Haulotte Group HA20RTJ O Product guide

Maintenance Book
HA20RTJ - HA20RTJ O - HA20RTJ PRO - HA61RTJ O - HA61RTJ PRO
4000427880 E 12.15 US / GB
Maintenance Book
HA20RTJ - HA20RTJ O - HA20RTJ PRO
HA61RTJ O - HA61RTJ PRO
USA

2 4000427880 E 12.15 US / GB
HA20RTJ - HA20RTJ O - HA20RTJ PRO - HA61RTJ O - HA61RTJ PRO

3
CONTENTS
Maintenance Book
CONTENTS
A
Preface -
Foreword
1 - Symbols and colors . . . . . . . . . . . . . . . . . . . . . . 8
B
Safety
1 - General safety rules . . . . . . . . . . . . . . . . . . . . . 11
1.1 - Maintenance implementation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 - Uncontrolled movement Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 - Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 - Explosion / Fire Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 - Maintenance and repair training . . . . . . . . . . . 15
2.1 - Owner's responsability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 - Technician's responsability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 - HAULOTTE Services®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 - Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5 - Product modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.6 - After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.7 - Product information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3 - Manufacturer's warranty . . . . . . . . . . . . . . . . . 17
3.1 - Warranty acceptance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 - Warranty period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 - Conditions of warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4 - Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4
Maintenance Book
C
Familiarization
1 - Primary machine components . . . . . . . . . . . . 20
1.1 - Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2 - Ground control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.2 - Display Panel (LED'S 1 - 10). . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3 - Platform control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.3.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.3.2 - Display Panel (LED'S 101 - 117). . . . . . . . . . . . . . . . . . . . . . . . 28
2 - Device layout . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.1 - Sensors and actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3 - Power source - Engine specifications . . . . . . 34
3.1 - General safety and specific interventions on motor. . . . . . . . . . . . . . . . 34
3.2 - General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3 - Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.4 - Ingredient. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4 - Lubrication diagram . . . . . . . . . . . . . . . . . . . . . 36
4.1 - Greasing points localization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5 - Consumables (Oils - Fuels - Engine oil -
Coolant level...).... . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1 - Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1.1 - Other fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2 - Engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3 - Hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6 - Machine specifications . . . . . . . . . . . . . . . . . . 43
6.1 - Movement speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5
CONTENTS
Maintenance Book
D
Inspection and
maintenance
schedule
1 - Maintenance Schedule. . . . . . . . . . . . . . . . . . . 45
2 - Inspection program . . . . . . . . . . . . . . . . . . . . . 47
3 - Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . 48
4 - Periodic inspection . . . . . . . . . . . . . . . . . . . . . 52
5 - Reinforced inspection . . . . . . . . . . . . . . . . . . . 57
6 - Major inspection . . . . . . . . . . . . . . . . . . . . . . . . 59
Machine sheet
MS0001 - Structural part inspection . . . . . . . . . . . . . . . 61
MS0002 -
Pins and bearing inspection . . . . . . . . . . . . . 65
MS0003 -
Cylinder inspection . . . . . . . . . . . . . . . . . . . . 69
MS0004 - Breaking test procedure . . . . . . . . . . . . . . . . 73
MS0005 -
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . 75
MS0008 -
Oscillating axles - Functional tests . . . . . . . 79
MS0009 - Fuel tank - Filling-up . . . . . . . . . . . . . . . . . . . 81
MS0019 -
Hydraulic oil - Level Replacement . . . . . . . . 83
MS0020 -
Hoses inspection - Replacement . . . . . . . . . 87
MS0021 - Hydraulic filter cartridge Replacement . . . . 89
MS0024 -
Battery (ies) . . . . . . . . . . . . . . . . . . . . . . . . . . 91
MS0025 -
Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . 97
MS0026 - Dismantling / Reassembling wheels
reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
MS0028 - Procedure of dismantling / reassembling
hydraulic rotary actuators . . . . . . . . . . . . . . . . . . . . 117
MS0029 - KUBOTA diesel engine. . . . . . . . . . . . . . . . 135
MS0055 -
Tires (Tyres) and pressures - Wheel
replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
163
MS0056 -
Slew ring inspection . . . . . . . . . . . . . . . . . . 167
MS0057 - Overload system . . . . . . . . . . . . . . . . . . . . . 171
MS0058 -
Ramps and speeds adjustment . . . . . . . . . 179
MS0063 -
Sensor ILS adjustment . . . . . . . . . . . . . . . . 185
MS0066 - Check and replacing the pads . . . . . . . . . . 193
MS0067 -
Remove - Re-install counterweight . . . . . . 201
MS0068 -
Remove - Re-install arm assembly. . . . . . . 207
MS0069 - Remove / Re-install telescope cylinder . . . 221
MS0070 -
Remove / replace arm cylinder . . . . . . . . . . 233
MS0071 -
Remove / Re-install boom assembly . . . . . 243
MS0074 - Remove / Replace Boom cylinder . . . . . . . 253

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Maintenance Book
MS0075 - Boom and arm pads adjustment . . . . . . . . 259
MS0076 -
Remove / Re-install turret/platform CAN BUS
wiring harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
263
MS0077 -
Remove / Re-install load cell . . . . . . . . . . . 271
MS0079 -
Remove/Re-install output compensation
cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
279
MS0078 -
Remove/Re-install rotary actuator . . . . . . . 285
MS0080 - Remove/Re-install input compensation
cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
MS0081 - Remove/Re-install jib cylinder . . . . . . . . . . 299
MS0082 -
Remove/Re-install wheel reduction gear. . 305
MS0083 -
Remove/Re-install slip ring (electric rotary
coupling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
315
MS0107 -
Resetting to zero the maintenance
counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
325
E
Trouble shooting
and diagram
1 - Trouble shooting . . . . . . . . . . . . . . . . . . . . . . 329
1.1 - Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
1.2 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
1.3 - Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
2 - Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
2.1 - PCB Turret. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
3 - Electric diagram . . . . . . . . . . . . . . . . . . . . . . . 346
4 - Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . 358
F
Records
1 - Intervention register. . . . . . . . . . . . . . . . . . . . 365

74000427880 E 12.15 US / GB
HA20RTJ - HA20RTJ O - HA20RTJ PRO - HA61RTJ O - HA61RTJ PRO
A - Preface - Foreword
Preface - Foreword
Preface - Foreword
You have just purchased a HAULOTTE® product and we would like to thank you for your business.
The Aerial Work Platform is a mechanical device primarily designed and manufactured with the intent to position people
with the necessary tools and material to overhead elevated temporary workplaces. All other uses or alterations/modifi-
cations to the aerial work platform must be approved by HAULOTTE®.
This manual shall be considered a permanent component of the machine and shall be kept with the aerial work platform
in the designated Manual Holder, at all times.
Safe operation of this product can only be assured if you follow the operating instructions contained in this manual are
followed. To ensure proper and safe use of this equipment, it is strongly recommended that only trained and authorized
personnel operate and maintain the aerial work platform.
We would particularly like to draw your attention to 2 essential points :
• Compliance with safety instruction (machine, use, environment).
• Use of the equipment within the performance limits.
With regard to the designation of our equipment, we stress that this is purely for commercial purposes and not to be con-
fused with the technical specifications. Only the specifications in this manual should be used to study the suitability of
the equipment for the intended use.
This maintenance and repairs book is specific to the HAULOTTE® products listed on the cover page of this manual. The
maintenance book is intended for the on-site maintenance technician.
It is the on-site maintenance technician's duty to carry out the regular maintenance work recommended by HAULOTTE
Services®.
This maintenance work is essential for correct 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 adjustments on
the safety systems or elements of HAULOTTE® machines. They carry genuine HAULOTTE spare parts and tools as
required, and also provide fully documented reports on all work completed.

8 4000427880 E 12.15 US / GB
HA20RTJ - HA20RTJ O - HA20RTJ PRO - HA61RTJ O - HA61RTJ PRO
A - Preface - Foreword
1 - Symbols and colors
Symbols and colors are used to alert the operator of safety precautions and/or to highlight important safety
information.
The following safety symbols are used throughout this manual to indicate specific hazards and the hazard
severity level when operating or maintaining the Aerial Work Platform.
Symbol
Symbol Description
Danger : Risk of injury or death
Caution : Risk of material damage
Prohibition relating to work safety and quality
Reminder to use good practice or follow pre-operation checks
Cross-reference to another part of the manual
Cross-reference to another manual
Cross-reference to repair (contact HAULOTTE Services®)
Maintenance sheet
Time required for intervention
Recommended tools
Recommended part
Safety
N.B. : Additional technical information

94000427880 E 12.15 US / GB
HA20RTJ - HA20RTJ O - HA20RTJ PRO - HA61RTJ O - HA61RTJ PRO
A - Preface - Foreword
Decals
N.B.-:-THE FOLLOWING SAFETY ADVISORIES ARE USED THROUGHOUT THIS MANUAL TO INDICATE SPECIFIC
HAZARDS WHEN OPERATING OR MAINTAINING THE MACHINE.
Color Title Description
Danger : Indicates a hazardous situation which if not avoided,
WILL result in death or serious injury.
Warning : Indicates a hazardous situation which if not avoided,
COULD result in death or serious injury.
Caution : Failure to comply could result in minor or moderate
injury.
Notice : Indicates practices not related to personal injury.
Procedure : Indicates a maintenance operation.

10 4000427880 E 12.15 US / GB
HA20RTJ - HA20RTJ O - HA20RTJ PRO - HA61RTJ O - HA61RTJ PRO
A - Preface - Foreword
Notes