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
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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.

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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

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A - Preface - Foreword
Decals
N.B.-:-THE FOLLOWING SAFETY ADVISORIES ARE USED THROUGHOUT THIS MANUAL TO INDICATE SPECIFIC
HAZARDS WHEN OPERATING 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 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.

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A - Preface - Foreword
Notes

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B - Safety
Safety
1 - General safety rules
1.1 - MAINTENANCE IMPLEMENTATION
Your safety and the safety of the people around are essential.
Make sure the work area is clean in order to not to pollute the system of the machine.
Before performing any maintenance interventions, 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 the elements of the machine in configuration of maintenance
thanks to mechanics devices.
Report that the machine is under maintenance by tagging the platform and ground control boxes.
Note :
• Using the machine during maintenance is strictly forbidden.
• Do not climb onto the covers.
• The handling of parts must be carried out using appropriate equipment (Chains, Lifting slings, Lifting
anchors).
• Plug the end of any hoses removed, and cap any open ports to prevent contamination during
maintenance.
Return the machine to operating configuration after maintenance has been completed :
1. Remove the turntable rotation locking pin.
2. Pull the E-stop button.
1. Place the machine on firm, level ground.
2. Stow the machine completely.
3. Push the E-stop button to cut off the electricity supply.
4. Insert the turntable rotation locking pin.

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B - Safety
1.2 - UNCONTROLLED MOVEMENT HAZARD
Be aware 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 electrical components to water (high pressure washer, rain).
• Never tow the machine over extended distances.
• In case of a machine breakdown, it is possible to tow short distance to load it onto a trailer.
• Never leave the hydraulic cylinders fully extended before switching off the machine, or when
stationary for an extended period of time.
• Retract and lower the boom to the stowed position rotate the turntable so that the boom is between
the non-steering wheels.
• Select a safe parking location, on a firm level surface, clear of obstruction and traffic.
• Ensure all compartments are closed and secured.
• Chock the wheels.
1.3 - ELECTRIC SHOCK HAZARDS
The machine is not electrically insulated and does not provide protection from contact or proximity to
electrically charged conductors.
Always position the lift at a safe distance from electrically charged conductors to ensure that no part of
the machine is within an unsafe area.
Respect the local rules and the minimum safety distance from power lines.
Minimum safe approach distances
N.B.-:-THIS TABLE IS APPLICABLE, EXCEPT WHEN THE LOCAL REGULATIONS ARE MORE STRICT.
Electric voltage Minimum safety distance
Mètre Feet
0 - 300 V Avoid contact
300 V - 50 kV 310
50 - 200 kV 515
200 - 350 kV 620
350 - 500 kV 825
500 - 750 kV 11 35
750 - 1000 kV 14 45

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B - Safety
1.4 - EXPLOSION / FIRE HAZARDS
Do not operate the machine :
• Do not 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 lightning, thunderstorms, snow/ice or
any weather condition that could compromise operator safety.
• Do not operate the machine during lightning or storms.
• Do not use the machine as a welding earth.
• Do not wash electrical components with a high pressure washer.
• Do not weld on the machine without first disconnecting the battery
terminals.
• The machine must not be used while charging the batteries.
• When using the platform AC power line, ensure it is protected with a circuit
breaker.
Keep away from the machine if it contacts energized power lines. Personnel
on the ground or in the platform must not touch or operate the machine until
energized power lines are shut off.
In the event of accidental contact with a high voltage line, wait for the power
to the line be de-energized before attempting to operate the machine.
Always wear protective clothing and eye wear when working
with batteries and power sources/systems.
N.B.-:-ACID IS NEUTRALIZED 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 atmosphere /
environment.
• Do not touch hot components.
• Do not bridge the battery terminals with metallic objects.
• Do not service the battery in proximity of spark, open flame,
lit cigarettes.
• Do not fill up the fuel tank, when the engine is running and/
or near a flame.

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B - Safety
2 - Maintenance and repair training
2.1 - OWNER'SRESPONSABILITY
The owner (or hirer) has the obligation to inform technician of the instructions contained in the Operator
Manual and Maintenance Book.
The owner (or hirer) has the obligation to renew all manuals or decals that are either missing or in bad
condition.
Additional copies can be ordered from HAULOTTE Services®.
The owner (or hirer) is responsible for applying the local regulations regarding maintenance of the
machine.
2.2 - TECHNICIAN'SRESPONSABILITY
The technician must read and understand the contents of this 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 machine.
2.3 - HAULOTTE SERVICES®
The HAULOTTE® is at your service in all 5 continents of the world via an extensive network of its own
factory trained technicians, who are ready to respond to your every need.
2.4 - TRAINING
Whether you want to just service your equipment or carry out a complete overhaul, HAULOTTE® can
provide you with a structured training program or we can tailor a program to suit your specific
requirements or circumstances. Training can cover the general operation of the equipment,
breakdowns, engine maintenance and repairs and electrical/hydraulic/mechanical repairs and trouble
shooting.
Only authorized and qualified operators may operate HAULOTTE® machines.

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B - Safety
2.5 - PRODUCT MODIFICATION
In a constant effort to improve the quality of machines, HAULOTTE continually monitors technical
improvements that enable to develop products with improved safety and greater reliability. The target
being that HAULOTTE® always work to build confidence in the relationships with our customers.
These improvements will be shared via the following documents :
• OI : Obligatory Intervention, Safety information requiring immediate action (take into account
by HAULOTTE®).
• NI : Technical improvement requiring immediate action (take into account by HAULOTTE®).
• RI : Improvement proposed to customers to take into account during maintenance operation.
• PI : Product information for knowledge.
2.6 - AFTER SALES SERVICE
Our HAULOTTE Services® After Sales Service is at your disposal throughout 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 machine operation.
• If there is an equipment malfunction involving a HAULOTTE® product, then contact HAULOTTE
Services® immediately even if the malfunction does not involve material and/or bodily damage.
2.7 - PRODUCT INFORMATION
Without the written permission from Haulotte, modifying a HAULOTTE® product is a Safety concern.
Any modification may violate Haulotte design parameters, local regulations and industry standards.
If you desire a modification to the product, submit a request in writing to HAULOTTE.
With the utmost care to ensure enhanced reliability and greater safety of the HAULOTTE® products, it
is pertinent that when a "Service or Safety Bulletin" is issued, action is taken immediately. Once the
bulletinhasbeenaddressed,makesurethatthe completedformissubmittedto HAULOTTEServices®.
Do not hesitate to contact HAULOTTE Services® , should you have any questions relating to the issued
bulletin(s) or with questions on the policy itself.
3 - Conditions of warranty
Our warranty conditions and extension contracts are now available on the websites of our sales network :
www.haulotte.com

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B - Safety
Notes

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C - Familiarization
Familiarization
Notes

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C - Familiarization
1 - Primary machine components
1.1 - LAYOUT
HT43RTJ PRO - HT132RTJ PRO
C71 C7
C6
C29
C42
C8
C22
C72
C15
C27 - C28
C11
C10
C20
C166
C24
C14C3C1C14C2
C25
C17
C19
C12
C18
C9
C4