Haulotte Group H14TX, Maintenance Book

Page 1: ...Maintenance book H14TX HB40 H16TPX HB44J 4000364740 E12 16 USA GB Maintenance book H14TX HB40 H16TPX HB44J 2420333230 E12 16 USA...

Page 2: ...2 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J...

Page 3: ...cals and markings locations 22 C MAINTENANCE 1 Maintenance Schedule 33 2 Inspection program 35 3 Daily inspection 36 4 Periodic inspection 41 5 Reinforced inspection 47 6 Major inspection 49 7 Mainten...

Page 4: ...7 D DIAGNOSIS ASSISTANCE 1 Recommendations 89 2 Troubleshooting 90 E ELECTRIC CIRCUIT 1 Wiring diagram Main components 93 2 Fuses 95 3 Relays and terminals 96 4 Connectors 97 5 Diagnosis assistance in...

Page 5: ...ghout your machine s service life to ensure the optimum use of your HAULOTTE product When contacting our After Sales Service ensure that you provide the machine model and serial number When ordering a...

Page 6: ...cations and to make improvements or modifications to the machine without modifying this manual Certain options can modify the machine s operating characteristics and its associated safety If your mach...

Page 7: ...t machine operation If regular maintenance is not carried out this may Void the warranty Cause machine malfunction Reduce machine reliability and shorten its service life Jeopardize operator safety To...

Page 8: ...material damage Prohibition relating to work safety and quality Reminder No identified risk but a reminder of the need for common sense good practice or pre action prerequisites Cross reference to ano...

Page 9: ...e For Russia and the Ukraine only The decals must be kept in good condition Additional decals can be ordered from HAULOTTE Services Decals Color Description Red Potentially fatal danger Orange Risk of...

Page 10: ...wner or rental company In the event of operation or use which does not comply with the instructions or recommendations in the maintenance book warranty claims will not be accepted The machine utilisat...

Page 11: ...any other equipment in direct contact with fuel or lubricants Wearing parts pads bearings tires tyres connections etc These parts are by definition subject to deterioration during the period of opera...

Page 12: ...f sold hired or resold equipment Owner or hirer Qualified HAULOTTE Services technician Operator s manual Pre operation inspection Before operation or when the operator changes Operator Operator Operat...

Page 13: ...following situations Do not work in an explosive or flammable atmosphere spark flame etc Do not touch the hot parts of the hydraulic power source engine filters etc Do not bridge the battery terminal...

Page 14: ...14 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J A Safety precautions Notes...

Page 15: ...A B C D E F G H I 15 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J B Recommendations Notes Recommendations...

Page 16: ...16 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J B Recommendations 1 Lubrication diagram Diagram H14TX HB40 H16TPX HB44J 2 2 6 1 2 2 6 6 5 6 6 6 6 4 3...

Page 17: ...nter option 4000010660 2 Gear box oil Can 20 l 5 3 gal US 2420801370 2 Gear box oil Barrel 209 l 55 2 gal US 2420801380 3 Hydraulic oil Standard Barrel 209 l 55 2 gal US 2420801310 3 Hydraulic oil Win...

Page 18: ...4TX HB40 H16TPX HB44J Air filter system 2427003170 H14TX HB40 H16TPX HB44J Diesel pre filter 2324000620 H14TX HB40 H16TPX HB44J Diesel filter 2427003150 H14TX HB40 H16TPX HB44J Engine oil filter 23240...

Page 19: ...gas oil according to EN590 European fuel oil according to BS2869 class 2 American gas oil according to ASTMD975 07b Japanese gas oil according to NATO F54 HATZ 41C DEUTZ 2011 2012 PERKINS 403 804 110...

Page 20: ...depending on the environmental conditions are as follows Biodegradable oils may be used if they comply with the following requirements Ambient operating temperature between 15 C 9 F and 40 C 104 F HEE...

Page 21: ...A B C D E F G H I 21 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J B Recommendations Notes...

Page 22: ...22 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J B Recommendations 3 Decals and markings locations CE and AS standards...

Page 23: ...HAULOTTE logo Red machine 1 307P220360 5 Other Large format HAULOTTE logo Bright machine 1 307P217230 5 Other Large format HAULOTTE logo Dark machine 1 307P224930 5 Other Large format HAULOTTE logo R...

Page 24: ...9890 In swedish CE standard 307P222820 In ukrainian CE standard 4000359910 22 Orange Wound foot Do not place foot 2 4000027090 23 Red Risk of crushing Driving direction 1 4000024690 24 Red Danger of e...

Page 25: ...A B C D E F G H I 25 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J B Recommendations Notes...

Page 26: ...26 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J B Recommendations EAC standard...

Page 27: ...g hazard Risk of crushed hands 1 307P227660 19 Blue Operation instructions 1 For Russia 307P227190 For Ukraine 307P227840 20 Red Operation instructions 1 4000359920 22 Red Wound foot Do not place foot...

Page 28: ...12 V 1 307P227700 225 Other Cold weather oil 1 307P223700 226 Yellow Verification of tilt operation Large size 1 4000011690 229 Red Do not travel down slopes in high speed 1 4000275680 230 Red No admi...

Page 29: ...A B C D E F G H I 29 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J B Recommendations Notes...

Page 30: ...30 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J B Recommendations ANSI and CSA standards...

Page 31: ...Other Large format HAULOTTE logo Dark machine 1 307P224930 5 Other Large format HAULOTTE logo Red machine 1 307P224920 6 Other Identification plate 1 307P218170 9 Other Control of movements GREEN dir...

Page 32: ...27310 33 Blue Anchorage point Elevation 4 4000027330 37 Red Explosion hazard 1 In english 4000025010 In french 4000068130 In spanish 4000086560 38 Orange Hand crushing hazard Heat burns 1 In english 4...

Page 33: ...ears 7 years 10 years 200 h 250 h 300 h 500 h 1000 h Work platform floor guardrails access and extensions Extension desk platform fastening Frame axle steering system stabilizers arms Screw and bolt w...

Page 34: ...r 13 Wear pads and devices of guidance Wear pads Cylinder and hydraulic component pump filters manifold Hydraulic oil Hydraulic oil filter Adjusting the hydraulic pressure Energy storage and motorisat...

Page 35: ...d overseen by the company manager This register or machine log book and the list of competent repair persons must be made available to the Government Work Inspector and company safety committee at any...

Page 36: ...e in maintenance book In case of leaks tighten or replace the damaged part before placing the machine in service In case of structural part deformation cracks broken weld paint chipped replace the par...

Page 37: ...and cleanliness of the control box No deterioration All decals at the control boxes are clean and legible Operation of start stop device Operation of E stop button device Operation of enable switch Op...

Page 38: ...nt chipped No visible damage No screws missing loose parts No foreign body in joints or slides State of tires refer to E 4 2 on limits to wear and damage Wheel reducer is undamaged and operates smooth...

Page 39: ...ing loose parts Presence and good condition of hydraulic hose Presence and good condition of engine components Presence and good condition of the batteries terminations and clamps electrolyte level El...

Page 40: ...ctivation of Activ Shield Bar Emergency stop Enable switch Fault detector displays Overload sensing system Slope sensor Travel speed limitation Serial number Hours of operation HAULOTTE Services contr...

Page 41: ...ections Otherwise or in addition use the detailed program below This inspection is the responsibility of the owner and must be conducted by a qualified technician To ensure user safe use and improve t...

Page 42: ...f the manufacturer s plate Control box Operation of emergency lowering device Work Platform Floor guardrails access and extensions No cracks broken weld paint chipped No deterioration and visible dama...

Page 43: ...slides Condition of tires tyres wear cutting damage Anchor points for handling fixed undamaged and signalized if equipped Wheel reducer Rotation systems orientation turret basket and jib No cracks bro...

Page 44: ...No deformation visible damage broken weld or leaks on hydraulic cylinder No screw or missing loose parts Absence of cylinder leakage Energy storage and motorisation tanks batteries and engine No scre...

Page 45: ...device operate properly if equipped Test and if needed adjustment of load sensing system Test and if needed adjustment of work area limitation device if equipped Presence and good operation of sensors...

Page 46: ...46 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J C Maintenance Serial number Hours of operation HAULOTTE Services contract reference Intervention record number Date Name Model Signature...

Page 47: ...al inspection with small disassembly or movement needed to reach the part Replacement is necessary Proof tests Need HAULOTTE Services authorization For countries where machines are not subject to cont...

Page 48: ...ire rop Cylinder and hydraulic component pump filters manifold No torn or split wire sheaths Shielding is not apparent No evidence of chemical damage or corrosion on all cables Energy storage and moto...

Page 49: ...rced inspections Visual inspection with small disassembly or movement needed to reach the part Replacement is necessary Systematic replacement Proof tests Need HAULOTTE Services authorization For coun...

Page 50: ...50 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J C Maintenance Serial number Hours of operation HAULOTTE Services contract reference Intervention record number Date Name Model Signature...

Page 51: ...chine during maintenance is strictly forbidden Return the machine to operating configuration after maintenance has been completed N B For Russia and the Ukraine only All the fillings drain and lubrica...

Page 52: ...to be replaced must be replaced with bolts of identical specification Type Length Diameter Class Tighten to the torque indicated when reassembling If there are no specific requirements apply the norm...

Page 53: ...he bearing the bearing drift and the bearing housing must be correctly aligned during the assembly process The recommended values for the bearing drift are given on the diagram below Recommended Value...

Page 54: ...nal pollutants and potential damage Clean the bearing with a suitable solvent Replace the bearing in the following cases Presence of abrasions in the bearing housing and or inside the bearing itself P...

Page 55: ...middle of the front wheels and the reference mark on the ground If the distance is between 0 2 m 0 ft8 in and 1 5 m 4 ft11 in the test validates correct operation Otherwise contact HAULOTTE Services t...

Page 56: ...TTE recommendations Section B 1 Lubrication diagram List of ingredients or contact HAULOTTE Services Do not mix two oils with different characteristics If necessary drain and clean the whole system Ch...

Page 57: ...vention Identify and memorise the hose path of the hose to be replaced Use an oil collection pan to avoid polluting the environment After hose removal plug the the hose ends and components the ports f...

Page 58: ...uld be fully extended and in the horizontal position For machines fitted with Boom lifting cylinder or Jib cylinder Lift the concerned equipment boom or jib of approximately half way Extend the telesc...

Page 59: ...lectric 7 3 4 1 Replacing damaged cables Locate the faulty wire s and its their points of connection to ensure continuity of machine operation after the wire is replaced Note the cable path to facilit...

Page 60: ...60 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J C Maintenance Notes...

Page 61: ...1 must be between the upper and lower markers 4 Filling up 5 Additional operation 1 Place the machine in its operating configuration 3 3 2 Placing in operating configuration Standard tool kit Protecti...

Page 62: ...62 4000364740 E12 16 USA GB Control Filling up Oil tank E001 15 min Notes...

Page 63: ...ection pan Place barriers around the perimeter of the work area 1 Turn the wheel to obtain the following configuration 2 Plug 1 is on a horizontal line 3 Plug 2 is on a vertical line 4 Loosen and remo...

Page 64: ...64 4000364740 E12 16 USA GB Control Oil change Wheel reducer E002 15 mn Notes...

Page 65: ...in operating configuration Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area Clogging must be checked when hot When cold oil viscosity may simulate filt...

Page 66: ...66 4000364740 E12 16 USA GB Replacement Hydraulic filter cartridge E003 15 min Notes...

Page 67: ...g configuration 3 3 2 Placing in operating configuration Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area Touch the exterior of the filling hole with th...

Page 68: ...68 4000364740 E12 16 USA GB Filling up Oil change Fuel tank E004 15 mn Notes...

Page 69: ...greasing as indicated in the program Standard tool kit Steel shims Protective goggles Gloves Place barriers around the perimeter of the work area The illustrations in this paragraph do not necessaril...

Page 70: ...N m 158 lbf ft HA260PX HA80JRT 21 5 daN m 158 lbf ft HA32RTJ PRO HA100RTJ PRO 21 5 daN m 158 lbf ft HA41RTJ PRO HA130RTJ PRO 21 5 daN m 158 lbf ft H14TX HB40 8 7 daN m 64 lbf ft H16TPX HB44J 8 7 daN m...

Page 71: ...th missing or damaged Presence of metal particles in the grease Wear on gear teeth Step 2 Measurement of the clearance Place the machine in the following conditions On flat ground Set up barriers to d...

Page 72: ...n chassis or turret and the slew ring as previously If the difference between two measurements does not exceed 2 mm the test validates correct operation Otherwise contact HAULOTTE Services to repair t...

Page 73: ...y of the following conditions exist Presence of cracks damage deformation or other faults on the hub Damage to the tire Cut or hole 3 cm 2 in in the rubber side wall Blister or pronounced lump on the...

Page 74: ...heel nuts on the wheel to be removed 2 Raise the machine using a jack or a hoist 3 Remove the wheel nuts 4 Remove the wheel 5 Install the new wheel 6 Lower the machine to the ground 7 Tighten the whee...

Page 75: ...A61JRT Drive wheel 320 236 Steer wheel 320 236 HA260PX HA80JRT Drive wheel 320 236 Steer wheel 320 236 HA32RTJ PRO HA100RTJ PRO Drive wheel 650 479 Steer wheel 650 479 HA41RTJ PRO HA130RTJ PRO Drive w...

Page 76: ...76 4000364740 E12 16 USA GB Replacement Tightening Wheel E006 15 min Notes...

Page 77: ...3 630 790 464 66 582 67 890 990 656 43 730 19 1070 1180 789 19 870 32 M27x3 930 1150 685 93 848 2 1300 1400 958 83 1032 59 1560 1730 1150 6 1275 98 M30x3 5 1260 1570 929 33 1157 97 1770 1960 1305 49 1...

Page 78: ...78 4000364740 E12 16 USA GB Tightening Screws bolts and nuts E007 15 min Notes...

Page 79: ...Refit and tighten the drain out 2 5 Top up the oil level as indicated above 6 Refit the filling cap 1 5 Additional operation 1 Place the machine in its operating configuration 3 3 2 Placing in operati...

Page 80: ...80 4000364740 E12 16 USA GB Control Oil change Turntable rotation gearbox E008 15 mn Notes...

Page 81: ...in maintenance configuration 3 3 1 Placing the machine in maintenance configuration 3 Control N B Packers of different thicknesses can be used for adjustment 4 Lubrication Standard tool kit Protectiv...

Page 82: ...GB Control Lubrication Replacement Pulleys and wear pads E013 15 mn 5 Replacement Replace the friction pads 6 Additional operation 1 Place the machine in its operating configuration 3 3 2 Placing in...

Page 83: ...the caps located on the top of the battery The level of electrolyte in the battery must be approx 0 01 m 0 ft39 in above the plates 4 Filling up Standard tool kit Protective goggles Gloves Place barr...

Page 84: ...batteries with distilled water to the minimum electrolyte level if any of the elements are below this minimum level Work in a clean and well ventilated area away from naked flames Open the bay Use the...

Page 85: ...machine in its operating configuration 3 3 2 Placing in operating configuration To keep your batteries in good condition test the density of each element once a month using a batttery hydrometer acco...

Page 86: ...86 4000364740 E12 16 USA GB Control Filling up Battery charge Battery E018 10 min Notes...

Page 87: ...3 3 1 Placing the machine in maintenance configuration 3 Lubrication Oil the parts of the telescope subject to friction with a spatula Oil the telescoping cable 4 Additional operation 1 Place the mach...

Page 88: ...88 4000364740 E12 16 USA GB Lubrication Telescope E022 15 mn Notes...

Page 89: ...engine oil Sufficient hydraulic oil in the tank Batteries are charging Control box E stop push buttons are pulled out The control box selector key is set to platform or ground control box Control box...

Page 90: ...l box selector key to platform control box position Enable Switch control validation device is not enabled Enable the device and keep pressed down during movement Faulty joystick Replace the joystick...

Page 91: ...tion G 1 Main characteristics Platform overload indicator Remove some weight Do not exceed the authorised limit Section G 1 Main characteristics Hydraulic oil temperature too high Allow to cool down P...

Page 92: ...92 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J D Diagnosis assistance Notes...

Page 93: ...form movement control circuit fuse FU7 20 A Solenoid valve power supply circuit fuse FU8 5 A Permanent power supply circuit fuse FU9 20 A Accessory power supply circuit fuse FU10 3 A LS valve circuit...

Page 94: ...YV15a Lifting compensation YV15b Lowering compensation YV16a b Front steering control solenoid valve Rear steering control solenoid valve YV18a Jib lowering YV18b Jib raising YV19a Left platform rota...

Page 95: ...0 A Accelerator circuit fuse FU4 30 A Low power control circuit main fuse and calculator FU5 3 A Turntable movement control circuit fuse FU6 3 A Platform movement control circuit fuse FU7 20 A Solenoi...

Page 96: ...A43 Back up unit cut off relay KM4 Electric pump relay KMG General power supply relay KP1 Engine power supply relay KT2 Accelerator relay 0 Battery 101 Battery 102 Emergency stop circuit 103 Starter 1...

Page 97: ...scope shift relay KA50 14 Buzzer HA4 15 Extension control solenoid valve for arm tube n 2 YV36 Chassis solenoid valves YV8 Outrigger or steering selection YV9 Differential lock YV22A Reverse right han...

Page 98: ...n n 1 breakage sensor SQ12 37 Retracted front outrigger sensor SQ35 38 37 way loom N1 N2 39 4 tilt sensor SQ1 40 Hydraulic tank temperature probe B4 41 Arm tube n 1 impulsion sensor SQ44 42 Retracted...

Page 99: ...e 4x4 YV15A Compensation lowering control solenoid valve YV15B Compensation elevation control solenoid valve YV16A Compensation lowering control solenoid valve YV16B Compensation elevation control sol...

Page 100: ...B40 H16TPX HB44J Marking Description B1 Engine air filter clogging pressure switch B3 Engine oil pressure switch B4 Hydraulic oil overheating pressure switch SQ1 Tilt sensor SQ2 Jib from 0 to 90 SQ3 B...

Page 101: ...A4 Buzzer Overload Tilt sensor Engine temperature Driving buzzer option Movement buzzer option Marking Description HA1 Buzzer HA2 Buzzer Platform control box Overload HA4 Buzzer Overload Tilt sensor E...

Page 102: ...102 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J E Electric circuit Notes...

Page 103: ...lifting control solenoid valve YV5 Turntable rotation control solenoid valve YV6 Driving YV7 Boom telescoping control solenoid valve YV8 13 GV YV9 Differential locking control solenoid valve YV10 12 1...

Page 104: ...104 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J F Hydraulic circuit Notes...

Page 105: ...ntervention 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 106: ...106 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J G Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number...

Page 107: ...A B C D E F G H I 107 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J G Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number...

Page 108: ...108 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J G Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number...

Page 109: ...A B C D E F G H I 109 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J G Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number...

Page 110: ...110 4000364740 E12 16 USA GB H14TX HB40 H16TPX HB44J G Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number...

Page 111: ...1 4000364740_US_GB_E12 16 Electrical diagram H14TX HB40 H16TPX HB44J 1 H14TX HB40 H16TPX HB44J 1 1 POWER...

Page 112: ...2 Electrical diagram H14TX HB40 H16TPX HB44J 1 2 STATION SELECTION...

Page 113: ...3 Electrical diagram H14TX HB40 H16TPX HB44J 1 3 INPUT OUTPUT CALCULAT0R I...

Page 114: ...4 Electrical diagram H14TX HB40 H16TPX HB44J 1 4 INPUT OUTPUT CALCULAT0R II...

Page 115: ...5 Electrical diagram H14TX HB40 H16TPX HB44J 1 5 JOYSTICKS...

Page 116: ...6 Electrical diagram H14TX HB40 H16TPX HB44J 1 6 OPTIONS...

Page 117: ...7 Electrical diagram H14TX HB40 H16TPX HB44J 1 7 OPTIONS...

Page 118: ...8 Electrical diagram H14TX HB40 H16TPX HB44J 1 8 OPTIONS...

Page 119: ...1 Hydraulic diagram H14TX HB40 H16TPX HB44J 1 H14TX HB40 1 1 FOLIO 1 1...

Page 120: ...2 Hydraulic diagram H14TX HB40 H16TPX HB44J 2 H16TPX HB44J 2 1 FOLIO 1 1...