Haulotte H28TJ+ Product guide

Maintenance book
T
ELESCOPIC
MACHINES
, 28 - 43
M
2420333140 E06.13 EN
Maintenance book
TELESCOPIC MACHINES, 28 - 43 M
H28TJ+ (HB86TJ+)
H43TPX (HB135JRT)
2420333140
E06_13
EN

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Telescopic machines, 28 - 43 m

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CONTENTS
Maintenance book
CONTENTS
1 - Maintenance book. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 - After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 - Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
A
SAFETY PRECAUTIONS
1 - Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 - Maintenance book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 - Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 - Label colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 - Manufacturer's warranty . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 - Warranty acceptance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 - Warranty period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 - Conditions of warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 - Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 - Scope of intervention . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 - Instructions for intervention . . . . . . . . . . . . . . . . . . . . . . 15
B
RECOMMENDATIONS
1 - Lubrication diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 - Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1 - Fuels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 - Motor oils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 - Hydraulic oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3 - Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.1 - Classification plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.1.1 - Red labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.1.2 - Orange labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1.3 - Yellow labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1.4 - Other labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1.5 - Green labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1.6 - Blue labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2 - Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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Maintenance book
C
MAINTENANCE
1 - General program / Recommendations . . . . . . . . . . . . . . 35
2 - Detailed program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3 - Maintenance sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.1 - Placing the machine in maintenance configuration. . . . . . . . . . . . . . . . 89
3.2 - Placing in operating configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.3 - General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.3.1 - Recommendations on the conditions of maintenance . . . . . . . . 89
3.3.2 - Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.3.2.1 - Bolts and Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.3.2.2 - Pins and bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.3.2.3 - Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.3.2.4 - Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.3.3 - Hydraulics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.3.3.1 - Oil replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.3.3.2 - Replacing damaged of hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.3.3.3 - Evaluation of leaks on hydraulic cylinders . . . . . . . . . . . . . . . . . 95
3.3.4 - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.3.4.1 - Replacing damaged cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
E002 - Wheel reducer. . . . . . . . . . . . . . . . . . . . . . . . 97
E003 - Hydraulic filter cartridge . . . . . . . . . . . . . . . 99
E004 -
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
E005 - Slew ring . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
E006 - Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
E007 -
Screws, bolts and nuts . . . . . . . . . . . . . . . 111
E008 - Turntable rotation gearbox . . . . . . . . . . . . 113
E013 - Pulleys and wear pads. . . . . . . . . . . . . . . . 115
E016-1 - Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
E016-2 -
Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
E053 - Specific adjustment procedure H43TPX
(HB135JRT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
E018 - Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
E022 - Telescope . . . . . . . . . . . . . . . . . . . . . . . . . . 137
E041 -
Generator option (For HB135JRT only). . 139
E048 - Cable carrier cat track . . . . . . . . . . . . . . . . 141
D
DIAGNOSIS ASSISTANCE
1 - Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
2 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

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CONTENTS
Maintenance book
E
ELECTRIC CIRCUIT
1 - Wiring diagram-Main components . . . . . . . . . . . . . . . . 147
2 - Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
3 - Relays and terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4 - Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5 - Diagnosis assistance indicators . . . . . . . . . . . . . . . . . . 159
6 - Locations and functions of the main safety features . 160
6.1 - Location of the limit switch and sensors. . . . . . . . . . . . . . . . . . . . . . . . . 162
6.2 - Locations of the solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7 - Buzzers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
8 - Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
F
HYDRAULIC CIRCUIT
1 - Hydraulic diagram-Main components. . . . . . . . . . . . . . 167
2 - Solenoid valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
G
INTERVENTION REGISTER
1 - Intervention register . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

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Maintenance book

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2420333140 E06.13 EN
Telescopic machines, 28 - 43 m
You have just purchased a HAULOTTE® product
and we would like to thank you for your business.
1 - Maintenance book
As indicated on the delivery slip, this maintenance book is one of the documents in our on-board case
supplied on delivery of your machine.
Person using this product must do so in accordance with the instruction provided in this manual.
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.
2 - After Sales Service
Our HAULOTTE Services® After Sales Service is at your disposal throughout your machine's service
life to ensure optimal 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..
• HAULOTTE® must be informed in the event of an incident that either involves one of these products
or has caused bodily injury or significant deterioration of property (personal property or the product);
contact HAULOTTE Services® immediately (See : HAULOTTE Services® contact details)

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3 - Compliance
We would like to remind you that HAULOTTE® complies with the provisions of any applicable
directives applicable to this type of machine.
HAULOTTE advises you that NO modifications carried out without the written permission
of HAULOTTE® will void the HAULOTTE warranty..
HAULOTTE® cannot be held liable for any changes to the technical specifications contained in this
manual.
HAULOTTE® reserves the right to alter technical specifications 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 installation
itself (static test).
Otherwise, it is essential to follow the manufacturer's recommendations below :
• Installation by authorised HAULOTTE® personnel only.
• Update the manufacturer's identification plate.
• Have stability tests carried out by a certified agency/competent person.
• Ensure label compliance.

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A - Safety precautions
Safety precautions
1 - Recommendations
1.1 - MAINTENANCE BOOK
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.
• Cause operator safety problems.
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,
and carry genuine HAULOTTE spare parts and tools as required, and also provide fully
documented reports on all work completed..

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A - Safety precautions
1.2 - SYMBOLS USED
Symbols are used to alert the operator to safety precautions or to highlight practical
information.
Symbol meanings
Symbol Meaning
Danger : Risk of injury or death (work safety)
Caution : Risk of material damage (work quality)
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
Recommended tools
Recommended part
Safety
N.B. : Additional technical information

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A - Safety precautions
1.3 - LABEL COLORS
The potential dangers and any specific regulations are indicated around the product by labels
and identification plates.
Familiarize yourself with the labels and their respective color codes.
Label color code
Label color code-For Russia and the Ukraine only
The labels must be kept in good condition. Additional labels can be obtained from HAULOTTE Services®.
Labels Color Meaning
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
Labels Color Meaning
Red Prohibitions - Danger
Yellow Warning : Risk of material damage and/or minor injury
Blue Precaution
Blue Information
Other Additional technical information

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A - Safety precautions
2 - Manufacturer's warranty
2.1 - WARRANTY ACCEPTANCE
On reception of his machine, the owner or rental company must check the machine's condition
and fill out the machine reception slip provided.
2.2 - WARRANTY PERIOD
The present warranty is granted for a period of 12 months or a limit of 1000 operating hours
for lifting and handling equipment and 2000 operating hours for public works machinery, to run
from delivery and terminating with the first period to be reached.
Spare parts are covered by a 6 month warranty.
2.3 - CONDITIONS OF WARRANTY
HAULOTTE® guarantees its products against defects, faults or manufacturing defects when
the owner or rental company has informed HAULOTTE® of the defect.
The warranty does not cover the consequences of normal wear, nor any defects, failure or
damage resulting from poor maintenance or abnormal usage, in particular overloading, impact
by an external source, faulty installation or any modification made to products marketed
by HAULOTTE® and performed by the owner or rental company.
In case of operation or use which does not comply with the instructions or recommendations
in this maintenance book, 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 justify maintenance at the recommended time.
Warranty obligations for the time period stated above will cease immediately in situations
where the defect is due to the following reasons :
• Use of spare parts that are not HAULOTTE® originals.
• If elements or products other than those recommended by the manufacturer are used.
• If the HAULOTTE® name, serial numbers or identification marks are removed or altered.
• After an unreasonably long delay before reporting a manufacturing problem.
• If the owner or rental company continues to use the machine despite problems.
• If damage is caused by modifications that do not comply with HAULOTTE® specifications.
• If lubricants, hydraulic oils or fuels that do not comply with HAULOTTE® recommendations are used.
• If the machine is incorrectly repaired or used by the customer or in case of an accident caused by a
third party.
If no particular agreement has been made, any claims made after the previously established
warranty period has expired will be refused..

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A - Safety precautions
The present warranty does not cover damage that may result directly or indirectly from any
flaws or defects covered by the latter :
• Consumables : No claims will be accepted for objects or parts replaced in the context of normal
machine usage.
• Settings : Adjustments of all sorts may become necessary at any time. Therefore adjustments are
considered a part of normal machine usage conditions and are not covered by the warranty.
• Hydraulic and fuel circuit contamination : Every possible precaution is taken to ensure that fuel and
hydraulic liquid delivered is clean. On the other hand, in certain cases it is possible to contaminate fuel
and hydraulic circuits, especially when fuel and lubricants are stored on the work site. Moreover,
irregular or poor cleaning of the decanting device may also cause fuel/hydraulic circuit contamination
and therefore damage the parts in direct contact with these liquids. HAULOTTE® will not accept any
claims concerning cleaning of the fuel circuit, filter, injection pump or any other equipment in direct
contact with fuel or lubricants.
• Wearing parts (pads, bearings, 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 present warranty, the owner or rental company must inform the nearest
HAULOTTE® branch or the branch that delivered the machine (the only dealer authorised to
carry out an intervention under the manufacturer's warranty agreement) of the defect in writing
as quickly as possible.
The branch will decide whether to repair or replace the part that proves to be faulty.
The owner or rental company must present the duly completed maintenance book supplied
with the machine as proof that the maintenance operations recommended by the manufacturer
have been carried out.
The owner or rental company must ensure that the defect covered by the HAULOTTE®
warranty is reported to and acknowledged by the HAULOTTE® branch (the only dealer
authorised to carry out work covered by the warranty) as rapidly as possible or must report the
defect in writing.
Work carried out under the HAULOTTE® warranty will be performed by the branch which
participated in delivery of the machine, wherever possible.

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A - Safety precautions
3 - Scope of intervention
The inspection and maintenance table below, identifies the role and the responsibilities of each party
in periodical machine maintenance..
Inspections and maintenance
If the machine is operated in a hostile environment or intensively, increase the frequency of maintenance.
Type of
intervention Frequency Person-in-charge Intervenor Reference document
Pre-delivery
inspection
Before each delivery 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 visit
2 times a year or at the
latest 6 months after the
last periodic visit, and
according to the local
regulations
Owner (or hirer)
Organization or
technician approved
by the employer or by
the intermediary
of HAULOTTE
Services® in
accordance with
the HAULOTTE
Services® contract
Maintenance book

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A - Safety precautions
4 - Instructions for intervention
N.B.-:-Acid is neutralised with sodium bicarbonate and water.
Do not use the machine during while maintenance work is being completed on it.
For any intervention on the power sources, wear glasses and protective clothes (acid spray).
Do not operate the product in the 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 close to a spark, naked flame, glowing tobacco (emissions of gas).
• Never expose the batteries or electrical components to water (pressure cleaner, rain).
• Never disable the safety devices.
• Do not climb onto the covers.
• Do not fill up the fuel tank, when the engine is running and/or close to a naked (open) flame.
Use an oil collection pan to avoid polluting the environment.

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A - Safety precautions

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B - Recommendations
Recommendations
1 - Lubrication diagram
Diagram
5
2
6
6
6 6 6 6
6
6 6
2
1
2 22
2
4
3
Seulement pour
Only for
H43TPX /
HB135JRT
Seulement pour
Only for
H43TPX /
HB135JRT
Seulement pour
Only for
H43TPX /
HB135JRT

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B - Recommendations
List of ingredients
2 - Consumables
List of consumables
Marking Ingredient Symbol HAULOTTE® code
1
Engine oil - Can 20 l(5,3 gal US) 2420801360
Engine oil - Barrel 209 l(55,2 gal US) 2420801350
Engine oil (+30° / - 20° ) 2820305670
Engine oil (Winter option) 4000010660
2
Box oil - Can 20 l(5,3 gal US) 2420801370
Box oil - Barrel 209 l(55,2 gal US) 2420801380
3
Hydraulic oil (Standard) - Barrel 209 l(55,2 gal US) 2420801310
Hydraulic oil (Winter option) 2505002640
4Biological hydraulic oil - Barrel 209 l(55,2 gal US) 2820304310
5Extreme-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
7Molybdenum grease
8 Oil
9High-pressure lubricant
Consumable HAULOTTE® code Applicability
Hydraulic filter cartridge- Movements 2427002910 H43TPX (HB135JRT)
H28TJ+ (HB86TJ+)
Hydraulic filter cartridge- Driving 2427003110 H43TPX (HB135JRT)
H28TJ+ (HB86TJ+)
Primary air filter 2427003090 H43TPX (HB135JRT)
H28TJ+ (HB86TJ+)
Secondary air filter 2427003100 H43TPX (HB135JRT)
H28TJ+ (HB86TJ+)
Diesel filter 2427003070 H43TPX (HB135JRT)
H28TJ+ (HB86TJ+)
Engine oil filter 2427003080 H43TPX (HB135JRT)
H28TJ+ (HB86TJ+)
Filter pack(1)
(1.) 1 hydraulic filter cartridge + 1 air filter + 1 diesel pre-filter + 1 diesel filter + 1 engine oil filter
KKIT250H-HA32 H43TPX (HB135JRT)
H28TJ+ (HB86TJ+)

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B - Recommendations
2.1 - FUELS
These fuels can be used on any type of mechanical injection engine. Please see machine
configuration.
N.B.-:-The fuel to be used is regulated by national laws; refer to these requirements and to the table
below to define the appropriate fuel.
Table of technically permitted fuels
Compliant
Not compliant
Engines Fuels
Hydraulic filter
cartridge
European 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, please contact HAULOTTE Services®.
• Jet engine fuels (kerosene) : F34 and F35 types under OTAN designation are possible on some
engines and under certain conditions. For more information, please contact HAULOTTE Services®.
The use of vegetable oils is forbidden.

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B - Recommendations
2.2 - MOTOR OILS
In order to ensure that the engine will run properly, it is recommended to use the following oils
Viscosity table