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Haulotte HT23RTJ O, Maintenance Book

Get your hands on the maintenance book for the Haulotte HT23RTJ O manual lift. Download the user manual for free from manualshive.com and ensure proper care and operation of your machinery. Stay informed and keep your equipment running smoothly with this essential resource.

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162

 4001055250 

E 10.21 

USA / GB

Chassis and turret

Dismantling / Reassembling wheels reducer

MS0026

8 -  Cover disassembly

1.

Remove O-Ring ( 17 ) from groove in Cover ( 6A ). 

2.

Remove Thrust Washer ( 2 ) from Cover ( 6A ) pockets, if necessary. 

3.

Unscrew  2 Hex Head Bolts ( 6C ) and remove Disengage Cap ( 6B ) from Cover ( 6A ). 

4.

Pull Disengage Rod ( 6D ) out from Cover ( 6A ). 

5.

Use appropriate tool to remove O-ring ( 6E ) from internal groove in Cover ( 6A ). 

6.

Remove  2 O-Ring Pipe Plugs ( 6F ) from Cover ( 6A ). 

N.B.-:-P

AINT

 

BOOTH

 O-R

ING

( 6K ) 

CAN

 

BE

 

DISCARDED

 

IF

 

DESIRED

. 

N.B.-:-F

OR

 

REASSEMBLING

 

UNIT

, 

PLEASE

 

REFER

 

TO

 

THE

 

EXPLODED

 

VIEWS

 

IN

 

THE

 

DISASSEMBLY

 

SECTIONS

. 

Summary of Contents for HT23RTJ O

Page 1: ...intenance Book HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO 4001055250 E 10 21 USA GB MAINTENANCE BOOK HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PR...

Page 2: ...2 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO...

Page 3: ...on 13 1 2 UncontrolledmovementHazard 14 1 3 ElectricShockHazards 15 1 4 Explosion FireHazards 16 2 Maintenance and repair training 17 2 1 Owner sresponsability 17 2 2 Technician sresponsability 17 2 3...

Page 4: ...ndactuators 56 2 2 Theworkingzonecontrol 59 2 2 1 Machine positions 59 3 Power source Engine specifications 61 3 1 Generalsafetyandspecificinterventionsonmotor 61 3 2 GeneralSpecifications 61 3 3 Cons...

Page 5: ...9 Fuel tank Filling up 105 MS0010 Slew ring inspection 107 MS0012 Condition of the cables inspection Criteria of replacement 113 MS0013 Check and replacing the pads 117 MS0014 Procedure of dismantling...

Page 6: ...m cylinder 341 MS0238 Links to engine manufacturer manuals Fuel powered machines 353 MS0240 Remove Re install output compensation cylinder 355 MP0001 Wheel tightening procedure 363 MP0002 Wheel reduce...

Page 7: ...e 437 MP0023 Starter battery inspection 441 MP0024 Checking the bushings and pins 445 MP0025 Checking the condition of belts 447 MP0026 Checking and cleaning the fuel filter 449 MP0027 Steering system...

Page 8: ...agram 1 Trouble shooting 487 1 1 Recommendations 487 1 2 Description 487 1 3 Requirements 487 1 4 Listoffailurespercategory 488 2 Legend 508 2 1 PCBTurret 508 3 Electric diagram 512 4 Hydraulic diagra...

Page 9: ...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...

Page 10: ...te 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 Prohib...

Page 11: ...ERATING 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 situatio...

Page 12: ...12 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO A Preface Foreword Notes...

Page 13: ...nterventions 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 t...

Page 14: ...re 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 el...

Page 15: ...t 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 li...

Page 16: ...D 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 at...

Page 17: ...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...

Page 18: ...ng 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 m...

Page 19: ...19 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization Familiarization Notes...

Page 20: ...HT23RTJ PRO SW HT67RTJ PRO C Familiarization 1 Primary machine components 1 1 LAYOUT HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C9 C7 C35 C29 C17 C72 C12 C33 C113 C14 C14...

Page 21: ...ntrol box C35 Document holder C8 Input jib leveling cylinder C42 Foot Switch C9 Upper boom C72 Output jib compensation cylinder C10 Slew ring C113 Beacon light C11 Turntable assembly C140 Propane bott...

Page 22: ...22 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization 1 2 GROUND CONTROL BOX 1 2 1 Layout General view...

Page 23: ...Boom in 4 SA520U SA520D Boom raising switch By pressing on Boom raising By pressing on Boom lowering 6 SA905EN Enable Switch Back up unit selector By pressing on Validation of controls when engine st...

Page 24: ...screen Or Hydraulic oil temperature icon is active on on board screen Or Engine pressure icon is active on on board screen Or Engine stop icon is active on on board screen Or Overload machine status...

Page 25: ...ressing on Regeneration start up 22 Control box activation key switch De energizes control system SA901PF Platform control box energized SA901TU Ground control box energized 23 Activ Screen 2 1 For ma...

Page 26: ...vigation 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...

Page 27: ...J PRO HT23RTJ PRO SW HT67RTJ 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...

Page 28: ...orization 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 o...

Page 29: ...iption 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 wi...

Page 30: ...ine 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 energ...

Page 31: ...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...

Page 32: ...emperature 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...

Page 33: ...ription 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 ha...

Page 34: ...ription 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 fil...

Page 35: ...67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization Warning icons zone DPF regeneration in progress high temperature in the exhaust system HEST If fitted Light stays on during regeneratio...

Page 36: ...on 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 indicat...

Page 37: ...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...

Page 38: ...ne 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 slow...

Page 39: ...tor 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...

Page 40: ...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 te...

Page 41: ...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 i...

Page 42: ...zation 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...

Page 43: ...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 situ...

Page 44: ...d 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...

Page 45: ...chine 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 F...

Page 46: ...ill 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...

Page 47: ...47 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization Notes...

Page 48: ...48 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization 1 3 PLATFORM CONTROL BOX 1 3 1 Layout General view...

Page 49: ...h Toggle and hold Back up unit activated Release Back up unit deactivated 43 SA907 Horn button Horn 44 SA304 Fuel selector1 LPG Propane Gas supply G Petrol Liquid propane gas or diesel supply 45 SA110...

Page 50: ...the right Counter clockwise CCW rotation Move to the left Clockwise CW rotation Boom lift joystick Move forward Boom up Move backwards Lower boom 233 SM901 Boom telescope joystick Move forward Retrac...

Page 51: ...04 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 L...

Page 52: ...iarization LED 112 HL800 Tilt LED 113 HL804 Radius limit LED 114 HL802 Overload LED 115 HL250 Turret at 180 LED 116 HL720 Platform leveling LED 1172 HL806 Load selection 450 kg 1000 lbs 1 If machine e...

Page 53: ...d by the selector 82 Permanently lighted Limit of work zone with movement cut off or machine in 230 kg 500 lbs low load zone and load not validated Europe Australia 230 kg load selected Permanently li...

Page 54: ...e 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 faul...

Page 55: ...55 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization Notes...

Page 56: ...56 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization 2 List of actuators and sensors 2 1 SENSORS AND ACTUATORS Sensors and actuators...

Page 57: ...speed pressure SP300 Detector Tier III Engine oil pressure SP800 Sensor Strain gauges SP801 Sensor Strain gauges SQ300 Detector Fuel level SQ521 Proximity sensor for dual load option Boom stowed SQ52...

Page 58: ...530 Valve Boom s telescope movements YV620U Valve Jib raise YV620D Valve Jib descent YV720U Valve Platform level up YV720D Valve Platform level down YV750L Valve Platform rotation left YV750R Valve Pl...

Page 59: ...several specific machine position and corresponding sensors management requirements Transport position folded zone P1 0 450 Kg 1000 lbs position zone P1 P2 P3 P4 with dual load capability P5 can be r...

Page 60: ...SQ591 ON SQ533 ON SQ521 OFF Position changes Sensor state dual load configuration P1 P2 SQ590 ON OFF SQ591 ON OFF SQ521 OFF SQ533 ON P2 P3 SQ590 OFF SQ591 OFF SQ533 ON SQ521 OFF ON SQ523 ON P3 P4 SQ5...

Page 61: ...cation 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 fun...

Page 62: ...l 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 242...

Page 63: ...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...

Page 64: ...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 N B REFER TO CONSOMMABLES Engin...

Page 65: ...MA 24568 The recommended viscosity grades depending on the environmental conditions are as follows N B REFER TO CONSOMMABLES Viscosity grade HV46 HV46 Biodegradable HV32 HV68 Ambient temperature Betwe...

Page 66: ...the machine 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...

Page 67: ...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 1...

Page 68: ...ne completely to remove any trace of harsh environmental pollution Dry all the machine Apply directly a solvent based oil leaving an oily film after evaporation of the solvent Re apply the product eve...

Page 69: ...speed movement from the ground control box HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO Micro drive speed 0 5 km h 0 31 m h Low drive speed 1 7 km h 1 05 m h High drive spe...

Page 70: ...70 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO C Familiarization Notes...

Page 71: ...re 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 a...

Page 72: ...ented 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 Levellin...

Page 73: ...ering wheel pivot Grease the steering system MP0027 Grease the bushings and pins Drain the wheel reducer MP0043 Slew ring Grease the turntable slew ring MP0044 KUBOTA WG2503 engine Drain the engine oi...

Page 74: ...he 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 f...

Page 75: ...0H 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...

Page 76: ...2000H OK NOK 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 KU...

Page 77: ...ery 10 years Every 3000H Page or associated procedure Every 3000H OK NOK Corrected Comments KUBOTA D1803 CRTE5 V2403CR T4B V2403CR T5B engine Clean the diesel particulate filter Every 6000H Page or as...

Page 78: ...alified 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 Cor...

Page 79: ...ken 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 Ch...

Page 80: ...thorough inspection of the machine to ensure that it is 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...

Page 81: ...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 worki...

Page 82: ...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 a...

Page 83: ...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 o...

Page 84: ...teristics 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...

Page 85: ...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 work...

Page 86: ...k the absence of shaving in periphery of the pins Check the absence of heavy abrasion wear or oxidation of the bushes and bearing Check the absence of deformations cracks or breakage of the bushes and...

Page 87: ...o which the bearing is to be installed Insert the bearing using a bearing drift preferably out of mild steel The bearing the bearing drift and the bearing housing must be correctly aligned during the...

Page 88: ...espect the following stages Clean boring and or the pins to remove all the foreign bodies Slightly lubricate boring and or pins Lubricate the ring of the bearing slightly To fit bearing in a boring ta...

Page 89: ...igations 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...

Page 90: ...ty 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 proc...

Page 91: ...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 dama...

Page 92: ...92 4001055250 E 10 21 USA GB General data Cylinder inspection MS0003 Check 1 Pipe weld connection 2 Rod weld connection 3 Ring 4 Rod 5 Piston...

Page 93: ...iliar 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 a...

Page 94: ...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 ma...

Page 95: ...llow dry Dull dry Lubed Dry Dull dry Lubed Dry Dull dry Lubed Dry ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm 8 5 9 8 5 4 7...

Page 96: ...7 61 62 7 20 41 55 5 55 74 5 60 81 3 80 108 4 68 92 1 1 2 13 57 77 3 75 101 6 80 108 4 110 149 93 126 20 64 86 7 85 115 90 122 120 162 105 142 9 16 12 80 108 4 110 149 120 162 150 203 130 176 18 90 12...

Page 97: ...e 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 Tor...

Page 98: ...2 125 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...

Page 99: ...Slew ring 105 Nm ECU ECU Carrier 6 Nm Engine Hydraulic pump Engine housing 125 Nm Exhaust 95 Nm Engine Carrier side pump 125 Nm Engine Carrier side fan 85 Nm Engine Silentbloc support 125 Nm Screw fa...

Page 100: ...100 4001055250 E 10 21 USA GB General data Torque Values MS0005 Notes...

Page 101: ...ted only to people having the necessary technical training Respect in addition to the instructions appearing in the present instructions the legal tendencies generally applicable for safety accident p...

Page 102: ...he rubber side wall Blister or pronounced lump on the external and lateral wall Damaged wheel stud Damage or wear on the side wall to the extent that the reinforcing wire is visible Consistent wear of...

Page 103: ...e new wheel Lower the machine to the ground Tighten the wheel nuts to the recommended torque Refer to maintenance and repair manuals Component Standard wheel Reference number 385 65 22 5 Filled foam o...

Page 104: ...104 4001055250 E 10 21 USA GB Chassis and turret Tires Tyres and pressures Wheel replacement MS0006 Notes...

Page 105: ...s 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...

Page 106: ...ng hole with the pump spout before starting pouring to avoid any risk of static electricity causing sparks Make sure you are standing up wind to avoid being splashed by the fuel 1 Loosen and remove th...

Page 107: ...nd safety devices must be positioned back completely and operational 3 Lubrication The maintenance of the slew ring is essential for the safety of the machine and to guarantee its service life Whateve...

Page 108: ...USA GB Chassis and turret Slew ring inspection MS0010 3 1 FOR HA16RTJ HA16RTJ O HA16RTJ PRO HA46RTJ O HA46RTJ PRO ONLY 2 by tie rod B Slew ring 2 nipples on the raceways inside the slew ring 3 nipple...

Page 109: ...crown gear teeth Greasing the sidewall telescope Machine type Metric torque value Imperial torque value HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO 215 Nm 158 6 lb ft HA16...

Page 110: ...abnormal wear in the raceway Contact HAULOTTE Services Replace slew ring in the following cases Abnormal noise during the turret rotation Movement jolts during the rotation of the turret Gear teeth m...

Page 111: ...s maximum position Don t extend the telescopic boom Telescope the boom to its maximum angle completely extend the telescope Jib in horizontal position if fitted In its new configuration note the clear...

Page 112: ...112 4001055250 E 10 21 USA GB Chassis and turret Slew ring inspection MS0010 Notes...

Page 113: ...completion of work all the covers and safety devices must be positioned back completely and operational 3 Control wire rope system To guarantee a full safety use of the machine Haulotte recommends res...

Page 114: ...stenings of the cables on the visible points of fixing To extend the structure to obtain an access to the wire rope To extend the boom at least 3 m 9 ft 10 in for the telescopic machines Using a flash...

Page 115: ...ds or more are broken along the length of the cable Replacement is compulsory when 1 strand is broken near the ends No deformed folds or frayed strands must be observed No signs of corrosion must be o...

Page 116: ...rocedure 5 Criteria of replacement Machine operates in a particularly hostile environment Abnormal noises are produced during movement of structure Machine has been in storage for more than 6 months M...

Page 117: ...ructions 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 c...

Page 118: ...the top intermediate tube and telescope upper and side pads without removing the boom Check the telescoping friction pad wear indicators Change the pad if the indicator is not visible Machine stowed b...

Page 119: ...he rear hood by removing the 4 flanged nuts Take off the connecting rod 1 by removing 2 pins 2 and 3 Remove the 2 hoses Take out the 2 screws Remove the telescoping block When removing the block make...

Page 120: ...the lifting beam Use a caliper to measure the compression of the spring washers and adjust to the same compression when reassembling the unit Remove the 2 screws holding the lifting beam Unscrew the...

Page 121: ...ck and replacing the pads MS0013 Undo the 6 screws 2 First pull then remove the cross member 3 N B THE FINAL CONFIGURATION IS AS FOLLOWS N B THE FINAL CONFIGURATION IS AS FOLLOWS The final configurati...

Page 122: ...replacing the pads MS0013 Remove the top right side pad 2 Remove top left pad 3 Remove the top left side pad 4 N B THE FINAL CONFIGURATION IS AS FOLLOWS The final configuration is as follows Remove th...

Page 123: ...BE PUT IN POSITION BLIND MAKING REASSEMBLY EASIER Pull the cable support plate 1 back to the rear of the telescope cylinder N B GENTLY PULL THE CABLE SUPPORT PLATE 1 ON THE BACK SO THAT YOU CAN RECOV...

Page 124: ...124 4001055250 E 10 21 USA GB Upper boom Check and replacing the pads MS0013 Notes...

Page 125: ...s completely disconnected and must be entrusted only to people having the necessary technical training Respect in addition to the instructions appearing in the present instructions the legal tendencie...

Page 126: ...d by removing the 4 flanged nuts Take off the connecting rod 1 by removing 2 pins 2 and 3 Dismantling the lifting beam assembly extension cables Undo the nuts to remove the cables from the lifting bea...

Page 127: ...MS0014 Remove the 2 screws holding the lifting beam Unscrew the position switch cable Remove the lifting beam cables Remove the lifting beam Take off the rear hood by removing the 1 flanged nuts Remo...

Page 128: ...NOT DISCONNECT THE LIFTING BEAM FROM THE RETRACTION CABLES Removing the cylinder guide cross member Remove the 2 pads 1 from the top of the cross member Undo the 6 screws 2 First pull then remove the...

Page 129: ...stop covers which must be replaced with new covers when reassembling Undo the screws holding the retraction cables The final configuration is as follows Remove the telescope extension cable support pl...

Page 130: ...the cylinder via the connecting rod fastening Lift the cylinder to free it from the recesses then pull it Pull the cylinder up to the opening at the back of the turntable N B BEFORE COMPLETELY FREEING...

Page 131: ...the wooden prop to prop up the cylinder so that you can position the cylinder retaining strap on the other side of the opening Pull the cylinder out to approximately 2500 mm 8 ft 2 in from the pulley...

Page 132: ...001055250 E 10 21 USA GB Upper boom Procedure of dismantling reassembling telescope cylinder MS0014 N B REASSEMBLE IN THE REVERSE ORDER OF DISMANTLING Remove the cylinder Replace the cables and the pu...

Page 133: ...y to people having the necessary technical training Respect in addition to the instructions appearing in the present instructions the legal tendencies generally applicable for safety accident preventi...

Page 134: ...cope Lower the boom Extend the telescoping boom between 100 and 200 mm Loosen the lock nut on the basket side 4 On the basket side Tight the chain for having a length of 20 mm 0 1 mm between the last...

Page 135: ...ring 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 comp...

Page 136: ...een 52 and 50 Outside this range adjust the sensor Sensor adjustment Set the mechanical cam sensor to change state at this position passage from ON to OFF having previously set the position of the sen...

Page 137: ...pe 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 goo...

Page 138: ...achine 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 tan...

Page 139: ...erimeter of the work area Exclusively use tools and auxiliary average adapted Always wear necessary safety clothing Description In Bar In PSI General 240 5 3481 72 Pressure LS 30 5 435 72 Emergency pu...

Page 140: ...055250 E 10 21 USA GB Hydraulics Pressure adjustment MS0022 3 Adjustment of pressures 3 1 PORT PLUG FOR PRESSURES CONTROL All pressures could be ckecked by connecting a pressure gauge on port M as sho...

Page 141: ...of 20b 2b 290 psi The pump is preset at a main pressure of 240b 5b 3480 psi Settings Marking Function Value 1 Load Sensing 20b 2 Pmaxi 240b Designation Pressure Adjustment port Maxi pressure setting 2...

Page 142: ...142 4001055250 E 10 21 USA GB Hydraulics Pressure adjustment MS0022 Notes...

Page 143: ...ulic ways MS0023 Hydraulics Hydraulic ways 1 You will need Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area Exclusively use tools and auxiliary average...

Page 144: ...144 4001055250 E 10 21 USA GB Hydraulics Hydraulic ways MS0023 2 Turntable HT23RTJ O HT23RTJ O SW HT67RTJ O Folio 1 2...

Page 145: ...145 4001055250 E 10 21 USA GB Hydraulics Hydraulic ways MS0023 Folio 2 2...

Page 146: ...146 4001055250 E 10 21 USA GB Hydraulics Hydraulic ways MS0023 3 Turntable HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO Folio 1 2...

Page 147: ...147 4001055250 E 10 21 USA GB Hydraulics Hydraulic ways MS0023 Folio 2 2...

Page 148: ...148 4001055250 E 10 21 USA GB Hydraulics Hydraulic ways MS0023 4 Chassis HT23RTJ O HT23RTJ O SW HT67RTJ O Folio 1 2...

Page 149: ...149 4001055250 E 10 21 USA GB Hydraulics Hydraulic ways MS0023 Folio 2 2...

Page 150: ...150 4001055250 E 10 21 USA GB Hydraulics Hydraulic ways MS0023 5 Chassis HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO Folio 1 2...

Page 151: ...151 4001055250 E 10 21 USA GB Hydraulics Hydraulic ways MS0023 Folio 2 2...

Page 152: ...HOLDER 158P344440 GUIDE CHAINE et FLEXIBLES CABLE and CHAIN HOLDER 158P344440 GUIDE CHAINE et FLEXIBLES CABLE and CHAIN HOLDER 158P344440 C 2 1 2 3 4 L gende des d trompages couleur par collier plast...

Page 153: ...153 4001055250 E 10 21 USA GB Hydraulics Hydraulic ways MS0023 7 Jib...

Page 154: ...154 4001055250 E 10 21 USA GB Hydraulics Hydraulic ways MS0023 Notes...

Page 155: ...orted hydraulic fittings System for recovery oils Drive reducer Oil Hydraulic hand pump 0 250 psi Pressure gauge 0 300 psi Special tools refer plans at end of document Place barriers around the perime...

Page 156: ...specified torque The following steps describe how to tighten and torque bolts or socket head cap screws in a bolt circle Tighten but do not torque bolt A until snug Go to the opposite side of the bol...

Page 157: ...Remove the Cover 6 from the unit The unit can be carefully pressurized with air to pop the cover out of the unit 5 Remove the First Stage Sun Gear 10 if applicable N B ON UNITS WITH RATIOS GREATER TTH...

Page 158: ...Spindle 1A 14 Using a 1 8 diameter punch drive the Roll Pin 4G out of the Planet Shaft 3E N B THE ROLL PINS 4G SHOULD NOT BE REUSED WHEN REASSEMBLING THE UNIT 15 Slide the Planet Gear 4 out of the Spi...

Page 159: ...rier 3A 2 Using a soft face hammer tap the Planet Shaft 3E out of the Carrier 3A 3 Using a 1 8 diameter punch drive the Roll Pin 4G out of the Planet Shaft 3E N B THE ROLL PINS 4G SHOULD NOT BE REUSED...

Page 160: ...1G THE HOLES WILL NEED TO BE CLEANED UP PRIOR TO REMOVING THE SET SCREWS 3 While supporting the unit on Hub 1D flange press Spindle 1A out of Hub 1D 4 Remove outbound position Bearing Cone 1C from Be...

Page 161: ...rize the brake port in the Spindle 1A until the Piston 8A comes out of piston bore of Spindle 1A then pull the Piston 8A out of the Spindle 1A by hand 4 Remove Backup Ring 8H and O ring 8F from groove...

Page 162: ...ockets if necessary 3 Unscrew 2 Hex Head Bolts 6C and remove Disengage Cap 6B from Cover 6A 4 Pull Disengage Rod 6D out from Cover 6A 5 Use appropriate tool to remove O ring 6E from internal groove in...

Page 163: ...E WHILE INSTALLING THE PLANET GEARS 5 Place 1 Thrust Washer 3B onto the end of Planet Shaft 3E Make sure the flat faces towards the inside of the carrier and make sure the button fits in the pocket on...

Page 164: ...ll counterbore 2 Place Stator 8K into the Spindle 1A callop cuts 3 Place Rotor 8J on top of Stator 8K 4 Repeat steps 2 3 until there are a total of 9 Stators 8K and 8 Rotors 8J installed 5 Place Sprin...

Page 165: ...8422 into hub using 1C pressing tool 3 Place inbound Bearing Cone of part 1C into Bearing Cup of part 1C 4 Grease Seal 1B lip and press seal inlo Hub 1D using appropriate tool until seal is flush with...

Page 166: ...indle FIRST 14 Now insert Planet Shaft 4E through the first set of Thrust Washers 4B Planet gear then the sec ond set of Washers 4B Use an alignment punch or similar tool to align roll pin holes on Sp...

Page 167: ...ng 6G into groove in Ring Gear 1E 15 Roll leak Brake testing Torque Hub units should always be roll and leak tested before disassembly and after assembly to make sure that the unit s gears bearings an...

Page 168: ...1 Using appropriate fittings to connect hydraulic line from hand pump to the brake port 2 Check to see that brake is set by trying to rotate Input Shaft 9 This can be accomplished by install ing an a...

Page 169: ...re torque 1 Screw 1 bolt down into the hub and rotate the hub so that the bolt is at twelve o clock 2 Position the torque wrench so that it is perpendicular to the vertical centerline as shown 3 The c...

Page 170: ...21 USA GB Chassis and turret Dismantling Reassembling wheels reducer MS0026 18 Assembly drawing 1A Spindle 1B Lip seal 1C Tapered bearing assembly 1D Housing 1E Ring gear 1F Bearing nut 1G Socket hea...

Page 171: ...e bearing 4D Thrust spacer 4E Planet shaft 4F Planet gear 4G Roll pin 4H Thrust washer 5 Retaining ring internal 6A Cover 6B Disengage cap 6C Bolt 6D Dowel pin 6E O ring 6F Pipe plug 6G Retaining ring...

Page 172: ...172 4001055250 E 10 21 USA GB Chassis and turret Dismantling Reassembling wheels reducer MS0026 17 O ring 18 O ring 19 Bolt 20 Retaining ring 21 Bolt 22 Pressure plug...

Page 173: ...ke 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 a...

Page 174: ...E 10 21 USA GB Upper boom Procedure of dismantling reassembling cage MS0027 1 Control box cover 2 ASB2 3 Upper control box 4 Link part Platform 5 Vibrating cords 6 Platform support 7 Flooring 8 Platfo...

Page 175: ...and remove the 4 bolts nuts A B C D that fasten the control box to the ASB2 Unscrew and remove the 4 bolts nuts E F G H that fasten the ASB2 to the guard rails The Control box support and tool tray ca...

Page 176: ...GED N B THE FLOOR PANELS CAN BE REMOVED WITHOUT REMOUNTING ANY OTHER PIECES 2 2 1 Removal D visser la p dale pied du panneau de plancher et la sortir du panier non illustr Remove the bolts nuts ref A...

Page 177: ...B THE CAGE CAN BE REMOVED WITHOUT DEMOUNTING ANY OTHER PIECES BUT THE FLOORING AND ENTRY GATE WILL STAY FIXED TO THE CAGE IT IS RECOMMENDED TO FIRST REMOVE THE FLOOR PANELS TO ALLOW EASIER ACCESS 2 3...

Page 178: ...rm with its harness Remove the upper control box 2 1 Remove re install the control box support and tool tray Remove the 2 clevis pins and the 2 axles at the platform side Remove all harness from the p...

Page 179: ...mbly Disconnect the load cell harness Remove the 2 clevis pins and the 2 axles at the platform link side Slide the load cell out and remove 2 4 2 Replace Assembly of the load cell 2 on the link part G...

Page 180: ...cage MS0027 Put the platform support 6 on the load cell 2 Grease the pins 7 and 8 Put the pins 7 and 8 through the parts 6 and 2 Fix it with the clevis pins 3 Complementary operations Calibrate the o...

Page 181: ...used and check the particular conditions of environment in which the material can be found see safety information specific to the operation site Position the machine on a flat ground stabilized and in...

Page 182: ...182 4001055250 E 10 21 USA GB Upper boom Procedure of dismantling reassembling hydraulic rotary actuators MS0028 Exploded View...

Page 183: ...1 202 T Seal 1 204 O Ring 1 205 Cup seal 2 207 Back up ring 1 304 1 Exclusion seal 2 302 Wear guide 2 304 Thrust washer 2 400 Stop tube 1 401 Counterbalance valve 1 403 Motion control valve 1 Inspect...

Page 184: ...AMINATION TO MACHINED PARTS MAKE SURE WORK AREA IS CLEAN 1 Remove port plugs 106 1 106 2 and drain oil In spect oil for signs of contamination i e water metal shav ings 2 Remove the cap screws 113 tha...

Page 185: ...MS0028 6 Using a metal bar or similar tool unthread the end cap 4 by turning it counterclockwise 7 Remove the end cap 4 and carefully set aside for later inspection 8 Remove the stop tube 400 if the a...

Page 186: ...otation and accurate end positions it is essential that the actuator be correctly timed when it is re assembled The punched timing marks can be used but it is easier to highlight punched marks with a...

Page 187: ...the housing 1 ring gear the piston 3 and the shaft 2 13 To remove the piston 3 use a rubber mallet and a plas tic mandrel so the piston and housing bore are not dam aged 14 At the point when the pist...

Page 188: ...mbling hydraulic rotary actuators MS0028 16 Remove the wear guide 302 from the end cap 4 and shaft 2 17 Remove the main pressure seal 205 18 Remove the thrust washer 304 from the end cap 4 and shaft 2...

Page 189: ...250 E 10 21 USA GB Upper boom Procedure of dismantling reassembling hydraulic rotary actuators MS0028 20 Remove the outside diameter piston seal 202 from the piston 21 Remove the inside diameter pisto...

Page 190: ...T BE CLOSELY FOLLOWED TO INSURE PROPER OPERATION OF THE ACTUATOR 1 Clean all parts in a solvent tank and dry with compressed air prior to inspecting 2 Carefully inspect all critical areas for any surf...

Page 191: ...ntents under pressure Use caution when removing port plugs and fittings N B TO AVOID CONTAMINATION TO MACHINED PARTS MAKE SURE WORK AREA IS CLEAN 1 Gather all the components and tools into one locatio...

Page 192: ...ar motion 5 Install the wear guide 302 on the end cap 4 and shaft 2 6 Install the O ring 204 and back up ring 207 into the inner seal groove on the end cap 4 7 Install the inner T seal 200 into the ap...

Page 193: ...until the outer piston seal 202 contacts the inside housing bore 12 Looking into the housing bore from the shaft flange end rotate the piston 3 until the marks you put on the piston and the housing 1...

Page 194: ...shaft 2 with the gear teeth on the inside of the piston 3 When the marks align gently tap the flange end of the shaft with a rubber mallet until the gear teeth en gage 16 Install two bolts in the thre...

Page 195: ...19 Thread the end cap 4 onto the shaft 2 Make sure the wear guide remains in place on the end cap as it is threaded into the housing 1 20 Tighten the end cap 4 using a metal bar In most cases the ori...

Page 196: ...ith cap screws 113 or set screws Remove the grease port screws from the shaft flange and end cap See exploded view N B IF A HYDRAULIC TEST BENCH IS NOT AVAILABLE THE ACTUATOR CAN BE ROTATED BY HAND OP...

Page 197: ...the test procedure outlined above for the other port If there is an internal leak disassemble inspect and repair 8 Installation and Bleeding N B TO AVOID CONTAMINATION TO MACHINED PARTS MAKE SURE WORK...

Page 198: ...bes in a clean 5 gal container to collect the purged oil The oil can be returned to the reservoir after this proce dure is completed 2 With an operator in the platform open both bleed nipples a 1 4 tu...

Page 199: ...laced if a steady flow of fluid is seen coming from the valve ports 4 Piston and or shaft seal leak Remove the plug and the housing s valve ports Operate the actuator through the housing ports Conduct...

Page 200: ...200 4001055250 E 10 21 USA GB Upper boom Procedure of dismantling reassembling hydraulic rotary actuators MS0028 Notes...

Page 201: ...assis and turret KUBOTA diesel engine To ensure the maintenance of the engines please go to our website https www e technical information com to consult the supplier manuals whose reference for this e...

Page 202: ...5250 E 10 21 USA GB Chassis and turret KUBOTA diesel engine MS0029 1 Localization identification plate If you need to contact HAULOTTE Services for spare parts or other think up the serial number of y...

Page 203: ...203 4001055250 E 10 21 USA GB Chassis and turret KUBOTA diesel engine MS0029 2 Names of parts D1503 M E3 D1703 M E3 D183 M E3 V2003 M E3 V2403 M E3 V2004 M T E3 D1803 M DI E3 V2403 M DI E3...

Page 204: ...204 4001055250 E 10 21 USA GB Chassis and turret KUBOTA diesel engine MS0029 V3600 E3 V600 T E3 V3300 E3BG V3600 T E3BG...

Page 205: ...ifold 2 Speed control lever 3 Engine stop lever 4 Shut off solenoid 5 Fuel feed pump 6 Cooling fan 7 Engine hook 8 Oil filter cartridge 9 Fuel filter 10 Oil filler plug 11 Exhaust manifold 12 Alternat...

Page 206: ...206 4001055250 E 10 21 USA GB Chassis and turret KUBOTA diesel engine MS0029 D1803 CR E5 D1803 CR TE5 D1803 CR TIE5 V2403 CR E5 V2403 CR TE5 V2403 CR TIE5...

Page 207: ...Feed pump 7 Oil filler plug 8 Oil pan 9 Fuel line 10 Cooling fan 11 Fan belt 12 Engine hook 13 Oil drain tap 14 Oil drain plug 15 Fan belt 16 Intake manifold 17 Oil separator 18 Alternator 19 Exhaust...

Page 208: ...rate the machine while under the influence of alcohol or drugs Do not wear loose torn or bulky clothing around the machine It may catch on moving parts or controls leading to the risk of accidents Use...

Page 209: ...stopped immediatly since engine oil circulation is cut quickly leading to serious trouble 3 3 1 How to tell when the engine starts running backwards 1 Lubricating oil pressure drops sharply Oil pressu...

Page 210: ...be loose Tighten the bolts by the specified torque Do not put any tools on the battery or battery terminals may short out Severe burns or fire could result Detach the battery from the engine before th...

Page 211: ...to No 2 D and use No 1 D S15 diesel fuel as an alternative to No 1 D for ambient temperatures below 10 C 14 F No 1 Dor No 2 D S15 Ultra Low Sulfur Diesel 15 ppm or 0 0015 wt CJ 4 classification oil is...

Page 212: ...Keep the engine away from the fire Be sure to stop the engine while refueling or bleeding and when cleaning or changing fuel filter or fuel pipes Do not smoke when working around the battery or when...

Page 213: ...ota diesel engines of less than 56 kW 75 hp utilize EPA Tier 4 and Interim Tier 4 standards the use of ultra low sulfur fuel is mandatory for these engines when operated in US EPA regulated areas Ther...

Page 214: ...spill onto a hot exhaust manifold creating a danger of fire For fuel tanks that are lower than the injection pump 1 The fuel system must be pressurized by the fuel system electric fuel pump 2 If an e...

Page 215: ...ng the engine Broken fuel pipes can cause fires Check the fuel pipes every 50 hours of operation If the clamp band is loose apply oil to the screw of the band and tighten the band securely If the fuel...

Page 216: ...ns and tube 4 Check to see if the fan belt is too loose 5 Check to see if radiator water pipe is clogged 5 2 3 Cleaning radiator core outside If dust is between the fin and tube wash it away with runn...

Page 217: ...er to SAE J1034 standard more specifically also to SAE J814c 5 Adding the LLC Add only water if the coolant level reduces in the cooling system by evaporation If there is a coolant leak add the LLC of...

Page 218: ...lace 5 When the engine is not used for a long period of time run it for about 10 minutes under no load every 2 to 3 months to keep it free from rust If the engine is stored without any running moistur...

Page 219: ...operly To attain proper fuel injection pressure check carefully for loosened fuel line coupling loose cap nut etc Loosen joint bolt stop fuel filter and air vent screws of fuel injection pump to elimi...

Page 220: ...e with a new nozzle Moving parts are overheated due to shortage of lubrication oil or improper lubrication Check amount of engine oil with oil level gauge Check lubricating oil system At every 2 times...

Page 221: ...e specified mixing ratio Radiator net or radiator fin clogged with dust Clean net or fin carefully Inside of radiator or coolant flow route corroded Clean or replace radiator and parts Fan or radiator...

Page 222: ...222 4001055250 E 10 21 USA GB Chassis and turret KUBOTA diesel engine MS0029 Notes...

Page 223: ...ill need 2 Technical specifications Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area Exclusively use tools and auxiliary average adapted Always wear nec...

Page 224: ...ove 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 c...

Page 225: ...250 E 10 21 USA GB Electric Battery ies MS0110 Photo 1 HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO Photo 2 B B HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW H...

Page 226: ...ture 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 Wa...

Page 227: ...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 wi...

Page 228: ...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...

Page 229: ...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 HAU...

Page 230: ...tandard NF EN 166 EN 170 Specific protective measures to be used for the stage concerned Risk of electric arc Face shield and insulating gloves must be worn for the steps with these images Standard to...

Page 231: ...the machine on a flat ground stabilized and in a released environment Mark out the work area Cut the contact to remove the key open the battery cut if fitted Place a DO NOT USE label near the start st...

Page 232: ...oad cell 2 on the link part Grease the pins 4 and 5 Put the pins 4 and 5 through the parts 1 and 2 Fix it with the clevis pins Plug the cable 3 on the load cell 2 with contact grease NYE 760 G 2820308...

Page 233: ...become out of correct range or when any of the platform sub assembly components cage support flooring etc are replaced The calibration is according to the following logigram N B THE TARE COULD BE DONE...

Page 234: ...is required The access to the menu is via the following menu MACHINE SETTING CALIBRATION OFFSET 0kg tare Before any calibration procedure make sure to remove from the basket platform all options weig...

Page 235: ...235 4001055250 E 10 21 USA GB Platform Weighing adjustment procedure calibration MS0164 N B CHECK THE LOAD ACCORDING TO V RIFICATIONS IF NOT OK GO TO CALIBRATION WITH A LOAD...

Page 236: ...ARES The access to the menu is via the following menu MACHINE SETTINGS CALIBRATION adjustable weight 75 300kg Access code LEVEL 3 is required Before any calibration procedure make sure to remove from...

Page 237: ...237 4001055250 E 10 21 USA GB Platform Weighing adjustment procedure calibration MS0164 Select the desired value...

Page 238: ...238 4001055250 E 10 21 USA GB Platform Weighing adjustment procedure calibration MS0164 Gain of Load Management System with adjustable weight...

Page 239: ...the nominal load in the basket No overload alarm must be activated Note For dual loads machines check the 2 loads If this test failed replace the load cell 2 Put the test load in the basket Nominal lo...

Page 240: ...240 4001055250 E 10 21 USA GB Platform Weighing adjustment procedure calibration MS0164 Notes...

Page 241: ...t 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 descri...

Page 242: ...00 Personal protective equipment Standard tool kit Oil collection pan Pin diameter 30 mm 1 18 in length 500 mm 20 in Pin diameter 25 mm 1 in length 300 mm 12 in 1 ratcheting straps that support 1000 k...

Page 243: ...the boom stowed and the telescope retracted support the platform on a stable wedge Wedges under the platform of 200 mm 7 87 in Switch off the ignition and remove the ignition key Place a do not opera...

Page 244: ...tall jib cylinder MS0224 Remove the 2 end play take up screws Withdraw the pin from the cylinder but leave the pin used for withdrawal in place Only remove it after removing the pin on the rod side Re...

Page 245: ...cylinder MS0224 6 Re installation If you are installing a new cylinder note the traceability number Hold the cylinder and remove the extraction pin on the back side Slide the cylinder to free it of th...

Page 246: ...erse order of dismantling Position the cylinder so that the greasers are accessible N B CLEAN OFF ANY RESIDUAL OIL OR GREASE Remember to refit the pin stop screws Tightening at a torque of 22 Nm N B C...

Page 247: ...moving connections Top up the hydraulic oil if necessary machine in stowed position Perform a static test by putting 320 kg 705 lbs on the platform Machine unfolded 15 mn after checking the performanc...

Page 248: ...248 4001055250 E 10 21 USA GB Jib Remove Re install jib cylinder MS0224 Notes...

Page 249: ...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 HAUL...

Page 250: ...ength of 2 m 6 Ft 7 in 1 hoisting strap s for 1000 kg 2205 lbs at a length of 2 m 6 Ft 7 in Wedges to support approximately 370 mm 14 5 in under the chassis with a load capacity of 6 T 13227 lbs Greas...

Page 251: ...ion 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 Make a stable pallet stack about 370 mm 14 5 in t...

Page 252: ...e the wheel and lay it down flat on a pallet with the outer side downwards Loosen the screw and remove the clevis pin Relive the pin connecting the steering tie rod to the wheel steering pivot Mark di...

Page 253: ...wheel pivot and gear motor unit Apply a small amount of tension on the bridge crane Remove the locking pin screws and withdraw the pins connecting the steering pivot to the chassis Remove the wheel p...

Page 254: ...hassis Remove Replace wheel pivot and gear motor MS0225 Sling the assembly by the holes in the wheel steering pivot Position the unit inserting the studs through the rim Unscrew the 2 screws holding t...

Page 255: ...ws 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 Sling the hydra...

Page 256: ...to the new gear motor To make installation easier grease the surfaces of the wheel pivot that will be in contact with the gear motor Remove the hydraulic motor If the reduction gear has been replaced...

Page 257: ...of 57 Nm N B USE A WRENCH WITH AN EXTENSION CORD When reinstalling the wheel pivot grease the pivots Remember to refit the bronze rings Remember to refit the pin stop screws Tighten the screws to the...

Page 258: ...NSCREW THE GEAR UNIT TO FACILITATE WHEEL ASSEMBLY SEE CHAPTER ADDITIONAL OPERATIONS Grease the pins via the greasers Position the conical part of the nut facing the wheel rim The flat part of the nut...

Page 259: ...259 4001055250 E 10 21 USA GB Chassis Remove Replace wheel pivot and gear motor MS0225 Tighten the wheel nuts evenly to the torque of 300 Nm Tighten the screws crosswise...

Page 260: ...operations Check the oil level in the reduction gear when the wheels lift off the ground Unscrew the 2 central plate screws Flip the plate over Screw the 2 screws back on The wheel reducer has been di...

Page 261: ...d drain plugs N B THE LEVEL CAN ONLY BE ESTABLISHED WHEN THE PLUG IS POSITIONED IN THE HORIZONTAL AXIS OF THE REDUCTION GEAR Remove the level plug N B THE OIL SHOULD BE JUST LEVEL WITH THE HOLE If nec...

Page 262: ...262 4001055250 E 10 21 USA GB Chassis Remove Replace wheel pivot and gear motor MS0225 Notes...

Page 263: ...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 describ...

Page 264: ...d and the telescope retracted support the platform on a stable wedge Wedges under the platform of 300 mm 1 ft With handling equipment lift the platform slightly Load cell 4000068580 DO NOT OPERATE tag...

Page 265: ...start stop switch location to inform personnel that the equipment is being worked on Cut the clamp bands Unscrew the screw closing the wiring harness guide 1 Open the hose clamp 2 Remove the technical...

Page 266: ...B Platform Remove Replace load cell MS0226 Disconnect the load cell Loosen the screws and remove the clevis pins N B HOLD THE LOAD CELL WITH ONE HAND TO PREVENT IT FALLING Extract the 2 pins on the ji...

Page 267: ...torque of 44 Nm 1 Facing the jib 2 Facing the platform 3 Load cell positioning arrow Apply contact grease for the connector 7 Additional operations Clean the work area Calibrate the load cell Refer t...

Page 268: ...268 4001055250 E 10 21 USA GB Platform Remove Replace load cell MS0226 Notes...

Page 269: ...ork 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 HAULO...

Page 270: ...Nm Torque wrench for 76 Nm 22 mm pin with extension Medium threadlocker Hose clamps Contact grease 2820308450 Grease Greasing the pads 2326005410 2 hoisting strap s for 2000 kg 4410 lbs at a length of...

Page 271: ...e area restricted access sign Raise the boom to horizontal From the ground control box position the telescopic cylinder so as to have access to the retraction cable screws Pin the 3 blocks using the h...

Page 272: ...E 10 21 USA GB Upper boom Remove replace the telescope cylinder MS0227 Remove the cover 2 Remove the pads 1 on each side of the cover Remove the front pad 1 Unscrew the 4 nuts from the rear cover Rem...

Page 273: ...om Remove replace the telescope cylinder MS0227 Disconnect the plugs The twilight sensor 1 The light 2 Remove the plate Use a sliding caliper and measure the compression of the retraction cables on th...

Page 274: ...re the compression of the extension cables on the counterweight side and record the values Identify the cables on each side of the boom before dismantling Alternate unscrewing the nuts to gradually lo...

Page 275: ...lescope cylinder MS0227 Remove the retraction cable guide pads Remove the nuts and washers from the output cables Remove the nuts and washers from the retraction cables Disconnect the cable from the c...

Page 276: ...elescope cylinder MS0227 Remove the 2 stop wedges 1 Remove the extension cable lifting beam 2 Unscrew the screw from the extension cable bracket Loosen the 2 screws located on each side of the telesco...

Page 277: ...escope cylinder MS0227 Lift the tube and cable carrier chain to free access to the screw located on the other side of the boom Remove the pin stops located on each side of the boom Loosen the screw 1...

Page 278: ...s Plug the openings after disassembly N B PLACE A CONTAINER UNDERNEATH THE CONNECTIONS Refit the pin 2 of the tie rod to sling the cylinder Unscrew the 6 screws from the telescopic cylinder bracket Un...

Page 279: ...ylinder has come out far enough and the guidance portion of the cylinder is still in the foot of the boom position fork lift or another means of handling the movement under the cylinder Extend the cyl...

Page 280: ...twisting when they are connected to the rigid tubes Make sure the hoses and harnesses are set in their correct routes Grease the entrance to the tube and the corners of the telescopic cylinder to faci...

Page 281: ...ke care not to put white grease in the threading of the pads Remove the extension cable plate the right way round Glue the 2 screws of the adjustment stops with medium threadlocker Tightening at a tor...

Page 282: ...le bracket fastening screw must be glued with medium threadlocker and tighted to torque N B TIGHTENING AT A TORQUE OF 45 NM Refit the chocks and glue the screws using medium threadlocker tightening th...

Page 283: ...ightening in order to recenter the position sensor mark 2 The sensor must remain parallel to the edge of the pivot jib Lock it with locknuts Power up the retraction cables The adjustment should be don...

Page 284: ...ing caliper to check that the cable compression values are within the tolerance 0 2 mm as compared to the measurements taken before dismantling Remove the pin that is locking the blocks together From...

Page 285: ...at the removing connections Top up the hydraulic oil if necessary machine in stowed position From the ground and platform control boxes apply weight through all of the machine s movements Perform a s...

Page 286: ...286 4001055250 E 10 21 USA GB Upper boom Remove replace the telescope cylinder MS0227 Notes...

Page 287: ...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 H...

Page 288: ...ted access sign Steering cylinder 4000708900 ORFS plug kit 2505001600 ORFS seal kit 2505000470 DO NOT OPERATE tag Personal protective equipment Standard tool kit Oil collection pan 1 hoisting strap s...

Page 289: ...p switch location to inform personnel that the equipment is being worked on Place the sling around the boom tube vertically in relation to the steering cylinder Pass the ratchet strap through the loop...

Page 290: ...cope cylinder feed hoses Plug the orifices of the steering cylinder Loosen the screw remove the clevis pin and put the pin to one side Uncouple the steering tie rod to the wheel pivot Perform the same...

Page 291: ...hydraulic oil if necessary Use the ratchet strap to gradually lower the cylinder via the bottom Remove the cylinder Loosen the 2 setting screws Apply the measurement made before dismantling for the 2...

Page 292: ...292 4001055250 E 10 21 USA GB Chassis Removal Replacement of the steering cylinder MS0228 Notes...

Page 293: ...e 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 disasse...

Page 294: ...t the work area barriers cones marking tape Restrict access to the area restricted access sign Oscillating axle cylinder 158B165030 ORFS plug kit 2505001600 ORFS seal kit 2505000470 DO NOT OPERATE tag...

Page 295: ...g maintenance operations Steer the machine so the wheels are straight ahead Unscrew the 4 nuts from the rear cover Remove the top cover Switch off the ignition and remove the ignition key Place a do n...

Page 296: ...sconnect and plug the telescope cylinder feed hoses Plug the orifices of the oscillation cylinder N B POSITION AN OIL COLLECTION PAN TO AVOID POLLUTING THE ENVIRONMENT Attach a sling to the cylinder S...

Page 297: ...297 4001055250 E 10 21 USA GB Chassis Removing re installing the oscillating axle actuator MS0229 Remove the rod side clevis pin The bottom one Lift the cylinder out from the top Remove the cylinder...

Page 298: ...n drain and the pressure can drop After the pressure drops remove the block When reinstalling on the new cylinder check that there are seals Install the screws with threadlock Tighten the screws to th...

Page 299: ...o 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 HA...

Page 300: ...25 mm 1 in length 500 mm 20 in 1 hoisting strap s for 2000 kg 4409 lbs at a length of 5240 mm 17 ft 19 in 1 hoisting strap s for 2000 kg 4409 lbs at a length of 5000 mm 16 ft 40 in 1 hoisting strap s...

Page 301: ...k area Mark out the work area barriers cones marking tape Restrict access to the area restricted access sign Retract the telescope arm place the jib in the horizontal position and empty the platform C...

Page 302: ...E 10 21 USA GB Upper boom Remove Replace the boom jib box assembly MS0230 Remove the cover 2 Remove the pads 1 on each side of the cover Remove the front pad 3 Unscrew the 4 nuts from the rear cover R...

Page 303: ...twilight sensor 1 The light 2 Extract the pin from the tie rod on the telescopic cylinder side Loosen the screw 2 remove the clevis pin 1 and put the pin to one side 3 Locate and disconnect the 2 tel...

Page 304: ...MS0230 Remove the electric cable 1 Plug 220 V Disconnect the wiring harnesses 2 CAN BUS CN06 1 CAN BUS CN06 2 CN05A CN05B Disconnect the 4 hoses from the rear of the boom make a note of their positio...

Page 305: ...gs to the boom Apply a small amount of tension on the bridge crane N B 1 HOISTING STRAP S FOR 2000 KG 4409 LBS AT A LENGTH OF 2000 MM 6 FT 56 IN Disconnect the sensors SQ521 1 ILS SQ523 2 Identify and...

Page 306: ...t 2000 kg 4409 lbs at a length of 2 m 6 ft 56 in Wood pallet length 500 mm 1 ft 64 in width 200 mm 7 ft 87 in height 400 mm 15 ft 74 in estimated Loosen the screw 3 and remove the clevis pin 1 Apply a...

Page 307: ...small amount of tension on the bridge crane N B 1 HOISTING STRAP S FOR 2000 KG 4409 LBS AT A LENGTH OF 2000 MM 6 FT 56 IN Open the engine cover Remove screw that is blocking the engine compartment Pul...

Page 308: ...oom A 2400 mm 7 ft 87 in B 350 mm 1 ft 15 in C 4000mm 13 ft 12 in D 1 hoisting strap s for 2000 Kg 441 lbs at a length of 5240 mm 17 ft 19 in E 1 hoisting strap s for 2000 Kg 441 lbs at a length of 50...

Page 309: ...0 E 10 21 USA GB Upper boom Remove Replace the boom jib box assembly MS0230 Boom slinging Position the wood chocks to avoid crushing the hydraulic hoses 2 wooden chocks 500 mm 1ft 64 in long and 60 mm...

Page 310: ...box assembly MS0230 Apply a small amount of tension on the bridge crane Extract the pin from the boom Loosen the screw 3 remove the clevis pin 1 and put the pin to one side 2 Check before lifting the...

Page 311: ...311 4001055250 E 10 21 USA GB Upper boom Remove Replace the boom jib box assembly MS0230 Lift the jib and platform boom set Place the assembly on suitable supports...

Page 312: ...on Perform the operations in the reverse order of dismantling Respect the cable routing CN05A 1 CN05B 1 CAN BUS CN06 1 2 CAN BUS CN06 2 2 220 V electric cable 3 Telescopic cylinder hydraulic hoses 4 S...

Page 313: ...tract the telescope to flush out the hydraulic circuit Raise and lower the boom and check the displacement of the harnesses and hoses From the ground and platform control boxes test all of the machine...

Page 314: ...314 4001055250 E 10 21 USA GB Upper boom Remove Replace the boom jib box assembly MS0230 Notes...

Page 315: ...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 d...

Page 316: ...ndard tool kit Torque wrench for 10 Nm Torque wrench for 45 Nm Torque wrench for 76 Nm Medium threadlocker Upper pads 184P313520 Lower pads 4000000450 Side pads 4000000450 Grease Greasing the pads 232...

Page 317: ...ructions beware of power lines Mark out the work area barriers cones marking tape Restrict access to the area restricted access sign Extend the telescopic cylinder by 30 cm 1 Ft Switch off the ignitio...

Page 318: ...18 4001055250 E 10 21 USA GB Upper boom Remove Replace the rear pads MS0231 Remove the cover 2 Remove the pads 1 on each side of the cover Remove the front pad 3 Unscrew the 4 nuts from the rear cover...

Page 319: ...e rear pads MS0231 Disconnect the plugs The twilight sensor 1 The light 2 Set the panel aside Position a chock on the boom above the telescopic cylinder Strap the wood chock and the telescopic cylinde...

Page 320: ...n from the tie rod on the telescopic cylinder side Loosen the screw 2 remove the clevis pin 1 and put the pin to one side 3 Take care that the tie rod does not fall onto the cable breakage sensor wire...

Page 321: ...er boom Remove Replace the rear pads MS0231 Disconnect the cable from the chain breakage sensor to avoid crushing it during the operation Once the rod is retracted switch off the ignition and remove t...

Page 322: ...cylinder bracket Unscrew and remove the 8 pads 1 Part number 184P313520 2 Part number 4000000450 Before refitting fill the cells of the new pads with grease Take care not to put white grease in the th...

Page 323: ...emember to retighten the screw to a torque of 76 Nm 7 Additional operations Clean off any residual oil or grease Glue the 6 screws of the telescopic cylinder bracket using blue threadlocker Tightening...

Page 324: ...324 4001055250 E 10 21 USA GB Upper boom Remove Replace the rear pads MS0231 Notes...

Page 325: ...ork 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 HAULO...

Page 326: ...of power lines Stow the machine completely Mark out the work area barriers cones marking tape Restrict access to the area restricted access sign Wiring harness BUS CAN XXXXXX DO NOT OPERATE tag Perso...

Page 327: ...CAN CN06 1 CN06 2 Place the plugs inside a plastic bag for protection so as not to contaminate the connectors Cut the clamp bands N B MAKE A MARK ON THE CABLES WHERE THEY ENTER AND EXIT THE CLAMPS TH...

Page 328: ...55250 E 10 21 USA GB Upper boom Remove re install the harness BUS CAN MS0232 Extract the BUS CAN wiring harness from the tube black U shape Cut the clamp collars all along the tube Unscrew the 2 clamp...

Page 329: ...E 10 21 USA GB Upper boom Remove re install the harness BUS CAN MS0232 Unclip the fastening clips from the chain s spacers Turn the key a quarter turn to remove them Remove the BUS CAN harness from t...

Page 330: ...e re install the harness BUS CAN MS0232 Remove the protection cover from the cables in the black tube Extract the BUS CAN wiring harness cutting the clamp collars all the way along Unscrew the 1 clamp...

Page 331: ...ct the BUS CAN plug 1 from the platform control box Open the hose clamp 4 using a flat screwdriver Unscrew the screw closing the wiring harness guide 2 Cut the clamp bands Remove the BUS CAN harness 1...

Page 332: ...ess routing Put contact grease on the 2 connectors and the platform control panel socket Connect the 2 connectors and the control panel socket Attach the cables 7 Additional operations Maneuver the li...

Page 333: ...rson 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...

Page 334: ...ry important It can cause accidents Relieve the pressure before beginning any work and never search for oil leaks using your hands The engine exhaust gases contain harmful combustion products Always s...

Page 335: ...233 5 1 DISASSEMBLY ASSEMBLY 5 1 1 Part number 4000510640 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...

Page 336: ...ght Undo the 2 screws 1 Remove the light Carry out the operations in reverse order to refit Apply contact grease for the connector Open the cover on the control box side Cut the hose clamp Disconnect...

Page 337: ...t the hose clamp Disconnect the connector Unscrew the nut Remove Activ Lighting System Carry out the operations in reverse order to refit Apply contact grease for the connector Open the engine cover C...

Page 338: ...000466490 Go under the boom Disconnect the connector 2 from the light Remove the screw and the nut 1 Remove the light Carry out the operations in reverse order to refit Apply contact grease for the co...

Page 339: ...o refit Apply contact grease for the connector Marking 1 Two Activ Lighting System reference 4000466490 located in the platform control box base Marking 2 Two Activ Lighting System reference 400046649...

Page 340: ...f the platform control box without removing them from the base Open the control box Unscrew the 2 screws from the Activ Lighting System of the cover Disconnect the 4 connectors of the Activ Lighting S...

Page 341: ...rk 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 HAULOT...

Page 342: ...restricted access sign Boom cylinder 166P348520 ORFS plug kit 2505001600 Personal protective equipment Standard tool kit Torque wrench for 24 Nm Torque wrench for 76 Nm Grease Wooden pallets Height we...

Page 343: ...tand Use a ratchet strap to secure it Start the engine and slightly lift the boom Position the stand under the boom Lower the boom to rest it on the stand Put the platform on a pallet stack by using t...

Page 344: ...a small amount of tension on the bridge crane 1 hoisting strap s for 3000 kg 6 615 lbs at a length of 3 m 9 ft 10 in Bridge crane 3000 kg 6 615 lbs minimum Sling the boom lifting cylinder 1 ratcheting...

Page 345: ...345 4001055250 E 10 21 USA GB Boom cylinder Removal Replacement boom cylinder MS0239 Unscrew the screw on the cylinder using a socket wrench Remove the clevis and the screw and set them aside...

Page 346: ...placement boom cylinder MS0239 By manoeuvring the bridge connected to the boom relieve the stress on the pin in order to extract it Extract the pin using a hammer Extract the pin from its housing usin...

Page 347: ...ng on the boom Position the sling at the front of the cylinder passing between the chains and the tube Apply a small amount of tension on the bridge crane Remove the ratchet strap Remove the extractio...

Page 348: ...250 E 10 21 USA GB Boom cylinder Removal Replacement boom cylinder MS0239 Open the engine compartment by unscrewing the screw and nut Open the engine compartment to access the hydraulic hoses Identify...

Page 349: ...t boom cylinder MS0239 Position an oil collection pan to avoid polluting the environment Gradually unscrew the nuts to release the pressure in the cylinder Disconnect the hoses and plug them Unscrew a...

Page 350: ...cylinder MS0239 Position a ratchet strap between the boom and the arm of the cylinder to secure the cylinder Ensure the rigid tube above the boom is not crushed Open the cover on the control box side...

Page 351: ...ghten the screws of the male clevises to a torque of 76 Nm 56 lbs ft Hose tightening Tightening at a torque of 24 Nm 27 Nm 17lbs 7 ft 19 lbs 9 ft Tightening at a torque of 43 Nm 47 Nm 31 lbs 7 ft 36 l...

Page 352: ...ng connections Top up the hydraulic oil if necessary machine in road driving position From the ground and platform control boxes test all of the machine s functions Perform a static test by putting 29...

Page 353: ...l d atelier 9Y111 14251 In english Workshop manual 9Y111 07841 D1803 CRTE5 STAGE V Engine In french Manuel de l op rateur 1J783 8915 7FRA In english Operator s manual 1J783 8915 7ENG In french Manuel...

Page 354: ...1104D Engine In french Manuel de l op rateur Moteur PERKINS 1104D 44T In english Operator s manual PERKINS engine type 1104D 44T 4 DEUTZ TCD 2 9 L4 Engine In french Manuel de l op rateur 03124630_10_...

Page 355: ...ired 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 mach...

Page 356: ...es Gloves Personal protective equipment Hose clamps Grease for pins ORFS plug kit 2505001600 1 hoisting strap s for 3000 kg 6 615 lbs at a length of 3 m 9 ft 10 in 1 ratcheting straps that support 400...

Page 357: ...pin from the cylinder Make a stable pallet stack about 1 3 m 4 27 ft tall Retract the telescoping boom Fold the jib Position a strong stable chock attached with a strap under the platform at a height...

Page 358: ...the ratchet strap Pass the sling between the rigid tubes and the tube Do not climb on the counterweight Use an oil collection pan to avoid polluting the environment Locate disconnect and plug the hos...

Page 359: ...ing using an extraction pin and a hammer Leave the extraction pin in place Remove the sling Refit the sling between the boom and the cylinder Lift the bridge crane slightly to free the ratchet strap L...

Page 360: ...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...

Page 361: ...960 Tighten the hoses with a torque of 24 27 Nm 17 7 19 9 lbs ft From the lower control box operate the platform compensation functions to flush out the hydraulic circuit Check that there is no leak o...

Page 362: ...362 4001055250 E 10 21 USA GB Upper boom Remove Re install output compensation cylinder MS0240 Notes...

Page 363: ...at 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 364: ...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 Standar...

Page 365: ...procedure MP0001 7 Additional operations Clean the work area Wheel Reduction gear Check the tightening torque of the 9 studs 300 N m 221 lbf ft Chassis or wheel steering pivot Reduction gear Check th...

Page 366: ...366 4001055250 E 10 21 USA GB Chassis Wheel tightening procedure MP0001 Notes...

Page 367: ...ant 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 part...

Page 368: ...FTING THE MACHINE Packaging Part number HAULOTTE Can 1L 4000530610 Can 20L 2420801370 Barrel 209L 2420801380 Lift the machine with the jack to raise the wheel off the ground Place wedges under the cha...

Page 369: ...s correct oil should drain from the orifice 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 Rotate...

Page 370: ...370 4001055250 E 10 21 USA GB Chassis Wheel reducer level procedure MP0002 Notes...

Page 371: ...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 intervent...

Page 372: ...r of obstructions 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...

Page 373: ...pping the engine 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 tha...

Page 374: ...374 4001055250 E 10 21 USA GB Turntable Procedure for checking the level of engine oil Kubota V1505 V2403 engine MP0003 Notes...

Page 375: ...uired 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 mac...

Page 376: ...f obstructions 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 pro...

Page 377: ...ng the engine 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 t...

Page 378: ...378 4001055250 E 10 21 USA GB Turntable Procedure for checking the level of engine oil Kubota D1803 engine MP0003 Notes...

Page 379: ...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 disassemb...

Page 380: ...Oil filter wrench Rags Engine oil filter 4000076270 Container 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...

Page 381: ...rmits 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...

Page 382: ...h Rags Engine oil filter 4000353990 Container 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...

Page 383: ...s 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...

Page 384: ...DO NOT OPERATE 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 Loos...

Page 385: ...placement Kubota V1505 V2403 V2607 engine 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 mome...

Page 386: ...386 4001055250 E 10 21 USA GB Turntable Diesel filter replacement Kubota V1505 V2403 V2607 engine MP0005 Notes...

Page 387: ...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 authorizatio...

Page 388: ...is being worked on 5 1 DIESEL FILTER Diesel filter cartridge 4001037800 Diesel prefilter cartridge 4000077770 DO NOT OPERATE tag Standard tool kit Filter wrench Container Oil collection pan Place bar...

Page 389: ...e high pressure pump or injectors due to the presence of impurities in the fuel Refer to Section D 3 Preventive maintenance Dis assembly Replace the old water separator filter 1 using a filter wrench...

Page 390: ...390 4001055250 E 10 21 USA GB Turntable Diesel filter replacement Kubota D1803 CRTE5 engine MP0005 Notes...

Page 391: ...ns 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...

Page 392: ...nition 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 There are two hydraulic filters A and B Place...

Page 393: ...erson 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...

Page 394: ...r lines Put the machine in stowed position boom and arm fully retracted and lowered Do not start the engine and disconnect the battery Swivel the engine casing to access the belt Press halfway between...

Page 395: ...Turntable Procedure for checking engine belt tension Kubota V2403 engine MP0007 6 Additional operations Clean the work area If the value is not within this range Loosen the fastening screw of the alt...

Page 396: ...396 4001055250 E 10 21 USA GB Turntable Procedure for checking engine belt tension Kubota V2403 engine MP0007 Notes...

Page 397: ...rson 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...

Page 398: ...wed position boom and arm fully retracted and lowered Do not start the engine and disconnect the battery Remove the protective cover if there is not sufficient access 1 Swivel the engine casing to acc...

Page 399: ...rntable Procedure for checking engine belt tension Kubota D1803 CRTE5 engine MP0007 6 Additional operations Clean the work area If the value is not within this range Loosen the fastening screw of the...

Page 400: ...400 4001055250 E 10 21 USA GB Turntable Procedure for checking engine belt tension Kubota D1803 CRTE5 engine MP0007 Notes...

Page 401: ...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 co...

Page 402: ...er to the forward position and carefully drive machine up ascension ramp until left front wheels is on top of block Carefully extend the boom just enough to get it out of the transport position With b...

Page 403: ...eat the procedure for the right oscillation cylinder checking to see that the right front or left rear wheel remains elevated in position off of the ground If lockout cylinders do not function properl...

Page 404: ...404 4001055250 E 10 21 USA GB Chassis Front axle locking function check MP0008 Notes...

Page 405: ...aking 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 author...

Page 406: ...ions 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...

Page 407: ...ntable Air filter replacement Kubota V2403 engine MP0010 Remove the main element 2 and secondary element 3 Replace with new cartridges Close the cover using the pins 1 Pivot the motor tank and screw t...

Page 408: ...408 4001055250 E 10 21 USA GB Turntable Air filter replacement Kubota V2403 engine MP0010 Notes...

Page 409: ...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 authorizati...

Page 410: ...d firm surface clear of obstructions 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 no...

Page 411: ...250 E 10 21 USA GB Turntable Air filter replacement Kubota D1803 CRTE5 engine MP0010 Remove the main element 2 and secondary element 3 Replace with new cartridges Close the cover using the pins 1 Do n...

Page 412: ...412 4001055250 E 10 21 USA GB Turntable Air filter replacement Kubota D1803 CRTE5 engine MP0010 Notes...

Page 413: ...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 tho...

Page 414: ...he wear on the 16 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 bo...

Page 415: ...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...

Page 416: ...TE 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 HV...

Page 417: ...larly 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...

Page 418: ...s 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 Reference Part nu...

Page 419: ...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...

Page 420: ...420 4001055250 E 10 21 USA GB Turntable Emptying the hydraulic tank MP0014 Notes...

Page 421: ...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 spe...

Page 422: ...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 pers...

Page 423: ...tion to be used when implementing the range 4 You will need Only an authorised and qualified technician is permitted to work on the machines HAULOTTE The use of this form implies that its user has bee...

Page 424: ...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 torque of t...

Page 425: ...J PRO HT132 RTJ PRO 2 Warning 3 Risk prevention Means of protection to be used when implementing the range Only an authorised and qualified technician is permitted to work on the machines HAULOTTE The...

Page 426: ...cted 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 DO NOT OPERA...

Page 427: ...427 4001055250 E 10 21 USA GB Platform Checking the platform MP0017 Check the platform access rail or gate...

Page 428: ...428 4001055250 E 10 21 USA GB Platform Checking the platform MP0017 Notes...

Page 429: ...ts 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...

Page 430: ...ce J1 between chassis or turret and the slew ring Put the machine into the following configuration On flat ground No load in the platform Horizontal boom and jib platform set Fully extend the telescop...

Page 431: ...t 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 partic...

Page 432: ...tion 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 24 s...

Page 433: ...se 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...

Page 434: ...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 swit...

Page 435: ...sel 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 t...

Page 436: ...436 4001055250 E 10 21 USA GB Turntable Emptying the diesel tank MP0020 Notes...

Page 437: ...SW HT28 RTJ O HT28 RTJ O SW HT28 RTJ PRO HT28 RTJ PRO SW HT80 RT O HT85 RTJ O HT85 RTJ PRO 2 Warning Only an authorised and qualified technician is permitted to work on the machines HAULOTTE The use o...

Page 438: ...closed room ensure the exhaust gases are evacuated to the outside Do not wear any metal jewellery rings watches chains etc when working on the batteries ONLY use insulated tools when working on or ne...

Page 439: ...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 S...

Page 440: ...N TRAY Remove 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...

Page 441: ...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 i...

Page 442: ...d 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 k...

Page 443: ...le 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 tight...

Page 444: ...444 4001055250 E 10 21 USA GB Turntable Starter battery inspection MP0023 Notes...

Page 445: ...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...

Page 446: ...he position of the rings Check the absence of heavy abrasion wear or oxidation of the rings Check the absence of deformations cracks or breakage of the rings Criteria of replacement Replace as soon as...

Page 447: ...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 th...

Page 448: ...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 degre...

Page 449: ...rk 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 saf...

Page 450: ...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...

Page 451: ...s 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 fo...

Page 452: ...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 be...

Page 453: ...tant 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 par...

Page 454: ...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 Packaging Part number HAULOTTE Aerosol 40...

Page 455: ...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...

Page 456: ...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 282030434...

Page 457: ...e 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 specifica...

Page 458: ...or 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 3 and swivel the cap to remove it Remo...

Page 459: ...rson 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...

Page 460: ...ed Remove the drain valve let the particles escape then refit it 4 Pull the pin 3 and swivel the cap to remove it Remove the main element 5 Blow the inside of the main element 5 with clean and dry com...

Page 461: ...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...

Page 462: ...ngine and wait for the parts of the cooling system to cool down Then slowly unscrew the cooling system filler cap to release the pressure Check that the cooling liquid sits between the maximum 1 and m...

Page 463: ...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...

Page 464: ...at and firm surface clear of obstructions beware of power lines Put the machine in stowed position boom and arm fully retracted and lowered Mark out the work area barriers cones marking tape Restrict...

Page 465: ...ota V2403 D1803 CRTE5 engine MP0032 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...

Page 466: ...466 4001055250 E 10 21 USA GB Turntable Replace the belt Kubota V2403 D1803 CRTE5 engine MP0032 Notes...

Page 467: ...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 particu...

Page 468: ...m 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 28203043...

Page 469: ...orm 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...

Page 470: ...another Check that the cables under are equal tension Check that the pulleys are properly aligned with the cables Check that the cable is properly seated in the pulley 1 Check that nothing blocks the...

Page 471: ...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 Ge...

Page 472: ...on a flat and released ground Remove the protective cover SQ380 and SQ381 Insert a pin to lock the tubes 16mm Length 80cm It may be necessary to lift or lower the boom slightly to align the boom shaf...

Page 473: ...e nuts to have a side equal to the distance D 2mm They are adjusted under the boom on the cage side Step 3 Tighten the nuts of the output cables to obtain a dimension equal to the distance D 4mm Tight...

Page 474: ...474 4001055250 E 10 21 USA GB Turntable Check the tension of cables MP0035 Notes...

Page 475: ...ction to be used when implementing the 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 th...

Page 476: ...ine oil Kubota D1803 CRTE5 engine 7 L 1 8 gal US Kubota V1505 engine 6 7 L 1 7 gal US Kubota V2403 engine 9 5 L 2 5 gal US Personal protective equipment Standard tool kit DO NOT OPERATE tag Oil collec...

Page 477: ...obstructions beware of power lines Put the machine in stowed position boom and arm fully retracted and lowered Start the engine and leave it to turn over for a few minutes Shut off the engine before d...

Page 478: ...1 USA GB Turntable Drain the engine oil Kubota D1803 CRTE5 V1505 V2403 engine 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...

Page 479: ...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 t...

Page 480: ...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 2820...

Page 481: ...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 particular...

Page 482: ...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...

Page 483: ...eans 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...

Page 484: ...484 4001055250 E 10 21 USA GB Turntable Draining the wheel reducer MP0043 Notes...

Page 485: ...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 specifical...

Page 486: ...n stowed position boom and arm fully retracted and lowered Packaging Part number HAULOTTE Aerosol 0 4L 2820304330 Can 5L 2820304340 Packaging Part number HAULOTTE Extreme pressure lithium grease 28203...

Page 487: ...ntact 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 ACTIVEFAILUR...

Page 488: ...TierIII Check relay Check connection to ground Check connection to U106 ECU Failures N Dec Bit Description Relays F03 06 Horn Relay KA9 D Digital output s failure Horn relay KA9 FAIL Check relay Check...

Page 489: ...ntrol 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 YV9...

Page 490: ...D 1 b0 Proportional output s failure Telescope movement YV530O FAIL 2 b1 Digital output s failure Telescope extension movement YV530I FAIL 4 b2 Digital output s failure Safety telescope extend moveme...

Page 491: ...ted YV107 FAIL VAR 4WSEnable 2 b1 Digital output s failure Steering mode with 4 wheels steering option activated YV108 FAIL VAR 4WSEnable F04 34 Front Axle Unlocking YV101 YV104 D 1 b0 Digital output...

Page 492: ...oom joystick failure Out of range 0 2 4 8 V SM900Y 0 20V SM900Y 4 80V 2 b1 Boom joystick failure Analogue signal and out of neutral incoherence SM900N 1 2 45V SM900Y 2 55V 2 45V SM900X 2 55V Or SM900N...

Page 493: ...800 Not in 1500 20500 A VAR GaugesOutOfRange 1 Check SP800 connections to ground to U104 ECU analog inputs 2 b1 CFG LoadManagementSytem StrainGauges Gauges out of range load management system activate...

Page 494: ...ilure 5 Check the battery voltage minimum 8V 6 Replace weighing unit D 16 b4 Sensor 1 Loss of signal Internal wiring failure Sensor failure Card failure 7 Replace weighing unit 32 b5 Sensor 2 Loss of...

Page 495: ...dispersion Sensor mechanical slip 17 Check weighing system 18 Perform a new advanced calibration 512 b9 Sensor 2 Signal dispersion Sensor mechanical slip 19 Check weighing system 20 Perform a new adva...

Page 496: ...weighing unit 16 b4 High temperature threshold reached Ambient temperature too high Temperature sensor failure 34 Return to proper temperature conditions 35 Replace weighing unit 32 b5 Temperature in...

Page 497: ...SQ523 OFF SQ590 SQ591 Telescope retracted boom down SQ521 OFF SQ523 OFF SQ590 OFF SQ591 OFF To erase F07 04 failure fold the machine check the position detectors repair if one is broken power off the...

Page 498: ...machine and then power ON If failure is still active then one of the six detectors defining the machine position is not in the expected state D 1 b0 Incoherence between telescope position sensors Fall...

Page 499: ...position sensors Boom magnet detector and telescope magnet detector and folded position SQ590 ON SQ591 OFF SQ523 OFF SQ531 ON 32 b5 Incoherence between position sensors Boom magnet detector and teles...

Page 500: ...ply U106 5V regul D 1 b0 Failure on regulated 5 V 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 Che...

Page 501: ...ual fuel engine stop lamp code received from engine ECU Check DIAGNOSTIC FUNCTIONS Engine Failure SPN F09 10 D Engine alternator D Alternator failure alternator not charging battery only for future TI...

Page 502: ...0RPM CTRL Drive N VAR UnfoldedMachine 1 F10 17 Activ Lighting System A 1 b0 Short circuit detected on turret lights HL910 2 b1 Short circuit detected on counter weight lights EL906 4 b2 Short circuit...

Page 503: ...hes ECU U107 4 b2 CAN network failure detected with onboard screen ECU U101 F12 02 E2P Read Write Error Change U106 ECU D Internal failure of SPU access to EEPROM read or write Restart machine F12 04...

Page 504: ...achine serial number 8 b3 Some speed or ramp parameters are not set Set all speed and ramp parameter 16 b4 Some options are not set Set machine options Buzzer Flashing light Fleet management Activ Shi...

Page 505: ...rnal Function ID 210 Invalid Internal Version ID 211 Invalid Machine Maintenance ID 212 Invalid Event Counter ID 213 Invalid Internal Version ID F12 17 Internal error of diagnostic system set 4 Invali...

Page 506: ...te switch is active 2 b1 Neutral detection failure at machine s power on for lower console switches Boom switch is active 4 b2 Neutral detection failure at machine s power on for lower console switche...

Page 507: ...Neutral detection failure at machine s power on for upper console switches Engine start stop switch is active 32 b5 Neutral detection failure at machine s power on for upper console switches Emergency...

Page 508: ...508 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram 2 Legend 2 1 PCB TURRET Location on the machine...

Page 509: ...509 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Location...

Page 510: ...510 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram...

Page 511: ...al FU6 Not used FU7 Fuse 15A ECU FU8 Fuse 20A Option FU9 Fuse 20A Attachments FU10 Not used FU11 Fuse 7 5A Permanent FU12 Not used FU13 Fuse 20A Power FU14 Not used FU15 Not used FU16 Not used FU17 No...

Page 512: ...512 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram 3 Electric diagram Engine part Tier 3 4000421620J folio 2...

Page 513: ...513 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Turntable part PCB 4000421620JI folio 3...

Page 514: ...514 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Turntable part SPU 1 3 CLUSTER 4000421620J folio 4...

Page 515: ...515 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Turntable part SPU 2 3 4000421620J folio 5...

Page 516: ...516 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Turntable part SPU 3 3 4000421620J folio 6...

Page 517: ...517 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Cage part Noeud B B Node 1 2 4000421620J folio 7...

Page 518: ...518 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Cage part Noeud B B Node 2 2 4000421620J folio 8...

Page 519: ...519 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Engine part Tier 4 STAGE V 4000421620J folio 9...

Page 520: ...520 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Engine part Petrol gas 4000421620J folio 10...

Page 521: ...521 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Options 4000421620J folio 11...

Page 522: ...522 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram System architecture 4000421620J folio 12...

Page 523: ...523 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Notes...

Page 524: ...524 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram 4 Hydraulic diagram Turntable jib boom PVG 4 sides 4000466740F 1 2...

Page 525: ...525 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Turntable jib boom PVG 4 sides 4000466740F 2 2...

Page 526: ...526 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Frame and driving 4000466740F 1 2...

Page 527: ...527 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Frame and driving 4000466740F 2 2...

Page 528: ...528 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Direction chassis 4000466740F 1 2...

Page 529: ...529 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Direction chassis 4000466740F 2 2...

Page 530: ...530 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Hydraulic generator option Oil cooler 4000466740F 1 2...

Page 531: ...531 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Hydraulic generator option Oil cooler 4000466740F 2 2...

Page 532: ...532 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO E Trouble shooting and diagram Notes...

Page 533: ...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...

Page 534: ...34 4001055250 E 10 21 USA GB HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO F Records Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention numbe...

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