Haulotte HT43RTJ PRO Product guide

Maintenance Book
HT43RTJ PRO - HT132RTJ PRO
4001034910 E 06.21 USA / GB
MAINTENANCE BOOK
HT43RTJ PRO - HT132RTJ PRO
USA

2 24203 4001034910 0 E 06.21 USA / GB
HT43RTJ PRO - HT132RTJ PRO

3
CONTENTS
Maintenance Book
CONTENTS
A
Preface -
Foreword
1 - Symbols and colors . . . . . . . . . . . . . . . . . . . . . 10
B
Safety
1 - General safety rules . . . . . . . . . . . . . . . . . . . . . 13
1.1- Maintenance implementation................................... 13
1.2- Uncontrolledmovement Hazard................................ 14
1.3- Electric ShockHazards ........................................ 14
1.4- Explosion /FireHazards ....................................... 15
2 - Maintenance and repair training . . . . . . . . . . . 16
2.1- Owner'sresponsability. ........................................ 16
2.2- Technician's responsability ..................................... 16
2.3- HAULOTTEServices®........................................ 16
2.4- Training ...................................................... 16
2.5- Productmodification........................................... 17
2.6 - AfterSalesService ............................................ 17
2.7- Productinformation............................................ 17
3 - Conditions of warranty . . . . . . . . . . . . . . . . . . 17

4
Maintenance Book
C
Familiarization
1 - Primary machine components . . . . . . . . . . . . 20
1.1- Layout........................................................ 20
1.2- Groundcontrolbox............................................ 22
1.2.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.2 - Display Panel (LED'S 1 - 10). . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3- Platformcontrolbox ........................................... 26
1.3.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.3.2 - Display Panel (LED'S 101 - 117). . . . . . . . . . . . . . . . . . . . . . . . 28
1.4- Axleextensioncontrolbox. .. ................................... 30
1.4.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 - List of actuators and sensors . . . . . . . . . . . . . 32
2.1- Sensors. . . . . . . . . . ............................................ 32
3 - Power source - Engine specifications . . . . . . 34
3.1 - Generalsafetyand specificinterventionsonmotor................ 34
3.2- GeneralSpecifications. ..................... ................... 34
3.3- Consumables................................................. 35
4 - Consumables (Oils - Fuels - Engine oil -
Coolant level...) . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
4.1- Fuel. ............... .......................................... 36
4.1.1 - Other fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.2- Engine oil..................................................... 37
4.3- Hydraulicoil................................................... 38
4.4- Gearmotoroil. ...... ....................... ................... 39
4.5- Coolant....................................................... 39
4.6- Cylinderstorageoil . .. ......................................... 39
4.7- Grease. ............ .......................................... 40
4.8- Marineprotection.............................................. 40
5 - Machine specifications . . . . . . . . . . . . . . . . . . 41
5.1- Movementspeed ............................................. 41

5
CONTENTS
Maintenance Book
D
Inspection and
maintenance
schedule
1 - Inspection program . . . . . . . . . . . . . . . . . . . . . 43
2 - Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . 43
3 - Preventive maintenance . . . . . . . . . . . . . . . . . 44
4 - Periodic inspection . . . . . . . . . . . . . . . . . . . . . 51
5 - Major inspection. . . . . . . . . . . . . . . . . . . . . . . . 53
Machine sheet
MS0001 - Structural part inspection. . . . . . . . . . . . . . . 55
MS0002 -
Pins and bearing inspection. . . . . . . . . . . . . 59
MS0003 - Cylinder inspection . . . . . . . . . . . . . . . . . . . . 63
E004 -
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
MS0004 -
Braking test procedure . . . . . . . . . . . . . . . . . 69
MS0005 - Torque Values . . . . . . . . . . . . . . . . . . . . . . . . 71
E007 -
Screws, bolts and nuts . . . . . . . . . . . . . . . . . . . 75
E016-1 -
Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
E016-2 - Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
MS0031 -
Overload system . . . . . . . . . . . . . . . . . . . . . . 85
E041 -
Generator option (For HT132RTJ PRO only) . 93
E048 - Cable carrier cat track . . . . . . . . . . . . . . . . . . . . 95
E053 -
Specific adjustment procedure H43TPX
(HB135JRT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
97
MS0133 -
Universal plug . . . . . . . . . . . . . . . . . . . . . . . 105
MS0238 -
Links to engine manufacturer manuals -
Fuel-powered machines . . . . . . . . . . . . . . . . . . . . . .
107
MP0001 -
Wheel tightening procedure . . . . . . . . . . . . 109
MP0002 - Wheel reducer level procedure. . . . . . . . . . 111
MP0003 -
Procedure for checking the level of engine
oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115
MP0004 -
Replacing the engine oil filter. . . . . . . . . . . 117
MP0005 - Diesel filter replacement . . . . . . . . . . . . . . . 119
MP0006 -
Hydraulic oil filter replacement . . . . . . . . . 121
MP0007 -
Procedure for checking engine belt tension 123
MP0008 - Front axle locking function check . . . . . . . 127

6
Maintenance Book
MP0010 - Air filter replacement. . . . . . . . . . . . . . . . . . 131
MP0011 -
Wear pad check . . . . . . . . . . . . . . . . . . . . . . 133
MP0013 -
Hydraulic tank level. . . . . . . . . . . . . . . . . . . 137
MP0014 - Emptying the hydraulic tank. . . . . . . . . . . . 139
MP0015 -
Load cell tightness check. . . . . . . . . . . . . . 143
MP0016 -
Rotary cylinder tightness check. . . . . . . . . 145
MP0017 - Checking the platform. . . . . . . . . . . . . . . . . 147
MP0018 -
Slew ring clearance check . . . . . . . . . . . . . 151
MP0019 -
Torque tightening of the slew ring. . . . . . . 153
MP0020 - Emptying the diesel tank. . . . . . . . . . . . . . . 155
MP0021 -
Draining the cooling circuit . . . . . . . . . . . . 157
MP0024 -
Checking the bushings and pins . . . . . . . . 161
MP0025 - Checking the condition of belts . . . . . . . . . 165
MP0026 -
Checking and cleaning the fuel filter. . . . . 167
MP0028 -
Greasing the pads . . . . . . . . . . . . . . . . . . . . 169
MP0030 -
Cleaning of air cleaner element . . . . . . . . . 171
MP0031 -
Coolant level. . . . . . . . . . . . . . . . . . . . . . . . . 173
MP0032 -
Replace the belt . . . . . . . . . . . . . . . . . . . . . . 175
MP0034 -
Check the condition of cables . . . . . . . . . . 179
MP0035 -
Check the tension of cables . . . . . . . . . . . . 181
MP0036 -
Drain the engine oil . . . . . . . . . . . . . . . . . . . 185
MP0038 - Movement reducer level . . . . . . . . . . . . . . . 189
MP0039 -
Drain the movement reducer . . . . . . . . . . . 191
MP0040 -
Axle extension greasing . . . . . . . . . . . . . . . 193
MP0041 - Check the condition of the chains . . . . . . . 195
MP0042 -
Chain tension control . . . . . . . . . . . . . . . . . 197
MP0043 -
Draining the wheel reducer. . . . . . . . . . . . . 201
MP0044 - Greasing the turntable rotation gearbox. . 205

7
CONTENTS
Maintenance Book
E
Trouble shooting
and diagram
1 - Trouble shooting . . . . . . . . . . . . . . . . . . . . . . 207
1.1- Recommendations. . . . . . . . . . . . . . . . . . . . . . . .................... 207
1.2- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................... 207
1.3- Requirements.............................. . . . . . . . . . . . . . . . . . . 207
1.4- Listoffailurespercategory . . . . . . . . . . . . . . . . ....................208
2 - Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
2.1- System architecture ..........................................223
2.1.1 - The ECU modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
2.1.1.1 - U106 SPU 2515 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
2.1.1.2 - U104 node B2 slave. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
2.1.1.3 - EDC Deutz module (for TIER IV) . . . . . . . . . . . . . . . . . . . . . . 231
2.1.1.4 - EDC Deutz module (for STAGE V) . . . . . . . . . . . . . . . . . . . . 232
2.2- Hydrauliccircuit...............................................233
3 - Electric diagram . . . . . . . . . . . . . . . . . . . . . . . 234
4 - Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . 246
F
Records
1 - Intervention register. . . . . . . . . . . . . . . . . . . . 249

8
Maintenance Book

94001034910 E 06.21 USA / GB
HT43RTJ PRO - HT132RTJ PRO
A - 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 listedon 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 adjust-
ments 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.

10 4001034910 E 06.21 USA / GB
HT43RTJ PRO - HT132RTJ 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
Recommended tools
Recommended part
Safety
N.B. : Additional technical information