GB Turntable Replacing the engine oil filter MP0004 Notes ...

Page 285: ... with the specific safety instructions at the intervention site Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE are described in this sheet Beware of the risk of burns the hydraulic system operates at high temperatures The pressure in the hydraulic system is very important It can cause accidents Relieve the pressure before beginning any...

Page 286: ...s of protection to be used when implementing the range 5 You will need Appropriate workwear Gloves Safety shoes Safety goggles DO NOT OPERATE tag Personal protective equipment Standard tool kit Oil filter wrench Rags Engine oil filter 4000389200 Container Place barriers around the perimeter of the work area 1 person ...

Page 287: ...ch location to inform personnel that the equipment is being worked on The oil cartridge is at the rear of the engine To access it swivel the engine by removing the screw 1 Undo the cartridge holder cover 1 by performing 3 complete turns and wait 1 minute Unscrew the cartridge holder cover 1 and check that the oil in the filter support 2 has flowed Remove the cartridge from the oil filter support R...

Page 288: ...288 4001055180 E 06 21 USA GB Turntable Replacing the engine oil filter Kohler engine MP0004 Notes ...

Page 289: ...d on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fi...

Page 290: ...tag Standard tool kit Filter wrench Container Oil collection pan Place barriers around the perimeter of the work area 1 person Dis assembly Set the handle of the separator to OFF 1 Loosen and remove the container 2 using a filter wrench Remove the cartridge from the diesel filter 3 Assembly Clean the inside of the diesel filter jar 2 Replace the seal of the container 4 and reassemble in the revers...

Page 291: ... Diesel filter replacement MP0005 6 Additional operations Clean the work area Disconnecting the engine start sensor to reboot the pump is recommended Switch on the engine for a few moments and check that there are no fuel leaks in the filter ...

Page 292: ...292 4001055180 E 06 21 USA GB Turntable Diesel filter replacement MP0005 Notes ...

Page 293: ...in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire permit etc and comply with the specific safety instructions at the intervention site Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE are described in this sheet B...

Page 294: ...nd lowered Switch off the ignition and remove the ignition key Place a do not operate tag at the start stop switch location to inform personnel that the equipment is being worked on Appropriate workwear Gloves Safety shoes Diesel filter cartridge 4000389280 DO NOT OPERATE tag Standard tool kit Filter wrench Container Oil collection pan Place barriers around the perimeter of the work area 1 person ...

Page 295: ...emble in the reverse order to disassembly Apply a thin layer of fuel to the surface of the seal of the container 6 Tighten the cartridge to a torque of 17 N m using a wrench Tighten the sensor 4 to a torque of 1 reconnect the 5N m pipes to the support and tighten the collars 2 Reprime the diesel circuit using the pump button 7 Switch on the engine for a few moments and check that there are no fuel...

Page 296: ...296 4001055180 E 06 21 USA GB Turntable Diesel filter replacement Kohler engine MP0005 Notes ...

Page 297: ... in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire permit etc and comply with the specific safety instructions at the intervention site Only risks linked specifically to activities relati...

Page 298: ...nd lowered Appropriate workwear Gloves Safety shoes Safety goggles Filter replacement every year or every 1000 h Hydraulic filter cartridge Red 2427002910 Hydraulic filter cartridge Black 2427003110 DO NOT OPERATE tag Personal protective equipment Standard tool kit Vacuum pump Rags Container Collection tray 1L Place barriers around the perimeter of the work area 1 person Switch off the ignition an...

Page 299: ...ic filters A and B Place a container under the filter Unlock the filter container using a wrench then unscrew by hand 1 Change the cartridge inside the container Re tighten the container by hand then tighten using a wrench to finish Wipe away any run off and check that the system has no leaks Perform the operation when it is at room temperature ...

Page 300: ...300 4001055180 E 06 21 USA GB Turntable Hydraulic oil filter replacement MP0006 Notes ...

Page 301: ...mation contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire permit etc and comply with the specific safety instructions at the intervention site Only risks linked specifically to a...

Page 302: ...nd firm surface clear of obstructions beware of power lines Put the machine in stowed position boom and arm fully retracted and lowered Appropriate workwear Gloves Safety shoes DO NOT OPERATE tag Tools for checking belt tension Standard tool kit Lever Place barriers around the perimeter of the work area 1 person Do not start the engine and disconnect the battery Remove the protective cover if ther...

Page 303: ... Press halfway between the fan drive pulley and the alternator pulley with a force of 98 N 10 kg to measure the deflection 1 The value measured must be between 7 mm and 9 mm If the value is within this range the tension is correct If the value is not within this range Loosen the fastening screw of the alternator 2 Adjust its position ...

Page 304: ...304 4001055180 E 06 21 USA GB Turntable Procedure for checking engine belt tension MP0007 Notes ...

Page 305: ...tory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire permit etc and comply with the specific safety instructions at the intervention site Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE are describe...

Page 306: ... flat and firm surface clear of obstructions beware of power lines Put the machine in stowed position boom and arm fully retracted and lowered Appropriate workwear Gloves Safety shoes DO NOT OPERATE tag Tools for checking belt tension Standard tool kit Lever Place barriers around the perimeter of the work area 1 person Do not start the engine and disconnect the battery Remove the protective cover ...

Page 307: ...the fan drive pulley and the alternator pulley to measure deflection Check that the value of the voltage is between 80 and 85Hz with an appropriate instrument If no instruments are available to check that the voltage is correct apply a force of approximately 10 kg to the point P 2 The belt flexion must be less than 10mm Otherwise adjust it ...

Page 308: ...belt tension Kohler engine MP0007 7 Additional operations Clean the work area If the value is not within this range Unscrew the fixing screws 3 4 Adjust its position Maintaining the position tighten the fastening screws 3 to a torque of 25 N m and 4 to a torque of 69 N m ...

Page 309: ... that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits auth...

Page 310: ... 6 Procedure Personal protective equipment Place barriers around the perimeter of the work area 1 person The front axles will oscillate when the boom is in transport position i e when the boom is less than 15 above horizontal and not extended beyond 30cm 12in on the machine and drive is selected ...

Page 311: ...ver to reverse and carefully drive machine off of block and ramp Have an assistant check to see that left front or right rear wheel remains elevated in position off of the ground Carefully return the boom to the transport position When boom reaches the transport position carefully activate drive to release cylinders To lockout cylinders should release and allow the wheel to rest on ground This ope...

Page 312: ...312 4001055180 E 06 21 USA GB Chassis Front axle locking function check MP0008 Notes ...

Page 313: ...important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire permit etc and comply with the ...

Page 314: ...ines Put the machine in stowed position boom and arm fully retracted and lowered Appropriate workwear Gloves Safety shoes DO NOT OPERATE tag Personal protective equipment Primary cartridge 4000044230 Secondary cartridge 4000044240 Place barriers around the perimeter of the work area 1 person Switch off the ignition and remove the ignition key Place a do not operate tag at the start stop switch loc...

Page 315: ...SA GB Turntable Air filter replacement MP0010 Pull the pin and swivel the cover to remove it 1 Remove the main element 2 and secondary element 3 Replace with new cartridges Close the cover again using the pin 1 Do not use oil ...

Page 316: ...316 4001055180 E 06 21 USA GB Turntable Air filter replacement MP0010 Notes ...

Page 317: ...pe of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire permit et...

Page 318: ... around the perimeter of the work area 1 person Front pads Telescope of the boom slightly Check the wear on the 8 wear pads If the chamfers 1 are visible on the pads the pad is compliant If the chamfers are not visible on the pads replace the pads Rear pads Remove the plate on the back of the boom Retract the telescoping boom Check the wear on the 8 wear pads If the chamfers 1 are visible on the p...

Page 319: ... and qualified technician is permitted to work on the machines HAULOTTE The use of this form implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specif...

Page 320: ...ATE tag Personal protective equipment Standard tool kit 2505003830 Hydraulic oil Rags Place barriers around the perimeter of the work area 1 person Reference Part number HAULOTTE Can 5L Standard oil HV46 4000530620 20L bucket Standard oil HV46 2420801320 Barrel 209L Standard oil HV46 2420801310 Barrel 209L Oil Winter option 2505002640 Barrel 209L Organic oil 2820304310 Check the filling level of t...

Page 321: ...he user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire permit etc and comply with the specific safety instructions at the intervention site Only risks linked specifically to activities relating to...

Page 322: ...e equipment Standard tool kit Vacuum pump Funnel with a pipe of around 1 m 3 ft 28 in 140 l 37 gal canister for hydraulic oil collection Oil collection pan Rags Hand pump 140 L 37 gals tank Place barriers around the perimeter of the work area 1 person Reference Part number HAULOTTE Can 5L Standard oil HV46 4000530620 20L bucket Standard oil HV46 2420801320 Barrel 209L Standard oil HV46 2420801310 ...

Page 323: ...position boom and arm fully retracted and lowered Jib is in transportation position and telescope is retracted Switch off the ignition and remove the ignition key Place a do not operate tag at the start stop switch location to inform personnel that the equipment is being worked on Place a recipient under the hydraulic oil tank 1 Remove the drain plug 2 under the tank and allow the oil to fully dra...

Page 324: ...s Clean the work area N B REMOVE THE FILLING CAP TO FACILITATE DRAINING 3 Refit and tighten the drain out 2 Fill the tank with new oil N B DO NOT FILL TO THE MAXIMUM LEVEL AS THE OIL COULD LEAK OUT Run several cycles with the machine and ensure that the oil is between the minimum and maximum level ...

Page 325: ... HT85 RTJ O HT85 RTJ PRO HT43 RTJ PRO HT132 RTJ PRO 2 Concerned area 3 Warning Only an authorised and qualified technician is permitted to work on the machines HAULOTTE The use of this form implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally spea...

Page 326: ...t the equipment is being worked on Appropriate workwear Gloves Safety shoes DO NOT OPERATE tag Standard tool kit Torque wrench Torque multiplier Place barriers around the perimeter of the work area 1 person Check the tightness of the jib side load cell Single load machine Torque wrench for 215 Nm Short 24 mm socket Dual load machine Torque wrench for 370 Nm Short 30 mm socket N B CHECK THE SCREWS ...

Page 327: ... PRO HT28 RTJ PRO SW HT80 RT O HT85 RTJ O HT85 RTJ PRO HT43 RTJ PRO HT132 RTJ PRO 2 Concerned area 3 Warning Only an authorised and qualified technician is permitted to work on the machines HAULOTTE The use of this form implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in ...

Page 328: ...ctions beware of power lines Put the machine in stowed position boom and arm fully retracted and lowered Appropriate workwear Gloves Safety shoes DO NOT OPERATE tag Standard tool kit Torque wrench Torque multiplier Place barriers around the perimeter of the work area 1 person Switch off the ignition and remove the ignition key Place a do not operate tag at the start stop switch location to inform ...

Page 329: ...0016 Check the torque of the rotatory cylinder central nut is at 800 Nm 590lbf ft N B USE A SPANNER AND A TORQUE SPANNER FOR TIGHTENING Visually inspect the 8 screws on the rotary cylinder N B DO NOT TIGHTEN USING A TORQUE WRENCH AS THE SCREWS ARE TIGHTENED WITH THREADLOCKER ...

Page 330: ...330 4001055180 E 06 21 USA GB Platform Rotary cylinder tightness check MP0016 Notes ...

Page 331: ...RTJ PRO SW HT80 RT O HT85 RTJ O HT85 RTJ PRO HT43 RTJ PRO HT132 RTJ PRO 2 Concerned area 3 Warning Only an authorised and qualified technician is permitted to work on the machines HAULOTTE The use of this form implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user m...

Page 332: ...and arm fully retracted and lowered Switch off the ignition and remove the ignition key Place a do not operate tag at the start stop switch location to inform personnel that the equipment is being worked on Appropriate workwear Gloves Safety shoes DO NOT OPERATE tag Personal protective equipment Standard tool kit Place barriers around the perimeter of the work area 1 person Check the platform floo...

Page 333: ...333 4001055180 E 06 21 USA GB Platform Checking the platform MP0017 Check the platform access rail or gate ...

Page 334: ...334 4001055180 E 06 21 USA GB Platform Checking the platform MP0017 Notes ...

Page 335: ... implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the perm...

Page 336: ... surface clear of obstructions beware of power lines Put the machine into the following configuration No load in the platform Boom raised as far as possible Telescope retracted Jib lifted as far as possible Boom aligned Fix the magnetic comparator between the chassis and turntable 100mm from the bearing aligned with the boom ...

Page 337: ...337 4001055180 E 06 21 USA GB Turntable Slew ring clearance check MP0018 Using the magnetic comparator read the clearance J1 between the chassis and the turntable ...

Page 338: ...ar as possible Boom aligned Using the magnetic comparator read the clearance J2 between the chassis and the turntable The clearance between J1 and J2 must be less than 2 mm If the clearance is greater than this check that the tightness of the slew ring Refer to MP0019 Serrage au couple de la couronne d orientation After checking the tightness if the value remains greater than 2 mm replace the slew...

Page 339: ... 21 USA GB Turntable Slew ring clearance check MP0018 Put the machine into the following configuration No load in the platform Boom raised as far as possible Telescope retracted Jib lifted as far as possible Turret at 90 ...

Page 340: ...340 4001055180 E 06 21 USA GB Turntable Slew ring clearance check MP0018 Using the magnetic comparator read the clearance J3 between the chassis and the turntable ...

Page 341: ...ar as possible Turret at 90 Using the magnetic comparator read the clearance J4 between the chassis and the turntable The clearance between J3 and J4 must be less than 2 mm If the clearance is greater than this check that the tightness of the slew ring Refer to MP0019 Serrage au couple de la couronne d orientation After checking the tightness if the value remains greater than 2 mm replace the slew...

Page 342: ...342 4001055180 E 06 21 USA GB Turntable Slew ring clearance check MP0018 Notes ...

Page 343: ... trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to ...

Page 344: ...tester DO NOT OPERATE tag Handling equipment Standard tool kit Hose clamps Torque wrench Place barriers around the perimeter of the work area 1 person Switch off the ignition and remove the ignition key Place a do not operate tag at the start stop switch location to inform personnel that the equipment is being worked on Tightening the chassis Slew ring Check the tightening torque on the 18 screws ...

Page 345: ...he slew ring MP0019 Tightening the turntable Slew ring Check the tightening torque on the 18 screws 215 N m 159 ft lbf Lift the boom to access the screws For the non accessible screws under the support and under the hoses check the tightening using a flat spanner ...

Page 346: ...346 4001055180 E 06 21 USA GB Turntable Torque tightening of the slew ring MP0019 Notes ...

Page 347: ...use of this form implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must h...

Page 348: ...s beware of power lines Put the machine in stowed position boom and arm fully retracted and lowered Switch off the ignition and remove the ignition key Place a do not operate tag at the start stop switch location to inform personnel that the equipment is being worked on Open the cover on the control box side Place a container under the diesel fuel tank ...

Page 349: ...esel tank MP0020 Once drained screw the drain plug back on At 15 N m Fill the tank back up with fuel 6 Additional operations Clean the work area Unscrew the drain plug from the diesel fuel tank Allow the fuel to completely drain Then rinse with clean diesel ...

Page 350: ...350 4001055180 E 06 21 USA GB Turntable Emptying the diesel tank MP0020 Notes ...

Page 351: ...t have all the permits authorizations required to work fire permit etc and comply with the specific safety instructions at the intervention site Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE are described in this sheet Beware of the risk of burns the hydraulic system operates at high temperatures The pressure in the hydraulic system i...

Page 352: ...ti freeze Antifreeze volume in 50 Solidification point 37 Boiling point 108 C 5 Procedure Position the machine on a flat and firm surface clear of obstructions beware of power lines Put the machine in stowed position boom and arm fully retracted and lowered Restrict access to the area restricted access sign Appropriate workwear Gloves Safety shoes DO NOT OPERATE tag Personal protective equipment S...

Page 353: ...he plug from the radiator 1 in order to fully drain the coolant liquid N B GENTLY UNSCREW THE RADIATOR PLUG TO RELEASE THE PRESSURE Position the collection tray Open the drain valve 2 N B IT IS ADVISABLE TO PLACE A PIPE BETWEEN THE DRAIN VALVE AND THE COLLECTION TRAY Remove the expansion bottle and empty it Once all of the coolant liquid is drained close the drain valve again ...

Page 354: ...e radiator cap 1 and into the expansion tank up to the maximum mark 3 Start the engine and leave it to turn over for a few minutes Stop the engine and leave the coolant to reach room temperature Check the coolant liquid level in the radiator and expansion tank 3 N B WHEN MIXING ANTI FREEZE AND WATER ENSURE THAT THE PROPORTION OF ANTI FREEZE IS 50 ...

Page 355: ...n this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire ...

Page 356: ...atches chains etc when working on the batteries ONLY use insulated tools when working on or near batteries or electrical connections Do not produce sparks or flames or smoke near the battery Do not stop the engine suddenly stop it after about 5 minutes of unloaded idling Work only after letting the engine and radiator cool off completely more than 30 minutes after it has been stopped Do not remove...

Page 357: ...0 Solidification point 37 Boiling point 108 C 6 Procedure Position the machine on a flat and firm surface clear of obstructions beware of power lines Put the machine in stowed position boom and arm fully retracted and lowered Restrict access to the area restricted access sign Stop the engine and leave the coolant to reach room temperature Pivot the engine compartment Remove the plug from the radia...

Page 358: ...the expansion bottle and empty it Once all of the coolant liquid is drained close the drain valve again Fill with liquid through the radiator cap 1 and into the expansion tank up to the maximum mark 3 Start the engine and leave it to turn over for a few minutes Stop the engine and leave the coolant to reach room temperature Check the coolant liquid level in the radiator and expansion tank 3 N B WH...

Page 359: ...d technician is permitted to work on the machines HAULOTTE The use of this form implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to wor...

Page 360: ...nd arm fully retracted and lowered Mark out the work area barriers cones marking tape Restrict access to the area restricted access sign DO NOT OPERATE tag Personal protective equipment Standard tool kit Place barriers around the perimeter of the work area 1 person Open the engine cover Remove screw 1 that is blocking the engine compartment Pull then swivel the engine compartment Lock the engine c...

Page 361: ...ble Starter battery inspection MP0023 Carry out the operations in the reverse order Check battery terminals for oxidation Check terminals for oxidation Check battery terminals for cleanliness and tightness Check that the battery is secure ...

Page 362: ...362 4001055180 E 06 21 USA GB Turntable Starter battery inspection MP0023 Notes ...

Page 363: ...he machines HAULOTTE The use of this form implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load...

Page 364: ...r or oxidation of the rings Check the absence of deformations cracks or breakage of the rings Criteria of replacement Replace as soon as the anomaly indicated above appears Check the absence of radial gap 0 5 mm 19690 µ in on the pins Check the absence of shaving in periphery of the pins Criteria of replacement Replace as soon as the anomaly indicated above appears ...

Page 365: ...d Only an authorised and qualified technician is permitted to work on the machines HAULOTTE The use of this form implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly t...

Page 366: ...d firm surface clear of obstructions beware of power lines Put the machine in stowed position boom and arm fully retracted and lowered Do not start the engine and disconnect the battery Check the degree of wear on the fan belt Check the subsidence of the belt in the pulley groove A Proper B Wear Replace it them if necessary ...

Page 367: ...ork on the machines HAULOTTE The use of this form implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and man...

Page 368: ... area 1 person Check whether the water and dirt contained in the fuel has been decanted into the water separator If there are no impurities in the water no action to be taken If there are impurities or water in the bottom of the container Set the handle of the separator to OFF 1 Loosen and remove the container 2 using a filter wrench Clean with diesel Clean the filtering part with diesel Replace t...

Page 369: ...pe of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire permit et...

Page 370: ...boom and arm fully retracted and lowered Packaging Part number HAULOTTE Aerosol 0 4L 2820304330 Can 5L 2820304340 On each of the steering wheels Place the grease pump on each of the two greasers located between the steering pivot and the chassis There is enough grease when you can see grease running from the axle Place the grease pump on the greaser on the steering rod There is enough grease when ...

Page 371: ... is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire permit etc and comply with the specific safety instructions at the intervention...

Page 372: ...e Position the machine on a flat and firm surface clear of obstructions beware of power lines Put the machine in stowed position boom and arm fully retracted and lowered Fully extend the boom Clean the greased surfaces Apply the Teflon grease to the boom using a spray or brush ...

Page 373: ...is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire permit etc and comply with t...

Page 374: ...hine on a flat and firm surface clear of obstructions beware of power lines Put the machine in stowed position boom and arm fully retracted and lowered Place the grease pump on each of the two greasers at the ends of the jib cylinder There is enough grease when you can see grease running from the axle ...

Page 375: ... the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire permit etc and comply with the specific safety instructions at the ...

Page 376: ... sign Turn on the engine Check the clogging indicator 1 If the LED is green the filter does not need to be changed If the LED turns red Remove the drain valve let the particles escape then refit it 4 Pull the pin 2 and swivel the cap to remove it Remove the main element 3 Blow the inside of the main element 3 with clean and dry compressed air Pressure of compressed air must be under 205 kPa 2 1 kg...

Page 377: ...e machines HAULOTTE The use of this form implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load ...

Page 378: ...e cooling system filler cap to release the pressure Check that the cooling liquid sits between the maximum 1 and minimum 2 levels of the expansion vessel If the cooling liquid level is too low find out why this is the case Case 1 Evaporation has lowered the cooling liquid level top up with clean fresh water only Case 2 A leak has lowered the cooling liquid level top up with a cooling liquid with t...

Page 379: ...at the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire permit etc and comply with the specific saf...

Page 380: ...ere is not sufficient access 3 Loosen the alternator using the screw 2 Remove the fan belt 1 Replace the belt with a new one Refit the alternator Check the belt deflection to tighten it correctly Press halfway between the fan drive pulley and the alternator pulley with a force of 98N 10 kg to measure the deflection 1 The value measured must be between 7 mm and 9 mm If the value is within this rang...

Page 381: ...e range Only an authorised and qualified technician is permitted to work on the machines HAULOTTE The use of this form implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particul...

Page 382: ...onal protective equipment Standard tool kit DO NOT OPERATE tag Oil collection pan Place barriers around the perimeter of the work area 1 person Packaging Part number HAULOTTE Can 5L 4000530600 20L bucket 2420801360 Barrel 209L 2820305720 Start the engine and leave it to turn over for a few minutes Shut off the engine before draining the engine oil Place a container under the engine Remove the drai...

Page 383: ...83 4001055180 E 06 21 USA GB Turntable Drain the engine oil MP0036 Open the cap 2 and fill the engine with new oil until it reaches the upper mark of the gauge 3 Do not touch the hot parts of the engine ...

Page 384: ...384 4001055180 E 06 21 USA GB Turntable Drain the engine oil MP0036 Notes ...

Page 385: ... important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire permit etc and comply with the...

Page 386: ...owed position boom and arm fully retracted and lowered Personal protective equipment Standard tool kit DO NOT OPERATE tag Oil collection pan Place barriers around the perimeter of the work area 1 person Packaging Part number HAULOTTE Can 5L 4000530600 20L bucket 2420801360 Barrel 209L 2820305720 Start the engine and leave it to turn over for a few minutes Shut off the engine before draining the en...

Page 387: ...e MP0036 Place a container under the engine Remove the drain plug 3 under the engine and leave the oil to drain out completely Refit and tighten the drain out 3 N B REPLACE THE JOINT S Fill the engine with oil up to the dipstick level Do not touch the hot parts of the engine ...

Page 388: ...388 4001055180 E 06 21 USA GB Turntable Drain the engine oil Kohler engine MP0036 Notes ...

Page 389: ...d to work on the machines HAULOTTE The use of this form implies that its user has been trained on this type of equipment It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity a...

Page 390: ...d firm surface clear of obstructions beware of power lines Put the machine in stowed position boom and arm fully retracted and lowered Packaging Part number HAULOTTE Aerosol 0 4L 2820304330 Can 5L 2820304340 Place the grease pump on the greasers located under the basket rotation cylinder pin There is enough grease when you can see grease running from the axle ...

Page 391: ...It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire permit etc and comply wit...

Page 392: ...Barrel 209L 2420801380 You have a means of lifting the machine Lift the machine with the jack to raise the wheel off the ground Place wedges under the chassis and lower the jack slowly Disconnect the gear system Loosen the 2 screws from the central plate and turn it over to disengage the reduction gear 1 Manually turn the wheel to place the drain plug to the bottom of the vertical axis 2 and the o...

Page 393: ...ou do not have the means to lift the machine Turn the wheel slowly to place a drain plug to the bottom of the vertical axis 2 and the other horizontal 1 Position the oil collection tray under the plug 2 Open the caps 1 2 Allow the liquid to drain completely To make the flow easier the oil should still be hot Rotate the wheel moving it slowly to place a filler cap at the top of the vertical axis 1 ...

Page 394: ...394 4001055180 E 06 21 USA GB Turntable Draining the wheel reducer MP0043 Notes ...

Page 395: ...It is important that the person working on the machine is familiar with all of the safety information contained in the user manual Generally speaking the user must comply with regulatory obligations in force particularly those relating specifically to working alone co activity and manual load handling The user must have all the permits authorizations required to work fire permit etc and comply wit...

Page 396: ...Part number HAULOTTE Aerosol 0 4L 2820304330 Can 5L 2820304340 Packaging Part number HAULOTTE Extreme pressure lithium grease 2820304320 Place the grease pump on each of the 3 greasers located on the worm screw system Lead free grease Place the grease pump on each of the 2 greasers located inside the slew ring Lead free grease Lift the arm in order to access the 2 greasers Grease the slew ring usi...

Page 397: ...m contact HAULOTTE Services 1 2 DESCRIPTION The FAILURES function describes the requirements relative to failures monitoring information recording information reading 1 3 REQUIREMENTS N B VAR ACTIVEFAILURE 1 IF ONE OR MORE OF THE FOLLOWING FAILURES ARE IN ACTIVE STATE Requirements Definition FAIL_xx_001 An ACTIVE failure A signals that the failure is stive active FAIL_xx_002 A DETECTED failure D s...

Page 398: ...t Tier IV KM160 FAIL CFG Engine TierIII Check relay Check connection to ground Check connection to U106 ECU Failures N Dec Description Relays F03 06 Horn Relay KA9 D Digital output s failure Horn relay KA9 FAIL Check relay Check connection to ground Check connection to U106 ECU F03 08 Start Relay KA4 D Digital output s failure Starter relay KA4 FAIL Check relay Check connection to ground Check con...

Page 399: ... 3A 07 Failures are acknowledged if Movement set point corresponding to the failing electro valve is neutral AND movement control corresponding to the failing electro valve is neutral AND electrovalve failure state corresponds to the no failure flag generally state OK or for safety electrovalve state OC F04 01 Steering YV901 YV150L YV150R D 1 Proportional output s failure Steering movement YV902 F...

Page 400: ...vement speed YV530 FAIL 2 Digital output s failure Outwards telescope movement YV530O FAIL 4 Digital output s failure Inwards telescope movement YV530OI FAIL 8 Digital output s failure Safety telescope extend movement YV801 FAIL Normal state of YV801 output when boom control is neutral is open circuit Normal state of YV801 output when boom control is neutral is OK When state is different from thes...

Page 401: ...ol is neutral is open circuit Normal state of GND1 output when boom control is neutral is OK When state is different from these defined states GND1 output is seen as failing The failure is then acknowledged when state is Open circuit with neutral set point and neutral control F04 20 Drive Speed YV110 D Digital output s failure YV110 valve YV110 FAIL F04 21 Differential locking YV100 D Digital outp...

Page 402: ...failure Out of range 0 2 4 8 V SM900Y 0 20V SM900Y 4 80V 2 Boom joystick failure Analogue signal and out of neutral incoherence SM900N 1 2 45V SM900Y 2 55V 2 45V SM900X 2 55V Or SM900N 0 SM900Y 2 00V SM900Y 3 00V SM900X 2 00V SM900X 3 00V F05 05 Turntable Joystick SM900X D 1 Turret rotation joystick failure Out of range 0 2 4 8 V SM900X 0 20V SM900X 4 80V 2 Turret rotation joystick failure Analogu...

Page 403: ...ECU analogue inputs F06 04 Incoh Gauges SP800 SP801 D SP800 measured weight and SP801 measured weight are more than 50kg far and gauges are not out of range and gauges are calibrated VAR GaugesIncoherent 1 Check SP800 and SP801 connections to ground to U104 ECU analog inputs Redo calibration F06 05 Low Power Gauges supply D Low power for strain gauges detected lower than 8 5V while engine is not s...

Page 404: ...Incoherence between boom position sensors Falling edge on boom high detector out of the allowed zone boom limit not detected SQ521 SQ523 OFF 4 Incoherence between boom position sensors Raising edge on boom high detector out of the allowed zone boom limit not detected SQ521 SQ523 OFF 8 Incoherence between boom position sensors Raising edge on limit switch angle sensor during boom descent movement a...

Page 405: ...n sensors Raising edge on telescope extended sensor out of the allowed zone telescope limit not detected SQ533 SQ532 OFF 8 Incoherence between telescope position sensors Raising edge on telescope limit detector not in allowed zone telescope extended sensor during telescope extend movement SQ533 OFF SQ532 16 Incoherence between telescope position sensors Falling edge on telescope limit detector not...

Page 406: ...ut of normal operative range SP160F 200mV SP160F 4800mV 2 Drive hydraulic circuit pressure sensor is out of normal operative range SP160B 200mV SP160F 4800mV F07 39 Fuel level sensor SL300 D 1 Open circuit on fuel level sensor 2 Short circuit to ground on fuel level sensor F07 40 Twilight sensor SN900 D 1 Open circuit on SN900 twilight sensor Short circuit to ground on SN900 twilight sensor Failur...

Page 407: ...utput is measured out the range 4 5 5 5 V and 5 V output not failing Check fuses Check the harness check short circuit to power supply to ground supply open circuit 4 Failure on regulated 5V output of U104 ECU basket slave node supplying the joysticks Detected failure on 5V output Switch OFF ON the machine check the failure has gone probable cause internal failure of the ECU F08 07 Circuit Selecto...

Page 408: ... dual fuel engine warning lamp received from engine ECU Check DIAGNOSTIC FUNCTIONS Engine Failure SPN F09 08 Red stop lamp Check Engine D Available with Tier III variable RPM electronic engine and Tier III dual fuel engine stop lamp code received from engine ECU Check DIAGNOSTIC FUNCTIONS Engine Failure SPN F09 10 Engine D Engine alternator D Alternator failure D is OFF while thermal engine is run...

Page 409: ... calibration adjusting pressure F10 05 Drive 3 A Engine speed detected above 2550RPM when drive function is active with unfolded machine micro speed F10 17 Activ Lighting System A 1 Active short circuit on output controlling HL910 HL911 lights turret ECU HL910_HL911 FAIL 2 Active short circuit on output controlling EL906 lights turret ECU EL906 FAIL 3 Active short circuit on output controlling EL9...

Page 410: ...supplies line Check address connections for each B2 ECU CN106 18 CN106 19 CN106 20 F12 02 E2P Read Write Error Change U106 ECU D 1 Internal failure of SPU access to EEPROM read or write Restart machine 2 Internal failure of SPU EEPROM stack full Restart machine F12 04 E2P Param Reset Change SETTINGS D 1 Detected change in software machine identification all the settings forced to default values ra...

Page 411: ...d Internal Function ID 210 Invalid Internal Cut out ID 211 Invalid Machine Maintenance ID 212 Invalid Event Counter ID 213 Invalid Internal Version ID F12 17 Internal error of diagnostic system set A 4 Invalid Maintenances Log ID 6 Invalid Events log ID 7 Invalid Events log ID 193 Invalid Failure ID 196 Invalid Machine Parameter Speed or Ramp ID 197 Invalid Machine Calibration ID 198 Invalid Optio...

Page 412: ...n failure at machine s power on for lower console switches Boom switch is active 8 Neutral detection failure at machine s power on for lower console switches Boom telescope switch is active 16 Neutral detection failure at machine s power on for lower console switches Jib switch is active 32 Neutral detection failure at machine s power on for lower console switches Platform level switch is active 6...

Page 413: ...console switches Engine start stop switch is active 64 Neutral detection failure at machine s power on for upper console switches Emergency pump switch is active 128 Neutral detection failure at machine s power on for upper console switches Horn switch is active 256 Neutral detection failure at machine s power on for upper console switches Enable switch is active 512 Neutral detection failure at m...

Page 414: ...414 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram 2 Legend 2 1 PCB TURRET Location on the machine ...

Page 415: ...415 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram Location ...

Page 416: ...416 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram Notes ...

Page 417: ...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 4W 5 K A D9 1N4004 J1 1 J1 11 J1 8 X_FU5 4450715 K A D10 3mm verte R6 1K 1 4W 5 J1 3 K A D11 1N4004 FU1 10A FU2 20A FU3 15A FU4 25A FU5 30A FU10 25A 85 86 KA3 A 12V 87 87A 30 KA3 B 12V 85 86 KA4 A 12V 87 87A 30 KA4 B 12V 85 86 KA5...

Page 418: ...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 E16 116 1 2 E17 117 1 2 E18 118 X_FU17 4450715 K A D24 3mm verte R18 1K 1 4W 5 K A D25 1N4004 1 2 E19 119 1 2 E20 120 1 2 E21 121 1 2 E22 122 X_FU7 4450715 K A D26 3mm verte R19 1K 1 4W 5 K A D27 1N4004 X_FU6 4450715 K A D28 3mm verte R20 1K 1 4W 5 J3 9 J3 10 J3 11 J3 12 J...

Page 419: ... used FU11 Fuse 7 5A Permanent FU12 Not used FU13 Fuse 20A Power FU14 Not used FU15 Not used FU16 Not used FU17 Fuse 5A Selection ground upper controls FU18 Not used FU19 Not used FU23 Option overspeed relay 40A FU34 Supply strain gauges 1A FU122 Emergency pump 250A FU161 Preheating 100A FU180 Cooler option 30A KA1 Not used KA2 Relay 1RT 12V Generator 192 KA3 Engine shutdown Acceleration 170 KA5 N...

Page 420: ...420 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram 3 Electric diagram Engine part Tier III 4000498810K folio 02 ...

Page 421: ...421 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram Turntable part PCB 4000498810K folio 03 ...

Page 422: ...422 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram Turntable part SPU 1 3 CLUSTER 4000498810K folio 04 ...

Page 423: ...423 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram Turntable part SPU 2 3 4000498810K folio 05 ...

Page 424: ...424 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram Turntable part SPU 3 3 4000498810K folio 06 ...

Page 425: ...425 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram Cage part Node B 1 2 4000498810K folio 07 ...

Page 426: ...426 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram Cage part Node B 2 2 4000498810K folio 08 ...

Page 427: ...427 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram Engine part Tier IV Stage 5 Kubota 4000498810K folio 09 ...

Page 428: ...428 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram Engine part Petrol gas 4000498810K folio 10 ...

Page 429: ...429 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram Option 4000498810K folio 11 ...

Page 430: ...430 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram STAGE V Kohler Engine 4000498810K folio 12 ...

Page 431: ...431 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram System architecture 4000498810K folio 14 ...

Page 432: ... E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram 4 Hydraulic diagram Lower part Sheet 1 HA26 RTJ O HA26 RTJ O SW HA80 RTJ O 4000560890H 1 2 ...

Page 433: ...4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram Lower part Sheet 1 HA26 RTJ O HA26 RTJ O SW HA80 RTJ O 4000560890H 2 2 ...

Page 434: ...1055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram Lower part Sheet 1 HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ PRO 4000571610H 1 2 ...

Page 435: ...1055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram Lower part Sheet 1 HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ PRO 4000571610H 2 2 ...

Page 436: ...001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram Upper section Sheet 2 HA26 RTJ O HA26 RTJ O SW HA80 RTJ O 4000560890H 1 2 ...

Page 437: ...001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram Upper section Sheet 2 HA26 RTJ O HA26 RTJ O SW HA80 RTJ O 4000560890H 2 2 ...

Page 438: ...055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram Upper section Sheet 2 HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ PRO 4000571610H 1 2 ...

Page 439: ...055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram Upper section Sheet 2 HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ PRO 4000571610H 2 2 ...

Page 440: ...440 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO E Trouble shooting and diagram Notes ...

Page 441: ...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 INTERVENTION THE QUALIFIED TECHNICIAN MUST INDICATE THE HAULOTTE SERVICES INTERVENTION NUMBER Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 442: ... 4001055180 E 06 21 USA GB HA26 RTJ O HA26 RTJ O SW HA26 RTJ PRO HA26 RTJ PRO SW HA80 RTJ O HA80 RTJ PRO F Records Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

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