Haulotte HT132RTJ PRO, Maintenance Book

Page 1: ...Maintenance book HT43RTJ PRO HT132RTJ PRO 4000392130 E03 16 USA GB Maintenance book HT43RTJ PRO HT132RTJ PRO 4000392140 E03 16 USA ...

Page 2: ...2 4000392130 E03 16 USA GB HT43RTJ PRO HT132RTJ PRO ...

Page 3: ...Decals and markings locations 22 C MAINTENANCE 1 Maintenance Schedule 35 2 Inspection program 37 3 Daily inspection 38 4 Periodic inspection 42 5 Reinforced inspection 47 6 Major inspection 49 7 Maintenance sheets 51 7 1 Placingthemachineinmaintenanceconfiguration 51 7 2 Placinginoperatingconfiguration 51 7 3 Generalpoints 52 7 3 1 Recommendations on the conditions of maintenance 52 7 3 2 Mechanic...

Page 4: ...TJ PRO 87 E018 Battery 95 E022 Telescope 99 E041 Generator option For HT132RTJ PRO only 101 E048 Cable carrier cat track 103 D DIAGNOSIS ASSISTANCE 1 Recommendations 105 2 Troubleshooting 106 E ELECTRIC CIRCUIT 1 Wiring diagram Main components 109 2 Fuses 113 3 Relays and terminals 114 4 Connectors 115 5 Diagnosis assistance indicators 117 6 Locations and functions of the main safety features 118 ...

Page 5: ...5 CONTENTS Maintenance book F HYDRAULIC CIRCUIT 1 Hydraulic diagram Main components 123 2 Solenoid valves 123 G INTERVENTION REGISTER 1 Intervention register 125 ...

Page 6: ...6 Maintenance book ...

Page 7: ...ughout your machine s service life to ensure the optimum use of your HAULOTTE product When contacting our After Sales Service ensure that you provide the machine model and serial number When ordering any consumables or spare parts please use this manual and the Haulotte Essential catalogue to receive your genuine HAULOTTE spare parts your only guarantee of parts interchangeability and correct mach...

Page 8: ...ications and to make improvements or modifications to the machine without modifying this manual Certain options can modify the machine s operating characteristics and its associated safety If your machine was originally delivered with options fitted replacing a safety component associated with a particular options not require any particular precautions other than those associated with the installa...

Page 9: ...ct machine operation If regular maintenance is not carried out this may Void the warranty Cause machine malfunction Reduce machine reliability and shorten its service life Jeopardize operator safety To ensure that the regular maintenance requirements are fully satisfied contact HAULOTTE Services HAULOTTE Services technicians are specially trained to carry out extensive repairs interventions or adj...

Page 10: ...f material damage Prohibition relating to work safety and quality Reminder No identified risk but a reminder of the need for common sense good practice or pre action prerequisites Cross reference to another part of the manual see section or sheet Cross reference to another manual see manual Cross reference to repairs contact HAULOTTE Services Maintenance sheet Time required for intervention Recomm...

Page 11: ...ode 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 serious injury Yellow Risk of material damage and or minor injury Other Additional technical information Green Maintenance operation or information Decals Color Description Red Prohibitions Danger ...

Page 12: ... owner 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 utilisation period must be recorded by reading the engine hour meter whenever an intervention is made The engine hour meter must be maintained in good working order to guarantee maximum working life and to ...

Page 13: ...r any other equipment in direct contact with fuel or lubricants Wearing parts pads bearings tires tyres connections etc These parts are by definition subject to deterioration during the period of operation Wearing parts will therefore not be covered by the warranty agreement 2 4 WARRANTY CONDITIONS To benefit from the warranty the owner or rental company must inform the nearest HAULOTTE subsidiary...

Page 14: ...of sold hired or resold equipment Owner or hirer Qualified HAULOTTE Services technician Operator s manual Pre operation inspection Before operation or when the operator changes Operator Operator Operator s manual Periodical preventive maintenance At the specified intervals 250 hours or 1 year Owner or hirer On site technician or qualified HAULOTTE Services technician Maintenance book Periodical vi...

Page 15: ...he following situations Do not work in an explosive or flammable atmosphere spark flame etc Do not touch the hot parts of the hydraulic power source engine filters etc Do not bridge the battery terminals with metallic objects Do not service the battery in proximity of spark open flame lit cigarettes Never expose the batteries or electrical components to water pressure cleaner rain Never disable th...

Page 16: ...16 4000392130 E03 16 USA GB HT43RTJ PRO HT132RTJ PRO A Safety precautions Notes ...

Page 17: ...T132RTJ PRO B Recommendations Recommendations 1 Lubrication diagram Diagram 5 2 6 6 6 6 6 6 6 6 6 2 1 2 2 2 2 4 3 Seulement pour Only for HT43RTJ PRO HT132RTJ PRO Seulement pour Only for HT43RTJ PRO HT132RTJ PRO Seulement pour Only for HT43RTJ PRO HT132RTJ PRO ...

Page 18: ...US 2820304310 5 Extreme pressure lithium grease 2820304320 6 Lead free grease Aerosol 0 4 l 0 1 gal US 2820304330 Lead free grease Can 5 l 1 32 gal US 2820304340 7 Molybdenum grease 8 Oil 9 High pressure lubricant Consumable HAULOTTE code Applicability Hydraulic filter cartridge Movements 2427002910 HT43RTJ PRO HT132RTJ PRO Hydraulic filter cartridge Driving 2427003110 HT43RTJ PRO HT132RTJ PRO Pri...

Page 19: ...an 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 1104 LOMBARDINI LDW 1404 KUBOTA D1105 W1 Other fuels Biofuels According to EN14214 EU and ASTM D6751 07a USA biofuels are allowed on some engines and under certain conditions For more information pleas...

Page 20: ...s 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 HEES type biodegradable oil only according to standards ISO 15380 and VDMA 24568 Necessary characteristics Environmental conditions ISO Viscosity grade Ambient temperature between 15 C 9 F and 40 C 104...

Page 21: ...A B C D E F G H I 21 4000392130 E03 16 USA GB HT43RTJ PRO HT132RTJ PRO B Recommendations Notes ...

Page 22: ...22 4000392130 E03 16 USA GB HT43RTJ PRO HT132RTJ PRO B Recommendations 3 Decals and markings locations CE standard HT43RTJ PRO ...

Page 23: ...rrow 4 3078143940 11 Other Lanyard attachment points 9 307P216290 12 Other Material risk Yellow and black adhesive tape 4 4000421700 13 Other Hydraulic oil 1 307P221080 14 Red Remove the blocking pin before rotating 1 4000027080 15 Green Greasing the turntable rotation gear 1 4000025160 16 Other Max and min oil level 1 307P221060 17 Red Risk of crushing 3 4000024800 18 Orange Hand crushing hazard ...

Page 24: ...ard 307P222810 In romanian CE standard 4000359870 In Russian CE standard 4000359920 In slovakian CE standard 4000359880 In slovenian CE standard 4000359890 In swedish CE standard 307P222820 Ukrainian CE standard 4000359910 36 Red Risk of crushing Platform 1 4000027460 37 Red Explosion hazard 1 4000027370 38 Orange Hand crushing hazard Heat burns 1 4000027450 39 Other Oil CJ 4 if fitted 1 400001970...

Page 25: ...A B C D E F G H I 25 4000392130 E03 16 USA GB HT43RTJ PRO HT132RTJ PRO B Recommendations Notes ...

Page 26: ...26 4000392130 E03 16 USA GB HT43RTJ PRO HT132RTJ PRO B Recommendations AS standard HT43RTJ PRO ...

Page 27: ... 3 4000024800 18 Orange Hand crushing hazard Risk of crushed hands 2 4000024890 19 Red Operation instructions 1 4000025140 21 Red Prohibited use of the PVG 1 4000027070 22 Orange Wound foot Do not place foot 2 4000027090 23 Red Risk of crushing Driving direction 1 4000024690 24 Red Danger of electrocution 2 4000227500 25 Red Risk of crushing Closing drop rail 1 4000025080 26 Red Danger of electroc...

Page 28: ...28 4000392130 E03 16 USA GB HT43RTJ PRO HT132RTJ PRO B Recommendations Russia and the Ukraine version HT43RTJ PRO ...

Page 29: ...040 24 Red Danger of electrocution 2 307P226960 25 Red Risk of crushing Closing drop rail 1 307P226950 26 Red Danger of electrocution Ground for welding 2 307P226970 27 Blue Verification of tilt operation 1 For Russia 307P227060 For Ukraine 307P227870 28 Red Do not interchange 1 3078145180 29 Red Calibration after dismantling 2 307P216930 32 Blue Anchorage point Traction 4 4000135970 33 Blue Ancho...

Page 30: ... helmet compulsory 1 307P226680 219 Blue hand protection compulsory 1 307P227490 220 Blue Obligatory routing 1 307P227510 221 Yellow Danger unstable side 1 307P227680 222 Blue Plug12 V 1 307P227700 224 Yellow Winter grade hydraulic oil 1 307P223700 225 Yellow Tilt verification 1 4000011690 227 Blue Horn 1 4000014830 228 Red Do not travel down slopes in high speed 1 307P226990 229 Red No admittance...

Page 31: ...A B C D E F G H I 31 4000392130 E03 16 USA GB HT43RTJ PRO HT132RTJ PRO B Recommendations Notes ...

Page 32: ...32 4000392130 E03 16 USA GB HT43RTJ PRO HT132RTJ PRO B Recommendations ANSI and CSA standards HT132RTJ PRO ...

Page 33: ...ive tape 4 4000421700 13 Other Hydraulic oil 1 307P221080 14 Red Remove the blocking pin before rotating 1 In english 4000024830 In french 4000068080 In spanish 4000086510 15 Green Greasing the turntable rotation gear 1 4000025160 16 Other Max and min oil level 1 307P221060 17 Red Risk of crushing 3 In english 4000024640 In french 4000067680 In spanish 4000086460 18 Orange Hand crushing hazard Ris...

Page 34: ...078151730 44 Other Oscillating axle extension retraction 1 307P219990 45 Other Fixed axle extension retraction 1 307P219980 46 Red Maximum effort on the stabilizers 2 307P219880 47 Blue Information Explanation LOW SULFUR 1 307P232480 52 Blue Socket 110 V 1 4000027590 202 Blue Diesel Fuel Only 2 4000201430 203 Other Internal combustion engine 1 4000097490 Marking Color Description Quantity HT132RTJ...

Page 35: ...0 h Work platform floor guardrails access and extensions Extension desk platform fastening Frame axle steering system stabilizers arms Screw and bolt wheel tightenning Wheel bearing Wheel reducer Steering system tightenning Steering system greasing Rotation systems orientation turret basket and jib Exterior gear wheel greasing Slewing device tightenning Pin pin stop bearing Pin and bushes Bushed a...

Page 36: ...Cylinder and hydraulic component pump filters manifold Hydraulic oil Hydraulic oil filter Adjusting the hydraulic pressure Energy storage and motorisation talns batteries and engine Engine oil filter and replacement KUBOTA DEUTZ Engine air filter KUBOTA DEUTZ Engine fuel filter KUBOTA DEUTZ Batteries acid level ...

Page 37: ...and overseen by the company manager This register or machine log book and the list of competent repair persons must be made available to the Government Work Inspector and company safety committee at any time According to applicable regulatory requirements If there are no local requirements then inspection must be performed at least once a year When Responsible Stakeholder What Before sale Owner or...

Page 38: ...ble 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 part before placing the machine in service Sample of broken welds Inspection Forms are provided to assist your inspection process We recommend these forms to be completed daily and stored to assist wit...

Page 39: ...ration of E stop button device Operation of enable switch Operation of horn from platform control box Operation of movement from platform control box Test warning alarm lights and buzzer No abnormal noise and jerky movements from platform control box Joysticks and movement switches return to neutral Work Platform Floor guardrails access and extensions No cracks broken weld paint chipped No visible...

Page 40: ... or slides Exterior gear wheel greasing Pin pin stop bearing Presence of turret rotation pin and locking device No bent cracked or broken pins pin stops bushes or bearings Pulleys chains and wire rope No cracked or broken chains links and fittings Pulleys and clamps are not worn rusted or damaged Cylinder and hydraulic component pumps filters manifold No leaks on the pump tank or fittings No defor...

Page 41: ... securely in position Slope limiting device operates properly Axle locking device operate properly Pothole safety device operate properly if equipped Test of load sensing system visual warning at control box Check that the safety devices operates correctly Emergency stop Enable switch Fault detector displays Overload sensing system Slope sensor Travel speed limitation Serial number Hours of operat...

Page 42: ... 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 the life of machines HAULOTTE recommended performing this inspection every HAULOTTE months This inspection should include the daily inspection Intervention to be made after Extensive dismantling and reassembl...

Page 43: ...uardrails access and extensions No cracks broken weld paint chipped No deterioration and visible damage Harness anchor points are not cracked or damaged with the decal attached and legible No screws missing loose parts Entry bar gate closes automatically and is not prevented from closing Locking in closed position of folding guard rail if equipped Work platform floor guardrails access and extensio...

Page 44: ...on slewing system Slewing device screw and bolt presence and tightenning if equipped Pin pin stop bearing Presence of the turret pin and its locking device No abrasion damage or oxidation of pin pin stop bushes and bearing No radial gap 0 5mm on the pin No bent cracked or broken pins pin stops bushes or bearings Position and state of bushes and bearing Pulleys chains and wire rope No wear more tha...

Page 45: ...ence and good condition of the engine oil filter Presence and good condition of the engine air filter Presence and good condition of the engine fuel filter Absence of deformation visible damage and broken weld on exhaust system Engine at idle and fast track the engine runs at steady pace and appropriate Electric cables No torn or split wire sheaths No evidence of chemical damage or corrosion on al...

Page 46: ...g device adjustment Load sensing system adjustment Working area limiter device adjustment Oscillating axles blocking system Absence of non allowed modifications Safety bulletin take into account and OTI applicable performed Periodic inspection date stamped Owner information provided to the manufacturer Serial number Hours of operation HAULOTTE Services contract reference Intervention record number...

Page 47: ...HAULOTTE Services authorization For countries where machines are not subject to controlled periodic maintenance Yes No Corrected Not applicable Work Platform Floor guardrails access and extensions No deterioration and visible damage Lift assembly jib boom mast arm turret No deterioration and visible damage No abnormal gap in joints and slides Frame axle steering system stabilizers arms No deterior...

Page 48: ...nt No evidence of chemical damage or corrosion on all cables Energy storage and motorisation tanks batteries and engine No screws missing loose parts Additional inspection Daily inspection checked Periodic inspection checked Maintenance program realized Serial number Hours of operation HAULOTTE Services contract reference Intervention record number Date Name Model Signature ...

Page 49: ...forced 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 countries where machines are not subject to controlled periodic maintenance Yes No Corrected Not applicable Frame axle steering system stabilizers arms No deterioration and visible damage Pin pin stop b...

Page 50: ...50 4000392130 E03 16 USA GB HT43RTJ PRO HT132RTJ PRO C Maintenance Serial number Hours of operation HAULOTTE Services contract reference Intervention record number Date Name Model Signature ...

Page 51: ...achine 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 lubrication points tanks caps engines drain plugs are red 7 1 PLACING THE MACHINE IN MAINTENANCE CONFIGURATION 7 2 PLACING IN OPERATING CONFIGURATION 1 Remove the turntable rotation locking pin 2 Pull the E...

Page 52: ...ed to be replaced must be replaced with bolts of identical specification Type Length Diameter Class Tighten to the torque indicated when reassembling If there are no specific requirements apply the normalized tightening torques Section C 3 Maintenance sheets E007 7 3 2 2 Pins and bearings Except maintenance schedule check pins and bearings in the following cases Abnormal noise during the movements...

Page 53: ... The 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 Values After inserting the bearing lubricate and fit the pin Marking Description A At least 0 5 times the nominal diameter B Make a chamfer C Nominal diameter of the bearing 0 2 0 3 mm D Bearing drift E ...

Page 54: ...ernal pollutants and potential damage Clean the bearing with a suitable solvent Replace the bearing in the following cases Presence of abrasions in the bearing housing and or inside the bearing itself Presence of abrasion wear oxidation deformations of the balls or rollers and the ring rollers Reassembly of the bearing pivot Clean the bearing housing or pin in order to remove all the foreign objec...

Page 55: ...e 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 to repair the system Second test On ramp On non slipping loading ramp maximum slope 20 Draw a line on the slope to create a stopping reference Climb on the ramp at microspeed Release the joystick whe...

Page 56: ... tank 1 Perform a complete cycle fully extend and retract of each cylinder 2 Fill the tank if necessary Never above of the maximum level Repeat the step 1 and 2 for each cylinder on the machine 7 3 3 2 Replacing damaged of hoses Replace hoses in the following circumstances Tears in the outer casing Cracks in the outer casing Apparent shielding Visible leak in the hose Damage to the outer casing ca...

Page 57: ...distance between the floor of the cage or of the platform and the ground If the difference between two measurements does not exceed 4 cm the test validates correct operation If the difference between two measurements exceeds 4 cm contact HAULOTTE Services or carry out the additional tests described below After hose removal plug the the hose ends and components the ports from which the hose was rem...

Page 58: ... 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 facilitate reassembly Respect the order configuration of origin during the reassembly Type of cylinders Maximum drift authorised due to an internal leak of the cylinder Lift cylinder arm or boom Machine with workin...

Page 59: ...lection pan Place barriers around the perimeter of the work area 1 Turn the wheel to obtain the following configuration 2 Plug 1 is on a horizontal line 3 Plug 2 is on a vertical line 4 Loosen and remove plug 1 5 Check the oil level 6 Top up the oil level to the hole if necessary 7 Refit and tighten plug 1 1 Turn the wheel until plug 2 is directed downwards 2 Loosen and remove plugs 1 and 2 3 Let ...

Page 60: ...60 4000392130 E03 16 USA GB Control Oil change Wheel reducer E002 15 mn Notes ...

Page 61: ...g 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 filter clogging Do not touch the hot parts of the hydraulic power source engine filters etc 1 When the clogging indicator 2 comes on replace the cartridge 1 2 Loosen and remove the base nut 3 3 Loosen an...

Page 62: ...62 4000392130 E03 16 USA GB Replacement Hydraulic filter cartridge E003 15 min Notes ...

Page 63: ...erating configuration 3 3 2 Placing in operating configuration Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area Touch the exterior of the filling hole with the pump spout before starting pouring to avoid any risk of static electricity causing sparks Make sure you are standing up wind to avoid being splashed by the fuel Do not smoke Loosen and remove ...

Page 64: ...64 4000392130 E03 16 USA GB Filling up Oil change Fuel tank E004 15 mn Notes ...

Page 65: ...greasing as indicated in the program Standard tool kit Steel shims Protective goggles Gloves Place barriers around the perimeter of the work area The illustrations in this paragraph do not necessarily correspond to the range of products designated in the manual 1 Check for the presence of all the locating bolts 2 Check that the accessible screws are not loosened If neces sary tighten the screws Re...

Page 66: ...aN 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 64 lbf ft H21TX HB62 21 5 daN m 158 lbf ft H23TPX HB68J 32 daN m 236 lbf ft H25TPX HB76J 21 5 daN m 158 lbf ft H28TJ HB86TJ 21 5 daN m 158 lbf ft HT43RTJ PRO HT132RTJ PRO 21 5 daN m 158 lbf ft STAR ...

Page 67: ... box align the turret at 90 to the chassis Lift the boom approximatively 30 from the ground Completely retract the boom Jib in horizontal position if fitted From the magnetic comparator note the clearance J1 between chassis or turret and the slew ring Clearance between chassis or turret and slew ring After having carried out the measurement Lower the boom at horizontal position Lift the arm if exi...

Page 68: ...ine in its operating configuration 3 3 2 Placing in operating configuration 2 Rotate the slew ring by one complete turn Consult the After Sales Service HAULOTTE Services A tight spot or grinding sound during rotation or the presence of metal particles escaping from the lip seal are signs of abnormal wear in the raceway Contact HAULOTTE Services ...

Page 69: ...ny of the following conditions exist Presence of cracks damage deformation or other faults on the hub Damage to the tire Cut or hole 3 cm 2 in in the rubber side wall Blister or pronounced lump on the external and lateral wall Damaged wheel stud Damage or wear on the side wall to the extent that the reinforcing wire is visible Nonlinear wear of the ground contact surface greater than 10 Standard t...

Page 70: ...wheel nuts on the wheel to be removed 2 Raise the machine using a jack or a hoist 3 Remove the wheel nuts 4 Remove the wheel 5 Install the new wheel 6 Lower the machine to the ground 7 Tighten the wheel nuts to the recommended torque For safety reasons always use original HAULOTTE spare parts that are specific to this machine Refer to the spare parts catalog ...

Page 71: ...HA61JRT 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 wheel 570 420 Steer wheel 570 420 H14TX HB40 Drive wheel 320 236 Steer wheel 320 236 H16TPX HB44J Drive wheel 320 236 Steer wheel 320 236 H21TX HB62 Drive wheel 320 236 Steer wheel 320 236 H23TPX HB68...

Page 72: ...72 4000392130 E03 16 USA GB Replacement Tightening Wheel E006 15 min Notes ...

Page 73: ...x3 630 790 464 66 582 67 890 990 656 43 730 19 1070 1180 789 19 870 32 M27x3 930 1150 685 93 848 2 1300 1400 958 83 1032 59 1560 1730 1150 6 1275 98 M30x3 5 1260 1570 929 33 1157 97 1770 1960 1305 49 1445 62 2200 2350 1622 64 1733 27 Nominal diameter Torque in N m lbf ft Class 8 8 Class 10 9 Class 12 9 M8x1 24 29 17 7 21 39 33 37 24 34 27 29 40 44 29 5 32 45 M10x1 25 46 57 33 93 42 04 64 71 47 2 5...

Page 74: ...74 4000392130 E03 16 USA GB Tightening Screws bolts and nuts E007 15 min Notes ...

Page 75: ... Refit and tighten the drain out 2 5 Top up the oil level as indicated above 6 Refit the filling cap 1 5 Additional operation 1 Place the machine in its operating configuration 3 3 2 Placing in operating configuration Standard tool kit Protective goggles Gloves Oil collection pan Place barriers around the perimeter of the work area 1 Loosen and remove the filling cap 1 2 Check that the oil level i...

Page 76: ...76 4000392130 E03 16 USA GB Control Oil change Turntable rotation gearbox E008 15 mn Notes ...

Page 77: ...uration 3 Control N B Packers of different thicknesses can be used for adjustment 4 Lubrication 5 Replacement Replace the friction pads 6 Additional operation 1 Place the machine in its operating configuration 3 3 2 Placing in operating configuration Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area Check the telescoping friction pad wear indicators C...

Page 78: ...78 4000392130 E03 16 USA GB Control Lubrication Replacement Pulleys and wear pads E013 15 mn Notes ...

Page 79: ...etely and operational 3 Lubrication Lubricant must be applied with a brush to the external chains at least every 250 hours or every 6 months The frequency of application depends on surrounding conditions and conditions of use The frequency of application must ensure that a sufficient quantity of fluid oil is present in the chain links If the chain has been exposed to corrosive fluids clean the cha...

Page 80: ... over 12 segments of the original chain length is permitted Measure the value of 3 using an appropriate method Compare with the value of 1 indicated in the table below Check for external wear on rollers and links External wear must not measure more than 2 from the section of the original link 2 see table above Measure the value of 1 using an appropriate method Check that no line or element is dama...

Page 81: ...stments not detailed in this maintenance logbook Contact Haulotte Services for further advice 6 Replacing the chains The chains must imperatively be changed every 10 years Contact Haulotte Services for further advice Les chains and chain elements are made from case hardened steel in a high quality process Deliver any scrap chains or chain elements to a dealer specialised in metal recycling in comp...

Page 82: ...82 4000392130 E03 16 USA GB Control Lubrication Chains E016 Notes ...

Page 83: ...cable transmission system In order to ensure safe use of machinery Haulotte Group recommends that you perform the following inspections Daily inspection Place the machine on flat and firm ground Power up the machine and select the console located on the turntable Raise the boom to horizontal For machines fitted with Execute a complete extension retraction cycle of the telescope assembly over appro...

Page 84: ...0 in for telescopic machines Raise the mast assembly up to the inspection flaps Using a flash light perform a visual inspection of the following items Check that cables are properly aligned with one 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 Check that nothing blocks the cha...

Page 85: ...ngth of the cable Replacement is compulsory when 1 strand is broken near the ends No deformed folds or frayed strands must be observed No signs of corrosion must be observed 4 Check the tension of the cables Refer to the technical data sheet for your product following this sheet To make any other adjustments not detailed in this maintenance logbook Contact Haulotte Services for further advice ...

Page 86: ...ates in a particularly hostile environment Abnormal noises are produced during movement of structure Machine has been in storage for more than 6 months Machine has been submitted to an abusive load or serious collision Machine has been exposed to an electrical arc Contact Haulotte Services for further advice Cables and cable elements are made from case hardened steel in a high quality process Deli...

Page 87: ...e performed each 250 h imperatively Every precaution must be taken before working on or near the machine Comply with the recommendations in the maintenance book for your machine For all tightening actions quoted in this document ensure the symmetry of the cable tension is complied with by tightening the threaded rods one by one in quarter turns Fully stow the machine on flat ground with the boom f...

Page 88: ...ntil element N 3 moves complying with the measurement of 301 15 mm Start the thermal engine Lift the boom to the highest position without telescoping to ensure that the sections are fully retracted Come back to horizontal position Stop the engine Do not turn the cables 1 during the tightening operation Prevent them from turning using a 19 wrench on the flat bars or if there are no flat bars jam th...

Page 89: ...ustment procedure HT43RTJ PRO HT132RTJ PRO E053 Element No 3 Tighten the extension chains from the end of element No 2 to element No 4 complying with the measurement of 30 15 mm N B In this position the threaded rod must extend beyond the nut by at least 50 mm ...

Page 90: ...90 4000392130 E03 16 USA GB Cables and chains Specific adjustment procedure HT43RTJ PRO HT132RTJ PRO E053 Element No 4 ...

Page 91: ...ction cables at the end of element No 1 until element No 3 moves Tighten retraction cables B at the ends of elements No 1 and 2 Unscrew the extension chain and cable nuts by exactly 3 Make a mark on the nut to count the number of turns Do not turn the cables A during the tightening operation Prevent the cables from rotating ...

Page 92: ...E03 16 USA GB Cables and chains Specific adjustment procedure HT43RTJ PRO HT132RTJ PRO E053 Refit the retraction cable nut stops at the ends of elements No 1 and 2 Tighten the extension cables and chains by 2 5 turns ...

Page 93: ...nd of element No 2 Refit the stop plate for the extension cable nuts at the rear of the boom and the locknuts for each cable Move each telescope forwards and backwards 3 times by approximately 1 metre ensuring that the movements are synchronised Check that the measurements of 301 15 mm and 30 15mm are complied with If these dimensions are not compliant repeat the adjustment procedure above startin...

Page 94: ...94 4000392130 E03 16 USA GB Cables and chains Specific adjustment procedure HT43RTJ PRO HT132RTJ PRO E053 Notes ...

Page 95: ...n the caps located on the top of the battery The level of electrolyte in the battery must be approx 0 01 m 0 ft39 in above the plates 4 Filling up Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area The battery manufacturer s safety instructions must be followed Loosen the caps located on the top of the battery If the level of electrolyte is below the l...

Page 96: ... batteries with distilled water to the minimum electrolyte level if any of the elements are below this minimum level Work in a clean and well ventilated area away from naked flames Open the bay Use the machine s on board charger The charger has a charge rate compatible to the battery capacity During charging The machine s electric system is automatically deactivated while the external power supply...

Page 97: ...e machine in its operating configuration 3 3 2 Placing in operating configuration To keep your batteries in good condition test the density of each element once a month using a batttery hydrometer according to the temperature indicated in the curves below Battery charge status according to density and temperature ...

Page 98: ...98 4000392130 E03 16 USA GB Control Filling up Battery charge Battery E018 10 min Notes ...

Page 99: ... 3 3 1 Placing the machine in maintenance configuration 3 Lubrication Oil the parts of the telescope subject to friction with a spatula Oil the telescoping cable 4 Additional operation 1 Place the machine in its operating configuration 3 3 2 Placing in operating configuration Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area ...

Page 100: ...100 4000392130 E03 16 USA GB Lubrication Telescope E022 15 mn Notes ...

Page 101: ... and 70 C 158 F during the operations 3 Power supply voltage control Disconnect all equipment connected to the generator welder hand equipment Start up the machine Start the generator Wait for the generator to stabilize Measure the voltage at the welder outlet using a multimeter N B The voltage between each phase must be between 210 V AC and 240 V AC Measure the voltage at the 110 V outlet N B The...

Page 102: ...tabilize Press the TEST button on the 60 A cabinet Check that there is no voltage at the welder outlet Press the TEST button on the plug situated in the cage Check that there is no voltage at the outlet Reset the outlet by pressing the RESET button 5 Additional operation 1 Place the machine in its operating configuration 3 3 2 Placing in operating configuration Reset the contactor by pressing the ...

Page 103: ...arts of the the cable carrier chain Premature wear excessive friction Ensure that cables slide inside the cable carrier chain Ensure that cables don t leave their socket Locate them back in the socket if necessary Check the electric wires and cables Premature wear excessive friction non insulated cable Replace cables if necessary 4 Additional operation 1 Place the machine in its operating configur...

Page 104: ...104 4000392130 E03 16 USA GB Control Cable carrier cat track E048 30 min Notes ...

Page 105: ...t 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 relays are engaged Fuse status Ground control box solenoid valve status If the malfunction persists consult the troubleshooting table to identify the problem IF you cannot identify the problem conta...

Page 106: ...gged air filter indicator on Replace the air filter cartridge Faulty engine safety relay KP1 Replace the relay s Poor cable battery terminal contact Loosen and clean the terminals Boom telescope chain or cable breakage Contact HAULOTTE Services Internal machine fault Internal machine defect radius limit Stow the machine using the emergency power unit Contact HAULOTTE Services Connection failure be...

Page 107: ...ck No driving Failure following microspeed failure Stow the machine Switch off the power and then switch it back on again No steering Not enough hydraulic oil Top up the oil level Enable Switch control validation device is not enabled Enable the device and keep pressed down during movement No horizontal drive telescoping lifting or buzzer in operation Tilt or slope exceeding the authorised limit D...

Page 108: ...108 4000392130 E03 16 USA GB HT43RTJ PRO HT132RTJ PRO D Diagnosis assistance Notes ...

Page 109: ... buzzer M900 Engine cooler option FU1 10 A Engine power supply circuit fuse FU3 80 A Pre heating control 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 Solenoid valve power supply circuit fuse FU8 5 A Permanent power supply circuit fuse FU9 20 A Accessory power supply c...

Page 110: ...cator after engine shutdown HL807 Enable Switch pedal indicator HL900 Power ON indicator HL307 Fuel reserve indicator HL801 Platform fault indicator HL800 Tilt indicator light HL802 Platform overload indicator HL804 Platform radius limitation indicator HL803 load selection indicator HL300 Pre heating indicator HL805 Indicator for overload pre alarm at 230 Kg 500 Lb HL806 Indicator for overload pre...

Page 111: ... axle position limit switch SQ132 SQ133 Extended rear axle position limit switch SQ140 Retracted front outrigger ILS sensor SQ141 Retracted rear outrigger ILS sensor SQ130 SQ136 Extended axle ILS sensors SQ131 SQ137 Retracted axle ILS sensors SQ300 Fuel reserve indicator SQ250 Aligned turntable redundancy position sensor SB802 E stop button cage SA906 Generator start up option SA721 Platform compe...

Page 112: ...ng lowering control solenoid valve YV750R YV750L Platform rotation control solenoid valve YV150R YV150L Front steering control solenoid valve YV151R YV151L Rear steering control solenoid valve YV906 Generator control solenoid valve Option YV160F Pump horizontal drive generator control solenoid valve A YV160B Pump horizontal drive generator control solenoid valve B YV101 Oscillating axle unlocking ...

Page 113: ...r FU5 3 A Turntable movement control circuit fuse FU6 3 A Platform 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 fuse FU11 25 A Cooler circuit fuse Option FU13 250 A Emergency pump circuit fuse FU14 15 A Accelerator circuit fuse FU15 20 A Injection pu...

Page 114: ...7 Injection pump control relay KM800 Electric pump relay KM6 Pre heating relay KM300 Accelerator relay KA301 Accelerator relay KMG General power supply relay KA302 Engine power supply relay 0 Battery 101 Battery 102 Emergency stop circuit 103 Starter 119 Engine pre heating 120 General 215 Emergency stop circuit 240 General power supply after contactor KA301 KA300 KA302 101 120 103 118 240 102 215 ...

Page 115: ... movements YV807 20 LS control solenoid valve YV800 21 Turntable unlocking control solenoid valve YV805 22 Jib compensation platform rotation outrigger extension and steering PVG YV900 23 Boom lifting PVG YV520 24 Direction PVG YV250 25 Boom telescoping PVG YV530 27 Engine looms 29 Boom telescope length sensors SL530 SL531 Connection with ground control box door SA620 Rear axle angle sensor SR151 ...

Page 116: ...e ST900 41 Lower boom sensor SQ520 42 Telescope impulsion sensor SQ532 45 High speed driving detection sensor SP100 46 Aligned turntable sensor SQ250 47 Cable breakage sensor SQ802 48 Fuel reserve sensor SQ300 49 Emergency pump relay 50 Emergency stop line monitoring Connection with ground control box door SA720 51 Front axle angle sensor SR150 52 Horn HA907 54 Reverse drive proportional solenoid ...

Page 117: ... solenoid valve YV720D Compensation lowering control solenoid valve YV720U Compensation elevation control solenoid valve YV650R Not applicable YV650L Not applicable YV620D Not applicable YV620U Not applicable YV750R Not applicable YV750L Not applicable YV150R Front right hand steering control solenoid valve YV150L Front left hand steering control solenoid valve YV151R Reverse right hand steering c...

Page 118: ...n safety features 6 1 LOCATION OF THE LIMIT SWITCH AND SENSORS Locations HT43RTJ PRO HT132RTJ PRO SQ801 SQ520 SR520 SR521 SL530 SL531 ST900 SQ134 SQ135 SQ140 SR150 SQ300 SR151 SP100 SR250 SP600 SP601 SR601 SR600 SQ650 SQ651 SQ530 SQ532 ST300 SP300 GB1 SQ250 SQ800 SQ132 SQ133 SQ141 SQ130 SQ136 SQ131 SQ137 SQ802 ...

Page 119: ...tion limit switch High speed cut off To extend the boom out SQ532 Sensor Boom telescope detection ILS Telescope length detection SQ650 Jib position limit switch 5 5 Jib rotation detection in work position 5 5 SQ651 Jib position limit switch 90 180 Jib rotation detection in transport position 90 180 SQ530 Retracted boom telescope position limit switch Cuts boom lowering SQ801 Chain breakage positio...

Page 120: ...Electric circuit 6 2 LOCATIONS OF THE SOLENOID VALVES Locations HT43RTJ PRO HT132RTJ PRO YV720 YV650 YV620 YV750R YV750L YV900 YV420 YV520 YV250 YV530 YV650 YV805 YV804 YV806 YV807 YV160F YV160B YV900 YV106 YV100 YV110 YV150R YV150L YV151R YV151L YV103 YV101 ...

Page 121: ...n EL904 Work light option HL301 Particle filter indicator HL302 Regeneration of particle filter indicator HL303 Indicator for inhibition of regeneration of particle filter HL250 Indicator for turntable at 180 HL720 Turntable compensation fault indicator HL304 Engine warning indicator HL305 Indicator after engine shutdown HL807 Enable Switch pedal indicator HL900 Power ON indicator HL307 Fuel reser...

Page 122: ...122 4000392130 E03 16 USA GB HT43RTJ PRO HT132RTJ PRO E Electric circuit Notes ...

Page 123: ...draulic circuit 1 Hydraulic diagram Main components N B See end of manual 2 Solenoid valves Locations HT43RTJ PRO HT132RTJ PRO YV720 YV650 YV620 YV750R YV750L YV900 YV420 YV520 YV250 YV530 YV650 YV805 YV804 YV806 YV807 YV160F YV160B YV900 YV106 YV100 YV110 YV150R YV150L YV151R YV151L YV103 YV101 ...

Page 124: ...solenoid valve YV102 Brake release control solenoid valve YV720D YV720U Compensation control solenoid valve YV650R YV650L Jib rotation solenoid valve YV620D YV620U Jib lifting lowering control solenoid valve YV750R YV750L Platform rotation control solenoid valve YV150R YV150L Front steering control solenoid valve YV151R YV151L Rear steering control solenoid valve YV160F Pump horizontal drive gener...

Page 125: ...intervention register keeps a record of maintenance and repair work carried out inside or outside the maintenance programme N B In the case of a HAULOTTE Services intervention the qualified technician must indicate the HAULOTTE Services intervention number Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 126: ...126 4000392130 E03 16 USA GB HT43RTJ PRO HT132RTJ PRO G Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 127: ...A B C D E F G H I 127 4000392130 E03 16 USA GB HT43RTJ PRO HT132RTJ PRO G Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 128: ...128 4000392130 E03 16 USA GB HT43RTJ PRO HT132RTJ PRO G Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 129: ...A B C D E F G H I 129 4000392130 E03 16 USA GB HT43RTJ PRO HT132RTJ PRO G Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 130: ...130 4000392130 E03 16 USA GB HT43RTJ PRO HT132RTJ PRO G Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 131: ...1 4000392130_E03 16_USA GB Electrical diagram HT43RTJ PRO HT132RTJ PRO 1 HT43RTJ PRO HT132RTJ PRO 1 1 ENGINE UNIT I ...

Page 132: ...2 Electrical diagram HT43RTJ PRO HT132RTJ PRO 1 2 ENGINE UNIT II ...

Page 133: ...3 Electrical diagram HT43RTJ PRO HT132RTJ PRO 1 3 TURRET UNIT ...

Page 134: ...4 Electrical diagram HT43RTJ PRO HT132RTJ PRO ...

Page 135: ...5 Electrical diagram HT43RTJ PRO HT132RTJ PRO ...

Page 136: ...6 Electrical diagram HT43RTJ PRO HT132RTJ PRO ...

Page 137: ...7 Electrical diagram HT43RTJ PRO HT132RTJ PRO 1 4 FRAME UNIT ...

Page 138: ...8 Electrical diagram HT43RTJ PRO HT132RTJ PRO 1 5 BASKET UNIT ...

Page 139: ...9 Electrical diagram HT43RTJ PRO HT132RTJ PRO ...

Page 140: ...10 Electrical diagram HT43RTJ PRO HT132RTJ PRO 1 6 OPTION 12VPLUG TEMPSENSRUSSIA HORNLC B ANEMOMETER ST903 ...

Page 141: ...11 Electrical diagram HT43RTJ PRO HT132RTJ PRO 1 7 NEW ARCHITECTURE ...

Page 142: ...12 Electrical diagram HT43RTJ PRO HT132RTJ PRO ...

Page 143: ...1 Hydraulic diagram HT43RTJ PRO HT132RTJ PRO 1 HT43RTJ PRO HT132RTJ PRO 1 1 FOLIO 1 1 ...

Page 144: ...2 Hydraulic diagram HT43RTJ PRO HT132RTJ PRO ...