HT23RTJO

Maintenance Book
HT23RTJ PRO - HT23RTJ PRO SW - HT67RTJ PRO

HT23RTJ O - HT23RTJ O SW - HT67RTJ O -
Maintenance Book
HT23RTJ O - HT23RTJ O SW -
HT67RTJ O -
HT23RTJ PRO - HT23RTJ PRO SW -
HT67RTJ PRO
4000866050 E 10.18 USA / GB

HT23RTJ O - HT23RTJ O SW - HT67RTJ O - HT23RTJ PRO - HT23RTJ PRO SW - HT67RTJ PRO
2 4000866050 E 10.18 USA / GB

Maintenance Book
CONTENTS
Preface -
Foreword
1 - Symbols and colors . . . . . . . . . . . . . . . . . . . . . . 8
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
CONTENTS
3.2 - Warranty period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.3 - Conditions of warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4 - Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3
Maintenance Book
Familiarization
1 - Primary machine components . . . . . . . . . . . . 20
1.1 - Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2 - Ground control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.2 - HAULOTTE Activ'Screen 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.3 - Platform control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.3.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.3.2 - Display Panel (LED'S 101 - 117). . . . . . . . . . . . . . . . . . . . . . . . 47
2 - List of actuators and sensors . . . . . . . . . . . . . 52
2.1 - Sensors and actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3 - Power source - Engine specifications . . . . . . 55
3.1 - General safety and specific interventions on motor. . . . . . . . . . . . . . . . 55
3.2 - General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.3 - Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.4 - Ingredient. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4 - Lubrication diagram . . . . . . . . . . . . . . . . . . . . . 57
4.1 - Greasing points localization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5 - Consumables (Oils - Fuels - Engine oil -
Coolant level...) . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.1 - Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.1.1 - Other fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.2 - Engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.3 - Hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6 - Machine specifications . . . . . . . . . . . . . . . . . . 64
6.1 - Movement speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Inspection and
maintenance
schedule
1 - Inspection program . . . . . . . . . . . . . . . . . . . . . 65
2 - Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . 66
3 - Preventive maintenance . . . . . . . . . . . . . . . . . 67
4 - Periodic inspection . . . . . . . . . . . . . . . . . . . . . 73
5 - Major inspection . . . . . . . . . . . . . . . . . . . . . . . . 75
4
Maintenance Book
Machine sheet
MS0001 - Structural part inspection . . . . . . . . . . . . . . . 77
MS0002 - Pins and bearing inspection . . . . . . . . . . . . . 81
MS0003 - Cylinder inspection . . . . . . . . . . . . . . . . . . . . 85
MS0004 - Braking test procedure . . . . . . . . . . . . . . . . . 89
MS0005 - Torque Values . . . . . . . . . . . . . . . . . . . . . . . . 91
MS0006 - Tires (Tyres) and pressures -
Wheel replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
MS0007 - Wheel reducer - Control - Oil replacement . 99
MS0008 - Oscillating axles - Functional tests . . . . . . 101
MS0009 - Fuel tank - Filling-up . . . . . . . . . . . . . . . . . . 103
MS0010 - Slew ring inspection . . . . . . . . . . . . . . . . . . 105
MS0011 - Gearbox inspection - Oil replacement . . . . 111
MS0012 - Condition of the cables inspection -
Criteria of replacement . . . . . . . . . . . . . . . . . . . . . . . 113
MS0013 - Check and replacing the pads . . . . . . . . . . 119
MS0014 - Procedure of dismantling /
reassembling telescope cylinder . . . . . . . . . . . . . . . 127
MS0015 - Boom adjustment procedure . . . . . . . . . . . 137
MS0018 - Boom angle sensor adjustment . . . . . . . . . 141
MS0019 - Hydraulic oil - Level Replacement . . . . . . . 145
MS0020 - Hoses inspection - Replacement . . . . . . . . 149
MS0021 - Hydraulic filter cartridge Replacement . . . 151
MS0022 - Pressure adjustment . . . . . . . . . . . . . . . . . . 155
MS0023 - Hydraulic ways. . . . . . . . . . . . . . . . . . . . . . . 159
MS0026 - Dismantling / Reassembling wheels
reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
reassembling cage . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
CONTENTS

reassembling hydraulic rotary actuators. . . . . . . . . 199
MS0029 - KUBOTA diesel engine - Tier III . . . . . . . . 217
MS0110 - Battery (ies) . . . . . . . . . . . . . . . . . . . . . . . . . 245
MS0133 - Universal plug . . . . . . . . . . . . . . . . . . . . . . . 249
MS0164 - Weighing adjustment procedure
(calibration). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
5
Maintenance Book
MS0224 - Remove/Re-install jib cylinder . . . . . . . . . . 263

MS0225 - Remove - Replace wheel pivot and
gear motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
MS0226 - Remove - Replace load cell. . . . . . . . . . . . . 285
MS0227 - Remove/replace the telescope cylinder. . . 291
MS0228 - Removal - Replacement of the steering
cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
MS0229 - Removing/re-installing the oscillating
axle actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
MS0230 - Remove - Replace the boom/jib/box
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
MS0231 - Remove - Replace the rear pads . . . . . . . . 337
MS0232 - Remove/re-install the harness BUS CAN . 347
MS0233 - Disassembly - Assembly
Activ' Lighting System. . . . . . . . . . . . . . . . . . . . . . . . 357
MS0239 - Removal - Replacement boom cylinder. . . 365
MS0240 - Remove/Re-install output
compensation cylinder . . . . . . . . . . . . . . . . . . . . . . . 377
Trouble shooting
and diagram
1 - Trouble shooting . . . . . . . . . . . . . . . . . . . . . . 385
1.1 - Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
1.2 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
2 - List of failures per category . . . . . . . . . . . . . 386
3 - Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
3.1 - PCB Turret. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
4 - Electric diagram . . . . . . . . . . . . . . . . . . . . . . . 408
5 - Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . 420
Records
1 - Intervention register . . . . . . . . . . . . . . . . . . . . 429
6
A - Foreword
Preface - Foreword
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 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.
4000866050 E 10.18 USA / GB 7

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
8 4000866050 E 10.18 USA / GB

Decals
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.
N.B.-:-THE FOLLOWING SAFETY ADVISORIES ARE USED THROUGHOUT THIS MANUAL TO INDICATE SPECIFIC
HAZARDS WHEN OPERATING OR MAINTAINING THE TELEHANDLER.
4000866050 E 10.18 USA / GB 9

Notes
10 4000866050 E 10.18 USA / GB

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.
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.
4000866050 E 10.18 USA / GB 11

B - Safety
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.
1.2 - 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.
12 4000866050 E 10.18 USA / GB

B - Safety
1.3 - ELECTROCUTION 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
Electric voltage Minimum safety distance

Mètre Feet
0 - 300 V Avoid contact
300 V - 50 kV 3 10
50 - 200 kV 5 15
200 - 350 kV 6 20
350 - 500 kV 8 25
500 - 750 kV 11 35
750 - 1000 kV 14 45
N.B.-:-THIS TABLE IS APPLICABLE, EXCEPT WHEN THE LOCAL REGULATIONS ARE MORE STRICT.
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.
4000866050 E 10.18 USA / GB 13

B - Safety
1.4 - EXPLOSION / FIRE HAZARDS
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.
14 4000866050 E 10.18 USA / GB

B - Safety
2- Maintenance and repair training
2.1 - OWNER'S RESPONSABILITY
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'S RESPONSABILITY
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.
Only authorized and qualified operators may operate HAULOTTE® machines.
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.
4000866050 E 10.18 USA / GB 15

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, government 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
bulletin has been addressed, make sure that the completed form is submitted to HAULOTTE Services®.
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.
16 4000866050 E 10.18 USA / GB

B - Safety
3- Manufacturer's warranty
3.1 - 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.
3.2 - WARRANTY PERIOD
The present warranty is valid for a period of 12 months or up to a maximum of 1000 operating hours
for personnel lifting machines and 12 months or up to a maximum of 1500 operating hours for the other
machines, including MJX or the Telescopic Handlers, starting from delivery and terminating when the
first limit is reached.
Spare parts are covered by a 6 month warranty.
3.3 - 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 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 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.
4000866050 E 10.18 USA / GB 17

B - Safety
If no particular agreement has been made, any claims made after the previously established warranty
period has expired will be refused.
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, 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.
3.4 - WARRANTY CONDITIONS
To benefit from the warranty, the owner or rental company must inform the nearest HAULOTTE®
subsidiary or the subsidiary 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 subsidiary 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® subsidiary 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 subsidiary which delivered
the machine, wherever possible.
18 4000866050 E 10.18 USA / GB

C - Familiarization
Familiarization
Notes
4000866050 E 10.18 USA / GB 19

C - Familiarization
1- Primary machine components
1.1 - LAYOUT
C7
C35
C29
C6
C9 C42
C150
C72
C146
C12
C113
C22 C8 C33
C11
C17
C27
C28 C145
C149 C20
C3
C148 C14 C2 C10 C140 C1
C14
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C - Familiarization
Marking Description Marking Description
C1 Chassis C27 Ground control box + Universal plug
C2 Front driven steering axle C28 Tilt sensor
C3 Rear drive and/or steer wheel C29 Platform rotation cylinder
C6 Platform C33 Counterweight
C7 Platform control box C35 Document holder
C8 Input jib leveling cylinder C42 Foot Switch
C9 Upper boom C72 Output jib compensation cylinder
C10 Slew ring C113 Beacon light
Propane bottles - (For petrol / gas
C11 Turntable assembly C140
machines)
C12 Side cover C145 Rear drive wheel
C14 Hydraulic drive motor and reducer C146 Telescopic jib
Right side compartment (hydraulic oil
C15 C148 Fixed axle
tank and fuel tank)
Left side compartment (engine, pump
C17 C149 Oscillating axle
and starter battery)
C20 Tie-down (and/or lifting) points C150 Jib lifting cylinder
C22 Boom lift cylinder C163 Handrail
Universal plug
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C - Familiarization
1.2 - GROUND CONTROL BOX
1.2.1 - Layout
General view
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C - Familiarization
Controls and indicators
Marking Description Function
By pressing on : Tilt the platform towards the front of the

machine.
1 Platform upgrade control
By pressing on : Tilt the platform towards the back of the

machine.
By pressing on : Jib lifting

2 Jib lifting / lowering switch 1
By pressing on : Jib lowering
By pressing on : Boom extend

3 Boom telescoping switch
By pressing on : Boom in
By pressing on : Boom raising

4 Boom raising switch
By pressing on : Boom lowering
By pressing on :
6 Enable Switch / Back-up unit selector • Validation of controls when engine started
• automatic switching of emergency electropump if the engine is
stopped
By pressing on : Counter clockwise (CCW) rotation

7 Turntable rotation switch
By pressing on : Clockwise (CW) rotation
By pressing on : Clockwise (CW) rotation

8 Platform rotation switch
By pressing on : Counter clockwise (CCW) rotation
Pulled out : Ground control box energized

9 E-stop button
Pushed in (activated) : De-energizes control system
Indicator of the ground control box
10 LED lights up - ground control box icon
selection
11 "Overriding system" control By pressing on : This should be used ONLY when normal
operation from the ground box is unavailable - use in emergency ONLY
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C - Familiarization
Marking Description Function
12 Horn button
By pressing on : Horn activation
Indicator of the platform control box

13 LED lights up - platform control box icon
selection
14 Beacon light on/off

By pressing on : Beacon light ON / OFF
Alarm icon :
• Is ON at power up of the machine, at the same time as the icon ( 19 )
Is blinking if overriding is active :
15 Overload indicator / Fault
• An active or detected failure is displayed on on-board screen
• Or Hydraulic oil temperature icon is active on on-board screen
• Or Engine pressure icon is active on on-board screen
• Or Engine stop icon is active on on-board screen
• Or Overload machine status is active on on-board screen
16 Engine start-up selector By pressing on : Engine start / stop
17 Propane Gas supply2 By pressing on : Propane Gas supply selection
18 Petrol/Gasoline or diesel supply3 By pressing on : Fuel supply selection
Alarm icon :
Engine warning indicator / Engine pre- • Is ON at power up of the machine at the same time as the icon ( 15 )
19 Is blinking if overriding is active Warning icon is ON if :
heating
• Engine warning icon is active on on-board screen
• Or Tilt machine status is active on on-board screen
• Or Engine is pre-heating
20 DPF regeneration inhibited4 By pressing on : Refusal of the request for regeneration
21 DPF regeneration required5 By pressing on : Regeneration start-up
: De-energizes control system
22 Control box activation key switch

: Platform control box energized
: Ground control box energized
23 Activ'Screen 2
1. For machines fitted with
24 4000866050 E 10.18 USA / GB

C - Familiarization
1.2.2 - HAULOTTE Activ'Screen 2
Upon starting and during operation of the machine, the LCD screen "Activ'Screen" located on the
ground control box displays in real time the machine operating status.
HAULOTTE Activ'Screen 2
Icon Description Function Icon Description Function

HAULOTTE Activ'Screen 2
Navigation buttons - Above Activ'Screen display
Permits scrolling up
Allows return to the
Home Button Up Navigation through the screen (if
home screen at any time
present)
Permits allows scrolling

Permits navigation to
down through the screen
Left navigation screens to the left (if Down Navigation
and onto the following
present)
screen (if present)
Permits navigation to
Used to refuse or cancel
screens to the right of
Right Navigation Cancel Button a selection within the
the current screen (if
menu
present )
Used to confirm
Returns the user to the
Back button Validation Button selection within the
previous screen
menus
On initial start-up of the machine or after 3 day of inactivity, the following screens are displayed in order.
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C - Familiarization

Machine power up (Start-up screen)
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C - Familiarization
Access code not yet entered
Access code entered is correct (Level 1, 2

or 3 depending on authorization of
technician)
Access code
(Will be visible -
depending on the
machine)
Access code entered is incorrect
The machine can be personalized with a user identification code.

Personalization is only possible with level 1 access.
Machine properties display : Soft version, machine serial number,
adjustment parameters.
Possible change of parameters : Language, fault display format,
brightness setting, time, and some options availables.
Operator PIN code not yet entered
Access code NIV 1 Operator PIN code entered is correct

(Will be visible -
depending on the
machine)
Operator PIN code entered is incorrect
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C - Familiarization

The machine can be personalized with a user identification code.
Personalization is only possible with level 2 access.
Contact HAULOTTE Services®.
Operator PIN code not yet entered
Operator PIN code entered is correct
Operator PIN code

(Will be visible -
depending on the
machine)
Operator PIN code entered is incorrect

Emergency mode is activated when :
• The E-Stop at platform control box is
pushed in (de-energized).
• The machine is in overload state.
• Ground control box is selected/energized.
• The emergency overriding button is
activated.
Emergency mode is deactivated when :
• The E-Stop at platform control box is pulled
out (energized).
Emergency mode • The machine is NOT in overload state.
• Ground control box is NOT selected/
energized.
The Emergency mode is out of service/non-
functional
Emergency mode has been used and

activation of its function saved in the memory
of the machine. A HAULOTTE® certified
technician is required to reset the Emergency
Mode system.
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C - Familiarization

Home screen (dashboard)
(Will be visible - depending on the machine)
Machine model zone Machine Model • Machine model display
• The timer flashes if the

Hourmeter engine is switched on and
the hourmeter increases.
The Maintenance Tool
icon and the number of
hours remaining until the
next maintenance are
displayed for 5 seconds
when the machine is
Hour meter/next maintenance zone started up.
Maintenance Tool icon
Maintenance use blinks; if maintenance is
due.
The maintenance tool
icon turns RED when the
next scheduled
maintenance must be
carried out in under 25
hours.
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C - Familiarization

• Icon is ON if there is no
charge output detected from
the alternator
Battery State
• Icon is flashing if a failure
code for the alternator is
detected (code F09.10)
Icon is ON when the
temperature in the hydraulic
reservoir has exceeded the
Hydraulic oil
maximum required
temperature
temperature. Stop using the
machine and allow the oil to
cool down.
Icon is ON if engine oil
pressure is lower than required
Warning icons zone limit while engine is running.
Engine oil pressure
The Engine must be switched
OFF immediately to avoid
damaging the motor.
• The engine oil level is under

the acceptable limit for correct
Engine oil level
engine operation. Top up the
oil level.
• Icon is ON if an engine failure

is detected (coolant, pressure,
alternator etc)
Stop motor • Or if the Engine shuts down
after 3 seconds of running.
• Or after 1 second when
engine fails to start.
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C - Familiarization

• Icon is ON if Engine warning
is detected. Or one of the
Engine warning engine maintenance
schedules has been
exceeded.
• Engine decontamination
Engine system fault. In this case, you
decontamination must contact HAULOTTE
fault (If fitted) Services® as soon as
possible.
• Permanently lighted if the

DPF regeneration particle filter requires
Warning icons zone
required (If fitted) regeneration with a high
clogging level
DPF regeneration • Light stays on if regeneration

inhibited (If fitted) is inhibited
Regeneration DPF • Light stays on during

in progress (If fitted) regeneration
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C - Familiarization

• Diesel
Power mode used • GPL / LPG
• Electrical
Functional information zone

Bargraph
The indicator changes

Digital Gauge - Fuel from GREEN to RED
reserve indicator (ON/ when the fuel level is
OFF) low and indicator is
activated
The fuel level
indicator switches
Analog Gauge - Fuel
from GREEN to RED
level gauge
when the fuel level is
low
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C - Familiarization

Displays the machine
battery voltage. The
Charge Battery
indicator switches to RED
if the voltage is low.
Engine Speed (rpm) Engine speed display
Displays Engine coolant

temperature. The
Temperature motor indicator switches from
GREEN to RED when the
engine overheats
Additional functions
Functional information zone
• The icon is ON when the

Beacon flashing light is switched
on
• The icon is ON when the

Working light
work light is switched on
• The icon is ON when

Activ' Lighting the Activ' Lighting
System System is switched on in
auto or manual mode
• The icon is ON if the

Stop Emission
system is active on the
System
machine
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C - Familiarization

• Displays the pictogram and

Pictogram and title
machine status
Machine ready, displayed

Ready when no failures and no other
machine state icons is active
Alarm icon is flashing slowly If

there is either an active or
Machine status zone detected machine failure, or if
the machine is in an overload
or tilt is active. When the
Alarm Alarm symbol is displayed,
there will also be a symbol
displayed to show either the
type of machine state, or
machine failure that
corresponds.
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C - Familiarization

Layout
Platform control Selector switch is in platform

selected control box position
Ground control Selector switch is in ground

selected control box position
The machine is elevated , and

is on a slope greater than the
permitted slope. Depending
Tilt on the machine configuration,
machine raise and extend
functions may be slowed or
prevented.
The platform is overloaded.
Remove the excessive load to
or below the rated capacity, to
Overload restore functions. In case of
an emergency, to rescue the
operator in platform, use the
Overriding system.
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C - Familiarization

Layout
Engine’s automatic preheat

system is active. The time to
pre-heat will vary according
Pre-heating
to engine and ambient
temperature. Wait before
starting the machine
Icon is ON if the range limit is

Radius limitation
active or faulty
The machine is charging by

Machine is charging
the engine
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C - Familiarization

Fuel level is low. Refill the fuel
tank to the marked level.
Attention: Lack of fuel may
Low fuel level
damage the motor/engine
and will not be covered under
warranty.
Stop Emission Icon is ON when the function

System cuts the engine
Activ' Lighting The function is off. To switch it

System on, go to the 'Settings' menu
• Permanently lighted if the

DPF regeneration particle filter requires
required regeneration with a high
clogging level
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C - Familiarization

Layout
Diagnostic in The HaulotteDiag console is

progress connected to the machine
Screen software update

Screen software
essential Contact HAULOTTE
obsolete
Services®
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C - Familiarization

F12.01 bus CAN CAN network fault between the

fault screen and the rest of the machine
Activ' Shield Bar The secondary safety system is

disable switched off
The secondary safety system is

triggered. An operator may be
trapped on the platform :
• In this situation, supervisor(s) at
ground level must turn the control
box key selector ( 22 ) to the ground
Activ' Shield Bar control box position to take

triggered
control.
• The platform box controls are now
de-energized.
• Check that the E-Stop button ( 9 )
at ground is not pressed in.
• To safely activate movements from
the ground control box, the Enable
Switch ( 6 ) must be
pressed and held.
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C - Familiarization

• Displays the reference

Machine software and version of the
version and code software installed on the
machine
General information zone
Machine date and • Displays the date and

time time of the machine ECU
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C - Familiarization

Machine fault
Machine fault icons
Failure code F01.xx Fault - Variator Failure code F09.xx Fault - IC Engine
Failure code F02.xx Fault - power contactor Failure code F10.xx Fault - Functions
Fault - machine
Failure code F03.xx Fault - command relay Failure code F11.xx
safety
Fault - electronic
Failure code F04.xx Fault - electro-valve Failure code F12.xx
control unit ECU
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C - Familiarization

Machine fault
Machine fault icons
Failure code F05.xx Fault - joystick Failure code F13.xx Fault - Switches
Fault - weight
Failure code F06.xx Failure code F14.xx Fault - Driving pump
management system
Fault - data
Fault - limit switch or
Failure code F07.xx Failure code F15.xx communication
sensor
system CAN
Failure code F08.xx Fault - electrical circuit Failure code F16.xx Fault - Electric motor
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C - Familiarization
Notes
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C - Familiarization
1.3 - PLATFORM CONTROL BOX
1.3.1 - Layout
General view
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C - Familiarization
Marking Name Description Function

Move forward : Forward drive
Drive joystick
Move backwards : Reverse drive
33 SM902 Press right side of button : Steer right -

Steering thumb / rocker According to selected mode ( 201 )
switch Press left side of button : Steer left - According
to selected mode ( 201 )
Move to the right : Counter clockwise (CCW)
38 SA751 Platform rotation switch rotation
Move to the left : Clockwise (CW) rotation
Move upwards : Raise platform
40 SA721 Platform leveling switch
Move downwards : Platform lowers
Toggle and hold : Back-up unit activated
41 SA800 Auxiliary power switch
Release : Back-up unit deactivated
43 SA907 Horn button Horn
LPG : Propane Gas supply
44 SA304 Fuel selector1
G : Petrol/Liquid propane gas or diesel supply
High-speed drive
45 SA110 Drive speed selector
Low-speed drive
Pulled out : Platform control box energized

46 SB802 E-stop button Pressed in : De-energizes control system
(Engine stopped)
78 Not used
Move to the left : Generator deactivated
79 SA906 Generator selector2
Move to the right : Generator activated
823 Move to the left : 230 kg (500 lbs) load selected

230 kg (500 lbs) or 450 kg
230 kg 450 kg (1000 lbs) load selector Move to the right : 450 kg (1000 lbs) load
500 lbs 1000 lbs selected
Toggle and hold : Jib raising / lowering
129 SA621 Jib raising / lowering switch4
Release : No movement
Synchronised axle : 4 wheel steering mode
201 SA101 Steering mode selector5 2 front steering wheels from axle
Crab mode axle
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C - Familiarization
Marking Name Description Function
Start or stop the engine (depending on the
Engine start-up / stop
230 SA303 machine's operating status) by pressing the
selector
push-button
Move to the right : Counter clockwise (CCW)
Turntable rotation joystick rotation
232 SM900 Move to the left : Clockwise (CW) rotation

Move forward : Boom up
Boom lift joystick
Move backwards : Lower boom
Move forward : Retract boom Upper boom
233 SM901 Boom telescope joystick
Move backwards : Extend boom Upper boom
ON / OFF
Activ' Lighting System
259 SA910
selector
Automatic lighting

3. If machine equipped with dual load
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C - Familiarization
1.3.2 - Display Panel (LED'S 101 - 117)
Platform control box display
LED 101 LED 102 LED 103 LED 104 LED 105 LED 106 LED 107 LED 108 LED 109
LED 110 LED 111 LED 112 LED 113 LED 114 LED 115 LED 116 LED 117
Marking Name Symbol Function
LED 101 HL 102 Power ON
LED 102 HL 150 Combustion engine pre-heating
LED 103 HL 164 Low fuel level
LED 104 HL 169 Engine warning
LED 105 HL 168 Engine shutdown
LED 106 HL 165 DPF regeneration required (If equipped)
LED 107 HL 166 Regeneration DPF in progress (If equipped)
LED 108 HL 167 DPF regeneration inhibited (If equipped)
230 kg
LED 1091 HL 158
500 lbs
Load selection 230 kg (500 lbs)
LED 110 HL 103 Foot Switch / Stop Emission System
LED 111 HL 140 Fault
LED 112 HL 148 Tilt
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C - Familiarization
Marking Name Symbol Function
LED 113 HL 147 Radius limit
LED 114 HL 142 Overload
LED 115 HL 880 Turret at 180°
0°
LED 116 HL 561 Platform leveling
0°
LED 1172 HL 159 450 kg Load selection 450 kg (1000 lbs)

1000 lbs

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C - Familiarization
Symbol Description
Machine switched on :
• Rapid flashing : Machine is ON, but platform control box is not active but the ground control box is ON
• Illuminated : Machine is turned on and platform control panel is active
Foot Switch :
• Illuminated when Foot Switch activated
• Blinks after 90 s of inactivity
Faults :
• Rapid flashing : If a fault is active (current fault)
Overload (If machine equipped with weighing system) :

• Rapid flashing : Faulty weighing / overload system
• Illuminated in case of overload
Tilt sensor (if fitted) :

• Permanently on in case of tilting, machine folded or unfolded
Radius limitation :
• Rapid flashing : Reach limitation system fault
• Slow flashing : The machine is in the 230 kg (500 lbs) low load zone, the low load is validated and 450 kg
(1000 lbs) heavy load is selected by the selector ( 82 )
• Permanently lighted : Limit of work zone with movement cut-off or machine in 230 kg (500 lbs) low load
zone and load not validated
Europe - Australia :
230 kg
500 lbs • 230 kg load selected : Permanently lighted whatever the position of the machine when the 230 kg load is
validated, otherwise off
450 kg • 450 kg load selected : Permanently lighted, machine in the 450 kg zone and the 450 kg load is
1000 lbs
validated, otherwise off1
United States - Canada :

• 500 lbs load selected
230 kg • Permanently lighted, position of the machine in 500 lbs zone with the 500 lbs load validated
500 lbs • Flashes, the machine is in the 500 lbs zone, the low load is not validated and a telescope extension or
450 kg
boom lowering movement control is activated
1000 lbs • 1000 lbs load selected
• Permanently lighted if the machine is in the 1000 lbs zone
• Permanently lighted if the position of the machine is in the 1000 lbs zone and low load is not validated2
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C - Familiarization
Symbol Description
0° Platform leveling +/- 10° :
0° • Illuminated if the angle of the platform reaches +/- 10° in relation to the horizontal and movement control
Low fuel level
Combustion engine pre-heating :

• Illuminated while engine is pre-heating
• Off if engine started and if post-heating
Engine warning :
• Lighted in case of minor engine fault (e;g. water in the diesel, clogged air filter, etc.)
• Lighted or flashing in case of fault managed by the engine ECU
Engine shutdown :
• Lighted in case of major engine fault (e.g. engine overheating, oil pressure, alternator fault, etc.)
• Lighted in case of faults managed by the engine ECU
DPF regeneration required :

• Permanently lighted if the particle filter requires regeneration with a high clogging level1
DPF regeneration in progress, high temperature in the exhaust system ( HEST )2
DPF regeneration inhibited3
1. If engine equipped with Particulate Filter Regeneration

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C - Familiarization
Notes
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C - Familiarization
2- List of actuators and sensors
2.1 - SENSORS AND ACTUATORS
Sensors and actuators
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C - Familiarization
Name Description
EL907 Light - Activ' Lighting System Boom light
%L906 Light - Activ' Lighting System Counterweight light
HL910A Light - Activ' Lighting System Turret light
HL910B Light - Activ' Lighting System Turret light
HL911 Light - Activ' Lighting System Ground control box light
HL912A Light - Activ' Lighting System Platform control box light
HL912B Light - Activ' Lighting System Platform control box light
HL912C Light - Activ' Lighting System Platform light
HL912D Light - Activ' Lighting System Platform light
HL913 Light - Activ' Lighting System Under basket light
SA910 Activ’Lighting System selector
SN900 Sensor - Twilight sensor
SR721 Detector - Tilt + 10°
SR720 Detector - Tilt - 10°
SP800 Sensor - Strain gauges
SP801 Sensor - Strain gauges
YV720U Valve - Platform level up
YV720D Valve - Platform level down
YV620U Valve - Jib raise
YV620D Valve - Jib descent
YV750L Valve - Platform rotation left
YV750R Valve - Platform rotation right
SQ531 Detector - ILS Boom length
SQ533 Detector - Boom 1000 lbs length limit zone
SQ591 Detector - Boom retracted / down
SQ590 Detector - Boom retracted / down
SQ802 Detector - Cable break 2
YV390 Detector - Boom safety up / down
YV521 Detector - ILS boom angle
SQ523 Detector - Boom 1000 lbs angle limit zone
SQ990 Detector - Cable break 1
ST300 Detector(Tier III) - Engine overheating
SP300 Detector(Tier III) - Engine oil pressure
KA2 Relay - Generator control
YV160F Valve - Drive forward
YV160B Valve - Drive reverse
YV800 Valve - LS valve
YV900 Valve - Platform movements / steering
YV520 Valve - Boom movements
YV250 Valve - Turntable movements
YV530 Valve - Boom's telescope movements
YV807 Valve - Boom descent safety
YV801 Valve - Boom telescope extend safety
YV805 Valve - Turntable orientation safety
SQ800 Detector - Tilt sensor
SQ300 Detector - Fuel low level
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C - Familiarization
Name Description
ST900 Detector - Hydraulic oil overheating
YV110 Valve - High speed translation
YV102 Valve - Unbreaking front and rear
YV101 Valve - Axle unlocking
YV104 Valve - Axle unlocking
SP100 Detector - High speed pressure
YV107 Valve(4WS only) - Crab / synchro steering
YV108 Valve(4WS only) - Crab / synchro steering
YV150R Valve - Right forwards steering
YV150L Valve - Left forwards steering
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C - Familiarization
3- Power source - Engine specifications
3.1 - GENERAL SAFETY AND SPECIFIC INTERVENTIONS ON MOTOR
The technician should take all steps to protect themselves or others against all risks of injury inherent
in his intervention.
The technician should ensure that suitable PPE (personal protective equipment) for the job is used, and
check the particular conditions of environment in which the material can be found (see safety
information specific to the operation site).
• Turn off the ignition, remove the key, open the battery switch before working on the engine.
• Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid
accidental engine starting, disconnect the battery cable from the negative (-) battery terminal.
Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact
with other metal surfaces which could activate the engine electrical system. Place a do not operate
tag at the start/stop switch location to inform personnel that the equipment is being worked on.
• The hot engine parts can cause injury and burns. Before performing maintenance on the engine, cool
the engine and parts.
• By touching a functioning engine, there is a risk of burns from contact with hot parts, and injuries by
the rotating parts.
• To avoid any risk of accident, using compressed air (example : blowing air filter), always wear a
headband and goggles.
• The hot coolant, steam and alkalis can cause injury. At the operating temperature, the engine coolant
is hot and under pressure. Do not open the cap of the expansion chamber before letting the circuit
cool.
• The radiator and all the pipes going to the heaters or engine contain hot coolant or steam. Contact
can cause severe burns.
The engine exhaust gases contain harmful combustion products. Always start and run the engine in a well
ventilated area. In an enclosed area, evacuate the exhaust outside.
3.2 - GENERAL SPECIFICATIONS
N.B.-:-USING UNSUITABLE FUEL MAY CAUSE DIMINISHED PERFORMANCE, DIFFICULTIES STARTING, EXCESSIVE
POLLUTION AND PREMATURATE WEAR. TO ESTABLISHED THE TYPE OF THE FUEL SUITABLE FOR THE ENGINE
FITTED ON YOUR HAULOTTE®, PLEASE REFER TO THE ENGINE MANUFACTURER'S MANUAL. THE ENGINE
MAY NOT BE COVERED BY THE WARRANTY IN CASE OF DAMAGE CAUSED BY USING UNSUITABLE FUEL.
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C - Familiarization
3.3 - CONSUMABLES
Consumable HAULOTTE® code

Air filter (system) : 2324007620
Primary air filter 4000044230
Secondary air filter 4000044240
Diesel filter 4000053030
3.4 - INGREDIENT
HAULOTTE® code
Ingredient HT23RTJ O - HT23RTJ O SW - HT67RTJ O - HT23RTJ
PRO - HT23RTJ PRO SW - HT67RTJ PRO
Coolant 2326013640
Engine oil 2820305720
Engine oil - Winter option 4000010660
Hydraulic oil 25050003800
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C - Familiarization
4- Lubrication diagram
6
6
5
6
2 1
List of ingredients
Marking Ingredient Symbol HAULOTTE® code
1 Engine oil (+30° / - 20° ) 2820305720
Gear box oil - Can 20 l(5,3 gal US) 2420801370

2
Gear box oil - Barrel 209 l(55,2 gal US) 2420801380
Hydraulic oil (Standard) - Barrel 209 l(55,2 gal US) 2420801310
3
Hydraulic oil (Winter option) 2505002640
4 Biological hydraulic oil - Barrel 209 l(55,2 gal US) 2820304310
5 Extreme-pressure lithium grease 2820304320
Lead-free grease - Aerosol 0,4 l(0.1 gal US) 2820304330

6
Lead-free grease - Can 5 l(1,32 gal US) 2820304340
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C - Familiarization
4.1 - GREASING POINTS LOCALIZATION
Slew ring :
• 1 on the planetary gear drive
• 4 on screw drive system
• 1 on the Oscillating axle
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C - Familiarization
• 1 on the boom lift cylinder
• 4 on the steering cylinder if 2WS ( 8 if 4WS)
• 4 on the wheel articulation ( 8 if 4WS)
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C - Familiarization
• 2 on the jib lift cylinder
• 1 on the boom lift cylinder
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C - Familiarization
5- Consumables (Oils - Fuels - Engine oil - Coolant level...)
5.1 - FUEL
N.B.-:-THESE FUELS CAN BE USED ON ANY TYPE OF MECHANICAL INJECTION ENGINE. PLEASE SEE MACHINE
CONFIGURATION.
Table of technically permitted fuels
Engines Fuels
European fuel oil American gas oil Japanese gas oil
Hydraulic filter European gas oil
according to according to according to NATO
cartridge according to EN590
BS2869 class 2 ASTMD975-07b F54
HATZ 41C
DEUTZ 2011/2012
PERKINS 403/804/1104
LOMBARDINI LDW
1404
KUBOTA D1105-W1
KUBOTA V2403
KUBOTA V2703
Compliant
Not compliant
5.1.1 - 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.
4000866050 E 10.18 USA / GB 61

C - Familiarization
5.2 - ENGINE OIL
The correct SAE viscosity grade of oil is determined by the minimum ambient temperature during cold
engine start-up, and the maximum ambient temperature during engine operation.
Refer to Table "Engine Oil Viscosity" (minimum temperature) in order to determine the required oil
viscosity for starting a cold engine.
Refer to Table "Engine oil Viscosity" (maximum temperature) in order to select the oil viscosity for
engine operation at the highest ambient temperature that is anticipated.
Generally, use the highest viscosity oil that is available to meet the requirement for the temperature at
start-up.
Engine oil viscosity
EMA LGR-1 / API CH-4 Viscosity Ambient temperature

grade Minimum Maximum
SAE 0W20 -40°C (-40°F) 10°C (50°F)
SAE 0W30 -40°C (-40°F) 30°C (86°F)
SAE 0W40 -40°C (-40°F) 40°C (104°F)
SAE 5W30 -30°C (-22°F) 30°C (86°F)
SAE 5W40 -30°C (-22°F) 40°C (104°F)
SAE 10W30 -20°C (-4°F) 40°C (104°F)
SAE 15W40 -10°C (14°F) 50°C (122°F)
Engine sump
Engine Refill Capacities

Compartment or System Liters
Engine only 9,5 L (2,51 Imp. gal)
(1) The external system includes a radiator or an expension tank with the following components : heat
exchanger and piping. Refer to the QEM specifications. Enter the value for the capacity of the external
system in this row.
Classification API
Engine oil classification

Fuel type Engines with non EGR
Engines with internal EGR
CF
High sulfur fuel侑 [0.05% (500 ppm)]
(If the engine oil is used with a high sulfur level, change the
Sulfur content< 0.50% (5000 ppm)
engine oil at shorter intervals, approximately half)
EGR : Exhaust Gas Re-circulation
62 4000866050 E 10.18 USA / GB

C - Familiarization
5.3 - HYDRAULIC OIL
Hydraulic oils must comply with the following requirements :

• Oil filterability must be compatible with absolute filters
• Have properties such as :
• Antifoam and deaeration
• Anti-wear, anti-shear and antioxydant
• Rust and corrosion inhibitors (copper)
The recommended viscosity grades depending on the environmental conditions are as follows :
Environmental conditions ISO Viscosity grade

Ambient temperature between - 15° C (- 9° F) and + 40° C (+ 104° F) HV 46
Ambient temperature between - 35° C (- 31° F) and + 35° C (+ 95° F) HV 32
Ambient temperature between 0° C (32° F) and + 45° C (+ 113° F) HV 68
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 :
Viscosity grade ISO Viscosity grade

Viscosity at + 40° C (+ 104° F) 46 +/- 3 mm² / s
Viscosity at + 100° C (+ 260° F) > 8 mm² / s
Viscosity index > 160
Flashpoint > 220° C (> 572° F)
Pour point < - 40° C (> - 104° F)
4000866050 E 10.18 USA / GB 63

C - Familiarization
6- Machine specifications
6.1 - MOVEMENT SPEED
To allow checking operation, refer to the following table about originally time per movement. If the
values measured by test are not equal to the following :
• Do not use the machine.
• Setting updating is needed.
Always check speed movement from the ground control box.
HT23RTJ O - HT23RTJ O SW - HT67RTJ O - HT23RTJ

Micro drive speed 0,5 km/h - 0.31 m/h
Low drive speed 1,7 km/h - 1.05 m/h
High drive speed 6,5 km/h - 4.04 m/h
Maximum towing speed 1,6 km/h - 1 m/h
Time for telescopic boom extension 27 s
Time for telescopic boom retraction 27 s
Time for raising boom 42 s
Time for descent boom 42 s
Time for lifting at maximum height 51 s
Time for descent at height 0, platform at horizontal 32 s
Time for continue turntable rotation 64 s
Time for complete left / right cage rotation 22 s
64 4000866050 E 10.18 USA / GB

D - Inspection and maintenance schedule

Inspection and maintenance schedule
1- Inspection program
The machine must be inspected at regular intervals in accordance with the requirements set out in the country of
use and at least once a year. The purpose of the inspection is to detect any defect which could lead to an accident
during routine use of the machine.
Inspections and maintenance must be carried out by a qualified company or person chosen by the owner of the
machine.
The results of these visits must be recorded in a safety register created by the owner. This register as well as the
list of competent repair persons must made available to the work inspector, government inspector and company
safety committee at any time.
Frequency Person-in-charge Stakeholder Type Documentation

Before each hire Owner On-site technician Daily inspection Operator's manual
Before each use or each
Operator Operator Daily inspection Operator's manual
change of user
At intervals On-site technician,
recommended Owner qualified HAULOTTE Preventive maintenance Maintenance Book
by HAULOTTE® Services® technician
On-site technician,
Before sale Owner qualified HAULOTTE Periodic inspection Maintenance Book
Services® technician
On-site technician,
Annually ( 1 year) (*) Owner qualified HAULOTTE Periodic inspection Maintenance Book
Services® technician
Qualified
After 10 years then
Owner technician HAULOTTE Major inspection Maintenance Book
every 5 years
Services®
(*) Or according to local regulations.
4000866050 E 10.18 USA / GB 65


2- Daily inspection
The daily inspection must be performed every day, before the start of a new work shift and at every change of
user.
This inspection is performed by and under the responsibility of the user and includes the visual and functional
inspection of the machine as well as the testing of its safety systems.
A description of the daily inspection can be found in the machine's user manual.
We recommend these forms to be completed daily and stored to assist with your maintenance schedule.
66 4000866050 E 10.18 USA / GB


3- Preventive maintenance
Maintenance operations must be carried out by a qualified technician chosen by the owner and ensure that the
machine operates correctly.
Severity of operating conditions may require a reduction in time between maintenance periods.
Maintenance operations performed must be recorded in a register / log book of the machine.
The information contained in our manual is to be complemented by the information found in the engine
manufacturer's maintenance manual, which can be found on the link in the associated maintenance sheet MS0238.
Oil change Lubrication-Lubrication Tightening
Functional adjustments /
Levelling Systematic replacement
Checks / Cleaning
Visual inspection To check by test
Preventive Maintenance Level 1 - First 50H
Corrected
First 50H
Page or
First 50H associated OK NOK Comments
procedure
Chassis assembly : Wheel, reducer, steering, wheel pivot
Tighten the wheel nuts
KUBOTA V2403M engine
Drain the engine oil
Replace the oil filter
KUBOTA WG2503 engine
Hydraulic : oils, filters and hoses
Replace the hydraulic filter
Arm, boom
Control telescoping chains state and tension
4000866050 E 10.18 USA / GB 67


Preventive Maintenance Level 1 - Every 200H
Every 200H
Corrected
Page or
Every 200H associated OK NOK Comments
procedure
Grease the steering system
Grease the bushings and pins
Drain the wheel reducer**
Slew ring
Grease the turntable slew ring
Clean the fuel filter
Clean the air filter
Check the belt tension and condition
KUBOTA V2403CR engine
Clean the fuel filter
Arm, boom
Grease the pads
**Only in the first 200H
68 4000866050 E 10.18 USA / GB


Preventive Maintenance Level 1 - Every 6 months or 500H
Every 6 months or 500H
Corrected
Page or
Every 6 months or 500H associated OK NOK Comments
procedure
Tighten the wheel nuts
Check the wheel reducer level
Tighten the steering system
Slew ring
Tighten the slew ring
Replace the fuel filter*
Replace the belt*
Replace the belt*
Drain the engine oil*
Replace the oil filter*
Replace the fuel filter*
Replace the belt*
Check the hydraulic oil level
Jib
Tighten the rotary cylinder
Tighten the load cell
Platform
Tighten the mounting on the platform support,
the platform floor and the platform access
* Do not take into account the deadline of 6 months, only 500H.
4000866050 E 10.18 USA / GB 69


Preventive Maintenance Level 2 - Every 1 years or 1000H
Every 1 years or 1000H
Corrected
Page or
Every 1 years or 1000H associated OK NOK Comments
procedure
Drain the wheel reducer
Replace the air filter
Replace the fuel filter
Replace the hydraulic filter
Arm, boom
Check the pads-Replacement is necessary
Control telescoping cables state and tension
70 4000866050 E 10.18 USA / GB


Preventive Maintenance Level 2 - Every 2 years or 2000H
2 year(s) or 2000H
Corrected
Page or
Every 2 years or 2000H associated OK NOK Comments
procedure

Check the bushings and pins-Replacement is
necessary
Slew ring
Check the slew ring clearance
Drain the oil tank
Drain the cooling circuit
Drain the oil tank
Drain the oil tank
Drain the hydraulic oil
4000866050 E 10.18 USA / GB 71


Preventive Maintenance Level 2 - Every 3000H
Every 3000H
Corrected
Page or
Every 3000H associated OK NOK Comments
procedure
Clean the particulate filter
Preventive Maintenance Level 2 - Every 7 years
Every 7 years
Corrected
Page or
Every 7 years associated OK NOK Comments
procedure
Arm, boom
Replace telescoping cables
72 4000866050 E 10.18 USA / GB


4- Periodic inspection
The Periodic inspection is a thorough inspection of the operation and safety features of the machine. This must
take place prior to the sale or resale of the machine and every 1 year. Local regulations may have specific
requirements on frequency, and content of inspections.
This intervention must take place after :

• Extensive dismantling and reassembly
• Repairs involving the machine's essential components
• Any accident causing stress to the machine
This inspection is the responsibility of the owner, and must be conducted by a qualified technician.
Under no circumstances may this inspection replace the control required by local regulations.
Use the detailed program below.
Corrected
Periodic
Page or
Periodic associated OK NOK Comments
procedure
Check state of tires/tyres and inflations
Motor
Check that there are no leaks from the engine's
components (engine, hose, radiator)
Check the condition of the battery
Check for visible damage and broken welds on

the exhaust system
Check the operation of the lock on the engine
casing
Turntable
Test the operation of the turntable locking system

Check the hoses, blocks and pumps, fittings,
cylinders and the tank for the absence of leaks,
deformations and damage
Platform
Test the automatic closure and locking of access
basket
Check that the harness anchor points are not
cracked or damaged
4000866050 E 10.18 USA / GB 73

Corrected
Periodic
Page or
Periodic associated OK NOK Comments
procedure
General
Check for the presence, cleanliness and
readability of the manufacturer's plates, security
labels, user manual and maintenance manual
Check the cleanliness and readability of the
control box
Test the opening and closure of covers (chassis,
turntable, upper control box)
Check the condition of electrical harnesses,
cables and connectors
Check for the absence of abnormal noise and
jerky movements
Check for the absence of visible deterioration
and damage
Check for the absence of cracks, broken welds
and chipped paintwork on the structure
Check for the absence of missing or loose
screws and bolts
Check for the absence of deformation, cracking
and breakage of axis stops, bushing and axes
Check for the absence of foreign bodies in joints
and sliding parts
Safety devices
Test the operation of the upper and lower control
boxes: manipulators, switches, buttons, horn,
emergency stops, screens and lights
Check for the absence of visual and audible
alarms
Test the operation of the tilt system
Test the operation of the emergency lowering

system
Test the operation of the axle locking system
Test the operation of the loading control system

(visual alarm on the control box)
Test the operation of the Activ Shield Bar (If
equipped)
Test the operation of the drive speed limiter
systems
Test the speed and behavior of movements
Check the operation of the load control system-

Calibrate if necessary
74 4000866050 E 10.18 USA / GB


5- Major inspection
The inspection is a thorough inspection of the machine to ensure that it is fully functional. It must be carried out
after 10 years then every 5 years.
This inspection is the responsibility of the owner and must be carried out by a technician HAULOTTE Services®
or an authorized and qualified person.
In order to carry it out, contact the subsidiary HAULOTTE® or the authorized distributor.
Machine sheet
4000866050 E 10.18 USA / GB 75

Notes
76 4000866050 E 10.18 USA / GB

General data
Structural part inspection
MS0001
General data
1- You will need

• Standard tool kit
• Protective goggles • Place barriers around the perimeter of the work area
• Gloves
Exclusively use tools and auxiliary average adapted. Always wear necessary safety clothing.
For safety reasons, imperatively respect the following stages during the tests :
• To set up e beaconing of safety around the test area.
• To put the machine in position transport (horizontal jib accepted)
• Use safety straps.
2- Preliminary operation
The operations of disassembling if they exist should be carried out only on the installations completely disconnected
and must be entrusted only to people having the necessary technical training.
Respect, in addition to the instructions appearing in the present instructions, the legal tendencies generally applicable
for safety accident prevention.
All the precautions must be done in work before intervening on and near the machine.
After completion of work, all the covers and safety devices must be positioned back completely and operational.
4000866050 E 10.18 USA / GB 77

General data
MS0001
3- Control and maintenance
To guarantee the integrity of the machine, it is necessary to carry out periodical controls on the mechanical structure
such as defines hereafter.
3.1 - DAILY INSPECTION
All the accessible structural part without disassembling must be

subjected to a fast visual inspection.
If anomalies are noted, according to the list below, a reinforced

control will have to be carried out to judge conformity of the part :
• Absence of foreign body to the articulations and slides.
• Absence of deformation and visible damage.
• Absence of crack, broken welding, oxidation, glare of painting.
• Absence of excessive gap to the articulations and slides.
• Check that locking device are not damaged and are functional.
• No screws or missing part loosened or unscrew.
• Anchorage points firmly fixed and not damaged.
The list of part to check are define Section Familiarization.
78 4000866050 E 10.18 USA / GB

General data
MS0001
3.2 - MAJOR INSPECTION
A thorough inspection of the structural parts must be realized all the 5000 h or 10 years with disassembling
of the element to check the entirety of the welding. All structural part listed Section Familiarization must be
disassembled and all weldsmust be review using non-destructive checks.
The criteria quoted above are applicable.
The main items to be inspected are :

• Boss welds on chassis, turret, arms, booms and jib.
• Booms and arms welds.
Example
In the event of suspicion of crack, a cleaning and a sweating are to be carried out to guarantee the integrity
of the part before reassembly.
Check presence and torque of each bolts and screw used to assembly part listed in Section Familiarization.
Refer to spare part catalog for additional information if needed.
Some screws are not reusable and must be systematically changed (ex: screws from the gear ring).
4000866050 E 10.18 USA / GB 79

General data
MS0001
3.3 - FUNCTIONAL TESTS
The following tests must be carried out each 250 h or 6 months or afterwards :
• An important technical intervention.
• An accident resulting from a failure of a major component.
The following tests must be realized by a qualified staff under secure conditions.
The results of the tests must be entirely documented.
To avoid the swing of the machine during the test, it is imperative that a device of reserve (chain, not of
anchoring) is used during the test.
3.4 - DYNAMIC TESTS
The machine must be place on level and firm ground.
With 100% of the maximum allowed load, operate from ground control box (or emergency control box) all
the movements ; the platform floor must reach a height of about 1 above the ground.
The functional tests must show the following facts :

• The machine carried out all the movements without jolts while supporting the load.
• All the security device function correctly.
• Authorized maximum speeds of operation are not exceeded.
Refer to the user manual for the description of the safety device and technical characteristics to be reached.
3.5 - STRUCTURAL TEST (OVERLOAD)
The following test shows that the structure of the machine is in conformity with the safety requirements.
The machine must be place on level and firm ground.
With 100% of the maximum allowed load, operate from ground control box (or emergency control box) all
the movements ; the platform floor must reach a height of about 1 above the ground :
• Measure the distance between the ground and the basket (or of the platform).
• Leave the machine in static during 15 mnn.
• Measure the distance between the ground and the basket (or of the platform).
If the difference between two measurements does not exceed 4 cm (1.575 in) : the test is validated.
If the difference between two measurements exceeds 4 cm (1.575 in), to contact HAULOTTE Services® or
to carry out the additional tests described below. MS0003 - § 3.2 Cylinder inspection.
80 4000866050 E 10.18 USA / GB

General data
Pins and bearing inspection
MS0002
General data
1- You will need

• Gloves
4000866050 E 10.18 USA / GB 81

General data
MS0002
The control of pins, stop pins, bushes and bearing must be carried out according to the following recommendations :
• Every day before use : Fast visual inspection without disassembling.
• Check the presence of the pins and visible stops pins without disassembling.
• Check the presence of the screws.
• Check absence of deformations, cracks or breakage of pins and/or stops pins.
• Check absence of heavy abrasion, wear or oxidation of the pins, stops pins.
• All 250 h or 6 months : Reinforced visual inspection with disassembling of certain elements to reach the bushes or
bearing. In addition to the above cited criteria, verify the following :
• Check the presence and the position of the bushes and bearings.
• Check the absence of shaving in periphery of the pins.
• Check the absence of heavy abrasion, wear or oxidation of the bushes and bearing.
• Check the absence of deformations, cracks or breakage of the bushes and bearing.
• Check the absence of radial gap > 0,5 mm (19690 μ in) on the pins.
• Every 5 years : Complete disassembling of the pins, bushes and bearing. In complement of the inspections above
cited, it is necessary to check :
• For the stages :
• Check the presence of material of friction.
• For the bearings :
• After disassembling, protect the bearing from pollution and shocks.
• Clean the bearing with a suitable solvent.
• Check the absence of shaving in the housing of the bearing and/or the bearing.
• Check the absence of heavy abrasion, wear, oxidation, deformations of the balls (or rollers) and the ball races.
The periodicity can evolve under the following conditions :

• Abnormal noise during movements of the structure.
• Prolonged storage of the machine ( 6 months).
• Specific storage and use Environment (strong moisture and salinity of the air).
4- Criteria of replacement
The pins, stop pins, bushes and bearing must be replaced as soon as one of the anomalies quoted above is noted.
Bearing and bushes must be imperatively changed at the end of 10 years of use.
82 4000866050 E 10.18 USA / GB

General data
MS0002
5- Procedure of reassembly
5.1 - PINS AND BUSHES
When reassembling bearings and pins ensure that :

• Lightly lubricate the housing into which the bearing is to be installed.
• Insert the bearing using a bearing drift, preferably out of mild steel.
• 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
A D
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 (-7874 μ in / -11810 μ in)
D Bearing drift
E Diameter of the bearing guide - 0,20 / - 0,25 mm (-7874 μ in / -9843 μ in)
F Bearing
G Housing
• After inserting the bearing, lubricate and fit the pin.
4000866050 E 10.18 USA / GB 83

General data
MS0002
5.2 - BEARINGS
For the reassembly of bearings, respect the following stages :

• Clean boring and/or the pins to remove all the foreign bodies.
• Slightly lubricate boring and/or pins.
• Lubricate the ring of the bearing slightly.
• To fit bearing in a boring: take support on the external ring of the bearing.
• To fit bearing on an axis: take support on the interior ring of the bearing.
84 4000866050 E 10.18 USA / GB

General data
Cylinder inspection
MS0003
General data
Cylinder inspection
1- You will need

• Gloves
• To set up a beaconing of safety around the test area.
• Put the machine in stowed position.
4000866050 E 10.18 USA / GB 85

General data
Cylinder inspection
MS0003
3.1 - VISUAL INSPECTIONS
The hydraulic actuating cylinders must be subjected to visual inspections periodic all the 250 hours or 6
months such as defined below :
• Absence of leakage.
• Absence of deformations, visible damage , cracks on the body and fixing of the cylinder.
• Absence of rust and shock on the rod.
• Absence of foreign objects on all surfaces.
• Absence of missing or loosened part (bolt, nut, connection, flexible device, etc).
3.2 - FUNCTIONAL TESTS
To guarantee an optimal level of performance and safety, functional tests must be realized all the 250 hours
or 6 months.
The periodicity can evolve under the following conditions :

• Anomaly noted during visual inspection.
• Abnormal noise during movements of the structure.
• Prolonged storage of the machine ( 6 months).
• Specific storage and use Environment (strong moisture and salinity of the air).
Generic Control :
• Position a load equal to the rated capacity on the cage (or platform).
• Raise the cage (or the platform) using the ground control box. To activate the cylinder to be tested, proceed
as follows :
• Lift Arm hydraulic cylinder : Lift the arm to approximately half full height. The telescopic boom should be fully
extended and in the horizontal position. (For machines fitted with).
• Boom lifting cylinder or Jib cylinder : Lift the concerned equipment (boom or jib) of approximately half way. Extend
the telescope to its maximum.
• Telescoping cylinder : Lift the boom to its maximum angle and telescope approximately 50 cm (19.69 in).
• Measure the distance between the floor of the cage (or of the platform) and the ground.
• Leave the machine in this condition for 15 mn (minutes).
• Measure the 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 (1.575 in) : the test validates correct operation.
• If the difference between two measurements exceeds 4 cm (1.575 in), contact HAULOTTE Services® or carry out
the additional tests described below.
86 4000866050 E 10.18 USA / GB

General data
Cylinder inspection
MS0003
Control cylinder by cylinder :

• Position a load equal to the rated capacity on the cage (or platform).
• Perform the movement of the concern cylinder to half of its stroke.
• Fix the cylinder with a comparator :
• Attach the body of the comparator on the cylinder rod.
• The needle of the comparator must be in contact with the end of the casing of the cylinder.
• The target is to measure the creep of the cylinder rod.
• If the creep of the cylinder rod is higher than the values indicated in the table below, replace the cylinder.
Type of cylinders Maximum drift authorised due to an internal leak of the cylinder
Lift cylinder arm or boom (Machine
After 10 mn, creep < 0,2 mm (7874 μ
with working heights > 26 m(85 ft4 After 60 mn, creep < 1 mm (0.039 in)
in)
in))
Outriggers cylinder, Oscillating axle
After 10 mn, creep < 0,5 mm (0.01196 After 60 mn, creep < 2,5 mm (0.098
locking, Lift cylinder arm or boom
in) in)
(Machine with range-limiting system)
Lift cylinder arm or boom,
After 10 mn, creep < 1 mm (0.039 in) After 60 mn, creep < 6 mm (0.236 in)
Telescoping, Compensation, ...
After 10 mn, creep < 1,5 mm (0.059
Steering cylinder After 60 mn, creep < 9 mm (0.354 in)
in)
These tests must be made in conditions of equivalent temperatures.
4000866050 E 10.18 USA / GB 87

General data
Cylinder inspection
MS0003
3.3 - MAJOR INSPECTION
A thorough inspection of the structural parts must be realized all the 5000 h or 10 years with disassembling
of the element to check the entirety of the welding. Each Cylinder must be disassembled and must be review
using non-destructive checks.
The criteria quoted above are applicable :

• Absence of deformation and visible damage.
• Absence of crack, broken welding, oxidation, glare of painting.
Check :
1. Pipe weld connection.
2. Rod weld connection.
3. Ring.
4. Rod.
5. Piston.
88 4000866050 E 10.18 USA / GB

General data
Braking test procedure
MS0004
General data
1- You will need

• Gloves
• Set up a beaconing of safety around the test area.
• Put the machine in position transport (Pendular horizontal accepted).
3- Test procedure
The brake system is a significant component of the safety of the machine. It is necessary to carry out functional tests
periodically all the 250 hours or every 6 months.
High speed :
• On a flat ground or slightly inclined (always lower than the authorized slope: see plate manufacturer).
• Trace on the ground, a line being used as reference mark of stop.
• Roll moving front until reaching maximum speed :
• Between 3 km/h (1.9 mph) and 6,5 km/h (4,039 mph) according to the machines.
• Release the manipulator as soon as the wheels axles are on the level of the traced reference mark.
• Stopped machine, measure the distance between the wheel axles and traced reference mark on the ground :
• If the distance lies between 0.2 m (0ft 8in) and 2,7 m (8 ft 11 in), the test is validated.
• If not, Contact HAULOTTE Services® to repair the system.
4000866050 E 10.18 USA / GB 89

General data
MS0004
Notes
90 4000866050 E 10.18 USA / GB

General data
Torque Values
MS0005
General data
Torque Values
1- Metric torque chart
For screws HAULOTTE®, use columns ( A ), ( B ) and ( C ) :

1 2 3
• Screw ( 1 ) grey dull dry, use colums ( A )
• Screw ( 1 ) grey dull greasy, use column ( B )
• Screw ( 2 ) yellow dry, use column ( C )
• Screw ( 2 ) yellow greasy, use column ( B )
• Screw ( 3 ) grey bright dry, use column C
• Screw ( 3 ) grey bright greasy, use column ( B )
Metric fastener torque chart

This charts is to be used as a guide only unless noted elsewhere in this manual
Class 4.6 Class 8.8 Class 12.9
Yellow dry (C)
Yellow dry (C)
Yellow dry (C)

Dull dry (A)
Dull dry (A)
Dull dry (A)
Yellow dry
Lubed (B)
Lubed (B)
Lubed (B)
Dull dry
Lubed
Size (mm)
in- in- in- in- in- in- in- in- in- in-
in-lbs Nm Nm Nm Nm Nm Nm in-lbs Nm Nm Nm Nm Nm Nm
lbs lbs lbs lbs lbs lbs lbs lbs lbs lbs
5 17.7 2 16 1.8 21 2.4 44 5 41 4.63 54 6.18 68 7.7 58 6.63 78 8.84 79 9 68 7.75 91 10.3
6 30 3.4 19 3.05 36 4.07 80 9.1 69 7.87 93 10.5 118 13.4 100 11.3 132 15 139 15.7 116 13.2 155 17.6
Yellow
Size (mm)
Dull dry Lubed Dull dry Lubed Dry Dull dry Lubed Dry Dull dry Lubed Dry
dry
ft- ft- ft- ft- ft- ft- ft- ft- ft-
ft-lbs Nm Nm Nm Nm Nm Nm ft-lbs Nm Nm Nm ft-lbs Nm Nm Nm
lbs lbs lbs lbs lbs lbs lbs lbs lbs
8 5.9 8 5.4 7.41 7.2 9.88 16.2 22 14 19.1 18.8 25.5 23.6 32 20.1 27.3 26.9 36.5 28 38 23.6 32 31.4 42.6
10 12.17 16.5 10.8 14.7 14.4 19.6 32.45 44 27.9 37.8 37.2 50.5 47.2 64 39.9 54.1 53.2 72.2 55 75 46.7 63.3 62.3 84.4
12 20.65 28 19.8 25.6 25.1 34.1 56 76 48.6 66 64.9 88 81.8 111 69.7 94.5 92.2 125 95.9 130 81 110 108 147
14 33.19 45 30.1 40.8 40 54.3 89.24 121 77.4 105 103 140 131.28 178 110 150 147 200 154.15 209 129 175 172 234
16 52.37 71 46.9 63.6 62.5 84.8 139.4 189 125 170 166 226 205.04 278 173 235 230 313 239.7 325 202 274 269 365
18 72.28 98 64.5 87.5 86.2 117 192.5 261 171 233 229 311 283.2 384 238 323 317 430 331 449 278 377 371 503
20 102.5 139 91 124 121 165 272.9 370 243 330 325 441 401.2 544 337 458 450 610 469.8 637 394 535 525 713
22 140.87 191 124 169 166 225 345.4 509 331 450 442 600 551.7 748 458 622 612 830 645.3 875 536 727 715 970
24 176.27 239 157 214 210 285 469.8 637 420 570 562 762 690.3 936 583 791 778 1055 807.6 1095 682 925 909 1233
4000866050 E 10.18 USA / GB 91

General data
Torque Values
MS0005
2- SAE fastener torque chart
SAE fastener torque chart

This charts is to be used as a guide only unless noted elsewhere in this manual
A574 High
Grade 5 Grade 8 strength black
oxide bolts
Size Thread
Lubed Dry Lubed Dry Lubed
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
20 80 9 100 11.3 110 12.4 140 15.8 130 14.7
1/4
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
Lubed Dry Lubed Dry Lubed
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
18 13 17.6 17 23 18 24 25 33.9 21 28.4
5/16
24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
3/8
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
14 37 50.1 49 66.4 50 67.8 70 94.7 61 62.7
7/16
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
13 57 77.3 75 101.6 80 108.4 110 149 93 126
1/2
20 64 86.7 85 115 90 122 120 162 105 142
12 80 108.4 110 149 120 162 150 203 130 176
9/16
18 90 122 120 162 130 176 170 230 140 189
11 110 149 150 203 160 217 210 284 180 244
5/8
18 130 176 170 230 180 244 240 325 200 271
10 200 271 270 366 280 379 380 515 320 433
3/4
16 220 298 300 406 310 420 420 569 350 474
9 320 433 490 583 450 610 610 827 510 691
7/8
14 350 474 470 637 500 678 670 908 560 759
8 480 650 640 867 680 922 910 1233 770 1044
1
12 530 718 710 962 750 1016 990 1342 840 1139
7 590 800 790 1071 970 1315 1290 1749 1090 1477
1 1/8
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 1/4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 1/2
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
92 4000866050 E 10.18 USA / GB

General data
Torque Values
MS0005
3- HT23RTJ O - HT23RTJ O SW - HT67RTJ O - HT23RTJ PRO - HT23RTJ PRO

SW - HT67RTJ PRO
Sub-assemblies Concerned elements Torque

Axles Wheels 300 Nm
Wheel studs / Driving reducer Loctite 243 - Normal threadlocker
Hydraulic motor / Driving reducer 57 Nm
Wheel reducer / Chassis 260 Nm
Wheel reducer / Wheel steering pivots 260 Nm
Steering cylinder / Chassis 200 Nm
Slew ring / Chassis 215 Nm
Slew ring Turntable / Slew ring 215 Nm
Hydraulic motor / Slew ring 105 Nm
ECU ECU / Carrier 6 Nm
Hydraulic pump / Engine housing 125 Nm
Exhaust 95 Nm
Engine / Carrier side pump 125 Nm
Engine
Engine / Carrier side fan 85 Nm
Engine / Silentbloc support 125 Nm
Screw fastening elastic coupling / Flywheel 25 Nm
Counterweight Counterweight / Turntable 500 Nm
15 Nm
Telescope Pads rear telescope
Medium threadlocker
30 Nm
Boom tube Upper and lower front pads
Medium threadlocker
8 Nm
Input jib leveling cylinder Valve / Cylinder
Medium threadlocker
47 Nm
Cylinder / Link piece
Platform rotation cylinder Medium threadlocker
Screw connecting cylinder / link piece 485 Nm
4000866050 E 10.18 USA / GB 93

General data
Torque Values
MS0005
Sub-assemblies Concerned elements Torque

Mounting on platform support and link piece
Apply torque in 3 times :
1. 123 Nm
2. 246 Nm
3. 370 Nm
Tightening crosswise in the order below :
Strain gauge MOBA 370 Nm
Platform control box 16 Nm

Silentbloc fastening platform control boxPlatform Floor 22 Nm
94 4000866050 E 10.18 USA / GB

Chassis and turret
Tires (Tyres) and pressures - Wheel replacement
MS0006
Chassis and turret
1- You will need

• Protective goggles
• Gloves
• Place barriers around the perimeter of the work area
• Jack
• Hoist
• Torque spanner
3- Technical specifications
Characteristics Standard wheel
Filled foam or inflated wheel (pressure) Foam-filled
Ply rating 12
Wheel mass 277 kg +/- 17,5 kg (611 lb +/- 39 lb)
Size 1100 /401 mm
4000866050 E 10.18 USA / GB 95

Chassis and turret
MS0006
4- Wheel and tires/tyres inspections
Replace the wheels and the tires if any 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.
• Consistent wear of the ground contact surface greater than 25%
Tires and rims are critical components for the stability of the machine. For safety reasons. :
• Use only HAULOTTE® spare parts according to the technical characteristics of the machine. Refer to the spare parts
catalog.
• Never replace foam filled tire with a pneumatic (air filled) tire. .
96 4000866050 E 10.18 USA / GB

Chassis and turret
MS0006
5- Wheel replacement
Procedure of replacement :
• Loosen the wheel nuts on the wheel to be removed.
• Raise the machine using a jack or a hoist.
• Remove the wheel nuts.
• Remove the wheel.
• Install the new wheel.
• Lower the machine to the ground.
• Tighten the wheel nuts to the recommended torque Refer to maintenance and repair manuals.
Component Standard wheel

Reference number "385/65-22,5"
Filled foam or inflated wheel (pressure) Standard foam
Wheel mass 279 kg +/- 18kg (611 lb +/- 39 lb)
Size 1100 /401 mm
Torque 300 N.m / 221 lb.ft
Metric torque value / Imperial torque

Machine type Wheel type
value
HT23RTJ O - HT23RTJ O SW -
HT67RTJ O - HT23RTJ PRO - Drive wheel 300 N.m / 221 lb.ft
HT23RTJ PRO SW - HT67RTJ PRO
4000866050 E 10.18 USA / GB 97

Chassis and turret
MS0006
Notes
98 4000866050 E 10.18 USA / GB

Chassis and turret
Wheel reducer - Control - Oil replacement
MS0007
Chassis and turret
1- You will need

• Gloves
• Oil connection pan
4000866050 E 10.18 USA / GB 99

Chassis and turret
MS0007
3- Oil control
Unscrew the 2 nuts with an 11 mm spanner.
Turn the part and screw it back on.
The gears are released.

1. Loosen and remove plug .
2. Check the oil level.
3. Top up the oil level to the hole, if necessary.
4. Refit and tighten plug .
4- Oil replacement
1. Turn the wheel until plug ( 2 ) is directed downwards.

2. Loosen and remove plugs and .
3. Let the oil drain out.
5. Turn the wheel again to the level control position.
6. Fill the wheel reducer with oil up to hole
Ensure that some oil doesn't come to insinuate itself between the rim and the tire (wheel with air).
Use an oil collection pan to avoid polluting the environment.
100 4000866050 E 10.18 USA / GB

Chassis and turret
Oscillating axles - Functional tests
MS0008
Chassis and turret
1- You will need

• Gloves
4000866050 E 10.18 USA / GB 101

Chassis and turret
MS0008
3- Oscillating axles
The front axles will oscillate when the boom is in transport position (i.e. when the boom is less than 15° above
horizontal and not extended beyond 30 cm (12") on the machine and drive is selected.
Lockout system test must be performed quarterly, any time a system component is replaced, or when improper system
operation is suspected.
N.B.-:-ENSURE THE AXLES ARE EXTENDED AND THE BOOM IS FULLY RETRACTED, LOWERED, AND CENTERED
BETWEEEN THE REAR WHEELS PRIOR TO BEGINNING LOCKOUT CYLINDER TEST.
1. Place a 15 cm (6 in) high block with ascension ramp in front of left front wheel.
2. From platform control box, start engine.
3. Place the drive control lever to the forward position and carefully drive machine up ascension ramp
until left front wheels is on top of block.
4. Carefully extend the boom just enough to get it out of the transport position.
5. With boom in this position, place drive control lever to reverse and carefully drive machine off of block
and ramp.
6. Have an assistant check to see that left front or right rear wheel remains elevated in position off of the
ground.
7. Carefully return the boom to the transport position. When boom reaches the transport position, care-
fully activate drive to release cylinders. To lockout cylinders should release and allow the wheel to rest
on ground. This operation must be realized with extremes precautions by standing strongly on the
platform by the contact with the ground.
8. Repeat the procedure for the right oscillation cylinder checking to see that the right front or left rear
wheel remains elevated in position off of the ground.
9. If lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to
any further operation.
102 4000866050 E 10.18 USA / GB

Chassis and turret
Fuel tank - Filling-up
MS0009
Chassis and turret
1- You will need

• Gloves
• Do not smoke.
3- Consumable
Use only oils whose features correspond to HAULOTTE® recommendations (Section C - Familiarization -
Consumable) or contact HAULOTTE Services®.
Not mix two different characteristics fuel: if necessary, purge and clean the circuit.
4000866050 E 10.18 USA / GB 103

Chassis and turret
MS0009
4- Filling
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.
1. Loosen and remove the tank cap .

2. Fill up the tank.
3. Refit and tighten the tank cap .
4. Clean up any fuel that may have escaped from the tank.
104 4000866050 E 10.18 USA / GB

Chassis and turret
Slew ring inspection
MS0010
Chassis and turret
1- You will need

• Gloves
• Do not smoke.
4000866050 E 10.18 USA / GB 105

Chassis and turret
MS0010
3- Lubrication
The maintenance of the slew ring is essential for the safety of the machine and to guarantee its service life. Whatever
the type of system installed on the machine, interior or external teeth, follow the recommendations of greasing as
indicated in the program.
• Grease the (internal and external) crown gear teeth.
• Grease the raceways (access to greasers via the holes situated on the turntable, until the oil escapes from the crown
lip seal).
106 4000866050 E 10.18 USA / GB

Chassis and turret
MS0010
3.1 - FOR HA16RTJ - HA16RTJ O - HA16RTJ PRO - HA46RTJ O - HA46RTJ PRO ONLY
• 2 by tie rod (B)
Slew ring :
• 2 nipples on the raceways inside the slew ring
• 3 nipples on the worm screw
4000866050 E 10.18 USA / GB 107

Chassis and turret
MS0010
• Greasing the crown gear teeth
• Greasing the sidewall telescope
4- Tightening
To ensure safety operation, tightening check should be performed on slew ring.
Please refer to follow value for this procedure using a torque wrench.
Machine type Metric torque value Imperial torque value

HT23RTJ O - HT23RTJ O SW - HT67RTJ O - HT23RTJ PRO - HT23RTJ
215 Nm 158.6 lb ft
PRO SW - HT67RTJ PRO
HA16RTJ 215 Nm 158.6 lb ft
HA32PX - HA100JRT 215 Nm 158.6 lb ft
HA41PX-NT - HA130JRT-NT 215 Nm 158.6 lb ft
STAR 8 - STAR 22J - Ring on plate 135 Nm 100 lb ft
STAR 8 - STAR 22J - Plate on mast foot 195 Nm 144 lb ft
STAR 8 - STAR 22J - Ring on chassis 135 Nm 100 lb ft
STAR 10 - STAR 26J - Ring on plate 135 Nm 100 lb ft
STAR 10 - STAR 26J - Plate on mast foot 195 Nm 144 lb ft
STAR 10 - STAR 26J - Ring on chassis 135 Nm 100 lb ft
108 4000866050 E 10.18 USA / GB

Chassis and turret
MS0010
5- Slew ring inspection
Check the slewing system every 500 h or each major intervention done on the machine.
5.1 - VISUAL AND SOUND CHECK
• Check for the presence of all the locating bolts.

• Check that the accessible screws are not loosened. If necessary, tighten the screws. (Refer to the
"tightening torque" table. )
• Visually check the presence of the teeth and gear (if possible).
• Check the appearance of the teeth.
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®).
Replace slew ring in the following cases :

• Abnormal noise during the turret rotation.
• Movement jolts during the rotation of the turret.
• Gear teeth missing or damaged.
• Presence of metal particles in the grease.
• Wear on gear teeth.
• Abnormal clearance of the gear ring.
4000866050 E 10.18 USA / GB 109

Chassis and turret
MS0010
5.2 - MEASUREMENT OF THE CLEARANCE
Place the machine in the following conditions :

• On flat ground, Set up barriers to define the test area.
• No load in the platform.
• From the ground control box, align the turret at 90 ° to the chassis.
• Lift the boom approximatively 30 ° from the ground.
• Completely retract the boom telescope.
• 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
J1
After having carried out the measurement :

• Lower the boom at horizontal position.
• Lift the arm (if exists) as its maximum position. Don’t extend the telescopic boom.
• Telescope the boom to its maximum angle (completely extend the telescope).
• Jib in horizontal position(if fitted).
In its new configuration, note the clearance ( J1) between chassis (or turret) and the slew ring as previously.
• If the difference between two measurements does not exceed 2 mm (0.08 in) : the test validates correct
operation.
• Otherwise, contact HAULOTTE Services® to repair the system.
110 4000866050 E 10.18 USA / GB

Chassis and turret
Gearbox inspection - Oil replacement
MS0011
Chassis and turret
1- You will need

• Gloves
• Do not smoke.
3- Gearbox inspection
1. Loosen and remove the filling cap ( 1 ).

2. Check that the oil level is between the indicated minimum and max-
imum levels. 1
3. Top up the oil level, if necessary.
4. Refit the filling cap ( 1 ).
4- Oil gearbox replacement

1. Remove the filling cap ( 1 ).
2. Loosen the drain plug ( 2 ).
3. Let the oil drain out.
4. Refit and tighten the drain out ( 2 ).
5. Top up the oil level as indicated above.
6. Refit the filling cap ( 1 ).
Use an oil collection pan to avoid polluting the environment.
4000866050 E 10.18 USA / GB 111

Chassis and turret
MS0011
Notes
112 4000866050 E 10.18 USA / GB

Upper boom / Mast
Condition of the cables inspection - Criteria of replacement
MS0012
Upper boom / Mast
1- You will need

• Gloves
3- Control wire rope system
To guarantee a full safety use of the machine , Haulotte recommends respecting the following inspections :
3.1 - DAILY CHECK

3.1.1 - Articulated and telescopic machines
• To position the machine on a flat and firm ground.

• To put the machine under tension and select the ground control box.
• Raise the boom to horizontal. To carry out a cycle of extending/retracting of the boom assembly on
approximately 2 m (6ft 7 in).
• To check the synchronization and the symmetry of the movements and the absence of abnormal noises.
If these phenomena occur, carry out a reinforced control (see paragraph below).
3.1.2 - Mast machines

• Carry out a lifting / lowering cycle.
• To check the synchronization and the symmetry of the movements and the absence of abnormal noises.
If these phenomena occur, carry out a reinforced control (see paragraph below).
4000866050 E 10.18 USA / GB 113

Upper boom / Mast
MS0012
3.2 - PERIODIC CONTROL

3.2.1 - Articulated and telescopic machines
This operation must be realized as of the first 50 hours, then every 250 h hours or 6 months.
To reach the elements :

• Dismount the inspection door and/or covers.
• Raise the boom to horizontal.
• To check the presence and the tightening of the fastenings of the cables on the visible points of fixing.
• To extend the structure to obtain an access to the wire rope :
• To extend the boom at least 3 m (9 ft 10 in) for the telescopic machines.
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 chain guides.

• Check the condition of the cables. If any of the following defects are observed, replace the pair of cables.
Replace defective parts with genuine HAULOTTE® replacements.
114 4000866050 E 10.18 USA / GB

Upper boom / Mast
MS0012
Machine Original diameter

HA16JRT To be completed
HA20RTJ_O_PRO To be completed
H21TX - H23TPX - H25TPX 9 mm
HT23RTJ O - HT23RTJ O SW - HT67RTJ O - HT23RTJ
11,2 mm
H43TPX 19 mm
• No broken strands must be observed, in particular at the ends.

• Replacement is compulsory when 3 strands or more are broken along the length 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.
4000866050 E 10.18 USA / GB 115

Upper boom / Mast
MS0012
3.2.2 - Mast machines
This operation must be realized as of the first 50 hours, then every 250 hours or 3 months.
To reach the elements :

• Dismount the inspection door and/or covers.
• To check the presence and the tightening of the fastenings of the cables on the visible points of fixing. To
raise the masts unit to the doors inspection.
• To extend the structure to obtain an access to the wire rope :
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 chain guides.

• Check the condition of the cables. If any of the following defects are observed, replace the pair of cables.
Replace defective parts with genuine HAULOTTE® replacements.
116 4000866050 E 10.18 USA / GB

Upper boom / Mast
MS0012
Machine Original diameter

STAR 6 - STAR 13 - STAR 8 - STAR 22J - STAR 10 - STAR
3 mm
22J
• No broken strands must be observed, in particular at the ends.

• Replacement is compulsory when 3 strands or more are broken along the length 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.
4000866050 E 10.18 USA / GB 117

Upper boom / Mast
MS0012
4- Tension checking
4.1 - ARTICULATED AND TELESCOPIC MACHINES
This operation must be realized as of the first 50 hours, then every 250 h hours or 6 months.
For the particular procedures of adjustment untreated in maintenance book, it is necessary to

contact HAULOTTE Services®. MS0018Boom adjustment procedure.
4.2 - MAST MACHINES
This operation must be realized as of the first 50 hours, then every 250 hours or 3 months.
For the particular procedures of adjustment untreated in maintenance book, it is necessary to

contact HAULOTTE Services®. MS0018Boom adjustment procedure.
5- Criteria of replacement
Cables with a diameter measuring less than 6 mm must be replaced every 5 years.
All other cables must imperatively be replaced every 7 years.
Replacement may be required more frequently for the following reasons :

• Machine operates 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. Deliver any scrap cables or
cable elements to a dealer specialised in metal recycling in compliance with regulations.
118 4000866050 E 10.18 USA / GB

Upper boom
Check and replacing the pads
MS0013
Upper boom
1- You will need

• Gloves
3- Boom lubrication
Using adequate oil specification describe above :

• Oil the parts of the telescope subject to friction (with a spatula).
• Oil the telescoping cable.
4000866050 E 10.18 USA / GB 119

Upper boom
MS0013
4- Check the worn of friction pads
Check the telescoping friction pad wear indicators.
Change the pad if the indicator is not visible.
120 4000866050 E 10.18 USA / GB

Upper boom
MS0013
5- Removing / Replacing the pads
Changing the top intermediate tube and telescope upper and side pads without removing the boom.
• Machine stowed (boom retracted and in horizontal position).
• Insert a pin to lock the tubes.

• Attach the platform with slings.
• Put the platform on a flat horizontal surface.
• Take off the rear hood by removing the 4 flanged nuts.
• Take off the connecting rod ( 1 ) by removing 2 pins ( 2 ) and ( 3 ).
4000866050 E 10.18 USA / GB 121

Upper boom
MS0013
• Remove the 2 hoses.

• Take out the 2 screws.
• Remove the telescoping block.
When removing the block, make sure that the seals are in
perfect condition. Protect the telescoping cylinder orifices.
Dismantling the lifting beam assembly (extension cables) :

• Undo the nuts to remove the cables from the lifting beam.
• Use a caliper to measure the compression of the spring washers and

adjust to the same compression when reassembling the unit.
• Remove the 2 screws holding the lifting beam.
• Unscrew the position switch cable.
122 4000866050 E 10.18 USA / GB

Upper boom
MS0013
• Remove the lifting beam cables.

• Remove the lifting beam.
Removing the cylinder guide cross member :

• Remove the 2 pads ( 1 ) from the top of the cross member.
• Undo the 6 screws ( 2 ).
• First pull, then remove the cross member ( 3 ).
N.B.-:-THE FINAL CONFIGURATION IS AS FOLLOWS.
4000866050 E 10.18 USA / GB 123

Upper boom
MS0013
The final configuration is as follows :

• Remove the top right pad ( 1 ).
• Remove the top right side pad ( 2 ).
• Remove top left pad ( 3 ).
124 4000866050 E 10.18 USA / GB

Upper boom
MS0013
• Remove the top left side pad ( 4 ).

• Remove the telescope extension cable support plate( 1 ) screw ( 2 ).
• Pull the cable support plate ( 1 ) back to the rear of the telescope cylinder.
N.B.-:-GENTLY PULL THE CABLE SUPPORT PLATE ( 1 ) ON THE BACK

SO THAT YOU CAN RECOVER THE EXTENSION CABLES INSIDE THE
BOOM BASE HOUSING.
Removing the top and side pads at the top of the telescope : :
• Remove the top side and top left pads.
4000866050 E 10.18 USA / GB 125

Upper boom
MS0013
• Remove the top right pad.
• Remove the top right side pad.
N.B.-:-REPLACING THE PADS AND REASSEMBLING ARE DONE IN REVERSE ORDER TO REMOVING THEM. THE
HOUSINGS HAVE GUIDES SO THAT THE PADS CAN BE PUT IN POSITION "BLIND", MAKING REASSEMBLY EASIER..
126 4000866050 E 10.18 USA / GB

Upper boom
Procedure of dismantling / reassembling telescope cylinder
MS0014
Upper boom
1- Scope of intervention
In this document you will find the necessary information to remove the telescope cylinder
2- You will need

• Gloves
• Jack
• Hoist
• Torque spanner
4000866050 E 10.18 USA / GB 127

Upper boom
MS0014
4- Dismantling / Reassembling the telescope cylinder
• Machine stowed (boom retracted and in horizontal position).
• Insert a pin to lock the tubes.

• Attach the platform with slings.
• Put the platform on a flat horizontal surface.
• Take off the rear hood by removing the 4 flanged nuts.
• Take off the connecting rod ( 1 ) by removing 2 pins ( 2 ) and ( 3 ).
128 4000866050 E 10.18 USA / GB

Upper boom
MS0014
Dismantling the lifting beam assembly (extension cables) :

• Undo the nuts to remove the cables from the lifting beam.
• Use a caliper to measure the compression of the spring washers and

adjust to the same compression when reassembling the unit.
• Remove the 2 screws holding the lifting beam.

• Unscrew the position switch cable.

• Remove the lifting beam.
4000866050 E 10.18 USA / GB 129

Upper boom
MS0014
• Take off the rear hood by removing the ( 1 ) flanged nuts.
• Remove the 4 screws that hold the 2 the boom base return cables.
• Remove the 2 boom base return cables.
N.B.-:-D O NOT DISCONNECT THE LIFTING BEAM FROM THE

RETRACTION CABLES.
Removing the cylinder guide cross member :

• Remove the 2 pads ( 1 ) from the top of the cross member.
130 4000866050 E 10.18 USA / GB

Upper boom
MS0014
• First pull, then remove the cross member ( 3 ).
Removing the 2 flanges :

• Undo the screws holding the left- and right-hand side flanges.
• Remove the left- and right-hand side flanges.
Removing the retraction cables on the telescope :

• Fold back the pin stop covers which must be replaced with new covers
when reassembling.
4000866050 E 10.18 USA / GB 131

Upper boom
MS0014
• Undo the screws holding the retraction cables.

• Remove the telescope extension cable support plate( 1 ) screw ( 2 ).
• Pull the cable support plate ( 1 ) back to the rear of the telescope cylinder.
N.B.-:-GENTLY PULL THE CABLE SUPPORT PLATE ( 1 ) ON THE BACK

SO THAT YOU CAN RECOVER THE EXTENSION CABLES INSIDE THE
BOOM BASE HOUSING.
• Extend the cylinder :

• Sling the cylinder via the connecting rod fastening.
• Lift the cylinder to free it from the recesses, then pull it
132 4000866050 E 10.18 USA / GB

Upper boom
MS0014
• Pull the cylinder up to the opening at the back of the turntable.
N.B.-:-BEFORE COMPLETELY FREEING THE CYLINDER, YOU MUST

FIRST ATTACH ALL THE CABLES (UNDERNEATH AND ON TOP OF THE
CYLINDER) WITH PLASTIC COLLARS SPACED 1 METRE APART.
4000866050 E 10.18 USA / GB 133

Upper boom
MS0014
• Use the wooden prop to prop up the cylinder so that you can position the
cylinder retaining strap on the other side of the opening.
• Pull the cylinder out to approximately 2500 mm (8 ft 2 in) from the pulley
axis.
• Take hold of the cylinder 2300 mm (7 ft 7 in) away from the axis of the
pulleys to extract it completely.
134 4000866050 E 10.18 USA / GB

Upper boom
MS0014
• Remove the cylinder. Replace the cables and the pulleys.
N.B.-:-REASSEMBLE IN THE REVERSE ORDER OF DISMANTLING.
4000866050 E 10.18 USA / GB 135

Upper boom
MS0014
Notes
136 4000866050 E 10.18 USA / GB

Upper boom
Boom adjustment procedure
MS0015
Upper boom
1- You will need

• Gloves
N.B.-:-THE MACHINE IS NOT TILTED AND THE BOOM IS IN THE HORIZONTAL POSITION.
4000866050 E 10.18 USA / GB 137

Upper boom
MS0015
3- Adjustment's procedure
1 - Basket side :
• Loosen the chains. (The lock-nut must be level with the extremity of the
screw, see the following picture).
• Tight the lock-nut.
• Check that the 7 lock washers are present in the position shown on the
diagram.
2 - On the front of the machine :

• Tight the chain until having a length of 20 mm +/- 1 mm. (From the lock-
nut to the extremity of the screw, see the following picture).
• Tight the lock-nut.
• Check that the 6 lock washers are present in the position shown on the
diagram.
138 4000866050 E 10.18 USA / GB

Upper boom
MS0015
3 - Raise the boom :

• Extend and retract totally the telescope :
• Lower the boom.
• Extend the telescoping boom between 100 and 200 mm.
• Loosen the lock-nut on the basket side.
4 - On the basket side :

• Tight the chain for having a length of 20 mm + 0 - 1 mm
between the last washer and the plan of the boom (See
the following picture). .
5 - Extend the telescopic boom to 1 meter approximately :

• Retract the telescope totally.
• Extend the telescope between 100 and 200 mm.
• Check that the length of 20 mm is OK.
6 - If it's not, repeat the operations of the paragraphs 4 and 5 until the stabilization of the length to 20 mm :
• Lock the lock-nut when the length of 20 mm is OK.
4000866050 E 10.18 USA / GB 139

Upper boom
MS0015
Notes
140 4000866050 E 10.18 USA / GB

Upper boom
Boom angle sensor adjustment
MS0018
Upper boom
1- You will need

• OPTIMIZER console
• Gloves
4000866050 E 10.18 USA / GB 141

Upper boom
MS0018
3- Boom angle sensor adjustment
• Raise the boom not telescoped at 52°.

• Measure with an electronic level, between the boom angle and the chassis
angle if the ground of reference are not at 0°.
• Set the sensor ILS in front of magnet in the middle.
• Loosen the nuts ( 1 ) to adjust the sensor.
Sensor adjustment :
• Set the mechanical cam sensor to change state at this position (passage
from ON to OFF) having previously set the position of the sensor on the
bracket adjustment for the wheel is perfectly centered on the profile of the
cam.
• Once the sensor is tight on the bracket, move it through the light that the
sensor status to the console is on ON.
• Approach screws to the support without tightening finally.
142 4000866050 E 10.18 USA / GB

Upper boom
MS0018
• Drive slowly the bracket so that the sensor going to OFF.

• Tightening the screws of the support bracket.
• Put the machine in position load 450 kg (1000 lb) (selector on 450 kg (1000 lb) on the platform control box).
• Raise the boom at 75°.
• Extend the telescope to its maximum.
• From the ground or platform control box, lower the boom until the cut-of abacus of the machine.
• Check the boom angle included between 52° and 50°. Outside this range, adjust the sensor.
4000866050 E 10.18 USA / GB 143

Upper boom
MS0018
Notes
144 4000866050 E 10.18 USA / GB

Hydraulics
Hydraulic oil - Level Replacement
MS0019
Hydraulics
1- You will need

• Gloves
4000866050 E 10.18 USA / GB 145

Hydraulics
MS0019
3- Level control
Each day before use, check the hydraulic oil level to ensure safety operation.
N.B.-:-CHECK THE OIL LEVEL WHEN COLD AND WHEN THE MACHINE IS STOWED (BEFORE BEGINNING A NEW PERIOD
OF WORK)
The oil level ( 1 ) must be between the upper and lower markers .
If the oil level ( 1 ) is not visible :

1. Loosen and remove the tank cap ( 2 ).
2. Top up the oil level.
3. Refit and tighten the tank cap .
146 4000866050 E 10.18 USA / GB

Hydraulics
MS0019
4- Replacement of hydraulic oil
Hydraulic oil must be replaced all the 2000 hours or 2 years. This periodicity can be modified so important
interventions and/or anomaly was noted.
The state of cleanliness of the oil filter cartouche is another indicator of purging of the system :
• Dismount the cartouche of the oil filter.
• Check the absence of rubber, plastic or metal shaving.
4.1 - CONSUMABLE
Use only oils whose features correspond to HAULOTTE® recommendations (Section C - Familiarization -
Consumable) or contact HAULOTTE Services®.
Not mix two different characteristics oils. If necessary, purge and clean the circuit.
4.2 - FILLING
To fill the system correctly; respect the following stages :

• The machine must be completely folded (for the machines equipped: raised stabilizers).
• Fill the tank.
• Carry out a complete cycle (to go/return) of each cylinder.
• Fill the tank if necessary (never more than the maximum level).
• Repeat stages 1 and 2 for each cylinder of the machine.
When filling, it is forbidden to remove the strainer filter.
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Hydraulics
MS0019
Notes
148 4000866050 E 10.18 USA / GB

Hydraulics
Hoses inspection - Replacement
MS0020
Hydraulics
1- You will need

• Gloves
2- Control and inspections
The state of hoses devices plays a significant role in the safety of the machines.
For the hoses device accessible without consequent disassembling, a visual inspection must be realized all the 250
hours or 1 year :
• Check the absence of leakage to the junctions of the hoses.
• Check that all the hoses are correctly tightened.
• Check the absence of tear and crack of the external hoses.
• Check that the shielding of the hose is not apparent.
• Check the absence of chemical aggression of the membrane of the hose.
For the non visible hoses without disassembling, a reinforced visual inspection must be realized all the 5000 hours
or 5 years.
If anomalies are noted, it is necessary to replace the elements by respecting the following recommendations.
4000866050 E 10.18 USA / GB 149

Hydraulics
MS0020
3- Hoses Disassembling
For safety reasons, respect imperatively the following conditions of disassembling :
• Fold the machine on a flat and released ground :
• The machine is not in slope.
• The boom is horizontal.
• Put the turret (if equipped) in the axis.
• Carry out a beaconing of the sector (maximum risk zone = machine height).
• Locate the hoses and their connections points to guarantee the good performance of the machine after intervention.
• Locate the hoses course to facilitate the reassembly.
To recover oil, use an oils container in order not to pollute the environment.
Unscrew the flexible device slowly in order to make fall residual water pressure.
It is imperative to secure and maintain cylinders when removing hoses cylinders. An analysis of the hydraulic system
is imperative.
After disassembling :
• Close the hose openings and the hydraulic components to avoid the pollution of the hydraulic system.
• Check the cleanliness of the hoses and the hydraulic components :
• Absence of plastic, rubber or metal shaving.
• If necessary, purge and clean the circuit (tank included).
4- Hoses Reassembly
For safety reasons, respect imperatively the following conditions of reassembly :
• Using the reference marks carried out previously; carry out the courses of hoses.
• During the fixing of the hoses, respect the tightening torques below.
Tightening torque table
Description Torque (JIC) Torque (ORFS)
Hose 1/4" (diameter 6mm) 1,5 daN.m(11,08 lbf.ft) 2,6 daN.m(19,22 lbf.ft)
Hose 3/8" (diameter 10mm) 3,5 daN.m(25,86 lbf.ft) 4,2 daN.m(31,04 lbf.ft)
Hose 1/2" (diameter 12mm) 5 daN.m(36,95 lbf.ft) 5,7 daN.m(42,12 lbf.ft)
Hose 5/8" (diameter 16mm) 8 daN.m(59,12 lbf.ft) 8,5 daN.m(62,82 lbf.ft)
Hose 3/4" (diameter 19) 10 daN.m(73,91 lbf.ft) 12,2 daN.m(90,17 lbf.ft)
Once all the hoses are correctly tight :

• Put the machine in operational configuration
• Carry out some movements implementing the hoses concerned in order to purge the hydraulic system.
• Check the absence of leakage.
• Control the level of hydraulic oil tank.
• Check the pressures.
150 4000866050 E 10.18 USA / GB

Hydraulics
Hydraulic filter cartridge Replacement
MS0021
Hydraulics
1- You will need

• Gloves
All hydraulic components (pump, tanks….) except cylinders must be subjected to periodic visual inspections such as
defined below.
For all the visible components without disassembling a fast visual inspection must be realized every day before use :
• Absence of leakage (pump, tanks, hydraulic block, connections…).
• Absence of rust on the hydraulic blocks.
• Absence of deformations, damage, crack on tanks, pump and block hydraulics.
• Absence of foreign objects on all surfaces.
• Absence of missing or loosened part (bolt, nut, connection, flexible device, etc).
• Hydraulic oil level (to supplement if necessary, machine in folded up position).
• Presence and good state of the hydraulic oil filter (absence of filling).
For all the non visible components without disassembling a reinforced visual inspection must be realized all the 250
hours or 1 year with the same criteria as quoted above.
4000866050 E 10.18 USA / GB 151

Hydraulics
MS0021
2- Hydraulic filter cartridge Replacement
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.).
2 2
1 1
3 3
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Hydraulics
MS0021
1. When the clogging indicator ( 2 ) comes on, replace the cartridge ( 1 ) (Cold oil).
2. Loosen and remove the base nut ( 3 ).
3. Loosen and remove the cartridge ( 1 ).
4. Screw in a new cartridge.
5. Refit and tighten the base nut ( 3 ).
6. Reset the clogging indicator ( 2 ) by pressing it until it becomes green again.
4000866050 E 10.18 USA / GB 153

Hydraulics
MS0021
Notes
154 4000866050 E 10.18 USA / GB

Hydraulics
Pressure adjustment
MS0022
Hydraulics
Pressure adjustment
1- You will need

• Gloves
2- Pressure adjustment
To allow checking operation, refer to the following table about originally pressure adjustment
If the values measured by test are not equal to the following :

• Do not use the machine.
• Setting updating is needed.
Description In Bar In PSI

General 240 +/- 5 3481 +/-72
Pressure LS) 30 +/- 5 435 +/- 72
Emergency pump 240 +/- 2 3481 +/- 29
Boom raise 240 +/- 5 3481 +/- 72
Descent boom 100 +/- 5 1450 +/- 72
Telescoping boom extension 100 +/- 5 1450 +/- 72
Telescoping boom retraction 240 +/- 5 3481 +/- 72
Turret slewing 120 +/- 5 1740 +/- 72
Jib telescopinc extension 210 +/- 5 3046 +/- 72
Jib telescopic retraction 240 +/- 5 3481 +/- 72
Rotation basket 140 +/- 5 2031 +/- 72
Charge drive / brake circuit 25 +5 / -0 362 +72 / -0
Drive FWS - REV 320 +/- 5 4641 +/- 72
Change of cubic capacity drive motor 50 +5 / -0 725 +72 / -0
4000866050 E 10.18 USA / GB 155

Hydraulics
Pressure adjustment
MS0022
3- Adjustment of pressures
3.1 - PORT PLUG FOR PRESSURES CONTROL
All pressures could be ckecked by connecting a pressure gauge on port M as shown below
156 4000866050 E 10.18 USA / GB

Hydraulics
Pressure adjustment
MS0022
3.2 - PRESSURE ADJUSTMENTS ON PUMP
• Load Sensing.
• Main flow.
• The pump is preset at a load sensing pressure of 20b (+-2b)/290 psi.
• The pump is preset at a main pressure of 240b (+-5b)/3480 psi.
Marking Function Value

1 Load Sensing 20b
2 Pmaxi 240b
Settings
Designation Pressure Adjustment port

Maxi pressure setting 240 +/-5b On equipment pump
Load sensing setting 22 +/-2b On equipment pump
Pressure turret orientation 120 +/-5b On ECD proportional block
Emergency pump 240 +/-5b On emergency pump
4000866050 E 10.18 USA / GB 157

Hydraulics
Pressure adjustment
MS0022
Notes
158 4000866050 E 10.18 USA / GB

Hydraulics
Hydraulic ways
MS0023
Hydraulics
Hydraulic ways
1- You will need

• Gloves
4000866050 E 10.18 USA / GB 159

Hydraulics
Hydraulic ways
MS0023
2- Turntable - HT23RTJ O - HT23RTJ O SW - HT67RTJ O

Folio 1 / 2
160 4000866050 E 10.18 USA / GB

Hydraulics
Hydraulic ways
MS0023
Folio 2 / 2
4000866050 E 10.18 USA / GB 161

Hydraulics
Hydraulic ways
MS0023
3- Turntable - HT23RTJ PRO - HT23RTJ PRO SW - HT67RTJ PRO

Folio 1 / 2
162 4000866050 E 10.18 USA / GB

Hydraulics
Hydraulic ways
MS0023
Folio 2 / 2
4000866050 E 10.18 USA / GB 163

Hydraulics
Hydraulic ways
MS0023
4- Chassis - HT23RTJ O - HT23RTJ O SW - HT67RTJ O

Folio 1 / 2
164 4000866050 E 10.18 USA / GB

Hydraulics
Hydraulic ways
MS0023
Folio 2 / 2
4000866050 E 10.18 USA / GB 165

Hydraulics
Hydraulic ways
MS0023
5- Chassis - HT23RTJ PRO - HT23RTJ PRO SW - HT67RTJ PRO

Folio 1 / 2
166 4000866050 E 10.18 USA / GB

Hydraulics
Hydraulic ways
MS0023
Folio 2 / 2
4000866050 E 10.18 USA / GB 167

6-
168
Hydraulics
Hydraulic ways
1
VERIN RECEPTEUR DE COMPENSATION/ GUIDE CHAINE et FLEXIBLES /
SLAVE CYLINDER CABLE and CHAIN HOLDER 2
Upper boom
4000866050
4000007070 158P344440 3
4
E
1
2
C
GUIDE CHAINE et FLEXIBLES /

CABLE and CHAIN HOLDER 1
158P344440
E 10.18
GUIDE CHAINE et FLEXIBLES /
CABLE and CHAIN HOLDER
158P344440
VERIN EMETTEUR DE COMPENSATION /

1 MASTER CYLINDER
2 4000007560
3 Légende des détrompages couleur par collier plastique:
4
pas de collier
collier noir - code 2389002870
collier blanc - code 2389002810

C collier rouge - code 2326013450
3 4
3 collier orange - code 2326013460
2 1 2
3 collier jaune - code 2326013470
4
C
1 collier vert - code 2326013480
collier bleu - code 2326013490
collier violet - code 2326013500
USA / GB
MS0023
Hydraulics
Hydraulic ways
MS0023
7- Jib
4000866050 E 10.18 USA / GB 169

Hydraulics
Hydraulic ways
MS0023
Notes
170 4000866050 E 10.18 USA / GB

Chassis and turret
Dismantling / Reassembling wheels reducer
MS0026
Chassis and turret
1- You will need

• PPE (Personal Protective Equipment: glove, safety
shoes, glasses, etc ...)
• Grease-remover
• Rags
• Torque wrench (0-100in/lb)
• Torque wrench (0-50ft/lb)
• Grease for assembly
• Assorted hydraulic fittings
• System for recovery oils
• Drive reducer Oil
• Hydraulic hand pump 0 - 250 psi
• Pressure gauge 0 - 300 psi
• Special tools (refer plans at end of document)
• The technician should take all steps to protect themselves or others against all risks of injury related to this intervention.
• The technician should ensure that suitable PPE (personal protective equipment) for the job is used, and check the particular conditions of
environment in which the material can be found (see safety information specific to the operation site).
• Position the machine on a flat ground, stabilized and in a released environment.
• Cut the contact, to remove the key, to open cut it battery.
• Place a "DO NOT USE" decal near the start/stop contactor (key switch) to inform the personnel that interventions are being carried out on
the equipment.
• The pressure in the hydraulic system is very important. It can cause accidents. Relieve the pressure before any intervention and never
search for oil leaks by hand.
• Attention to the risks of burns, the hydraulic system works at high temperatures.
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Chassis and turret
MS0026
3- Tightening and torquing bolts
If an air impact wrench is used to tighten bolts, extreme care

should be taken to ensure that the bolts are not tightened beyond
their specified torque.
The following steps describe how to tighten and torque bolts or

socket head cap screws in a bolt circle.
• Tighten (but do not torque) bolt- A until snug.
• Go to the opposite side of the bolt circle and tighten bolt B until equally
snug.
• Crisscross around the bolt circle and tighten remaining bolts.
• Now use a torque wrench to apply the specified torque to bolt A.
• Using the same sequence, crisscross around the bolt circle and appaly an
equal torque to the remaining bolts
4- Main disassembly
172 4000866050 E 10.18 USA / GB

Chassis and turret
MS0026
1. Perform Roll Check, Leak Chake and Brake Check if applicable prior to disassembling the unit.
2. Drain oil from unit. Note the condition and volume of the oil.
3. Remove retaining Ring ( 6G ) by prying the open end of Retaining Ring out of the groove in the Ring
Gear ( 1E ) with a screwdriver, then grasp the loose end with pliers and pull the Retaining Ring com-
pletely out of the groove.
4. Remove the Cover ( 6 ) from the unit. The unit can be carefully pressurized with air to pop the cover
out of the unit.
5. Remove the First Stage Sun Gear ( 10 ) if applicable.
N.B.-:-ON UNITS WITH RATIOS GREATER TTHAN 36:1 NUMERICALLY, THERE WILL NOT BE A SEPARATE FIRST
STAGE SUN GEAR ( 10 ), AS THE GEAR TEETH WILL BE INTEGRAL TO THE INPUT SHAFT ( 9 ).
6. Remove the Input Carrier ( 3 ).

7. Remove the Second Stage Sun Gear ( 11 ).
8. Take the External retaining Ring ( 20 ) off the Sun Gear ( 11 ) if necessary.
9. Loosen and remove the 3 Flat Heat Bolts ( 19 ) that retain the Ring Gear ( 1E ) to the Housing ( 1G ).
10. Lift the Ring Gear ( 1E ) off the Housing ( 1D ).
11. Remove the O-ring ( 18 ) from between the Housing ( 1D ) and the Ring Gear ( 1E ).
4000866050 E 10.18 USA / GB 173

Chassis and turret
MS0026
12. Using a 1/8" diameter punch, drive the Roll Pin ( 4G ) into the Planet Shaft ( 4E ) until it bottoms
against the Spindle ( 1A ).
13. Grasp the Roll Pin ( 4G ) using needle nosed pliers or some sort of hooked tool, and pull the Planet
Shaft ( 4E ) out of the Spindle ( 1A ).
14. Using a 1/8" diameter punch, drive the Roll Pin ( 4G ) out of the Planet Shaft ( 3E ).
N.B.-:-THE ROLL PINS ( 4G ) SHOULD NOT BE REUSED WHEN REASSEMBLING THE UNIT
15. Slide the Planet Gear ( 4 ) out of the Spindle ( 1A ) being careful to not drop the Needle
Bearings ( 4C ) in the process.
16. Remove 4 Thrust Washers ( 4B ) , 28 Needle Rollers ( 4C ) and the Thrust Spacer ( 4D ) from the
Second Stage Planet Gear ( 4F ).
17. Repeat Steps for the remaining 2 Planet Gears.
18. Remove the Thrust Washer ( 4H ) from the counterbore in the Spindle ( 1A ).
19. Remove the Input Shaft ( 9 ).
174 4000866050 E 10.18 USA / GB

Chassis and turret
MS0026
5- Input carrier disassembly
1. Using a 1/8" diameter punch, drive the Roll Pin ( 4G ) into the Planet Shaft ( 3E ) until it bottoms
against the Carrier ( 3A ).
2. Using a soft face hammer, tap the Planet Shaft ( 3E ) out of the Carrier ( 3A ).
3. Using a 1/8" diameter punch, drive the Roll Pin ( 4G ) out of the Planet Shaft ( 3E ).
N.B.-:-THE ROLL PINS ( 4G ) SHOULD NOT BE REUSED WH EN REASSEMBLING THE UNIT.
4. Siide the Planet Gear ( 3F )and the 2 Thrust Washers ( 3B ) out of the Carrier ( 3A ).
5. Remove the 14 needle Bearings ( 3C ) from the bore of the Planet Gear ( 3F ).
6. Repeat steps for each of the 2 remaining planet gears.
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Chassis and turret
MS0026
6- Hub Spindle disassembly
1. Place unit on special fixture with Spindle ( 1A ) flange end down. Don't sit on Coupling ( 7 ).
2. Remove 2 Set Screws ( 1G ) and Bearing Nut ( 1F ) using T-206569. It may be necessary to heat
the Locknut ( 1F ) to break down the loctite.
N.B.-:-THE HOLES IN THE BEARING NUT ( 1F ) FOR THE SET SCREWS ( 1G ) WERE STAKED FOR RETENTION OF
THE SET SCREWS ( 1G ). THE HOLES WILL NEED TO BE CLEANED UP PRIOR TO REMOVING THE SET SCREWS.
3. While supporting the unit on Hub ( 1D ) flange, press Spindle ( 1A ) out of Hub ( 1D ).
4. Remove outbound position Bearing Cone ( 1C ) from Bearing Cup ( 1C ) in Hub ( 1D ).
5. Lift Hub ( 1D ) off of Spindle ( 1A ).
6. If necessary, press 9 Studs ( 1H ) out of Hub ( 1D ). Locate Hub ( 1D ) on Seal ( 1B ) end.
7. Remove Seal ( 1B ) from Hub ( 1D ).
N.B.-:-THE SEAL ( 1B ) SHOULD NOT BE REUSED WHEN REASSEMBLING THE UNIT.
8. Remove inbound position Bearing Cone ( 1C ) from Hub ( 1D ).

9. Using a soft steel rod, carefully knock both Bearing Cups ( 1C ) out of Hub ( 1D ).
N.B.-:-INBOUND CUP & CO NE SHOULD BE KEPT SEPARATE FROM OUTBOUND CUP & CO NE IF BEING REUSED.
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Chassis and turret
MS0026
7- Spindle brake disassembly
N.B.-:-THIS PROCEDURE APPLIES ONLY TO UNITS WITH INTEGRAL INPUT BRAKE ( 8 ).
Eye protection must be worn while performing the steps in this procedure.
1. Place Spindle ( 1A ) such that the flange side is up. Remove 8 Bolts ( 21 ) in X pattern by backing
each boit half way out, and then finish backing them out. Remove Motor Adaptor ( 1N ). If necessary,
remove Retaining Ring ( 8C ), knock Ball Bearing ( 8B ) out of Adaptor ( 1N ) counterbore, and check
Quad Seal ( 1K ) & O'Ring ( 8F ).
2. Remove Compression Springs ( 8L ) from Piston ( 8A ).
3. Using an air hose, slowly and carefully pressurize the brake port in the Spindle ( 1A ) until the
Piston ( 8A ) comes out of piston bore of Spindle ( 1A ), then pull the Piston ( 8A ) out of the
Spindle ( 1A ) by hand.
4. Remove Backup Ring ( 8H ) and O-ring ( 8F ) from grooves in Spindle ( 1A ) & Piston ( 8A ).
5. Remove Coupling ( 7 ) from brake cavity in Spindle ( 1A ).
6. Remove Backup Ring ( 8E ) and O-ring ( 8D ) from grooves in Spindle ( 1A ).
7. Remove Rotors ( 8J ) and Stators ( 8K ) from brake cavity in Spindle ( 1A ).
8. Remove Retaining Ring ( 5 ) out of the internai groove of Coupling ( 7 ) using Truarc #0100 or equiv-
alent pliers.
9. Remove the Spacer ( 1A ) & Spring ( 1L ) out of the bore of Coupling ( 7 ).
10. Knock Ball Bearing ( 8B ) out of Spindle ( 1A ) Counterbore if needed.
11. Remove Plastic Plug & Pipe Plug ( 12 ) from Spindle ( 1A ) if applicable.
4000866050 E 10.18 USA / GB 177

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MS0026
8- Cover disassembly
1. Remove O-Ring ( 17 ) from groove in Cover ( 6A ).

2. Remove Thrust Washer ( 2 ) from Cover ( 6A ) pockets, if necessary.
3. Unscrew 2 Hex Head Bolts ( 6C ) and remove Disengage Cap ( 6B ) from Cover ( 6A ).
4. Pull Disengage Rod ( 6D ) out from Cover ( 6A ).
5. Use appropriate tool to remove O-ring ( 6E ) from internal groove in Cover ( 6A ).
6. Remove 2 O-Ring Pipe Plugs ( 6F ) from Cover ( 6A ).
N.B.-:-PAINT BOOTH O-RING ( 6K ) CAN BE DISCARDED IF DESIRED.
N.B.-:-FOR REASSEMBLING UNIT, PLEASE REFER TO THE EXPLODED VIEWS IN THE DISASSEMBLY SECTIONS.
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MS0026
9- Assembly- Input carrier subassembly

1. Apply a liberal coat of grease to the bore of one Input Planet Gear ( 3F ).
2. Line the inside of the Planet Gear ( 3F ) with 14 Needle Rollers ( 3C ).
N.B.-:-THE LAST ROLLER INSTALLED MUST BE INSTALLED END WISE. THAT IS, THE END OF THE LAST ROLLER MUST
BE PLACED IN BETWEEN THE ENDS OF THE 2 ROLLERS WHICH FORM THE SPACE, AND THEN SLID, PARALLEL TO
THE OTHER ROLLERS, INTO PLACE.
3. Set Carrier ( 3A ) in an upright position.

4. Insert a Planet Shaft ( 3A ) into the planet shaft hole in the end of the Carrier ( 3A ) opposite the
splined end. The end of the planet shaft that does NOT have the roll pin ho le should be inserted into
the carrier FIRST.
N.B.-:-SOME GREASE MAY NEED TO BE APPLIED TO THE THRUST WASHERS ( 3B ) TO HOLD THEM IN PLACE WHILE
INSTALLING THE PLANET GEARS.
5. Place 1 Thrust Washer ( 3B ) onto the end of Planet Shaft ( 3E ). Make sure the flat faces towards
the inside of the carrier and make sure the button fits in the pocket on the inside of the Carrier ( 3A )
towards the OD.
6. Following the thrust washer, place Planet Gear ( 3F ) with needle rollers, onto Planet Shaft ( 3E ).
7. Following the planet gear, place one more Thrust Washer ( 3B )onto Planet Shaft ( 3E ). Align the
Thrust Washer ( 3B ). Make sure the flat faces towards the inside of the carrier and make sure the
button fits in the pocket on the inside of the Carrier ( 3A ) towards the OD.
8. Now inserl Planet Shaft ( 3E ) through the opposite planet shaft hole on Carrier ( 3A ). Use an align-
ment punch or similar tool to align the roll pin holes on Carrier ( 3A ) and Planet Shaft ( 3E ).
N.B.-:-BE SURE NOT TO HIT THE PLANET GEARS ( 3F ) WHEN DRIVING IN THE ROLL PINS ( 4G ).
9. Drive Roll Pin ( 4G ) down into the aligned roll pin holes . Pin should be flush with the flat of carrier.
10. Repeat all Steps for the installation of the 2 remaining Planet Gears ( 3F ).
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Chassis and turret
MS0026
10 - Assembly- Output planet gear subassembly

1. Apply a liberal coat of grease to the bore of one Output Planet Gear ( 4F ).
2. Line the inside of the Planet Gear ( 4F ) with 14 Needle Rollers ( 4C ).
N.B.-:-THE LAST ROLLER INSTALLED MUST BE INSTALLED END WISE. THAT IS, THE END OF THE LAST ROLLER MUST
BE PLACED IN BETWEEN THE ENDS OF THE 2 ROLLERS WHICH FORM THE SPACE, AND THEN SLID, PARALLEL TO
THE OTHER ROLLERS, INTO PLACE.
3. Place Spacer ( 4D ) into the bore of the Output Planet ( 4F ).

4. Repeat Step 2 to put in second roll of Needle Rollers ( 4C ).
5. Apply grease to hold 2 Thrust Washers ( 4B ) together and onto Output Planet Gear ( 4F ) counter-
bore. Do the same to the other side.
6. Repeat all Steps to finish the assembly of the 2 remaining Output Planet Gears ( 4F ).
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11 - Assembly- Spindle-Brake
N.B.-:-USE AN AIR GUN TO CLEAN THE BRAKE PORT AND MAKE SURE THERE IS NO DEBRIS INSIDE.
1. Place Spindle ( 1A ) such that the flange side is up. Press Ball Bearing ( 8B ) into Spindle ( 1A ) small
counterbore.
2. Place Stator ( 8K ) into the Spindle ( 1A ) callop cuts.
3. Place Rotor ( 8J ) on top of Stator ( 8K ).
4. Repeat steps 2 & 3 until there are a total of 9 Stators ( 8K ) and 8 Rotors ( 8J ) installed.
5. Place Spring ( 1L ) into Coupling ( 7 ) counterbore. Place the Pressure plate ( 1M ) on top of
Spring ( 1L ).
6. Use Truarc #0100 or equivalent pliers to install Retaining Ring ( 5 ) into the retaining ring groove in
the coupling counterbore.
7. Insert Coupling Subassembly ( 7 ) through Rotors ( 8J ).
8. Grease the 2 O-Rings ( 8F ) and ( 8D ) and the 2 Backup Rings ( 8H ) and ( 8E ).
9. Install small O-Ring ( 8F ) into the O-Ring groove in Spindle ( 1A ).
10. Install small Backup Ring ( 8H ) into the O-Ring groove in Spindle ( 1A ), on bottom of the small O-
Ring ( 8F ).
11. Set the Piston ( 8A ) so that the large diameter end id down. Install large Backup Ring ( 8E ) in the
large-diameter groove at the bottom of the Piston ( 8A ).
12. Install large O-Ring ( 8D ) in the large-diameter groove at the bottom of the Piston ( 8A ), on top of the
large Backup Ring ( 8E ).
13. Use appropriate tool to insert Piston ( 8A ) with backup ring and O-Ring into Spindle ( 1A ) until it con-
tacts Stator ( 8K ).
14. Insert 10 Springs ( 8L ) into Piston ( 8A ) holes.
15. Press Ball Bearing ( 8B ) in the Adaptor ( 1N ) and install Retaining Ring ( 8C ) into the retaining ring
groove.
16. Grease Seal ( 1K ) and insert it into groove of Adaptor ( 1N ).
17. Install O-Ring ( 8F ) into the outside O-Ring groove of the Adaptor ( 1N ).
18. Insert the Adaptor Subassembly into Spindle ( 1A ) with the O-Ring port on the spindle flange OD cen-
tered between 2 motor mounting holes on the Adaptor ( 1N ).
19. Secure the Adaptor ( 1N ) to the Spindle ( 1A ) with 8 bolts ( 21 ). Torque the bolts to 36-38 ft-lbs in
X pattern.
20. Use hydraulic hand pump to leak check the brake, record initial release pressure.
21. Disconnect 8rake Tester and Install O-Ring Plug or Plastic Plug ( 12 ). Tighten O-Ring plug according
to DIN standard if applicable.
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12 - Assembly- Hub- Spindle
N.B.-:-SPRAY A LIGHT FILM OF OIL ON AIL COMPONENT PARTS DURING ASSEMBLY. SPRAY A GENEROUS AMOUNT
OF OIL ON BEARINGS DURING INSTALLATION.
1. Sel Hub ( 1D ) flange side up. Press outbound Bearing Cup of part T-158422 into Hub using ( 1C )
pressing tool.
2. Turn hub over and press inbound Bearing Cup of part T-158422 into hub using ( 1C ) pressing tool.
3. Place inbound Bearing Cone of part ( 1C ), into Bearing Cup of part ( 1C ).
4. Grease Seal ( 1B ) lip and press seal inlo Hub ( 1D ) using appropriate tool until seal is flush with end
of hub.
5. Place Hub ( 1D ) into pressing base. Press 9 Studs ( 1H ) into Hub.
N.B.-:-USE ENOUGH PRESSURE TO PRESS IN STUDS. DON'T USE EXCESSIVELY HIGH PRESSURE TO PRESS IN SLUDS
OR HUB MAY CRACK.
6. Sel Spindle assembly ( 1A ) on special fixture with the flange down. Don't set unit on Coupling ( 7 ).
Turn Hub ( 1D ) over and lower onto Spindle ( 5 ).
7. Install oulbound Bearing Cone of part ( 1C ) into Bearing Cup, position ( A ).
8. Apply Loctite 272 on Bearing Nut ( 1F ) thread. Screw Nut ( 1F ) on top of Bearing Cone of part ( 1C ).
Leave .003-.005 inches endplay to check the inilial rolling torque with the unit tied down to the bench.
Then torque Bearing Nut ( 1F ) until rolling torque is 40 to 50 in-lbs greater than initial rolling torque.
Using tool T-206569 for the Bearing Nut.
N.B.-:-FINAL TORQUE IS INITIAL ROLLING TORQUE PLUS 40-50 IN-LBS. E.G., IF THE INITIAL ROLLING TORQUE IS
30 IN-LBS , THE FINAL ROLLING TORQUE IS BETWEEN 70-80 IN-LBS. BE SURE TO ROTATE HUB AS THE TORQUE IS
APPLIED TO PROPERLY SEAT THE BEARING. BE SURE THE TORQUE WRENCH IS LANGENT TO THE HUB OD *2.
9. Using appropriale tool install 2 Set Screws ( 1G ) into Bearing Nut ( 1F ) threaded holes. Make sure
Set Screw is driven into the spindle thread. Tighten the set screws to damage the thread and stake
the edge of Ihe nut around the Set Screws ( 1G ) so the nut will not loosen.
10. Insert input Shaft ( 9 ) into mesh with Coupling ( 7 ) intemal splines.
11. Place Thrust Washer ( 4H ) into counterbore of Spindle ( 1A ).
12. Place Planel Gear Subassembly ( 4 ) into Spindle ( 1A ) through gap between 2 Studs ( 1H ). Align
the planet gear bore with one of the planet shaft holes on the spindle ( 1A ) assembly using T-209919.
13. Insert a Planet Shaft ( 4E ) into the planet shaft hole described in Step ( 11 ) on Spindle ( 1A ). The
end of the planet shaft that does NOT have the roll pin hole should be inserted into the Spindle FIRST.
14. Now insert Planet Shaft ( 4E ) through the first set of Thrust Washers ( 4B ), Planet gear, then the sec-
ond set of Washers ( 4B ). Use an alignment punch or similar tool to align roll pin holes on
Spindle ( 1A ) and Planet Shaft ( 4E ).
N.B.-:-BE SURE NOT TO HIT THE PLANET GEARS ( 4F ) WHEN DRIVING IN ROLL PINS ( 4G ).
15. Drive Roll Pin ( 4G ) down into the aligned roll pin holes. Pin should be flush with ODof spindle.
16. Repeat Steps ( 11 - 14) ) for the installation of the 2 remaining Planet Gears ( 4F ).
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13 - Assembly- Cover
1. Grease O-Ring ( 6E ) and insert into internal groove in Cover ( 6A ).
2. Assemble Disengage Cap ( 6B ) onto Cover ( 6A ) using 2 Hex Head Bolts ( 6C ). Torque bolts to
70-80 in-lbs.
N.B.-:-NOT NECESSARY TO REINSTALL O-RING ( 6K ) UNLESS DESIRED.
3. Insert Disengage Rod ( 6D ) into hole in Cover ( 6A ) until it touches the inside of the Disengage
Cap ( 6B ).
N.B.-:-THE DISENGAGE ROD CAN BE INSERTED EITHER END FIRST.
4. Grease Face of Thrust Washer 2 and place in Cover ( 6A ) making sure that tangs on washer seat
into pockets in cover.
5. Install O-Ring Pipe Plugs ( 6F ) into Cover ( 6A ). The plugs should be hand tight.
14 - Assembly- Main Assembly
N.B.-:-ALI COMPONENTS SHOULD RECEIVE A GENEROUS AMOUNT OF LUBRICANT OIL AS THEY ARE BEING
ASSEMBLED.
1. Place Hub-Spindle Subassembly on the bench.

2. Grease O-Ring ( 18 ) and place it into groove of Hub ( 1D ).
3. Place Ring Gear ( 1E ) onto Hub ( 1D ). Align the 3 shipping Cap Screw Holes on Hub ( 1D ) and
Ring Gear ( 1E ).
4. Install 3 shipping Cap Screws ( 19 ) into ring gear and hub. Torque them to 15-20 ft-lbs.
5. Using appropriate tool to install Retaining Ring ( 20 ) into groove on Output Sun ( 11 ).
6. With the modified spline end facing up, place the Second Stage Sun Gear ( 11 ) into mesh with the
planet gears from the Hub-Spindle Subassembly.
7. Place Input Carrier Subassembly ( 3A ) onto Second Stage Sun Gear ( 11 ) splines. Drop Input
Sun ( 10 ) into mesh with planet gears for specifie ratios, if required. (No timing required).
8. Grease O-Ring ( 17 ) and insert into groove in Cover Subassembly ( 6 ).
9. Install Coyer Subassembly ( 6 ) into Ring Gear ( 1E ) counterbore and install Retaining Ring ( 6G )
into groove in Ring Gear ( 1E ).
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15 - Roll, leak & Brake testing
Torque-Hub units should always be roll and leak tested before disassembly and after assembly to make sure that the
unit's gears, bearings and seals are working properly. The following information briefly outlines what to look for when
performing these tests.
N.B.-:-THE BRAKE MUST BE RELEASED BEFORE PERFORMING THE ROLL TEST. THIS CAN BE ACCOMPLISHED BY
EITHER PRESSURIZING THE BRAKE USING THE BRAKE LEAK TEST PROCEDURE BELOW OR BY TIGHTENING THE
BOLTS INTO THE PISTON THROUGH THE END PLATE (SEE BRAKE DISASSEMBLY PROCEDURE).
N.B.-:-BOLTS MUST BE REMOVED WHILE PERFORMING BRAKE RELEASE TEST.
15.1 - THE ROLL TEST
The purpose of the roll test is to determine if the unit's gears are rotating freely and properly. You should be
able to rotate the gears in your unit by applying constant force to the roll checker. If you feel more drag in
the gears only at certain points, then the gears are not rolling freely and should be examined for improper
installation or defects. Do not be concerned if the gears in your unit seem to roll hard as long as they roll
with consistency. If a leak is detected in a seal, o-ring or gasket, the part must be replaced, and the unit
rechecked. Leak test at 10 psi for 20 minutes.
15.2 - THE LEAK TEST (MAIN UNIT)
The purpose of a leak test is to make sure the unit is air tight. You can tell if your unit has a leak if the pressure
gauge reading on your leak checking fitting starts to fall after the unit has been pressurized and allowed to
equalize. Leaks will most likely occur at the pipe plugs, the main seal or wherever o-rings or gaskets are
located. The exact location of a leak can usually be detected by brushing a soap and water solution around
the main seal and where the O-rings or gaskets meet on the exterior of the unit, then checking for air bubbles
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16 - Brake check
1. Using appropriate fittings to connect hydraulic line from hand pump to the brake port.
2. Check to see that brake is set by trying to rotate Input Shaft ( 9 ). This can be accomplished by install-
ing an appropriate tool (any tool that can locate on the splines of the Input Coupling ( 7 ) , such as a
mating splined shaft) into Input Coupling ( 7 ).
3. Bleed brake. Increase hydraulic pressure gradually while trying to rotate the input until brake just
starts to release. Note this pressure. Make sure the pressure falls into the appropriate range below :
• Brake code : H
• Just release pressure range : 180 - 200 psi
4. Increase pressure to 3,625 psi psi and hold for 60 s seconds to check for leaks. Repair leaks if nec-
essary.
N.B.-:-MAKE SURE THAT BRAKE RE-ENGAGES WHEN PRESSURE IS RELEASED.
N.B.-:-WHEN DONE, MAKE SURE INPUT COUPLING ( 7 ) IS CENTERED IN SPINDLE ( 1A ) TO MAKE INSTALLATION
OF MOTOR POSSIBLE WITHOUT RELEASE OF BRAKE.
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17 - Roll testing (Measure torque)

1. Screw 1 bolt down into the hub and rotate the hub so that the bolt is at twelve o'clock.
2. Position the torque wrench so that it is perpendicular to the vertical centerline as shown.
3. The correct reading can only be made if the torque wrench is pulled slowly (approximately 3.5 rpm )
and smoothly towards you.
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18 - Assembly drawing
Item Description
1A Spindle
1B Lip seal
1C Tapered bearing assembly
1D Housing
1E Ring gear
1F Bearing nut
1G Socket head set screw
1H Stud
1K Quad seal
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Item Description
1L Spring
1M Thrust washer
1N Motor adaptor
2 Thrust spacer
3A Carrier
3B Thrust washer
3C Needle bearing
3E Planet shaft
3F Planet gear
4B Thrust washer
4C Needle bearing
4D Thrust spacer
4E Planet shaft
4F Planet gear
4G Roll pin
4H Thrust washer
5 Retaining ring- internal
6A Cover
6B Disengage cap
6C Bolt
6D Dowel pin
6E O-ring
6F Pipe plug
6G Retaining ring- internal
7 Coupling
8A Brake piston
8B Ball bearing
8C Retaining ring
8D O-ring
8E Back-up ring
8F O-ring
8H Back-up ring
8J Brake rotor
8K Brake stator
8L Spring
9 Input shaft
10 Sun gear
11 Sun gear
12 O-ring plug or plastic plug
15 Identification plate
16 Drive screw
17 O-ring
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Item Description
18 O-ring
19 Bolt
20 Retaining ring
21 Bolt
22 Pressure plug
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Notes
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Procedure of dismantling / reassembling cage
MS0027
Upper boom
1- You will need

• PPE (Personal Protective Equipment: glove, safety
shoes, glasses, etc ...)
• Overhead crane or equivalent, for removal/replacement
of cage (Min 500 kg capacity)
• Suitable slings and lifting equipment for removing the
cage (Min 500 kg)
• Torque wrench suitable : 47 Nm
• Place a "DO NOT USE" decal near the start/stop contactor (key switch) to inform the personnel that interventions are being carried out
on the equipment.
• The exhaust fumes of the engines contain harmful products of combustion. Only start and run the engine in a well ventilated area. In a
closed room, you must use a suitable system to evacuate the exhaust to the outside.
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2- Procedure
The HT23RTJ O - HT23RTJ O SW - HT67RTJ O - HT23RTJ PRO - HT23RTJ PRO SW - HT67RTJ PRO series
machines feature an innovative modular cage design, which allows for the replacement of different components
individually, without the need to replace the complete cage. The cage assembly consists of the following components.
9
8
1 7
2
6
3
5
1. Control box cover
2. Control box
3. Control box support
4. Rotary coupling
5. 2 channel load cell
6. Independent Cage Support
7. Cage with drop bar type access
8. Interchangeable flooring
9. Cage with swing gate access
10. Tool tray
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2.1 - REMOVE/RE-INSTALL THE CONTROL BOX SUPPORT AND TOOL TRAY

2.1.1 - Removal
• Open control box cover.

• Disconnect the main cables at their connectors either side of the control box (not shown).
• Unscrew and remove the 2 x 8mm bolts/nuts (reference A and B) that fasten the control box support to
the handrail assembly.
• Unscrew and remove the 4 x 8mm bolts/nuts (reference C and D) that fasten the control box support to
the platform support.
• The Control box support and tool tray can now be removed.
C
B
1. Control box support

2. Tool tray
3. Platform support
2.1.2 - Replace
• Re-installation is a reversal of the removal procedure.

• Before tightening Nuts/bolts ref C and D, close the control box to check alignment of the latch. If required,
loosen the latch mounting bolts, close latch to align and re-tighten.
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2.2 - REMOVAL/REPLACEMENT OF FLOOR SECTION
N.B.-:-THE FLOOR PANELS ARE IN 2 OR 3 SECTIONS, DEPENDING ON THE PLATFORM SIZE.

N.B.-:-THERE ARE DIFFERENT OPTIONS FOR THE FLOOR MATERIAL BUT THE PROCEDURE REMAINS UNCHANGED.
N.B.-:-THE FLOOR PANELS CAN BE REMOVED WITHOUT REMOUNTING ANY OTHER PIECES.
2.2.1 - Removal
• Dévisser la pédale à pied du panneau de plancher et la sortir du panier (non illustré).

• Remove the bolts/nuts (ref A and B) securing the floor panels to the cage. Attention to not loose the
washers.
• The floor panels can be now removed from the cage.
2.2.2 - Replace

• Before tightening Nuts/bolts ref A and B, ensure that the floor is correctly positioned and flat.
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2.3 - REMOVAL/REPLACEMENT OF CAGE ASSEMBLY
N.B.-:-THE CAGE CAN BE REMOVED WITHOUT DEMOUNTING ANY OTHER PIECES, BUT THE FLOORING AND ENTRY
GATE WILL STAY FIXED TO THE CAGE. IT IS RECOMMENDED TO FIRST REMOVE THE FLOOR PANELS TO ALLOW
EASIER ACCESS.
2.3.1 - Removal

• Remove the 2 bolts/nuts (ref A and B) securing the Cage to the upright of the cage support.
• Remove the 6 bolts/nuts (ref D and E) securing the Cage to the rear rail of the cage support.
• Remove the 2 bolts/nuts (ref F and G) securing the Cage to the front edge of the cage support.
• The cage is now free to be removed. Drag the platform rearward 10 cm to clear the load cell mounting
bolts, then with a suitable lifting device the cage can be lifted from the support.
2.3.2 - Replace
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2.4 - REMOVE/REPLACE LOAD CELL

2.4.1 - Removal

• Disconnect electrical connector for the load cell, located in the Cage support (connector not shown).
• Disconnect the wiring loom from the platform control box (not shown).
• Open or cut the ties securing the wiring harnesses to the cage, cage support and rotating cylinder, and
place the wiring out of the way on the jib section.
• Remove the circlip ref 2 from the security pin ref 13 and remove the pin.
• Support the weight of the cage assembly from above with a crane or underneath using a forklift or
equivalent.
• Unscrew and remove the 4 bolts ref 5 that secure the cage assembly to the load cell. Do not yet remove
the 4 bolts securing the load cell to the link piece.
• The Cage assembly can now be removed from the machine.
• Unscrew and remove the large central bolt and nut (ref 8 and 9) from the rotary cylinder.
• Unscrew and remove the 8 bolts securing the link piece to the rotary cylinder (ref 11).
• Remove the link piece ref 15 from the rotary cylinder, noting the shims (ref 6) as you remove it.
• Secure the support 15 in a vice then Unscrew and remove the 4 bolts securing the load cell to the link
piece.
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2.4.2 - Replace
Re-installation is a reversal of the removal procedure, with the following important points :
• The mounting faces between the supports and the load cell must be clean, flat, free from all rust, paint and
any other foreign materials.
• The load cell mounting bolts ref 5, must be replaced after every demounting.
• The load cell mounting bolts ref 5 need to be correctly tensioned to 370 Nm, using a cross pattern.
• The 8 bolts securing the link piece to the rotary cylinder (ref 11) need to have a thread lock sealant applied
then be tensioned to 47 Nm using a cross pattern.
• The rotary cylinder central bolt and nut (ref 8 and 9) needs to be tensioned to 485 Nm.
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3- Complementary operations
Calibrate the overload system as required.
4- Checks
Complete a full test of machine functions.
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Procedure of dismantling / reassembling hydraulic rotary actuators
MS0028
Upper boom
1- You will need

• PIPE VISE
• HEX WRENCH
• ASSORTED SCREWS
• SAFETY GLASSES
• END CAP REMOVAL TOOLS
• DRILL
• FLASHLIGHT
• RUBBER MALLET
• PLASTIC MANDREL
• PRY BAR
• FELT MARKER
• T-HANDLE SCREW EXTRACTOR
• HEX WRENCH SET
• SEAL TOOLS
• PUNCH
• DOWEL PINS
• Place a "DO NOT USE" decal near the start/stop contactor (key switch) to inform the personnel that interventions are being carried out
on the equipment.
• The exhaust fumes of the engines contain harmful products of combustion. Only start and run the engine in a well ventilated area. In a
closed room, you must use a suitable system to evacuate the exhaust to the outside.
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Exploded View
Item Description Quantity

1 Housing 1
2 Shaft 1
3 Piston sleeve 1
4 End cap 1
103.1 Screw 1
103.2 Washer 1
106.1 Port plug 1
106.2 Port plug 1
109 Lock pin 2
113 Set screw 6
200 T-Seal 1
202 T-Seal 1
204 O-Ring 1
205 Cup seal 2
207 Back-up ring 1
304.1 Exclusion seal 2
302 Wear guide 2
304 Thrust washer 2
400 Stop tube 1
401 Counterbalance valve 1
403 Motion control valve 1
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2- Before disassembly
All numbers that appear in parenthesis ( ) refer to items in parts list.
Inspect the actuator for corrosion prior to disassembly. Severe

corrosion can make it difficult to remove the lock pins ( 109 ) and
unthread the end cap ( 4 ). If corrosion is evident, soak the lock
pins and end cap with penetrating oil for several hours before
disassembling.
Disassembly is considerably easier if the actuator is firmly secured

to the work bench. A pipe vise or mounting fixture work well.
3- Disassembly
Avoid personal injury and machinery damage : Read the

Service and Repair Manual for proper installation,
maintenance and repair procedure.
To avoid injury or damage to product : Secure produc to

slotted table or vise.
Spraying fluids. Contents under pressure. Use caution when

removing port plugs and fittings.
N.B.-:-TO AVOID CONTAMINATION TO MACHINED PARTS : MAKE SURE

WORK AREA IS CLEAN.
1. Remove port plugs ( 106.1 ) ( 106.2 ) and drain oil. Inspect

oil for signs of contamination, i.e. water, metal shavings.
2. Remove the cap screws ( 113 ) that cover the end cap lock
pins ( 109 ).
3. Using a 1/8" (3 mm) drill bit, drill a hole in the center of each
lock pin to a depth of approximately 3/16" (5 mm).
4. Remove the lock pins using a screw extracting tool such as

an "Easy Out" (a size #2 is shown). If the pin cannot be re-
moved with the screw extractor, use a 5/16" bit to drill out
the entire pin. Do not drill deeper than 1/2" (12.7 mm).
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5. Install the end cap removal tools provided with the Helac
seal kit ( 1/4-20 ).
6. Using a metal bar or similar tool, unthread the end cap ( 4 )

by turning it counterclockwise.
7. Remove the end cap ( 4 ) and carefully set aside for later in-
spection.
8. Remove the stop tube ( 400 ) if the actuator is equipped with

one. The stop tube is an available option that limits the ro-
tation of the actuator.
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9. Every actuator has two sets of small punched timing marks

that indicate timing between the gear sets. The location and
appearance of the marks can vary slightly between models.
One set indicates the timing between the piston sleeve ( 3 )
and the housing ( 1 ) (photo at left), the second set between
the piston and the shaft (lower photo). To ensure correct ro-
tation and accurate end positions, it is essential that the ac-
tuator be correctly timed when it is reassembled. The
punched timing marks can be used, but it is easier to high-
light punched marks with a marker before disassembly as
outlined in the steps below.
10. Prior to removing the shaft ( 2 ), use a felt marker to clearly

indicate the timing between shaft and piston sleeve ( 3 ).
This will greatly simplify timing when the actuator is reas-
sembled.
11. Remove the shaft ( 2 ) by rotating counterclockwise. As the

shaft is rotated, it will disengage from the piston sleeve ( 3 )
and can be removed. It may be necessary to strike the
threaded end of the shaft with a rubber mallet.
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12. As in step 9 above, before removing the piston ( 3 ), mark

the housing ( 1 ) ring gear in relation to the piston outside di-
ameter gear. There should now be timing marks on the
housing ( 1 ) ring gear, the piston ( 3 ) and the shaft ( 2 ).
13. To remove the piston ( 3 ) use a rubber mallet and a plastic

mandrel so the piston and housing bore are not damaged.
14. At the point when the piston gear teeth come out of engage-
ment with the housing gear teeth, mark the piston and hous-
ing with a marker as shown.
15. Remove the O-ring ( 204 ) and backup ring ( 207 ) from end
cap ( 4 ).
N.B.-:-T O AVOID DAMAGE TO MACHINED PARTS : C AREFULLY

REMOVE SEALS USING REMOVAL TOOLS WITH ROUNDED EDGES.
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16. Remove the wear guide ( 302 ) from the end cap ( 4 ) and
shaft ( 2 ).
17. Remove the main pressure seal ( 205 ).
18. Remove the thrust washer ( 304 ) from the end cap ( 4 ) and
shaft ( 2 ).
19. Remove the O-ring ( 304.1 ) from its groove in the end
cap ( 4 ) and shaft ( 2 ).
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20. Remove the outside diameter piston seal ( 202 ) from the
piston.
21. Remove the inside diameter piston seal ( 200 ).
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MS0028
4- Inspection
N.B.-:-PRIOR TO ASSEMBLY OF ACTUATOR, THESE STEPS MUST BE CLOSELY FOLLOWED TO INSURE PROPER
OPERATION OF THE ACTUATOR.
1. Clean all parts in a solvent tank and dry with compressed air prior to inspecting.
2. Carefully inspect all critical areas for any surface finish abnormalities: Seal grooves, bearing grooves,
thrust surfaces, shaft surface, housing bore and gear teeth.
N.B.-:-SMALL OR MINOR SURFACE SCRATCHES CAN BE CAREFULLY POLISHED.
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5- Assembly
Avoid personal injury and machinery damage : Read the

Service and Repair Manual for proper installation,
maintenance and repair procedure.
To avoid injury or damage to product : Secure produc to

slotted table or vise.
Spraying fluids. Contents under pressure. Use caution when

removing port plugs and fittings.
N.B.-:-TO AVOID CONTAMINATION TO MACHINED PARTS : MAKE SURE

WORK AREA IS CLEAN.
1. Gather all the components and tools into one location prior
to re-assembly. Use the cut away drawing to reference the
seal orientations.
2. Coat the thrust washers ( 304 ) with a generous amount of

Lithium grease. Install the thrust washer ( 304 ) onto
shaft ( 2 ) and end cap ( 4 ).
3. Install the exclusion seal ( 304.1 ) into the appropriate

grooves on the shaft ( 2 ) and end cap ( 4 ) around the out-
side edge of the thrust washer ( 304 ).
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4. Using a seal tool install the main pressure seal ( 205 ) onto
shaft ( 2 ) and end cap ( 4 ). Use the seal tool in a circular
motion.
5. Install the wear guide ( 302 ) on the end cap ( 4 ) and

shaft ( 2 ).
6. Install the O-ring ( 204 ) and back-up ring ( 207 ) into the in-
ner seal groove on the end cap ( 4 ).
7. Install the inner T-seal ( 200 ) into the appropriate groove in

the piston ( 3 ). Use a circular motion to insure the seal is
correctly seated in the groove. Install the outer T-
seal ( 202 ) by stretching it around the groove in a circular
motion. Each T-seal has 2 back-up rings.
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8. Beginning with the inner seal ( 200 ) insert one end of back-
up ring in the lower groove and feed the rest in using a cir-
cular motion. Make sure the wedged ends overlap correctly.
9. Insert the other back up ring in upper groove.
10. Repeat both of these steps for the outer seal ( 2 ).
11. Insert the piston ( 3 ) into the housing ( 1 ) as shown, until

the outer piston seal ( 202 ) contacts the inside housing
bore.
12. Looking into the housing bore from the shaft flange end, ro-
tate the piston ( 3 ) until the marks you put on the piston and
the housing ( 1 ) during disassembly align as shown. Using
a rubber mallet, tap the piston into the housing until the gear
teeth contact.
13. Looking into the bore from the opposite end of the
housing ( 1 ) be sure the timing marks align correctly Rotate
the piston as necessary until aligned, then gently tap the
piston ( 3 ) into the housing until the gear teeth mesh togeth-
er. Tap the piston into the housing until it completely bot-
toms out against the ring gear.
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14. Insert the shaft ( 2 ) into the piston ( 3 ). Be careful not to

damage the piston seals. Do not engage the piston gear
teeth yet.
15. Looking at the actuator from the end opposite the shaft
flange, use the exisitng timing marks to align the gear teeth
on the shaft ( 2 ) with the gear teeth on the inside of the
piston ( 3 ). When the marks align, gently tap the flange end
of the shaft with a rubber mallet until the gear teeth engage.
16. Install two bolts in the threaded holes in the flange. Using a
metal bar, rotate the shaft in a clockwise direction until the
wear guides are seated inside the housing bore.
N.B.-:-AS THE SHAFT IS ROTATED, BE CAREFUL NOT TO DISENGAGE

THE PISTON AND HOUSING GEARING.
17. Install the stop tube ( 400 ) onto the shaft end if necessary.
Stop tubes are an available option to limit the rotation of an
actuator.
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18. Coat the threads on the end of the shaft with anti-seize
grease to prevent galling.
19. Thread the end cap ( 4 ) onto the shaft ( 2 ). Make sure the
wear guide remains in place on the end cap as it is threaded
into the housing ( 1 ).
20. Tighten the end cap ( 4 ) using a metal bar. In most cases
the original holes for the lock pins will align.
21. Insert the lock pins ( 109 ) provided with the seal kit into the
holes with the dimple side up. Then, using a punch, tap the
lock pins to the bottom of the hole.
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22. Insert the set screws ( 113 ) over the lock pins. Tighten to
25 in-lbs (2.8 Nm).
6- Greasing Thrust Washers
1. After the actuator is assembled but before it is put into ser-

vice, the thrust washer area must be packed with Lithium
grease. There are two grease ports located on both the
shaft flange and the end cap. They are plugged with cap
screws ( 113 ) or set screws. Remove the grease port
screws from the shaft flange and end cap (See exploded
view).
N.B.-:-I F A HYDRAULIC TEST BENCH IS NOT AVAILABLE , THE

ACTUATOR CAN BE ROTATED BY HAND, OPEN THE PRESSURE PORTS
AND USE A PRY BAR WITH CAP SCREWS INSERTED INTO THE SHAFT
FLANGE TO TURN THE SHAFT IN THE DESIRED DIRECTION.
Insert the tip of a grease gun into one port and apply grease to the
shaft flange. Continue applying until grease flows from the
opposite port. Cycle the actuator five times and apply grease
again. Repeat this process on the end cap. Insert the cap screws
into the grease ports and tighten to 25 in-lbs (2.8 Nm).
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7- Testing the Actuator

Avoid personal injury and machinery damage : Read the Service and Repair Manual for proper installation, maintenance
and repair procedure.
To avoid injury or damage to product : Secure produc to slotted table or vise.
Spraying fluids. Contents under pressure. Use caution when removing port plugs and fittings.
N.B.-:-TO AVOID CONTAMINATION TO MACHINED PARTS : MAKE SURE WORK AREA IS CLEAN.
If the equipment is available, the actuator should be tested on a hydraulic test bench. The breakaway pressure ; the
pressure at which the shaft begins to rotate ; should be approximately 400 psi (28 bar). Cycle the actuator at least
25 times at 3000 psi (210 bar) pressure. After the 4500 psi (315 bar) rotations, increase the pressure to *2 to check
for leaks and cracks. Perform the test again at the end of the rotation in the opposite direction.
7.1 - TESTING THE ACTUATOR FOR INTERNAL LEAKAGE
If the actuator is equipped with with a counterbalance valve, plug the valve ports. Connect the hydraulic lines
to the housing ports. Bleed all air from the actuator. Rotate the shaft to the end of rotation at 3000 psi (210
bar) and maintain pressure. Remove the hydraulic line from the non-pressurized side.
Continuous oil flow from the open housing port indicates internal leakage across the piston. Replace the line
and rotate the shaft to the end of rotation in the opposite direction. Repeat the test procedure outlined above
for the other port. If there is an internal leak, disassemble, inspect and repair.
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8- Installation and Bleeding

Avoid personal injury and machinery damage : Read the Service and Repair Manual for proper installation, maintenance
and repair procedure.
To avoid injury or damage to product : Secure produc to slotted table or vise.
Spraying fluids. Contents under pressure. Use caution when removing port plugs and fittings.
N.B.-:-TO AVOID CONTAMINATION TO MACHINED PARTS : MAKE SURE WORK AREA IS CLEAN.
After installation of the actuator on the equipment, it is important that all safety devices such as tie rods or safety cables
are properly reattached.
To purge air from the hydraulic lines, connect them together to create a closed loop and pump hydraulic fluid through
them. Review the OEM's operating manual and/or hydraulic schematic to determine which hydraulic lines to connect.
The linear feet and inside diameter of the hydraulic supply lines together with pump capacity will determine the amount
of pumping time required to fully purge the hydraulic system.
Bleeding may be necessary if excessive backlash is exhibited after the actuator is connected to the hydraulic system.
The OEM does not specify all actuators with bleed nipples ( A ), see the drawing below for their location. The following
steps are recommended when a minimum of 2 gallons ( 8 liters) is purged.
1. Connect a 3/16" inside diameter x 5*16" outside diameter

x 5 clear, vinyl drain tube to each of the 2 bleed nipples.
Secure them with hose clamps. Place the vinyl tubes in a
clean 5 gal container to collect the purged oil. The oil can
be returned to the reservoir after this procedure is complet-
ed.
2. With an operator in the platform, open both bleed nipples a
1/4 turn. Hydraulically rotate the platform to the end of rota-
tion (either clockwise or counterclockwise), and maintain
hydraulic pressure. Oil with small air bubbles will be seen
flowing through the tubes. Allow a 1/2 gallon of fluid to be
purged from the actuator.
3. Keep the fittings open and rotate the platform in the oppo-
site direction to the end position. Maintain hydraulic pres-
sure until an additional 1/2 gallon of fluid is pumped into the
container.
4. Repeat steps 2 and 3. After the last 1/2 gallon is purged,
close both bleed nipples before rotating away from the end
position.
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9- Troubleshooting Guide
Problem See
Shaft rotates slowly or not at all 1-6
Operation is erratic or not responsive 7
Shaft will not fully rotate 8-9
Selected position cannot be maintained 3-4-7
Causes Solutions
1.Insufficient torque output Verify correct operating pressure. Do not exceed OEM's pressure
specifications. Load may be above maximum capacity of the
actuator.
2.Low rate of fluid flow Inspect ports for obstructions and hydraulic lines for restrictions and
leaks.
3.Control or Counterbalance valve has internal leak Disconnect hydraulic lines and bypass valve. Leave valve ports
open and operate the actuator through housing ports (do not exceed
OEM's operating pressure). The valve must be replaced if a steady
flow of fluid is seen coming from the valve ports.
4.Piston and/or shaft seal leak Remove the plug and the housing's valve ports. Operate the
actuator through the housing ports. Conduct the internal leakage
test as described in the Testing Section of this manual.
5.Corrosion build-up on the thrust surfaces Re-build the actuator. Remove all rust and then polish. Replacement
parts may be needed.
6.Swollen seals and composite bearings caused by in- Re-build the actuator. Use fluid that is compatible with seals and
compatible hydraulic fluid (Standard actuators only) bearings. Contact HAULOTTE Services® for more information.
7.Air in actuator Purge air from actuator. See bleeding procedure starting of this
manual.
8.Twisted or chipped gear teeth overload conditions Check for binding. Actuator may or may not be able to be rebuilt and
may need to be replaced.
9.Port fittings are obstructing the piston during stroke Check thread length of port fittings. Fittings should not reach inside
the housing bore.
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KUBOTA diesel engine - Tier III
MS0029
Chassis and turret
To ensure the maintenance of the engines, please go to our website https://www.e-technical-information.com to consult the
supplier manuals whose reference for this engine is 4000053020.
If access is denied, contact your HAULOTTE® branch..
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Notes
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1- Localization identification plate
• If you need to contact HAULOTTE Services® for spare parts or other,

think up the serial number of your engine.
2- Names of parts
D1503-M-E3 - D1703-M-E3 - D183-M-E3 - V2003-M-E3 -V2403-M-E3 - V2004-M-T-E3 - D1803-M-DI-E3 - V2403-
M-DI-E3
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V3600-E3 - V600-T-E3 - V3300-E3BG - V3600-T-E3BG
1 Intake manifold
2 Speed control lever
3 Engine stop lever
4 Shut off solenoid
5 Fuel feed pump
6 Cooling fan
7 Engine hook
8 Oil filter cartridge
9 Fuel filter
10 Oil filler plug
11 Exhaust manifold
12 Alternator
13 Starter
14 Fan belt
15 Oil pressure switch
16 Flywheel
17 Oil drain plug
18 Oil pan
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3- Operating the engine
3.1 - STARTING THE ENGINE (NORMAL)
To avoid personal injury :

• Do not allow children to approach the machine while the engine is running.
• Be sure to install the machine on which the engine is installed, on a flat place.
• Do not run the engine on gradients.
• Do not run the engine in an enclosed area. Exhaust gas can cause air pollution and exhaust gas poisoning.
• Keep your hands away from rotating parts (such as fan, pulley, belt, flywheel etc.) during operation.
• Do not operate the machine while under the influence of alcohol or drugs.
• Do not wear loose, torn or bulky clothing around the machine. It may catch on moving parts or controls, leading to
the risk of accidents. Use additional safety items, e.g. hard hat, safety boots or shoes, eye and hearing protection,
gloves, etc., as appropiate or required.
• Do not wear radio or music headphones while operating engine.
• Check to see if it is safe around the engine before starting.
• Reinstall safeguards and shields securely and clear all maintenance tools when starting the engine after maintenence.
• Do not use ether or any starting fluid for starting the engine, or a sever damage will occur.
• When starting the engine after a long storage (of more than 3 months), first set the stop lever to the "STOP" position
and then activate the starter for about 10 seconds to allow oil to reach every engine part.
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3.2 - CHECKS DURING OPERATION

3.2.1 - Oil pressure lamp
The lamp lights up to warn the operator that the engine oil pressure has dropped below the prescribed level.
If this should happen during operation or should not go off even after the engine is accelerated more than
1000rpm, immediately stop the engine and check the following :
1. Engine oil level
2. Lubricant system.
3.2.2 - Fuel

• Fluid escaping from pinholes may be invisible. Do not use hands to search for suspected leaks ; use a piece of
cardboard or wood, instead. If injured by escaping fluid, see a medical doctor at once. This fluid can produce
gangrene or a severe allergic reaction.
• Check any leacks from fuel pipes or fuel injection pipes. Use eye protection when checking for leaks.
Be careful not to empty the fuel tank. Otherwise air may enter the fuel system, requiring fuel system bleeding.
3.2.3 - Color of exhaust
While the engine is run within the rated output range :

• The color of exhaust remains colorless.
• If the output slightly exceeds the rated level, exhaust may become a littele colored with the output level
kept constant.
• If the engine is run continuously with dark exhaust emission, it may lead to trouble with the engine.
3.2.4 - Immediately stop the engine if :
• The engine suddenly slows down or accelerates.

• Unusual noises are suddenly heard.
• Exhaust fumes suddenly become very dark.
• The oil pressure lamp or the water temperature alarm lamp lights up.
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3.3 - REVERSED ENGINE REVOLUTION AND REMEDIES

• Reversed engine operation can make the machine reverse and run it backwards. It may lead to serious trouble.
• Reversed engine operation may make exhaust gas gush out into the intake side and ignite the air cleaner; it could
catch fire.
Reversed engine revolution must be stopped immediatly since engine oil circulation is cut quickly, leading to
serious trouble.
3.3.1 - How to tell when the engine starts running backwards
1. Lubricating oil pressure drops sharply. Oil pressure warning light, if used, will light.
2. Since the intake and exhaust sides are reversed, the sound of the engine changes, and
exhaust gas will come out of the air cleaner.
3. A louder knocking sound will be heard when the engine starts running backwards.
3.3.2 - Remedies
1. Immediately set the engine stop lever to the "STOP" position to stop the engine.
2. After stopping the engine, check the air cleaner, intake rubber tube and then other parts and
replace parts as needed.
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4- Maintenance

• Be sure to conduct daily checks, periodic maintenanc, refueling or cleaning on a
level surface with the engine shut off and remove the key.
• Before allowing other people to use your engine, explain how to operate, and have
them read this manual before operation.
• When cleaning any parts, do not use gasoline but use regular cleanser.
• Always use proper tools, that are in good condition. Make sure you understand
how to use them, before performing any service work.
• When installing, be sure to tighten all bolts lest they should be loose. Tighten the
bolts by the specified torque.
• Do not put any tools on the battery, or battery terminals may short out. Severe
burns or fire could result. Detach the battery from the engine before the
maintenance.
• Do not touch muffler or exhaust pipes while they are hot; Severe burns could
result.
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4.1 - SERVICE INTERVALS
Observe the following for service and maintenance.
The lubricating oil change intervals listed in the table below are for Classes CG-4, CH-4, CI-4 and CF
lubricating oil of API classification with a low-sulfur fuel in use.
If the CG-4, CH-4 or CI-4 lubricating oil is used with a high-sulfur fuel, change the lubricating oil at shorter
intervals than recommended in the table below depending on the operating condition.
Interval Item
Every 50 hours Check of fuel pipes and clamp bands.
See note Changing engine oil (depending on the oil pan).
• Cleaning of air cleaner element.
• Cleaning of fuel filter.
Every 100 hours • Check of battery electrolyte level.
• Check of fan belt tightness.
• Draining water separator.
• Check of radiator hoses and clamp bands.
Every 200 hours • Replacing the oil filter cartridge (depending on the oil pan).
• Check of intake air line.
• Replacement of fuel filter cartridge.
Every 400 hours
• Cleaning of water separator.
• Removal of sediment in fuel tank.
Every 500 hours • Cleaning of water jacket (radiator interior).
• Replacement of fan belt.
• Replacement of air cleaner element.
Every year
• Check of damage in electric wiring and loose connections.
Every 800 hours Check of valve clearance.
Every 1500 hours Check of fuel injection nozzle injection pressure.
• Check of turbo charger.
Every 3000 hours
• Check of injection pump.
• Change of radiator coolant.
• Replacement of battery.
Every 2 years • Replacement of radiator hoses and clamp bands.
• Replacement of fuel pipes and clamp bands.
• Replacement of intake air line.
Lubricating oil :
• With strict emission control regulations now in effect, the CG-4, CH-4 and CI-4 engine oils have been developed for
use with low sulfur fuels, for On-Highway vehicle engines. When a Non-Road engine runs on high sulfur fuel, it is
advisable to use a "CF or better" classification engine oil with a high Total Base Number (a minimum TBN of 10 is
recommended).
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• Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed.
Fuel
Lubricating oil classification Comments
Low-sulfur High-sulfur
Total Base Number (TBN)
CF Recommendable Recommendable
superior or equal 10
CF Recommendable Not recommendable
• Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all applicable
emission regulations for the area in which the engine is operated.
• Use of diesel fuel with sulfur content less than 0.10 % (1000 ppm) is strongly recommended.
• If high-sulfur fuel (sulfur content 0.50% (5000 ppm) to 1% (10000 ppm)) is used as a diesel fuel, change
the engine oil and oil filter at shorter intervals (approximately half).
• DO NOT USE Fuels that have sulfur content greater than 1.0 % (10000 ppm).
• Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4 standards,
the use of ultra low sulfur fuel is mandatory for these engines, when operated in US EPA regulated areas.
Therefore, please use No.2-D S15 diesel fuel as an alternative to No.2-D, and use No.1-D S15 diesel
fuel as an alternative to No.1-D for ambient temperatures below -10°C (14°F). No.1-Dor No.2-D, S15 :
Ultra Low Sulfur Diesel 15 ppm or 0.0015 wt.%.
• CJ-4 classification oil is intended for use in engines equipped with Diesel Particulate Filter and is Not
Recommended for use in Kubota E3 specification engines.
• Oil used in the engine should have API classification and Proper SAE Engine Oil according to the ambient
temperatures as shown below.
Above 25°C (77°F) SAE30, SAE10W-30 or 15W-40

-10 to 25°C (14°F to 77°F) SAE10W-30 or 15W-40
Below -10°C (14°F) SAE10W-30
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5- Periodic service
5.1 - FUEL
Fuel is flammable and can be dangerous. You should handle fuel with care.
• Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion.
• Be careful not to spill fuel during refueling. If fuel should spill, wipe it off at once, or it may cause a fire.
• Do not fail to stop the engine before refueling. Keep the engine away from the fire.
• Be sure to stop the engine while refueling or bleeding and when cleaning or changing fuel filter or fuel pipes. Do not
smoke when working around the battery or when refueling.
• Check the fuel systems at a well ventilated and wide place.
• When fuel and lubricant are spilled, refuel after letting the engine cool off.
• Always keep spilled fuel and lubricant away from engine.
5.1.1 - Fuel level check and refueling
1. Check to see that the fuel level is above the lower limit of the fuel level gauge.
2. If the fuel is too low, add fuel to the upper limit. Do not overfill.
Carbon redidus on, 10 percent

Flash point °C (°F) Water and sediment volume % Ash weight %
Residuum %
Minimum Maximum Maximum Maximum
52 (125) 0.05 0.35 0.01
Distillation temperatures °C (°F) 90% Point Viscosity Kinematic cSt or mm²/s at 40°C Viscosity Saybolt SUS at 37.8°C (100°F)
Minimum Maximum Minimum Maximum Minimum Maximum
282 (540) 338 (640) 1.9 4.1 32.6 40.1
Sulfur, weight Copper Strip Corrosion Cetane Number

Maximum Maximum Minimum
0.50 No. 3 40
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• Cetane Rating : The minimum recommended Fuel Cetane Rating is 45. A cetane rating greater than 50
is preferred, especially for ambient temperatures below -20°C (-4°F) or elevations above 1500 m (5000 ft).
• Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all applicable
emission regulations for the area in which the engine is operated.
• Use of diesel fuel with sulfur content less than 0.10% (1000 ppm) is strongly recommended.
• If high-sulfur fuel (sulfur content 0.50% (5000 ppm) to 1.0 % (10000 ppm) is used as a diesel fuel, change
the engine oil and oil filter at shorter intervals (approximately half).
• DO NOT USE Fuels that have sulfur content greater than1.0 % (10000 ppm).
• Diesel fuels specified to EN 590 or ASTM D975 are recommended. .
• No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service.
• Since Kubota diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4 standards,
the use of ultra low sulfur fuel is mandatory for these engines, when operated in US EPA regulated areas.
Therefore, please use No.2-D S15 diesel fuel as an alternative to No.2-D, and use No.1-D S15 diesel
fuel as an alternative to No.1-D for ambient temperatures below -10°C (14°F).
• SAE : Society of Automotive Engineers
• EN : European Norm
• ASTM: American Society of Testing and Materials
• US EPA: United States Environmental Protection Agency
• No 1-D / No 2-D S15 : Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt. %
Important :
• Be sure to use a strainer when filling the fuel tank, or dirt or sand in the fuel may cause trouble in the fuel injection
pump.
• For fuel, always use diesel fuel. You are required not to use alternative fuel, because its quality is unknown or it may
be inferior in quality. Kerosene, which is very low in cetane rating, adversely affects the engine. Diesel fuel differs in
grades depending on the temperature.
• Be careful not to let the fuel tank become empty, or air can enter the fuel system, necessitating bleeding before next
engine start.
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5.1.2 - Air bleeding the fuel system

• Do not bleed a hot engine as this could cause fuel to spill onto a hot exhaust manifold creating a danger of fire.
Air bleeding of the fuel system is required if :

• After the fuel filter and pipes have been detached and refitted.
• After the fuel tank has become empty.
• Or before the engine is to be used after a long storage.
5.1.2.1 - Procedure : Fuel tanks lower than injection pump
For fuel tanks that are lower than the injection pump :
1. The fuel system must be pressurized by the fuel
system electric fuel pump.
2. If an electric fuel pump is not used, you must
manually actuate the pump by lever to bleed.
3. The primary fuel filter must be on the pressure side
of the pump if the fuel tank is lower than the
injection pump.
4. To bleed, follow ( 3 ) through ( 5 ) above.
Tighten air vent plug of the fuel injection pump xcept when
bleeding, or it may stop the engine suddenly.
1 Fuel tank below injection pump 4 Electric or Mechanical pump

2 5 Main Filter
3 Pre-filter 6 Injection pump
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5.1.3 - Checking the fuel pipes

• Check or replace the fuel pipes after stopping the engine. Broken fuel pipes can
cause fires.
Check the fuel pipes every 50 hours of operation :

• If the clamp band is loose, apply oil to the screw of the band, and
tighten the band securely.
• If the fuel pipes, made of rubber, became worn out, replace them
and clamp bands every 2 years.
• If the fuel pipes and clamp bands are found worn or damaged
before 2 years' time, replace or repair them at once.
• After replacement of the pipes and bands, air-bleed the fuel
system.
When the fuel pipes are not installed, plug them at both ends
with clean cloth or paper to prevent dirt from entering. Dirt in
the pipes can cause fuel injection pump malfunction.
1 Clamp band
2 Fuel pipe
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5.1.4 - Cleaning the fuel filter pot
Every 100 hours of operation, clean the fuel filter in a clean place
to prevent dust intrusion :
• Close the fuel filter lever.
1 Fuel filter lever A OFF

2 Fuel filter pot B ON
• Remove the top cap, and rinse the inside with diesel fuel.
• Take out the element, and rinse it with diesel fuel.
• After cleaning, reinstall the fuel filter, keeping out of dust and dirt.
• Air-bleed the injection pump.
Entrance of dust and dirt can cause a malfunction of the fuel

injection pump and the injection nozzle. Wash the fuel filter
cup periodically.
1 O-ring 4 Filter bowl

2 Filter element 5 Screw ring
3 Spring
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5.2 - ENGINE OIL

• Be sure to stop the engine before checking and changing the engine oil and the oil filter cartridge.
• Do not touch muffler or exhaust pipes while they are hot; Severe burns could result. Always stop the engine and allow
it to cool before conducting inspections, maintenance, or for a cleaning procedure.
• Contact with engine oil can damage your skin. Put on gloves when using engine oil. If you come in contact with engine
oil, wash it off immediately.
N.B.-:-B E SURE TO INSPECT THE ENGINE , LOCATING IT ON A LEVEL PLACE . I F PLACED ON GRADIENTS
ACCURATELY, OIL QUANTITY MAY NOT BE MEASURED.
5.2.1 - Checking oil level and adding engine oil

1. Check the engine oil level before starting or more
than 5 minutes after stopping the engine.
2. Remove the oil level gauge, wipe it clean and
reinstall it.
3. Take the oil level gauge out again, and check the
oil level.
4. If the oil level is too low, remove the oil filler plug,
and add new oil to the prescribed level.
5. After adding oil, wait more than 5 minutes and
check the oil level again. It takes some time for the
oil to drain down to the oil pan.
1 Oil filter plug

2 Oil level gauge
A Engine oil level within this range is proper
5.2.2 - Changing engine oil

• Be sure to stop the engine before draining engine oil.
• When draining engine oil, place some container underneath the engine and
dispose it according to local regulations.
• Do not drain oil after running the engine. Allow engine to cool down sufficiently.
1. Change engine oil.

2. Remove the drain plug at the bottom of the engine,
and drain all the old oil. Drain oil will drain easier
when the oil is warm.
3. Add new engine oil up to the upper limit of the oil
level gauge.
1 Oil drain plug
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5.2.3 - Replacing the oil filter cartridge

• Be sure to stop the engine before changing the oil filter cartridge.
• Allow engine to cool down sufficiently, oil can be hot and cause burns.
1. Replace the oil filter cartridge.

2. Remove the old oil filter cartridge with a filter
wrench.
3. Apply a film of oil to the gasket for the new
cartridge.
4. Screw in the cartridge by hand. When the gasket
contacts the seal surface, tighten the cartridge
enough by hand. Because, if you tighten the
cartridge with a wrench, it will be tightened too
much.
5. After the new cartridge has been replaced, the
engine oil level normally decreases a little. Thus,
run the engine for a while and check for oil leaks
through the seal before checking the engine oil
level. Add oil if necessary.
N.B.-:-WIPE OFF ANY OIL STICKING TO THE MACHINE COMPLETELY.
1 Oil filter cartridge 2 Remove with a filter wrench (tighten with your hand)
5.3 - RADIATOR
Coolant will last for one day's work if filled all the way up before operation start. Make it a rule to check the
coolant level before every operation.
• Do not stop the engine suddenly, stop it after about 5 minutes of unloaded idling.
• Work only after letting the engine and radiator cool off completely (more than 30 minutes after it has been stopped).
• Do not remove the radiator cap while coolant is hot. When cool to the touch, rotate cap to the first stop to allow excess
pressure to escape. Then remove cap completely.
• If overheats should occur, steam may gush out from the radiator or recovery tank; Severe burns could result.
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5.3.1 - Checking coolant level, adding coolant
1. Remove the radiator cap, after the engine has

completely cooled, and check to see that coolant
reaches the supply port.
1 Radiator pressure cap
2. If the radiator is provided with a recovery tank,

check the coolant level of the recovery tank. When
it is between the "FULL" and "LOW" marks, the
coolant will last for one day's work.
1 Recovery tank
A Full
B Low
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MS0029
3. When the coolant level drops due to evaporation,

add water only up to the full level.
4. Check to see that two drain cocks; one is at the
crankcase side and the other is at the lower part of
the radiator as figures below.
1 Coolant drain tap
5.3.2 - Changing coolant
1. To drain coolant, always open both drain cocks and simultaneously open the radiator cap as
well. With the radiator cap kept closed, a complete drain of water is impossible.
2. Remove the overflow pipe of the radiator pressure cap to drain the recovery tank.
3. Prescribed coolant volume (8,4 l (2.22 US gals)).
4. An improperly tightened radiator cap or a gap between the cap and the seat quickens loss of
coolant.
5. Coolant (Radiator cleaner and anti-freeze). All seasons: Pure water and anti-freeze.
5.3.3 - Remedies for quick decrease of coolant
1. Check any dust and dirt between the radiator fins and tube. If any, remove them from the fins
and the tube.
2. Check the tightness of the fan belt. If loose, tighten it securely.
3. Check the internal blockage in the radiator hose. If scale forms in the hose, clean with the
scale inhibitor or its equivalent.
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5.3.4 - Checking radiator hoses and clamp

• Be sure to check radiator hoses and hose clamps periodically. If radiator hose is damaged or coolant leaks, overheats
or severe burns could occur.
Check to see if radiator hoses are properly fixed every 200 hours of operation or 6 months, whichever
comes first. :
1. If hose clamps are loose or water leaks, tighten hose clamp securely.
2. Replace hoses and tighten hose clamps securely, if radiator hoses are swollen, hardened or
cracked.
Replace hoses and hose clamps every 2 years or earlier, if checked and found that hoses are swollen,
hardened or cracked.
5.3.5 - Precaution at overheating
The event that the coolant temperature is nearly or more than the boiling point is called "OVERHEATING".
While running, make the following checks to see that all parts are working correctly. If anything is unusual,
inspect it, referring to the relevant description in "MAINTENANCE" and "PERIODIC SERVICE" section.
5.3.5.1 - Coolant
If the coolant temperature warning lamp lights up or if steam or coolant does not stop squirting from the
radiator overflow pipe, turn off the load and keep the engine idling (COOLING-DOWN) for at least 5 minutes
to let it cool down gradually. Then stop the engine and take the following inspection and servicing.
1. Check to see if the coolant runs short or if there is any coolant leak.
2. Check to see if there is any obstacle around the cooling air inlet or outlet.
3. Check to see if there is any dirt or dust between radiator fins and tube.
4. Check to see if the fan belt is too loose.
5. Check to see if radiator water pipe is clogged.
5.3.6 - Cleaning radiator core (outside)
If dust is between the fin and tube, wash it away with running water.
Do not clean radiator with firm tools such as spatulas or screwdrivers. They may damage specified fin or tube. It can
cause coolant leaks or decrease cooling performance.
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5.3.7 - Anti-freeze

• When using anti-freeze, put on some protection such as rubber gloves (Anti-freeze contains poison).
• If should drink anti-freeze, throw up at once and take medical attention.
• When anti-freeze comes in contact with the skin or clothing, wash it off immediately.
• Do not mix different types of antifreeze. The mixture can produce chemical reaction causing harmful substances.
• Anti-freeze is extremely flammable and explosive under certain conditions. Keep fire and children away from anti-
freeze.
• When draining fluids from the engine, place some container underneath the engine body.
• Do not pour waste onto the grounds, down a drain, or into any water source.
• Also, observe the relevant environmental protection regulations when disposing of anti-free.
Always use a 50/50 mix of long-life coolant and clean soft water in Kubota engines. Contact HAULOTTE
Services® concerning coolant for extreme conditions. :
1. Long-life coolant (hereafter LLC) comes in several types. Use ethylene glycol (EG) type for
this engine.
2. Before employing LLC-mixed cooling water, flush the radiator with fresh water. Repeat this
procedure 2 or 3 times to clean up the radiator and engine block from inside.
3. Mixing the LLC. Premix 50% LLC with 50% clean soft water. When mixing, stir it up well,
and then fill into the radiator.
4. The procedure for the mixing of water and antifreeze differs according to the make of the
antifreeze. Refer to SAE J1034 standard, more specifically also to SAE J814c.
5. Adding the LLC :
• Add only water if the coolant level reduces in the cooling system by evaporation.
• If there is a coolant leak, add the LLC of the same manufacturer and type in the same coolant percentage.
6. When the LLC is mixed, do not employ any radiator cleaning agent. The LLC contains anti-
corrosive agent. If mixed with the cleaning agent, sludge may build up, adversely affecting
the engine parts.
7. Kubota genuine long-life coolant has a service life of 2 years. Be sure to change the coolant
every 2 years.
Never add any long-life coolant of different manufacturer. Different brands may have different additive components, and
the engine may fail to perform as specified.
N.B.-:-THE ABOVE DATA REPRESENT INDUSTRY STANDARDS THAT NECESSITATE A MINIMUM GLYCOL CONTENT IN
THE CONCENTRATED ANTI-FREEZE.
Freezing point Boiling point

Vol % anti-freeze
°C °F °C °F
50 - 37 - 34 108 226
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5.4 - AIR CLEANER
Since the air cleaner employed on this engine is a dry type, never
apply oil to it :
1. Open the evacuator valve once a week under ordinary con-
ditions - or daily when used in a dusty place. This will get rid
of large particles of dust and dirt.
2. Wipe the inside air cleaner clean with cloth if it is dirty or wet.
3. Avoid touching the primary element except when cleaning.
4. When dry dust adheres to the primary element, blow com-
pressed air from the inside turning the element. Pressure of
compressed air must be under 205 kPa (2.1 kgf/cm2, 30
psi).
5. When carbon or oil adheres to the primary element, soak the
element in detergent for 30 minutes, then wash it several
times in water, rinse with clean water and dry it naturally.
6. After the primary element is fully dried, inspect inside of the
element with a light and check if it is damaged or not.
7. Replace the primary element every year or every 6 clean-
ings. If the primary element is stained heavily, replace it
soon. At this time, replace the secondary element too.
8. The secondary element should be removed only if it is to be
replaced.
9. To protect the engine, do not remove the secondary ele-
ment in servicing the primary element.
1 Air cleaner body 4 Primary element

2 Cover 5 Evacuator valve
3 Secondary element
• Make sure hooking clip for cover for the element is tight enough. If it is loose, dust and dirt may be sucked in, wearing
down the cylinder liner and piston ring earlier, and thereby resulting in poor power output.
• Do not overservice the air cleaner element. Overservicing may cause dirt to enter the engine causing premature wear.
Use the dust indicator as a guide on when to service.
• Be sure to refit the cover with the arrow (on the rear of the cover) upright. If the cover is improperly fitted, the
evacuator valve will not function and dust will adhere to the element.
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5.4.1 - Evacuator valve
Open the evacuator valve once a week under ordinary conditions - or daily when used in a dusty place - to
get rid of large particles of dust and dirt.
5.4.2 - Dust indicator (optional)
If the red signal on the dust indicator attached to the air cleaner is
visible, the air cleaner has reached the service level.
Clean the element immediately, and reset the signal with the
"RESET" button.
1 "RESET" button 3 Service level

2 Dust indicator 4 Signal
5.5 - BATTERY
• Be careful not to let the battery electrolyte contact your body or clothing.
• Wear eye protection and rubber gloves, since the diluted sulfuric acid solution burns skin and eats holes in clothing.
Should this occur, immediately wash it off with running water and get medical attention.
Mishandling of the battery shortens the service life and adds to maintenance costs. Obtain the maximum
performance and the longest life of the battery by handling properly and with care.
Engine starting will be more difficult, if the battery charge is low. Be careful to recharge it at an early occasion
before it is too late.
5.5.1 - Battery charging
The battery comes in two types: refillable and non-refillable. :

• For using the refillable type battery, follow the instructions below. Do not use or charge the battery if its fluid level
stands below the LOWER (lower limit level) mark. Otherwise, the battery component parts may deteriorate earlier
than expected, which may shorten the battery's service life or cause an explosion. Immediately, add distilled water
until the battery's fluid level is between the UPPER and LOWER levels.
• When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open
sparks and flames away from the battery at all times, especially when charging the battery.
• When charging the battery, remove the battery vent plugs.
• When disconnecting the cable from the battery, start with the negative terminal, and when connecting them, start with
the positive terminal first.
• DO NOT check the battery charge by placing a metal object across the terminals. Use a voltmeter or hydrometer.
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1. Make sure each electrolyte level is to the bottom of

vent wells, if necessary, add only distilled water in
a well-ventilated place.
1 Battery electrolyte level B Proper

A Too low C Too high
2. To slow charge the battery, connect the charger

positive terminal to the battery positive terminal,
and the negative to the negative, then recharge in
the standard fashion.
3. Quick recharging charges the battery at a high rate
in a short time. This is only for emergencies.
4. Recharge the battery as early as possible, or
battery life will be extremely shortened.
1 Thick cable red "+" 3 Earth cable black "-"

2 Battery case
5. When exchanging an old battery for a new one,

use battery of equal specification.
1 Plug A Highest level

B Lowest level
• Connect the charger positive terminal to the battery positive terminal, and negative to the negative.
• When disconnecting the cable from the battery, start with the negative terminal first. When connecting the cable to
the battery, start with the positive terminal first. If reversed, the contact of tools on the battery may cause a short.
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5.5.2 - Direction for long term storage
1. When storing the engine for long periods of time, remove the battery, adjust the electrolyte to
the proper level, and store in a dry and dark place. The battery naturally discharges while it
is stored.
2. The battery naturally discharges while it is stored. Recharge it once a month in summer, and
every 2 months in winter.
5.6 - FAN BELT

5.6.1 - Adjusting fan belt tension

• Be sure to stop the engine and remove the key before checking the belt tension.
• Be sure to reinstall the detached safety shield after maintenance or checking.
N.B.-:-PROPER FAN BELT TENSION : A DEFLECTION OF BETWEEN 7 TO 9 MM (0.28 TO 0.35 IN.) WHEN THE BELT
IS PRESSED IN THE MIDDLE OF THE SPAN.
1. Stop the engine and remove the key.

2. Apply moderate thumb pressure to belt between
the pulleys.
3. If tension is incorrect, loosen the alternator
mounting bolts and, using a lever placed between
the alternator and the engine block, pull the
alternator out until the deflection of the belt falls
within acceptable limits.
4. Replace fan belt if it is damaged.
7 to 9 mm (0.28 to 0.35 in.) (under load of 10 kgf (22.1

1 Fan belt A
lbs))
2 Bolt and nut
If belt is loosen or damaged and the fan is damaged, it could result in overheats or insufficient charging. Correct or
replace belt.
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6- Carriage and storage
6.1 - CARRIAGE

• Fix the engine securely not to fall during operation.
• Do not stand near or under the engine while carrying it.
• The engine is heavy. In handling it, be very alert not to get your hands and body caught in.
1. Use carrier such as crane when carrying the engine, or hurt your waist and yourself. Support the en-
gine securely with rope not to fall while carrying it.
2. When lifting the engine, put the hook securely to metal fittings attached to the engine. Use strong hook
and fittings enough to hang the engine.
6.2 - STORAGE

• Do not clean the machine with engine running.
• To avoid the danger of exhaust fume poisoning, do not operate the engine in a closed building without proper
ventilation.
• When storing the engine just after running, let the engine cool off.
Before storing the engine for more than a few months, remove any dirt on the machine, and :
1. Drain the coolant in the radiator. Open the cock at the bottom of the radiator, and remove the pressure
cap to drain water completely. Leave the cock open. Hang a note written "No water" on the pressure
cap. Since water may freeze when the temperature drops below 0°C (32°F), it is very important that
no water is left in the machine.
2. Remove dirty engine oil, fill with new oil and run the engine for about 5 minutes to let the oil penetrate
to all the parts.
3. Check all the bolts and nuts, and tighten if necessary.
4. Remove the battery from the engine, adjust the electrolyte level, and recharge it. Store the battery in
a dry and dark place.
5. When the engine is not used for a long period of time, run it for about 10 minutes under no load every
2 to 3 months to keep it free from rust. If the engine is stored without any running, moisture in the air
may condense into dew over the sliding parts of the engine, resulting in rust there.
6. If you forget to run the engine for longer than 5 to 6 months, apply enough engine oil to the valve
guide and valve stem seal and make sure the valve works smoothly before starting the engine.
7. Store the engine in a flat place and remove the key from engine.
8. Do not store the engine in a place where has flammable materials such as dry grass or straw.
9. When covering the engine for storage, let engine and muffler cool off completely.
10. Operate the engine after checking and repairing damaged wirings or pipes, and clearing flammable
materials carried by mouse.
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7- Troubleshooting
If the engine does not function properly, use the following chart to identify and correct the cause.
Diagnosis
Problem Probable cause Solution

• Check the fuel tank and fuel filter.
• Remove water, dirt and other impurities.
Fuel is thick and doesn't flow
• As all fuel will be filtered by the filter, if there should be water or
other foreign matters on the filter, clean the filter with kerosene.
• If air is in the fuel filter or injection lines, the fuel pump will not
work properly.
• To attain proper fuel injection pressure, check carefully for
Air or water mixed in fuel system
loosened fuel line coupling, loose cap nut, etc.
• Loosen joint bolt stop fuel filter and air vent screws of fuel
injection pump to eliminate all the air in the fuel system.
When it is difficult to start
the engine Valve clearance is not as specified • Adjust valve clearance when the engine is cold
Leaking valves • Grind valve.
Fuel injection timing is not as specified • Check injection timing.
Engine oil becomes thick in cold weather
• Change grade of oil according to the weather (temperature).
and engine cranks slow
• Bad valve or excessive wear of rings, pistons and liners cause
Low compression
insufficient compression. Replace with new parts.
• Charge battery.
Battery is discharged and the engine will
• In winter, always remove battery from machine, charge fully and
not crank
keep indoors. Install in machine at time of use.
• Bad valve and excessive wear of rings, pistons and liners cause
Compression is insufficient.
insufficient compression. Replace with new parts.
Leaking valves • Grind valve.
Fuel is insufficient • Check fuel system
• Check lubricating oil system
• Check to see if lubricating oil filter is working properly.
• Filter element deposited with impurities would cause poor
Overheating of moving parts lubrication. Change element.
• Check the clearance of bearing are within factory specs.
When output is insufficient • Check injection timing.
• Adjust timing.
Valve clearance is not as specified • Adjust to proper valve clearance when the engine is cold.
Air cleaner is dirty • Clean the element every 100 hours of operation.
Fuel injection pressure is not as specified • Check injection pressure.
• Do not use poor quality fuel as it will cause wear of the pump.
Only use No.2-D diesel fuel.
Injection pump wear
• Check the fuel injection pump element and delivery valve
assembly and replace as necessary
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Problem Probable cause Solution

• Check the fuel tank and refill the fuel, if necessary
Lack of fuel
• Also check the fuel system for air or leaks.
Bad nozzle • If necessary, replace with a new nozzle.
When engine suddenly • Check amount of engine oil with oil level gauge.
stops • Check lubricating oil system.
Moving parts are overheated due to
• At every 2 times of oil change, oil filter cartridge should be
shortage of lubrication oil or improper
replaced.
lubrication
• Check to see if the engine bearing clearances is within factory
specs.
Fuel governing device bad • Contact HAULOTTE Services® for repairs
Fuel is of extremely poor quality • Select good quality fuel.
When color of exhaust is Nozzle is bad • If necessary, replace with new nozzle.
especially bad • Cause is poor atomization, improper injection timing, etc.
Because of trouble in injection system or in poor valve
Combustion is incomplete
adjustment, or compression leakage, poor compression, etc.
Check for the cause.
Engine revolution suddenly decreases or
• Check the adjustments, injection timing and the fuel system.
increases
Unusual sound is heard suddenly • Check all moving parts carefully.
• Check the fuel injection system, especially the fuel injection
Color of exhaust suddenly turns dark
nozzle.
When engine must be Bearing parts are overheated • Check the lubricating system.
stopped immediately
• Check the lubricating system.
• Check, if the engine bearing clearances are within factory
specs.
Oil lamp lights up during operation
• Check the function of the relieve valve in the lubricating system.
• Check pressure switch.
• Check filter base gasket.
Engine oil insufficient • Check oil level. Replenish oil as required.
Fan belt broken or elongated • Change belt or adjust belt tension.
Coolant insufficient • Replenish coolant.
• Add water only or change to coolant with the specified mixing
Excessive concentration of antifreeze
ratio.
Radiator net or radiator fin clogged with
• Clean net or fin carefully.
dust
Inside of radiator or coolant flow route
When engine overheats • Clean or replace radiator and parts.
corroded
Fan or radiator or radiator cap defective • Replace defective parts.
Thermostat defective • Check thermostat and replace if necessary.
Temperature gauge or sensor defective • Check temperature with thermometer and replace if necessary.
Overload running • Reduce load.
Head gasket defective or water leakage • Replace parts.
Incorrect injection timing • Adjust to proper timing.
Unsuitable fuel used • Use the specified fuel.
N.B.-:-IF THE CAUSE OF TROUBLE CAN NOT BE FOUND, CONTACT HAULOTTE SERVICES®.
244 4000866050 E 10.18 USA / GB

Electric
Battery (ies)
MS0110
Electric
Battery (ies)
1- You will need

• Gloves
2- Technical specifications
Type 12 V DC, Group 34/78

Quantity 1
Cold cranking ampere 900 A
4000866050 E 10.18 USA / GB 245

Electric
Battery (ies)
MS0110
3- Battery inspection
Proper battery condition is essential to good engine performance and operational safety.
Improper fluid levels or damaged cables and connections can result in engine component
damage and hazardous conditions. :
1. Put on protective clothing and eye wear.
2. Be sure that the battery cable connections are free of corrosion.
3. Be sure that the battery separator wire connections are tight (if equipped).
4. Fully charge the battery(s) and allow the battery(s) to rest at least 6
hours.
5. Remove the battery vent caps and check the specific gravity of each bat-
tery cell with a hydrometer. Note the results.
6. Check the ambient air temperature and adjust the specific gravity reading
for each cell as follows :
• Result : All battery cells display an adjusted specific gravity of 1.277 or higher. The
battery is fully charged. Proceed to Step 9.
• Result : One or more battery cells display a specific gravity of 1.277 or below. Proceed
to Step 7.
7. Perform an equalizing charge OR fully charge the battery(s) and allow the
battery(s) to rest at least 6 hours.
8. Remove the battery vent caps and check the specific gravity of each bat-
tery cell with a hydrometer. Note the results.
9. Check the battery acid level. If needed, replenish with distilled water to
1/8 inch / 3 mm below the bottom of the battery fill tube. Do not overfill.
10. Install the vent caps and neutralize any electrolyte that may have spilled.
N.B.-:-TO ACCESS EASILY TO THE BATTERY, TURN THE ENGINE TRAY (PHOTO *1). THE BATTERY TERMINALS WERE
DEPORTED IN FRONT OF THE ENGINE TRAY (REP B+ AND B-).
246 4000866050 E 10.18 USA / GB

Electric
Battery (ies)
MS0110
Photo 1 - HT23RTJ O - HT23RTJ O SW - HT67RTJ O - HT23RTJ PRO - HT23RTJ PRO SW - HT67RTJ PRO
Photo 2- B+ / B- - HT23RTJ O - HT23RTJ O SW - HT67RTJ O - HT23RTJ PRO - HT23RTJ PRO SW - HT67RTJ

PRO
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Electric
Battery (ies)
MS0110
Battery charge status according to density and temperature
4- Battery
• Never leave the batteries discharged.
• Do not put off recharging the batteries in cold weather as the electrolyte may freeze.
• Top up the electrolyte level, if necessary.
• Avoid overflowing.
• Wash the top of the batteries without removing the caps.
• Dry with compressed air or clean cloths.
• Oil the terminals.
248 4000866050 E 10.18 USA / GB

Turntable
Universal plug
MS0133
Turntable
Universal plug
1- You will need

• The tracker with its cable.
• A clamp to strip the wires.
• A clamp to crimp the wires. • Place barriers around the perimeter of the work area
1
2- Procedure
Step 1 :
• Disconnect the plug 2.
• Remove the caps on the plug.
Step 2 :
• Pick up the pins in the plastic bag.
• Strip the wires of the tracker.
• Crimp the wires with the pins with a crimping clamp.
Step 3 :
• Take the wedgelock off the plug.
• Thread the wires in the positions regarding the information.
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Turntable
Universal plug
MS0133
C1 Universal connector
Pin 1 + permanent battery
Pin 2 GND (0 V)
Pin 3 + battery voltage
• Machine with engine : Engine ON information.
Pin 4
• Electrical machine : Movement and driving information.
Pin 5 Power ON information
Pin 6
Pin 7 Movement information (Flashing light option activation)
Pin 8 Driving information
Pin 9 CAN 1 H
Pin 10 CAN 1 L
Pin 11 CAN 2 H
Pin 12 CAN 2 L
N.B.-:-R EFER TO THE INSTRUCTIONS PROVIDED WITH THE TRACKER FOR THE WIRES CORRESPONDENCE .
DEPENDING OF THE TYPE OF UNIT, A RESISTANCE (200 OHMS, 1 W) MUST BE INTEGRATED BETWEEN SIGNAL AND
GROUND.
Step 4 :
• Put the wedgelock back on the plug to fix the pins.
Step 5 :
• Reconnect the plugs.
• Mount the tracker.
• The tracking device is operational.
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Platform
Weighing adjustment procedure (calibration)
MS0164
Platform
1- Concerned area
2- Warning
• The use of this card implies that its user is trained on this kind of machine and that this training was delivered
by HAULOTTE® or an authorised representative, following the program for LEVEL III.
• It is important that the person working on the machine is familiar with all of the safety information contained in the
user manual.
• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically
to working alone, co-activity and manual load handling...
• Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE® are
described in this sheet.
• After completion of work, all the covers and safety devices must be positioned back completely and operational.
Only an authorised and qualified technician is permitted to work on the machines HAULOTTE®.

• Mark out the work area.
• Cut the contact, to remove the key, open the battery cut if fitted.
• Place a `DO NOT USE' label near the start/stop contactor (key switch) to inform personnel that interventions are
currently underway on the equipment.
• Beware of the risk of burns; the hydraulic system operates at high temperatures.
• The pressure in the hydraulic system is very important. It can cause accidents. Relieve the pressure before beginning
any work and never search for oil leaks using your hands.
• The engine exhaust gases contain harmful combustion products. Always start and run the engine in a well ventilated
area. In a closed room, ensure the exhaust gases are evacuated to the outside.
• Do not wear any metal jewellery (rings, watches, chains, etc.) when working on the batteries.
• ONLY use insulated tools when working on or near batteries or electrical connections.
• Do not produce sparks or flames or smoke near the battery.
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Platform
MS0164
3- Risk prevention
Means of protection to be used when implementing the range :
• Appropriate workwear .
• Safety shoes .
• Insulating gloves — In accordance with standard NF EN 60 903.
• Face shield — In accordance with standard NF EN 166 / EN 170.
Specific protective measures to be used for the stage concerned :

• Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images :
4- You will need
• Safety shoes .
• Gloves .
• Personal computer with HAULOTTEDIAG and • Place barriers around the perimeter of the work area
diagnostic kit (400009300)
• Load lifting device (For 300 kg))
• Testing load (From 75 kg to 300 kg)
• 2 hoisting strap(s) for 500 kg at a length of 3 m
• Wrench No. 10
• Hammer
• Grease NYE 760 G (2820308450)
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Platform
MS0164
5- Assembly of the vibrating wire load cell

Picture of the parts
Platform lifting
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Platform
MS0164
6- Assembly of the vibrating wire load cell
• Assembly of the load cell ( 2 ) on the link part

• Grease the pins ( 4 ) and ( 5 )
• Put the pins ( 4 ) and ( 5 ) through the parts ( 1 ) and ( 2 )
• Fix it with the clevis pins
• Plug the cable ( 3 ) on the load cell ( 2 ) with contact grease NYE 760 G
(2820308450)
• Put the platform support ( 6 ) on the load cell ( 2 )
• Grease the pins ( 7 ) and ( 8 )

• Put the pins ( 7 ) and ( 8 ) through the parts ( 6 ) and ( 2 )
• Fix it with the clevis pins
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Platform
MS0164
7- Calibration procedure
The machine is equipped with a 2 channel load cell type weight management system, mounted between the platform
and the boom assembly.
The location of the load cell means calibration is required when the system values become out of correct range, or
when any of the platform sub assembly components (cage, support, flooring etc) are replaced.
The calibration is according to the following logigram.
N.B.-:-THE TARE COULD BE DONE INDEPENDENTLY FROM THE CALIBRATION.
Calibration procedure
Assembly of the load cell
Tare
Tare NO
OK ?
YES
Load checking : put the YES
load into the basket
Load YES
OK ? END : Machine Ready
NO
Calibration ON SITE
Calibration YES
END : Machine Ready
OK ?
NO
Calibration ADVANCED
NO Calibration YES
Replace the load cell END : Machine Ready
OK ?
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Platform
MS0164
7.1 - TARE CALIBRATION
To calibrate the tare follow the procedure(Access code LEVEL 2 is required).
The access to the menu is via the following menu : MACHINE SETTING/CALIBRATION/OFFSET 0kg (tare)
256 4000866050 E 10.18 USA / GB

Platform
MS0164
N.B.-:-CHECK THE LOAD ACCORDING TO VÉRIFICATIONS. IF NOT OK, GO TO CALIBRATION WITH A LOAD.
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Platform
MS0164
7.2 - CALIBRATION WITH A LOAD FROM 75 KG TO 300 KG
N.B.-:-ONLY NEEDED IF THE CHECK DONE ON VÉRIFICATIONS IS NOT OK AFTER 2 TARES

The access to the menu is via the following menu : MACHINE SETTINGS/CALIBRATION/ adjustable weight
75->300kg(Access code LEVEL 3 is required)
258 4000866050 E 10.18 USA / GB

Platform
MS0164
• Select the desired value
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Platform
MS0164
G a i n o f L o a d M a n a g e m e n t S y s t e m w i t h a d j u s t a b l e
w e i g h t
260 4000866050 E 10.18 USA / GB

Platform
MS0164
7.3 - CHECKS
7.3.1 - Control the load with HAULOTTE DIAG
N.B.-:-BEFORE ANY LOAD CHECK AND WAITS FOR THE STABILIZATION OF THE BASKET DURING 30 S. DON’T TOUCH
THE BASKET DURING THE MEASURE.
The access to the menu is via the following menu : MACHINE SETTING/CALIBRATION/CONTROL
WEIGHT
N.B.-:-THE WEIGHTING SYSTEM IS OK IF THE INDICATED VALUE IS EQUAL TO THE REAL ONE +/-10%.
Lexical
Weight Load( kg or lbs)
Overload Overload state( YES or NO)
Selected Load ode selected( 230 kg or 450 kg)
Inst. Load Instantaneous load(kg)
Aver. Load Average mode(kg)
F1 Sensor 1 frequency(Hz)
F2 Sensor 2 frequency(Hz)
7.3.2 - Control the overload alarm
1. Put the nominal load in the basket : No overload alarm must be activated. (Note : For dual
loads machines check the 2 loads)
• If this test failed replace the load cell.
2. Put the test load in the basket(Nominal load x 1,2) : The overload alarm must be activated.
(Note : For dual loads machines check the 2 loads)
• If this test failed replace the load cell.
3. Unload the basket.
Nominal load of the platform Test load

180 kg 216 kg
200 kg 240 kg
230 kg 276 kg
350 kg 420 kg
450 kg 540 kg
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Platform
MS0164
Notes
262 4000866050 E 10.18 USA / GB

Jib
Remove/Re-install jib cylinder
MS0224
Jib
1- Concerned area
2- Warning
• Only an authorised and qualified technician is permitted to work on the machines HAULOTTE®.
• The use of this form implies that its user has been trained on this type of equipment.
user manual.
• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific
safety instructions at the intervention site.
4000866050 E 10.18 USA / GB 263

Jib
MS0224
3- Risk prevention
• Safety shoes .
• Gloves .
• Safety goggles .
4- You will need

• Jib cylinder : 4000475520
• "DO NOT OPERATE" tag
• ORFS plug kit : 2505001600
• Personal protective equipment
• Oil collection pan
• Pin diameter 30 mm / 1.18 in, length 500 mm / 20 in
• Pin diameter 25 mm / 1 in, length 300 mm / 12 in
• 1 ratcheting straps that support 1000 kg / 2205 lbs at a
length of 2 m / 6 ft 56 in
• Torque wrench for 44 Nm
• Palettes for placement under the platform (about 200
mm / 7.87 in)
• 320 kg / 705 lbs load for static test
• Grease
• Medium threadlocker
• Weight of the jib cylinder : 23 kg / 51 lbs 1
264 4000866050 E 10.18 USA / GB

Jib
MS0224
5- Removal
• Position the machine on a flat and firm surface, clear of obstructions (beware of power lines).
• Mark out the work area (barriers, cones, marking tape).
• Restrict access to the area (restricted access sign).
• With the boom stowed and the telescope retracted, support the platform
on a stable wedge. Wedges under the platform of 200 mm / 7.87 in.
• Switch off the ignition and remove the ignition key.

• Place a do not operate tag at the start/stop switch location to inform
personnel that the equipment is being worked on.
• Mark, disconnect and plug the hoses supplying the jib cylinder. .
N.B.-:-U SE AN OIL COLLECTION PAN TO AVOID POLLUTING THE

ENVIRONMENT
• Strap the arm and jib tie-rods using a ratchet strap.
4000866050 E 10.18 USA / GB 265

Jib
MS0224
• Remove the 2 pin stop screws.
• Withdraw the pin from the cylinder but leave the pin used for withdrawal in
place. Only remove it after removing the pin on the rod side
• Remove the rod-side clevis pin and remove the pin.
266 4000866050 E 10.18 USA / GB

Jib
MS0224
• Hold the cylinder and remove the extraction pin on the back side.
• Slide the cylinder to free it of the ratchet strap.
• Remove the cylinder.
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Jib
MS0224
6- Re-installation
• If you are installing a new cylinder, note the traceability number.
• Perform the operations in the reverse order of dismantling.
• Position the cylinder so that the greasers are accessible.
N.B.-:-CLEAN OFF ANY RESIDUAL OIL OR GREASE
• Remember to refit the pin stop screws. Tightening at a torque of 22 Nm.
268 4000866050 E 10.18 USA / GB

Jib
MS0224
N.B.-:-CLEAN OFF ANY RESIDUAL OIL OR GREASE
• Grease the pins, the seals, and the bored holes.

• Check that the seals are on the connections before reconnecting the hoses.
To avoid the hoses twisting when they are connected to the rigid tubes, hold them firmly when tightening the couplings.
During reinstallation, pay attention to the hoses and cables.
7- Additional operations
• Clean off any residual oil or grease.
• Clean the work area.
• From the ground control box, operate the cylinder to flush out the hydraulic circuit.
• Check that there is no leak of oil at the removing connections.
• Top up the hydraulic oil if necessary (machine in stowed position).
• Perform a static test by putting 320 kg / 705 lbs on the platform.
• Machine unfolded, 15 mn after checking the performance of its parts :
• Boom lifting cylinder
• Boom telescopic cylinder
• Input jib leveling cylinder
• Jib cylinder
• Oscillating axle cylinder
In compliance with the country's laws, have the machine approved by an accredited organization.
4000866050 E 10.18 USA / GB 269

Jib
MS0224
Notes
270 4000866050 E 10.18 USA / GB

Chassis
Remove - Replace wheel pivot and gear motor
MS0225
Chassis
1- Concerned area
2- Warning
user manual.
• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific
safety instructions at the intervention site.
4000866050 E 10.18 USA / GB 271

Chassis
MS0225
3- Risk prevention
• Safety shoes .
• Gloves .
4- You will need

• — 4000596260 wheel pivot
• Gear motor – 4000563720
• Lifting and handling equipment(bridge crane, crane, etc)
: 1000 kg / 2205 lbs.
• Jack : 15 T / 33069 lbs
• 1 ratcheting straps that support 1000 kg / 2205 lbs at a
length of 2 m / 6 Ft 7 in.
• 1 hoisting strap(s) for 1000 kg / 2205 lbs at a length of
2 m / 6 Ft 7 in
• Wedges to support approximately 370 mm / 14.5 in
under the chassis with a load capacity of 6 T / 13227 lbs
• Grease pump
• 1 syringe for oil filling
• Oil SAE 80W90. Quantity for a reducer 0.77 l / 0.20 gal
• Wrench extension
• 24 mm socket
• Hose clamps
• 275 Kg / 606 lbs wheel
• 61 kg / 1340.5 lbs gear motor
• Reduction gear 45 kg / 99.2 lbs 1
• 16 kg / 35.3 lbs Engine
• 56 kg / 123.5 lbs wheel pivot
272 4000866050 E 10.18 USA / GB

Chassis
MS0225
5- Removal
• Position the machine on a flat and firm surface, clear of obstructions (beware of power lines). Mark out the work area
• Place the machine in its folded position(Unless repair or maintenance work requires it to be left in the machine in a
appropriate configuration).

• Make a stable pallet stack about 370 mm / 14.5 in tall.

• Unscrew the wheel nuts without removing them.
• Lift the machine with the jack to raise the wheel off the ground.
• Place wedges under the chassis and lower the jack slowly.
• Strap the wheel with the ratchet strap ( 2 ).
N.B.-:- 1000 KG / 2205 LBS RATCHET STRAP, 2 M / 6 FT 7IN IN

LENGTH.
• Thread strap ( 1 ) through strap ( 2 ) to slide the wheel.
N.B.-:- 1000 KG / 2205 LBS LIFT STRAP, 1 M / 3 FT 3 IN IN LENGTH.
4000866050 E 10.18 USA / GB 273

Chassis
MS0225
• Remove the wheel and lay it down flat on a pallet with the outer side
downwards.
• Loosen the screw and remove the clevis pin .

• Relive the pin connecting the steering tie-rod to the wheel steering pivot.
• Mark, disconnect and plug the hoses.

ENVIRONMENT.
274 4000866050 E 10.18 USA / GB

Chassis
MS0225
• Sling the wheel pivot and gear motor unit.

• Apply a small amount of tension on the bridge crane.
• Remove the locking pin screws and withdraw the pins connecting the
steering pivot to the chassis.
• Remove the wheel pivot and gear motor unit.

• Set aside the bronze washers.
• Remove the wheel pivot and gear motor unit.
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Chassis
MS0225
• Sling the assembly by the holes in the wheel steering pivot.
• Position the unit, inserting the studs through the rim.
• Unscrew the 2 screws holding the motor on the reduction gear.
276 4000866050 E 10.18 USA / GB

Chassis
MS0225
• Loosen the 8 screws connecting the reduction gear to the wheel steering
pivot. Mark the position of the reducer on the wheel pivot before removal.
• Sling the steering pivot.

• Remove the wheel steering pivot.
• Sling the hydraulic motor.

• Make a note of the position of the motor in relation to the reduction gear
before removing it.
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Chassis
MS0225
• Remove the hydraulic motor.
278 4000866050 E 10.18 USA / GB

Chassis
MS0225
6- Re-installation
• Remount in reverse order to removal.
• If the reduction gear has been replaced, note its traceability number. And
add the amount of oil per reduction gear 0.77 l / 0.20 gal.
• Clean the surfaces when installing components.

• Transfer the marking from the old gear motor to the new gear motor.
• To make installation easier, grease the surfaces of the wheel pivot that will be in contact with the gear motor.
Tighten the screws crosswise.
• Tighten the screws connecting the gear unit to the wheel pivot to a torque
of 260 Nm.
N.B.-:- 24 MM PIN WITH EXTENSION.
• Tighten the 2 screws on the reduction gear to a torque of 57 Nm.
N.B.-:-USE A WRENCH WITH AN EXTENSION CORD.
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Chassis
MS0225
• When reinstalling the wheel pivot, grease the pivots.

• Remember to refit the bronze rings.
• Remember to refit the pin stop screws. Tighten the screws to the
recommended torque. : 76 Nm.
• Couple the steering bolts to the wheel pivot.

• Fit the pin, the clevis pin and tighten the screw to a torque of 10 Nm.
280 4000866050 E 10.18 USA / GB

Chassis
MS0225
• Grease the pins via the greasers.
Position the conical part of the nut facing the wheel rim. The flat part of the nut is towards the outside of the wheel.
Sling the wheel and insert against the gear motor studs.
N.B.-:-UNSCREW THE GEAR UNIT TO FACILITATE WHEEL ASSEMBLY. SEE CHAPTER : ADDITIONAL OPERATIONS
4000866050 E 10.18 USA / GB 281

Chassis
MS0225
• Tighten the wheel nuts evenly to the torque of 300 Nm.

• Tighten the screws crosswise.
282 4000866050 E 10.18 USA / GB

Chassis
MS0225
• Check the oil level in the reduction gear when the wheels lift off the ground
:
• Unscrew the 2 central plate screws.
• Flip the plate over.
• Screw the 2 screws back on.
The wheel reducer has been disassembled.
• Turn the wheel by hand until the plugs are correctly positioned to fill or level
the oil.
4000866050 E 10.18 USA / GB 283

Chassis
MS0225
• Turn the reduction gear to position the oil top-up, filling and drain plugs.
N.B.-:-THE LEVEL CAN ONLY BE ESTABLISHED WHEN THE PLUG IS

POSITIONED IN THE HORIZONTAL AXIS OF THE REDUCTION GEAR.
• Remove the level plug.
N.B.-:-THE OIL SHOULD BE JUST LEVEL WITH THE HOLE.
• If necessary, top up through the upper plug using a syringe.
• Remember to refit the plugs and the plate in the right position once the
operation is finished.
• Clean any oil traces.
• Perform a drive test.
284 4000866050 E 10.18 USA / GB

Platform
Remove - Replace load cell
MS0226
Platform
1- Concerned area
2- Warning
• It is important that the person working on the machine is familiar with all of the safety information contained in the user
manual.
• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety
instructions at the intervention site.
4000866050 E 10.18 USA / GB 285

Platform
MS0226
3- Risk prevention
• Safety shoes .
• Gloves .
4- You will need

• Load cell — 4000068580
• Pin diameter of 15 mm / 0.6 in length of 25 mm / 1 in
• Hose clamps • Place barriers around the perimeter of the work area
• Contact grease – 2820308450
If slinging the platform :

• 2 hoisting strap(s) for 500 kg / 1102 lbs at a length of 3
m / 9 ft 84 in
• Weight of the load cell : 8,30 kg / 18.30 lbs
1
• Weight of platform alone around : 190 kg / 419 lbs
286 4000866050 E 10.18 USA / GB

Platform
MS0226
5- Removal
• With the boom stowed and the telescope retracted, support the platform on a stable wedge. Wedges under the
platform of 300 mm / 1 ft.
• With handling equipment, lift the platform slightly :

• Cut the clamp bands.

• Unscrew the screw closing the wiring harness guide ( 1 ).
• Open the hose clamp ( 2 ).
• Remove the technical plate ( 3 ).
4000866050 E 10.18 USA / GB 287

Platform
MS0226
• Loosen the screws and remove the clevis pins .

• Extract the 2 pins on the platform side.
• Gently move the platform backwards using the handling equipment.
• Disconnect the load cell.
• Loosen the screws and remove the clevis pins .
N.B.-:-HOLD THE LOAD CELL WITH ONE HAND TO PREVENT IT FALLING.
• Extract the 2 pins on the jib side.
288 4000866050 E 10.18 USA / GB

Platform
MS0226
• Remove the load cell.
4000866050 E 10.18 USA / GB 289

Platform
MS0226
6- Re-installation
• Tighten the screws of the male clevises to a torque of 44 Nm.
Ensure the load cell is refitted the right way round.
• ( 1 ) Facing the jib.

• ( 2 ) Facing the platform.
• ( 3 ) Load cell positioning arrow.
• Apply contact grease for the connector .
• Calibrate the load cell. Refer to machine sheet MS0057.
290 4000866050 E 10.18 USA / GB

Upper boom
Remove/replace the telescope cylinder
MS0227
Upper boom
1- Concerned area
2- Warning
manual.
4000866050 E 10.18 USA / GB 291

Upper boom
MS0227
3- Risk prevention
• Safety shoes .
• Gloves .
4- You will need

• The telescopic cylinder : 166P348020
• 22 mm pin with extension
• Hose clamps
• Contact grease – 2820308450
• Grease
• Greasing the pads — 2326005410
• 2 hoisting strap(s) for 2000 kg / 4410 lbs at a length of
2 m / 6 ft 7 in
• Pry bar
• Pin with diameter 18 mm / 0,71 in passing through the 3
boom sections to lock them together
• Locking plates 4000004140
• Cable tension procedure : See plan 4000392570
• Weight of the telescopic cylinder : 420 kg / 926 lbs
• Weight of the tie rod : 27 kg / 59.5 lbs 2
• Weight of the cylinder bracket : 17 kg / 37.5 lbs
292 4000866050 E 10.18 USA / GB

Upper boom
MS0227
5- Removal
• Raise the boom to horizontal.

• From the ground control box, position the telescopic cylinder so as to have
access to the retraction cable screws.
• Pin the 3 blocks using the hole provided for this purpose.
N.B.-:-PIN DIAMETER 18 MM / 0,71 IN.
• Stow the machine completely.

4000866050 E 10.18 USA / GB 293

Upper boom
MS0227
Remove the cover ( 2 ) :

• Remove the pads ( 1 ) on each side of the cover.
• Remove the front pad ( 3 ).
• Unscrew the 4 nuts from the rear cover.

• Remove the cover.
294 4000866050 E 10.18 USA / GB

Upper boom
MS0227
Disconnect the plugs :

• The twilight sensor ( 1 ).
• The light ( 2 ).
• Remove the plate.
• Use a sliding caliper and measure the compression of the retraction

cables on the platform side and record the values.
4000866050 E 10.18 USA / GB 295

Upper boom
MS0227
• Use a sliding caliper and measure the compression of the extension

cables on the counterweight side and record the values.
• Identify the cables on each side of the boom before dismantling.
• Alternate unscrewing the nuts to gradually loosen the 2 retraction cables.

• Loosen the nuts without removing them.
N.B.-:-THIS PROCEDURE SLACKENS THE RETRACTION CABLES.
296 4000866050 E 10.18 USA / GB

Upper boom
MS0227
• Remove the retraction cable guide pads.
• Remove the nuts and washers from the output cables.
• Remove the nuts and washers from the retraction cables.
• Disconnect the cable from the chain breakage sensor to avoid crushing it
during the operation.
4000866050 E 10.18 USA / GB 297

Upper boom
MS0227
• Remove the 2 stop wedges ( 1 ).

• Remove the extension cable lifting beam ( 2 ).
• Unscrew the screw from the extension cable bracket.
• Loosen the 2 screws located on each side of the telescope cylinder

connecting the retraction cables to the telescope.
298 4000866050 E 10.18 USA / GB

Upper boom
MS0227
• Lift the tube and cable carrier chain to free access to the screw located on
the other side of the boom.
• Remove the pin stops located on each side of the boom.
• Loosen the screw ( 1 ) and remove the clevis pin ( 2 ).
• Sling the tie rod.

• Pull out the pin.
4000866050 E 10.18 USA / GB 299

Upper boom
MS0227
Extract the pin from the tie rod on the telescopic cylinder side :
• Loosen the screw ( 2 ), remove the clevis pin ( 1 ), and put the pin to one
side ( 3 ).
• Remove the tie rod .
• Mark and disconnect the 2 telescope cylinder supply hoses.

• Plug the openings after disassembly.
N.B.-:-PLACE A CONTAINER UNDERNEATH THE CONNECTIONS.
• Refit the pin ( 2 ) of the tie rod to sling the cylinder.

• Unscrew the 6 screws from the telescopic cylinder bracket.
• Unscrew the 2 lower side pads ( 1 ).
• Remove the telescopic cylinder bracket.
• Place the hoses and wiring harnesses in the turntable.

• Gradually pull the cylinder from the rear.
• Before fully extending the cylinder, all the cables (under and over the
cylinder) must be attached every 50 cm / 19.6 in with plastic collars.
300 4000866050 E 10.18 USA / GB

Upper boom
MS0227
• When the cylinder has come out far enough and the guidance portion of the cylinder is still in the foot of the boom,
position fork lift (or another means of handling the movement) under the cylinder.
• Extend the cylinder.
• Place the cylinder on 2 trestles or a wooden wedge.
Center of gravity : A : 2280 mm / 7 ft 48 in
4000866050 E 10.18 USA / GB 301

Upper boom
MS0227
6- Re-installation
• Grease all the pins, seals, and bore holes.
• Hold the hoses to ensure that they don't turn while tightening the connections (risk of seal damage). This will avoid
the hoses twisting when they are connected to the rigid tubes.
• Make sure the hoses and harnesses are set in their correct routes.
• Grease the entrance to the tube and the corners of the telescopic cylinder
to facilitate reassembly :
Correctly position the retraction cables : :

• Before passing the cable through the jib: allow it to move freely so that the
cable finds its position naturally.
• From this position, rotate the cable in an ANTI-CLOCKWISE direction until
the first side appears with the engraving "TOP" on the top.
• Then place the cable in this position in the cable guides.
• Ensure the washers for cable tension are fitted the right way round.
• Grease the concave ( 2 ) and convex ( 1 ) washers.
302 4000866050 E 10.18 USA / GB

Upper boom
MS0227
• Glue the 6 screws of the telescopic cylinder bracket using blue

threadlocker. Tightening at a torque of 45 Nm.
• Tighten the screws on the tightening pads to a torque of 10 Nm and the
pad nuts to 45 Nm. Take care not to put white grease in the threading of
the pads.
• Remove the extension cable plate the right way round.
• Glue the 2 screws of the adjustment stops with medium threadlocker.

Tightening at a torque of 22 Nm.
• The 2 screws connecting the telescope retraction cables must be glued

with medium threadlocker.
N.B.-:-TIGHTENING AT A TORQUE OF 10 NM.
• The screw head of the clevis pins must face towards the outside of the boom.
• Fold in the locking plates 4000004140 after tightening the screws.
4000866050 E 10.18 USA / GB 303

Upper boom
MS0227
• The extension cable bracket fastening screw must be glued with medium
threadlocker and tighted to torque.
N.B.-:-TIGHTENING AT A TORQUE OF 45 NM.
• Refit the chocks and glue the screws using medium threadlocker,
tightening the screws to a torque of 10 Nm.
304 4000866050 E 10.18 USA / GB

Upper boom
MS0227
7- Cable tension adjustment procedure
• Before adjusting cable tension, place a pin with a diameter of 18 mm

through the 3 blocks to lock them together.
• Power up the output cables :

• The adjustment should be done 2 times (D - 4 mm).
• Start by compressing the washers by 2 mm then 2 mm to align the sensor
(ref. ( 2 )).
• Insert the nut H (mark 1) until it comes into contact with the stack of
washers.
• Measure the external dimension between the 2 flat washers (distance D).
• Tighten by alternating between the left nut and the right nut until the
distance is reached (D - 4 mm +/- 0,2 mm).
• In this position, make any small corrections by re-tightening in order to
recenter the position sensor (mark 2). The sensor must remain parallel to
the edge of the pivot jib.
• Lock it with locknuts.
4000866050 E 10.18 USA / GB 305

Upper boom
MS0227
• Power up the retraction cables :

• The adjustment should be done 2 times (D - 4 mm).
• Start by compressing the washers by 2 mm then 2 mm to align the sensor
(ref. ( 2 )).
• Insert the nut H (mark 1) until it comes into contact with the stack of
washers.
• Measure the external dimension between the 2 flat washers (distance D).
• Tighten by alternating between the left nut and the right nut until the
distance is reached (D - 4 mm +/- 0,2 mm).
• In this position, make any small corrections by re-tightening in order to
recenter the position sensor (mark 2). The sensor must remain parallel to
the edge of the pivot jib.
• Lock it with locknuts.
306 4000866050 E 10.18 USA / GB

Upper boom
MS0227
• Use a sliding caliper to check that the cable compression values are within
the tolerance +/- 0.2 mm as compared to the measurements taken before
dismantling.
• Remove the pin that is locking the blocks together.
• From the ground control box, slightly extend the telescopic cylinder to
extract the bar from the tubes.
4000866050 E 10.18 USA / GB 307

Upper boom
MS0227
From the ground control box, extend and retract the telescope in order to flush out the hydraulic circuit : :
• Check the articulation of the hoses.
• Check the articulation of the wire harnesses.
• From the ground and platform control boxes, apply weight through all of the machine's movements.
• Perform a static test by putting 320 kg / 705.5 lbs on the platform :
Machine unfolded, 15 mn after checking the performance of its parts :
Check that there is no leak of oil at the removing connections :

• Boom lifting cylinder.
• Boom telescopic cylinder.
• Input jib leveling cylinder.
• Jib cylinder.
308 4000866050 E 10.18 USA / GB

Chassis
Removal - Replacement of the steering cylinder
MS0228
Chassis
1- Concerned area
2- Warning
manual.
4000866050 E 10.18 USA / GB 309

Chassis
MS0228
3- Risk prevention
• Safety shoes .
• Gloves .
4- You will need

• Steering cylinder : 4000708900
• ORFS plug kit : 2505001600
• ORFS seal kit : 2505000470
• 1 hoisting strap(s) for 500 kg / 1,102 lbs at a length of 2
m / 6 ft 7 in
• 1 ratcheting straps that support 500 kg / 1.102 lbs at a
• Weight of steering cylinder : 27 kg / 59,5 lbs 1
310 4000866050 E 10.18 USA / GB

Chassis
MS0228
5- Removal
• Stowed jib, telescope retracted and boom lowered.
• Align the turntable to make access easier during maintenance operations.

• Steer the machine so the wheels are straight ahead.
• Remove the top cover.

4000866050 E 10.18 USA / GB 311

Chassis
MS0228
• Place the sling around the boom tube vertically in relation to the steering
cylinder.
• Pass the ratchet strap through the loops of the sling, then into the chassis
evacuation hole and around the steering cylinder to be removed.
• Bring the end of the ratchet strap out through the same hold and pull
slightly tight.
N.B.-:-POSITION AN OIL COLLECTION PAN TO AVOID POLLUTING THE

ENVIRONMENT.
• Mark, disconnect, and plug the telescope cylinder feed hoses.

• Plug the orifices of the steering cylinder.
312 4000866050 E 10.18 USA / GB

Chassis
MS0228
• Loosen the screw , remove the clevis pin , and put the pin to one side .
• Uncouple the steering tie rod to the wheel pivot.
• Perform the same operation on each side of the machine.
• Measure the 2 adjustment screws.

• Fully screw up the 2 adjustment screws to avoid being hindered by them
during removal / refitting.
• Unscrew the cylinder screws.
• Use the ratchet strap to gradually lower the cylinder via the bottom.
• Remove the cylinder
4000866050 E 10.18 USA / GB 313

Chassis
MS0228
6- Re-installation
• Tighten the male clevis screws on the steering tie rods to a torque of 10 Nm.
• Loosen the 2 setting screws.

• Apply the measurement made before dismantling for the 2 adjustment
screws.
• Tighten the locknut for each adjustment screw on the steering cylinder.
Tightening at a torque of 76 Nm.
• Slightly tighten the 4 screws on the steering cylinder without blocking
them to bring the heel of the cylinder against the chassis.
• Tighten the cylinder screws. Tightening at a torque of 200 Nm.
• Manoeuvre the steering several times to purge the circuit.
• Verify absence of any oil leaks.
• Top up the hydraulic oil if necessary.
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Chassis
Removing/re-installing the oscillating axle actuator
MS0229
Chassis
1- Concerned area
• The machine has 2 front oscillating axle cylinders.
2- Warning
manual.
4000866050 E 10.18 USA / GB 315

Chassis
MS0229
3- Risk prevention
• Safety shoes .
• Gloves .
4- You will need

• Oscillating axle cylinder : 158B165030
• ORFS plug kit : 2505001600
• ORFS seal kit : 2505000470
• Oil collection pan • Place barriers around the perimeter of the work area
• 1 100 kg / 220 lbs lifting rope(s) length 1 m / 3 ft 3 in
• Hydraulic oil
• Grease for pins and rings
• Normal threadlocker
• Weight of the oscillating axle cyclinder : 24 kg / 53 lbs 1
316 4000866050 E 10.18 USA / GB

Chassis
MS0229
5- Removal
• Stowed jib, telescope retracted and boom lowered.
Do not remove the 2 cylinders simultaneously, but replace them one after the other after if necessary.

• Remove the top cover.

personnel that the equipment is being worked on
• Move the hoses aside to free the area.
4000866050 E 10.18 USA / GB 317

Chassis
MS0229
• Loosen the screws ( 2 ) and remove the clevis pins ( 1 ).
• Mark, disconnect, and plug the telescope cylinder feed hoses.

• Plug the orifices of the oscillation cylinder.
N.B.-:-POSITION AN OIL COLLECTION PAN TO AVOID POLLUTING THE

ENVIRONMENT.
• Attach a sling to the cylinder.

• Slightly tighten the sling.
• Extract the pin on the back side (The top one).

• Remove the tool that was used to extract the pin from the back-side of the
cylinder.
318 4000866050 E 10.18 USA / GB

Chassis
MS0229
• Remove the rod-side clevis pin (The bottom one).

• Lift the cylinder out from the top.
6- Re-installation
• Check for the presence of seal on connections.
6.1 - SAFETY BLOCK
If the safety block is removed :

• Slightly release the block's fastening screw so that the oil can drain and the pressure can drop.
• After the pressure drops, remove the block.
• When reinstalling on the new cylinder, check that there are seals.
• Install the screws with threadlock. Tighten the screws to the recommended torque : 9 Nm.
4000866050 E 10.18 USA / GB 319

Chassis
MS0229
• Verify absence of any oil leaks.
Move the cylinders several times to empty them. Refer to machine sheet MS0213.
• Perform a static test by putting 320 kg / 705 lbs on the platform.
320 4000866050 E 10.18 USA / GB

Upper boom
Remove - Replace the boom/jib/box assembly
MS0230
Upper boom
1- Concerned area
2- Warning
manual.
4000866050 E 10.18 USA / GB 321

Upper boom
MS0230
3- Risk prevention
• Safety shoes .
• Gloves .
4- You will need

• ORFS seal kit : 2505000470
• ORFS plug kit : 2505001600
• Pin diameter 30 mm / 1.18 in, length 700 mm / 2 ft 30 in
• Pin diameter 25 mm / 1 in, length 500 mm / 20 in
• 1 hoisting strap(s) for 2000 kg / 4409 lbs at a length of 5240 mm / 17 ft 19 in
• Place barriers around the
perimeter of the work area
• 1 ratcheting straps that support 2000 kg / 4409 lbs at a length of 2000 mm / 6
ft 56 in
• Chock under boom of 2100 mm / 6 ft 9 in
• 2 wooden chocks 500 mm / 1ft 64 in long and 60 mm / 2,36 in wide
• Wood pallet length 500 mm / 1 ft 64 in, width 200 mm / 7 ft 87 in, height 400
mm / 15 ft 74 in estimated.
• Hydraulic oil
• Grease
• Contact grease - 2820308450
• Hose clamps
• Weight of boom/jib/platform assembly : 2065 kg / 4553 lbs 2
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Upper boom
MS0230
5- Removal
• Position the machine on a flat and firm surface, clear of obstructions (beware of power lines). Mark out the work
area.
• Retract the telescope arm, place the jib in the horizontal position and empty the platform. Chock under boom of 2100
mm / 6 ft 9 in.

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Upper boom
MS0230


324 4000866050 E 10.18 USA / GB

Upper boom
MS0230

side ( 3 ).
• Mark and disconnect the 2 telescope cylinder supply hoses.

• Plug the openings after disassembly.
N.B.-:-PLACE A CONTAINER UNDERNEATH THE CONNECTIONS.
4000866050 E 10.18 USA / GB 325

Upper boom
MS0230
• Disconnect the 4 hoses from the rear of the boom, make a note of their
positions and plug them.

ENVIRONMENT.
• Remove the electric cable ( 1 ) : Plug 220 V.

• Disconnect the wiring harnesses ( 2 ) :
• CAN BUS CN06–1.
• CN05A.
• CN05B.
326 4000866050 E 10.18 USA / GB

Upper boom
MS0230
Disconnect the sensors :

• SQ521 (1).
• ILS SQ523 (2).
• Identify and unscrew the fastening lugs to pass the sensors through.
• Bring the cables and hoses back to the boom.
• Attach slings to the boom.

• Apply a small amount of tension on the bridge crane :
N.B.-:- 1 HOISTING STRAP(S) FOR 2000 KG / 4409 LBS AT A LENGTH OF 2000 MM / 6 FT 56 IN
4000866050 E 10.18 USA / GB 327

Upper boom
MS0230
• Place a wedge under the cylinder and attach the rod with the ratchet strap :
• 1 ratcheting straps that support 2000 kg / 4409 lbs at a length of 2 m / 6
ft 56 in.
• Wood pallet length 500 mm / 1 ft 64 in, width 200 mm / 7 ft 87 in, height
400 mm / 15 ft 74 in estimated.

• Pull out the pin (2).
• Remove the boom sling and pass it around the boom lifting cylinder.
• Remove the ratchet strap.
• Place the cylinder on the wooden wedge.
328 4000866050 E 10.18 USA / GB

Upper boom
MS0230

N.B.-:- 1 HOISTING STRAP(S) FOR 2000 KG / 4409 LBS AT A LENGTH OF 2000 MM / 6 FT 56 IN
• Strap the level compensation cylinder using the ratchet strap.
• Open the engine cover.

• Remove screw that is blocking the engine compartment.
• Pull then swivel the engine compartment.
• Remove the locking lever .
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Upper boom
MS0230
Bottom-side of the cylinder :

• Pull out the pin (2).
Attach slings to the boom :

• A : 2400 mm / 7 ft 87 in.
• B : 350 mm / 1 ft 15 in.
• C : 4000mm / 13 ft 12 in.
• D : 1 hoisting strap(s) for 2000 Kg / 441 lbs at a length of 5240 mm / 17 ft 19 in.
• E : 1 hoisting strap(s) for 2000 Kg / 441 lbs at a length of 5000 mm / 15 ft 40 in.
330 4000866050 E 10.18 USA / GB

Upper boom
MS0230
Boom slinging
Position the wood chocks to avoid crushing the hydraulic hoses. 2 wooden chocks 500 mm / 1ft 64 in long and 60 mm
/ 2,36 in wide.
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Upper boom
MS0230
Extract the pin from the boom :

side ( 2 ).
Check before lifting the assembly that the level compensation cylinder is properly strapped
332 4000866050 E 10.18 USA / GB

Upper boom
MS0230
• Lift the jib and platform boom set.
• Place the assembly on suitable supports.
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Upper boom
MS0230
6- Re-installation
During reinstallation, pay attention to the hoses and cables.
Respect the cable routing :

• CN05A (1).
• CN05B (1).
• CAN BUS CN06–1 (2).
• CAN BUS CN06–2 (2).
• 220 V electric cable (3).
• Telescopic cylinder hydraulic hoses (4).
• SQ521 (5).
• ILS SQ523 (5).
View under the turntable
334 4000866050 E 10.18 USA / GB

Upper boom
MS0230
Put contact grease on the connectors :

• CN05A.
• CN05B.
• Twilight sensor.
• Work light.
• Grease the pins, the seals, and the bored holes.
• Remember to refit the pin stop screws. Tighten the screws to the recommended torque : 76 Nm.
• Tighten the boom pin stop screw to a torque of 190 Nm.
• From the low control panel, operate the platform leveling to bleed the circuit
• Operate the platform leveling functions to flush out the hydraulic circuit.
• Extend and retract the telescope to flush out the hydraulic circuit.
• Raise and lower the boom and check the displacement of the harnesses and hoses.
• From the ground and platform control boxes, test all of the machine's functions.
• Perform a static test by putting 320 kg / 705 lbs on the platform. Machine unfolded, 15 mn after checking the
performance of its parts :
• Boom lifting cylinder.
• Jib cylinder.
• Oscillating axle cylinder.
4000866050 E 10.18 USA / GB 335

Upper boom
MS0230
Notes
336 4000866050 E 10.18 USA / GB

Upper boom
Remove - Replace the rear pads
MS0231
Upper boom
1- Concerned area
2- Warning
manual.
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Upper boom
MS0231
3- Risk prevention
• Safety shoes .
• Gloves .
4- You will need

• Place barriers around the perimeter of the work
• Upper pads – 184P313520
area
• Lower pads – 4000000450
• Side pads – 4000000450
• Grease
• Greasing the pads — 2326005410
• 500 kg / 1102 lbs ratchet strap, 1000 mm / 3 ft 28 in in length
• Pin diameter 20 mm / 0.8 in, length 500 mm / 19.5 in
• Wood chock
• Weight of the tie rod : 27 kg / 59.5 lbs
1
• Weight of the cylinder bracket : 17 kg / 37.5 lbs
338 4000866050 E 10.18 USA / GB

Upper boom
MS0231
5- Removal
• Extend the telescopic cylinder by 30 cm / 1 Ft.

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Upper boom
MS0231

340 4000866050 E 10.18 USA / GB

Upper boom
MS0231

• Set the panel aside.
• Position a chock on the boom above the telescopic cylinder.

• Strap the wood chock and the telescopic cylinder rod.
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Upper boom
MS0231
• Unscrew the 6 screws from the telescopic cylinder bracket.
side ( 3 ). Take care that the tie rod does not fall onto the cable breakage
sensor wire.
• From the ground control box, control the retraction of the telescopic
cylinder rod. Pay attention to the ratchet strap placed around the cylinder
rod.
342 4000866050 E 10.18 USA / GB

Upper boom
MS0231
• Disconnect the cable from the chain breakage sensor to avoid crushing it
during the operation.
• Once the rod is retracted, switch off the ignition and remove the key.
• Tip the tie rod backwards.
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Upper boom
MS0231
• Pull the telescopic cylinder bracket.

• Unscrew and remove the 8 pads.
• (1) : Part number 184P313520
• (2) : Part number 4000000450
344 4000866050 E 10.18 USA / GB

Upper boom
MS0231
6- Re-installation
• Before refitting, fill the cells of the new pads with grease. Take care not to
put white grease in the threading of the 8 pads.
• Tighten the screws on the tightening pads to a torque of 10 Nm and the
pad nuts to 45 Nm.
• Place the tie rod on a pin to avoid damaging the tension cables.
• Glue the 6 screws of the telescopic cylinder bracket using blue

threadlocker. Tightening at a torque of 45 Nm.
• Don't forget the pin stop clevis and remember to retighten the screw to a torque of 76 Nm
4000866050 E 10.18 USA / GB 345

Upper boom
MS0231
Notes
346 4000866050 E 10.18 USA / GB

Upper boom
Remove/re-install the harness BUS CAN
MS0232
Upper boom
1- Concerned area
2- Warning
manual.
4000866050 E 10.18 USA / GB 347

Upper boom
MS0232
3- Risk prevention
• Safety shoes .
• Gloves .
4- You will need

• Wiring harness BUS CAN : XXXXXX
• Contact grease - 2820308450 • Place barriers around the perimeter of the work area
• Hose clamps
348 4000866050 E 10.18 USA / GB

Upper boom
MS0232
5- Removal

• Disconnect the plugs from the harness BUS CAN CN06-1 - CN06-2.
• Place the plugs inside a plastic bag for protection so as not to contaminate
the connectors.
N.B.-:-MAKE A MARK ON THE CABLES WHERE THEY ENTER AND EXIT

THE CLAMPS . T HIS WILL ENABLE THEM TO BE CO RRECTLY
REPOSITIONED WHEN RE-INSTALLING.
4000866050 E 10.18 USA / GB 349

Upper boom
MS0232
• Remove the harness from the turret and bring it to the boom.
• Unscrew the 2 clamp collars.
350 4000866050 E 10.18 USA / GB

Upper boom
MS0232
• Extract the BUS CAN wiring harness from the tube (black U shape). Cut the clamp collars all along the tube.
• Unclip the fastening clips from the chain's spacers. Turn the key a quarter turn to remove them.
4000866050 E 10.18 USA / GB 351

Upper boom
MS0232
• Remove the BUS CAN harness from the tube chain.
• Remove the protection cover from the cables in the black tube.
• Extract the BUS CAN wiring harness, cutting the clamp collars all the way along.
352 4000866050 E 10.18 USA / GB

Upper boom
MS0232
• Unscrew the ( 1 ) clamp collars
• Unscrew one of the 2 guide connectors .
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Upper boom
MS0232
• Cut the clamp collars holding the BUS CAN wiring harness along the jib
arm.
• Disconnect the BUS CAN plug ( 1 ) from the platform control box.
• Open the hose clamp ( 4 ) , using a flat screwdriver.
• Unscrew the screw closing the wiring harness guide ( 2 ).
• Remove the BUS CAN harness ( 1 ) from the sheath ( 3 ).
354 4000866050 E 10.18 USA / GB

Upper boom
MS0232
• Remove the BUS CAN harness.
6- Re-installation
• Start reinstallation from the platform side.
• Follow the initial harness routing.
• Put contact grease on the 2 connectors and the platform control panel socket.
• Connect the 2 connectors and the control panel socket.
• Attach the cables.
• Maneuver the lifting boom, extend and retract the telescope, and raise and lower the boom to check that the
movements are consistent. Test all functions from the platform control.
4000866050 E 10.18 USA / GB 355

Upper boom
MS0232
Notes
356 4000866050 E 10.18 USA / GB

Platform
Disassembly - Assembly Activ' Lighting System
MS0233
Platform
1- Concerned area
4000866050 E 10.18 USA / GB 357

Platform
MS0233
2- Warning
manual.
3- Risk prevention
• Safety shoes .
• Gloves .
4- You will need

• Activ' Lighting System Part number 4000466490
• Work light Part number 4000510640
• Standard tool kit • Place barriers around the perimeter of the work area
• Contact grease - 2820308450
• Hose clamps
358 4000866050 E 10.18 USA / GB

Platform
MS0233
5.1 - DISASSEMBLY - ASSEMBLY

• Place a do not operate tag at the start/stop switch location to
inform personnel that the equipment is being worked on.
5.1.1 - Part number 4000510640

4000866050 E 10.18 USA / GB 359

Platform
MS0233
• Disconnect the connector ( 2 ) from the light.

• Remove the light .
• Carry out the operations in reverse order to refit. Apply contact
grease for the connector .
5.2 - PART NUMBER 4000466490
• Open the cover on the control box-side.
• Cut the hose clamp.

• Disconnect the connector ( 1 ).
• Unscrew the nut ( 2 ).
• Remove Activ' Lighting System ( 3 ).
360 4000866050 E 10.18 USA / GB

Platform
MS0233
5.3 - PART NUMBER 4000466490

• Disconnect the connector .
• Unscrew the nut .
• Remove Activ' Lighting System .
5.4 - PART NUMBER 4000466490
• Open the engine cover.

• Unscrew the nut ( 2 ).
• Remove Activ' Lighting System ( 3 ).
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Platform
MS0233
5.5 - PART NUMBER 4000510640
• Go under the boom.
• Disconnect the connector ( 2 ) from the light.

• Remove the screw and the nut 1.
• Remove the light .
5.6 - PART NUMBER 4000466490
• Start the ignition and lift the platform by 1 m / 3 ft and switch off
the ignition.

• Disconnect the connector .
362 4000866050 E 10.18 USA / GB

Platform
MS0233
• Unscrew the nut .

• Remove Activ' Lighting System .
5.7 - ACTIV' LIGHTING SYSTEM PLATFORM
• Marking ( 1 ) : Two Activ' Lighting System, reference

4000466490, located in the platform control box base.
• Marking ( 2 ) : Two Activ' Lighting System, reference
4000466490, located in the cover of the platform control box.
• Remove the 2 grey plugs ( 1 ).

• Unscrew the 4 nuts ( 3 ) on the platform control box.
• Unscrew the 2 nuts of the Activ' Lighting System of the base.
4000866050 E 10.18 USA / GB 363

Platform
MS0233
• Unscrew the 12 screws of the platform control box without

removing them from the base.
• Open the control box.
• Unscrew the 2 screws from the Activ' Lighting System of the

cover.
• Disconnect the 4 connectors of the Activ' Lighting System of
the platform control box.
• Carry out the operations in reverse order to refit. Put contact
grease on the connectors.
• Carry out a test to check that the Activ' Lighting System are operating properly.
364 4000866050 E 10.18 USA / GB

Boom cylinder
Removal - Replacement boom cylinder
MS0239
Boom cylinder
1- Concerned area
2- Warning
manual.
4000866050 E 10.18 USA / GB 365

Boom cylinder
MS0239
3- Risk prevention
• Safety shoes .
• Gloves .
4- You will need

• Boom cylinder : 166P348520
• ORFS plug kit : 2505001600
• Grease
• Wooden pallets • Place barriers around the perimeter of
• Height wedge 140 mm / 5,5 in the work area
• 1 hoisting strap(s) for 3000 kg / 6,615 lbs at a length of 3 m
/ 9 ft 10 in
• 1 ratcheting straps that support 4000 kg / 8818,5 lbs at a
length of 6 m / 19 ft 7 in.
Major component • Boom cylinder : 247 kg / 567 lbs
1
masses • Upper boom : 3000 kg / 6614 lbs
366 4000866050 E 10.18 USA / GB

Boom cylinder
MS0239
5- Removal
• prepare a 2,10 m / 6,9 ft stand.

• Use a ratchet strap to secure it.
• Start the engine and slightly lift the boom.
• Position the stand under the boom.
• Lower the boom to rest it on the stand.
• Put the platform on a pallet stack by using the jib function. Wedges under
the platform of 140 mm / 5,5 in.
4000866050 E 10.18 USA / GB 367

Boom cylinder
MS0239

• 1 hoisting strap(s) for 3000 kg / 6,615 lbs at a length of 3 m / 9 ft 10 in.
• Bridge crane 3000 kg / 6,615 lbs (minimum).
• Sling the boom lifting cylinder :

• 1 ratcheting straps that support 4000 kg / 8818,5 lbs at a length of 6 m /
19 ft 7 in.
• Pass the strap between the chains and the boom.
368 4000866050 E 10.18 USA / GB

Boom cylinder
MS0239
• Unscrew the screw on the cylinder using a socket wrench.
• Remove the clevis and the screw and set them aside.
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Boom cylinder
MS0239
• By manoeuvring the bridge connected to the boom, relieve the stress on

the pin in order to extract it.
• Extract the pin using a hammer.
• Extract the pin from its housing using an extraction pin.
• Leave the extraction pin in place.
370 4000866050 E 10.18 USA / GB

Boom cylinder
MS0239
• Lower the bridge crane and remove the sling on the boom.
• Position the sling at the front of the cylinder, passing between the chains
and the tube.
• Remove the extraction pin.
• Place a wood chock under the cylinder.

• Lower the bridge crane until the cylinder is resting on the chock.
• Remove the sling.
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Boom cylinder
MS0239
• Open the engine compartment by unscrewing the screw and nut.
• Open the engine compartment to access the hydraulic hoses.
• Identify the hoses.
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Boom cylinder
MS0239
• Position an oil collection pan to avoid polluting the environment.

• Gradually unscrew the nuts to release the pressure in the cylinder.
• Disconnect the hoses marked *1 figure *2 and plug them.
• Unscrew and remove the screws.

• Remove the clevis.
• Set the elements aside.
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Boom cylinder
MS0239
• Position a ratchet strap between the boom and the arm of the cylinder to
secure the cylinder.
• Ensure the rigid tube above the boom is not crushed.

• Remove the pin from its housing using an extraction pin and a hammer.
374 4000866050 E 10.18 USA / GB

Boom cylinder
MS0239
• Lift the cylinder using 2 slings ( 1 front and 1 back).

• Position the slings on the left side of the boom.
• Lift the bridge crane by 10 cm / 3 in to remove the ratchet strap.
• Using the bridge crane, remove the cylinder by pulling back.

• Place the cylinder on the wooden wedges.
4000866050 E 10.18 USA / GB 375

Boom cylinder
MS0239
6- Re-installation
• Make sure to install the locking pin screws and circlips (change them if they became damaged during disassembly).
• Tighten the screws of the male clevises to a torque of 76 Nm / 56 lbs ft.
• Hose tightening :
• Tightening at a torque of 24 Nm - 27 Nm / 17lbs 7 ft - 19 lbs 9 ft.
• Tightening at a torque of 43 Nm - 47 Nm / 31 lbs 7 ft - 36 lbs 7 ft.
• Make sure the hoses and harnesses are set in their correct routes.
• From the lower control box, raise up and down boom up to purge the cylinder.
• Top up the hydraulic oil if necessary (machine in road driving position).
• From the ground and platform control boxes, test all of the machine's functions.
• Lift cylinder.
• Jib cylinder.
376 4000866050 E 10.18 USA / GB

Upper boom
Remove/Re-install output compensation cylinder
MS0240
Upper boom
1- Concerned area
2- Warning
manual.
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Upper boom
MS0240
3- Risk prevention
• Safety shoes .
• Gloves .
4- You will need

• Gloves
• Hose clamps
• Grease for pins
• ORFS plug kit : 2505001600
• 1 hoisting strap(s) for 3000 kg / 6,615 lbs at a
• 1 ratcheting straps that support 4000 kg / 8818,5
lbs at a length of 6 m / 19 ft 7 in. • Place barriers around the perimeter of the work
• Lifting and handling equipment(bridge crane, area
crane, etc)
• Mobile workshop stepladder
• Palettes for placement under the platform (about
600mm / 23.6in)
• Hydraulic oil
• Pry bar
• Torque wrench for 10Nm-100 Nm/7.38lbs ft- 73.76
lbs ft
• Extraction pin
Major component
• Compensation cylinder : 47 kg / 103.6 lbs 1
masses
378 4000866050 E 10.18 USA / GB

Upper boom
MS0240
5- Removal
• Start the engine to lift the boom and free the front pin of the cylinder from
its outlet.
• Start the engine.
• Lift the boom sufficiently to be able to extract the front pin from the cylinder.
• Make a stable pallet stack about 1,3 m / 4.27 ft tall
• Retract the telescoping boom. .
• Fold the jib.
• Position a strong, stable chock attached with a strap under the platform at
a height of approximately 1,3 m / 4.27 ft.
• Lower the boom to rest the platform on the chock.
• Sling the boom on the boom by passing the sling between the chains and
the tube.
• Lift the bridge crane slowly to secure the boom.
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Upper boom
MS0240
• Strap the level compensation cylinder using the ratchet strap.

• Pass the sling between the rigid tubes and the tube.
Do not climb on the counterweight.
• Use an oil collection pan to avoid polluting the environment.

• Mark, disconnect and plug the hoses supplying the output compensation
cylinder. .
• Turn slowly to release the pressure in the hoses.
380 4000866050 E 10.18 USA / GB

Upper boom
MS0240
• Ensure the presence of seal on the fittings.
• Loosen the screw and remove the clevis pin .
• Leave the extraction pin in place.
• Remove the sling.

• Refit the sling between the boom and the cylinder.
• Lift the bridge crane slightly to free the ratchet strap.
• Leave the ratchet strap in place.
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Upper boom
MS0240
• Open the engine cover to access the clevis.

• Use a 16mm socket wrench to unscrew the M12 screw.
• Remove the screw and knock out the clevis.
• Remove the extraction pin.
• Lower the bridge crane to free the sling.

• Place the sling at the centre of gravity of the cylinder.
• Lift the bridge crane.
• Extend the cylinder, ensuring the hoses are not damaged.
• Place the cylinder on the wooden wedges.
• Cylinder reference: 4000714780.
• Weight : 47 Kg / 103,6 lbs.
• Measure and record the extended length of the cylinder rod for when the
cylinder is refitted.
382 4000866050 E 10.18 USA / GB

Upper boom
MS0240
6- Re-installation
• To pin the cylinder on the back side more easily, extend the cylinder rod to give a longer lever arm.
• Remember to refit the locking pins in the pins, the immobilisation screws and the circlips.
• Hold the hoses to ensure that they don't turn while tightening the connections (risk of seal damage). This will avoid
the hoses twisting when they are connected to the rigid tubes.
• Use a manual pump to extend the cylinder rod to the length previously noted.
• Tighten the screws of the male clevises to a torque of 76 N.m / 56 lbs ft.
• Check the condition of the rings. Replace as necessary. Part number : 2390190960.
• Tighten the hoses with a torque of 24-27 Nm / 17.7-19.9 lbs ft.
• From the lower control box, operate the platform compensation functions to flush out the hydraulic circuit.
• Lift cylinder.
• Jib cylinder.
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Upper boom
MS0240
Notes
384 4000866050 E 10.18 USA / GB

E - Trouble shooting and diagram

Trouble shooting and diagram
1- Trouble shooting
1.1 - RECOMMENDATIONS
If a malfunction occurs, check the following points :

• There is sufficient fuel.
• Sufficient 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, contact HAULOTTE Services®.
1.2 - DESCRIPTION
The FAILURES function describes the requirements relative to failures : monitoring, information
recording, information reading.
4000866050 E 10.18 USA / GB 385


2- List of failures per category
Failures N Dec Bit Description

Contactors
• Digital output's failure : Emergency pump relay --> KM120
F02.02
• Check relay
Emergency Pump D
• Check connection to ground
KM120
• Check connection to U106 ECU
• Incoherence between the emergency stop status and the presence of voltage on power
line --> EMSTOP=0 & (12VD1>8.00V | 12VD2>8.00V | 12VD3>8.00V | 12VD4>8.00V |
F02.04 12VD5>8.00V | 12VF1>8.00V | 12VF2>8.00V | 12VF3>8.00V | 12VF4>8.00V)
Power Contactor D • Check emergency stops
KMP • Check relay KMP
• Check fuses
• Check wiring
• Digital output's failure : Preheating relay and engine is not Tier IV --> KM160=FAIL &
F02.05 CFG[Engine]=TierIII
Heating Relay D • Check relay
KM160 • Check connection to ground

Relays
• Digital output's failure : Horn relay --> KA9=FAIL
F03.06
• Check relay
Horn Relay D
KA9
• Platform emergency stop pushed while power is ON, overriding relay stuck (if not
F03.07 controlled) => overriding relay stuck --> SB802 = 1 & WUI = 1 & KA6 = 0
Relay failure D • Check relay
KA6 • Check connection to ground
• Digital output's failure : Starter relay --> KA4=FAIL
F03.08
• Check relay
Start Relay D
KA4
F03.09 • Digital output's failure : Engine supply relay --> KA3=FAIL
Supply/Key Switch • Check relay
D
Rel • Check connection to ground
KA3 • Check connection to U106 ECU
• Digital output's failure : Generator relay failure while generator on (And failure is not low
F03.11 current) --> KA2=FAIL& SETP[Generator]=ON
Generator Relay D • Check relay
KA2 • Check connection to ground
386 4000866050 E 10.18 USA / GB


Electrovalves
• For each failure, check the internal code.
For failures about digital electro valves controlled by the U104 ECU (platform slave ECU) :
• The detected failures are "open circuit" or "short circuit", check the harness between the ECU and the hydraulic block controlling
the movement, check the valves.
For failures about proportional or digital electro valves controlled by U106 ECU (turret master ECU) :
• The detected failures are open circuit ( OC), short-circuit to VBAT (SC+) , short-circuit to GROUND ( SC-), low current ( LC) and
power supply error ( PSE).
• First check the type of failure by reading the status of the output in the menu "INPUTS-OUTPUTS => DIGITAL OUTPUTS /
ANALOGUE OUTPUTS".
If OC/SC+/SC-/LC :
• check harness, check there is no misconnection between signal and ground supply or power supply.
If PSE :
• Check the supplies are well connected : 12VD1 (1B.18), 12VD2 (2A.08), 12VD3 (2B.02), 12VD4 (3A.01), 12VF1 (1B.32), 12VF2
(2A.07), 12VF4 (3A.07).
Failures are acknowledged if :
• Movement set point corresponding to the failing electro valve is neutral.
• AND movement control corresponding to the failing electro valve is neutral.
AND electrovalve failure state corresponds to the "no failure" flag (generally state =OK, or for safety electrovalve state =OC)
F04.01 1 b0 Proportional output's failure : Steering movement --> YV902=FAIL
Steering 2 b1 Digital output's failure : Left steering movement --> YV150L=FAIL
D
YV901 / YV150L /
4 b2 Digital output's failure : Right steering movement --> YV150R=FAIL
YV150R
F04.02 1 b0 Proportional output's failure : Platform level movement --> YV901=FAIL
Compensation 2 b1 Digital output's failure : Platform level raise movement --> YV720U=FAIL
D
YV902 / YV720U /
4 b2 Digital output's failure : Platform level descent movement --> YV720D=FAIL
YV720D
1 b0 Proportional output's failure : Leftwards turntable rotate movement --> YV250L=FAIL
2 b1 Digital output's failure : Rightwards turntable rotate movement --> YV250R=FAIL
Digital output's failure : Safety turntable rotate movement --> YV805=FAIL
F04.03 Failure is detected only during turntable or boom descent movement ( GND5 is the
4 b2
Turret rotation D common ground supply for YV805 and YV807 electrovalves). Otherwise, YV805 is
YV250L / YV250R / seen as open circuit.
YV805 / GND5 Digital output's failure : Safety ground turntable rotate movement --> GND5=FAIL
Failure is detected only during turntable or boom descent movement ( GND5 is the
8 b3
common ground supply for YV805 and YV807 electrovalves). Otherwise, GND5 is seen
as open circuit.
1 b0 Proportional output's failure : Upwards boom movement --> YV520U=FAIL
2 b1 Digital output's failure : Downwards boom movement --> YV520D=FAIL
Digital output's failure : Safety boom movement --> YV802=FAIL
Failure is detected only during telescope extend or boom movement ( GND2 is the
4 b2
common ground supply for YV801 and YV802 electrovalves). Otherwise, YV802 is
seen as open circuit.
F04.05 Digital output's failure : Safety ground boom movement --> GND2=FAIL
Boom 8 b3
D common ground supply for YV801 and YV802 electrovalves). Otherwise, GDN2 is seen
YV520U / YV520D /
as open circuit.
YV802 / GND2 / YV807
/ GND5 Digital output's failure : Safety boom descent movement --> YV807=FAIL
16 b4
common ground supply for YV805 and YV807 electrovalves). Otherwise, YV805 is
seen as open circuit.
Digital output's failure : Safety ground boom descent movement --> GND5=FAIL
32 b5
common ground supply for YV805 and YV807 electrovalves). Otherwise, GDN5 is seen
as open circuit.
4000866050 E 10.18 USA / GB 387


Electrovalves
1 b0 Proportional output's failure : Telescope movement --> YV530O=FAIL
2 b1 Digital output's failure : Telescope extension movement --> YV530I=FAIL
Digital output's failure : Safety telescope extend movement --> YV801=FAIL
F04.06 Failure is detected only during telescope extend or boom movement ( GND2 is the
4 b2
Telescope D common ground supply for YV801 and YV802 electrovalves). Otherwise, GDN2 is seen
YV530O / YV530I / as open circuit.
YV801 / GND2 Digital output's failure : Safety ground telescope extend movement --> GND2=FAIL
8 b3
common ground supply for YV801 and YV802 electrovalves). Otherwise, GDN2 is seen
as open circuit.
F04.07 1 b0 Proportional output's failure : Upper movements --> YV901=FAIL
Jib 2 b1 Digital output's failure : Jib raise movement --> YV620U=FAIL
D
YV902 / YV620U /
YV620D 4 b2 Digital output's failure : Jib descent movement --> YV620D=FAIL
F04.08 1 b0 Proportional output's failure : Platform rotation movement --> YV901=FAIL

Cage Rotation 2 b1 Digital output's failure : Platform rotation left movement --> YV750L=FAIL
D
YV902 / YV750R /
YV750L 4 b2 Digital output's failure : Platform rotation right movement --> YV750R=FAIL
F04.10 1 b0 Proportional output's failure : Drive movement, forward direction --> YV160F=FAIL
Drive D
2 b1 Proportional output's failure : Drive movement, reverse direction --> YV160B=FAIL
YV160F / YV160B
F04.11
Principal
D 1 b0 Digital output's failure : LS valve (HSD) --> YV800=FAIL
movements
Chk YV800
F04.20
Drive Speed D Digital output's failure : High speed drive --> YV110=FAIL
YV110
Digital output's failure : Steering mode with 4 wheels steering option activated -->
F04.33 1 b0
YV107=FAIL & VAR[4WSEnable]
Steering mode D
Digital output's failure : Steering mode with 4 wheels steering option activated -->
YV107 / YV108 2 b1
YV108=FAIL & VAR[4WSEnable]
F04.34 1 b0 Digital output's failure : Oscillating axle unlocking --> YV101=FAIL
Front Axle
D
Unlocking 2 b1 Digital output's failure : Oscillating axle unlocking --> YV104=FAIL
YV101 / YV104
F04.35
Brake Releasing D 1 b0 Digital output's failure : Brake releasing --> YV102=FAIL
YV102
388 4000866050 E 10.18 USA / GB


Joysticks
The following joysticks’ failures are relevant if failure F08.05 is not active (failure of 5 V supplying signal). First check the 5 V
supplying the joysticks, then the harness between ECU and joysticks
1 b0 Drive joystick failure : Out of range [0.2.4.8] V --> SM902Y<0.20V and SM902Y>4.80V
F05.01 Drive joystick failure : Analogue signal and out of neutral incoherence
Drive Joystick D --> SM902F = 1 & SM902B = 1 & 2.45V<SM902Y<2.55V
2 b1
SM902Y --> Or SM902F = 0 & SM902Y<2.00V
--> Or SM902B = 0 & SM902Y>3.00V
1 b0 Telescope joystick failure : Out of range [0.2.4.8] V --> SM901Y<0.20V | SM901Y>4.80V
F05.03
Telescope joystick failure : Analogue signal and out of neutral incoherence
Telescope Joystick D
2 b1 --> SM901N = 1 & 2.45V<SM901Y<2.55V
SM901Y
--> Or SM901N=0 & SM901Y<2.00V | SM901Y>3.00V
1 b0 Boom joystick failure : Out of range [0.2.4.8] V --> SM900Y<0.20V & SM900Y>4.80V
F05.04 Boom joystick failure : Analogue signal and out of neutral incoherence
Boom Joystick D --> SM900N = 1 & 2.45V<SM900Y<2.55V & 2.45V<SM900X<2.55V
2 b1
SM900Y --> Or SM900N = 0 & SM900Y<2.00V & SM900Y>3.00V & SM900X<2.00V |
SM900X>3.00V
Turret rotation joystick failure : Out of range [0.2.4.8] V --> SM900X<0.20V &
1 b0
SM900X>4.80V
F05.05 Turret rotation joystick failure : Analogue signal and out of neutral incoherence
Turret Joystick D Boom joystick failure : Analogue signal and out of neutral incoherence
SM900X 2 b1 --> SM900N = 1 & 2.45V<SM900Y<2.55V & 2.45V<SM900X<2.55V
--> Or SM900N = 0 & SM900Y<2.00V & SM900Y>3.00V & SM900X<2.00V &
SM900X>3.00V
F05.11 No detection of joystick's neutral position at machine's power-on
Joystick neutral A --> SM902Y<2.35V | SM902Y>2.65V
SM902Y Release joystick / Check joystick

Joystick neutral 2 A --> SM901Y<2.35V | SM901Y>2.65V
SM901Y Release joystick / Check joystick

Joystick neutral 3 A --> SM900X<2.35V | SM900X>2.65V | SM900Y<2.35V | SM900Y>2.65V
SM900X/Y Release joystick / Check joystick
4000866050 E 10.18 USA / GB 389


Load management system
No overload calibration, do/redo overload calibration
F06.01
CFG[LoadManagementSytem] = StrainGauges : [VAR[GaugesNotCalibrated]=1
No Loading Cal A
CFG[LoadManagementSytem] = VibratingWires : VAR[VibratingWiresNotCalibrated] = 1
Calibrate
Complete calibration
CFG[LoadManagementSytem] = StrainGauges
Gauges out of range (load management system activated) --> SP800 Not in [1500;
1 b0 20500]μA
F06.03
VAR[GaugesOutOfRange]=1
Gauges out of Check SP800 connections to ground, to U104 ECU analog inputs
D
Range
SP800/SP801
Gauges out of range (load management system activated) --> SP801 Not in [1500;
2 b1
20500]μA
Check SP801 connections to ground, to U104 ECU analog inputs
SP800 measured weight and SP801 measured weight are more than 50kg far (and
F06.04
gauges are not out of range and gauges are calibrated)
Incoh Gauges D
VAR[GaugesIncoherent]=1
SP800/SP801
Check SP800 and SP801 connections to ground, to U104 ECU analog inputs
Redo calibration
F06.05 CFG[LoadManagementSytem] = StrainGauges
Low Power D Low power for strain gauges is detected low : VbattB2 basket is under 8500 V
Gauges supply Check gauge's power supply
390 4000866050 E 10.18 USA / GB


CFG[LoadManagementSytem] = VibratingWires
Overvoltage on sensor 1
1 b0 Sensor and/or electronic card failure
1. Replace weighing unit
Overvoltage on sensor 2
2 b1 Sensor and/or electronic card failure
Low voltage on sensor 1
• Battery voltage too low
A
4 b2 • Electronic card failure
3. Check the battery voltage (minimum 8V)
Low voltage on sensor 2
• Battery voltage too low
8 b3 • Electronic card failure
5. Check the battery voltage (minimum 8V)
Sensor 1 : Loss of signal
• Internal wiring failure
16 b4 • Sensor failure
F06.06
• Card failure
Weighing sensors
Remark : Failure
masked during engine Sensor 2 : Loss of signal
starting • Internal wiring failure
• Sensor failure
• Card failure
32 b5
8. Check the load in the basket
9. Check if the basket is bearing against something
Sensor 1 : Out of range
D • Excessive mechanical stress
• Sensor and/or unit failure
• Sensor assembly
64 b6
Sensor 2 : Out of range
• Excessive mechanical stress
• Sensor and/or unit failure
• Sensor assembly
128 b7
4000866050 E 10.18 USA / GB 391


Sensor 1 : Signal dispersion
• Sensor mechanical slip
256 b8 17. Check weighing system
18. Perform a new advanced calibration
A
Sensor 2 : Signal dispersion
• Sensor mechanical slip
F06.06
Weighing sensors
Remark : Failure Sensor 1 displacement
masked during engine • Sensor disconnected of the unit
starting 1024 b10 21. Check weighing system
D
Sensor 2 displacement
• Sensor disconnected of the unit
392 4000866050 E 10.18 USA / GB


Weighing system memory erroneous
D 1 b0 • Electronic card failure
Dynamic correction out of service
• Accelerometer failure
N 2 b1
Weighing active without this correction
Information received from the weighing system not refreshed
• CAN bus connection
• Card failure
D 4 b2 29. Check weighing system unit connection (CAN bus)
30. Check harness state
Low temperature threshold reached
F06.07 • Ambient temperature too low
Weighing system 8 b3 • Temperature sensor failure
Remark : Failure 32. Return to proper temperature conditions
masked during engine
starting
High temperature threshold reached
A • Ambient temperature too high
16 b4 • Temperature sensor failure
34. Return to proper temperature conditions
Temperature information incoherent
32 b5 • Temperature sensor failure
64 b6 -
N
128 b7 -
Weighing system not responding
• Bad battery supply
D 256 b8 • Electronic card failure
37. Check the battery
38. Check the wiring connection of the weighting system
Strong overload detected
F06.08 39. Check the load in the basket
Strong overload A
40. Check the integrity of the structure
Failure active for a load 侒 700 Kgs
1 b0 Negative load (<-40kg)
Gauge 1 measures negative load below -40kg VAR[WeightSP800] < -40kg
F06.09 Gauge 2 measures negative load below -40kg VAR[WeightSP801] < -40kg
Negative load A 41. Check the platform does not lie on an obstacle
2 b1
Gauges supply
42. Check weighing system
43. Check the integrity of the structure
4000866050 E 10.18 USA / GB 393


Sensors
Telescope's cable alarm, check cable and sensors
F07.02 1 b0
--> SQ801=OFF
Cable break D
Telescope's cable alarm, check cable and sensors
SQ801 / SQ802 / cable 2 b1
--> SQ802=OFF
General check on angle position can be done as following :
Telescope retracted, boom down :
--> SQ521=OFF & SQ523=OFF & SQ590=OFF & SQ591=OFF
Raise the boom (nearly 10deg) :
--> SQ521=OFF & SQ523=OFF & SQ590= & SQ590=
Raise the boom (nearly 50deg) :
--> SQ521=OFF & SQ523= & SQ590=OFF & SQ590=OFF
Raise the boom (nearly 50deg+) :
--> SQ521= & SQ523=ON & SQ590=OFF & SQ590=OFF
Raise the boom (nearly 50deg++) :
--> SQ521=ON & SQ523= & SQ590=OFF & SQ590=OFF
Raise the boom to high end :
--> SQ521=ON & SQ523=OFF & SQ590=OFF & SQ590=OFF
Descent the boom (nearly 50deg++) :
Descent the boom (nearly 50deg+) :
Descent the boom (nearly 50deg) :
F07.04 Descent the boom (nearly 10deg) :

Boom Angle --> SQ521=OFF & SQ523=OFF & SQ590= & SQ591=
SQ521 / SQ523 / Telescope retracted, boom down :
SQ590 / SQ591 --> SQ521=OFF & SQ523=OFF & SQ590=OFF & SQ591=OFF
To erase F07.04 failure: fold the machine, check the position detectors (repair if one is broken), power off
the machine and the power on.
If failure is still active then one of the six detectors defining the machine position is not in the expected
state.
Incoherence between boom position sensors : Falling edge on limit switch angle sensor
1 b0 ( SQ521) out of the allowed zone (in front of boom zone magnet detector SQ523)
--> SQ521= & SQ523=OFF
Incoherence between boom position sensors : Raising edge on limit switch angle sensor
2 b1 ( SQ521) out of the allowed zone (in front of boom zone magnet detector SQ523)
--> SQ521= & SQ523=OFF
Incoherence between boom position sensors : Raising edge on boom zone magnet
detector SQ523 not in allowed zone (limit switch sensor SQ521 inactive) during boom
D 4 b2 descent
--> SQ523= & SQ521=OFF & CTRL[Boom]=D
Incoherence between boom position sensors : Falling edge on boom zone magnet
detector SQ523 not in allowed zone (limit switch sensor SQ521 active) during boom
8 b3 descent
--> SQ523= & SQ521=ON & CTRL[Boom]= D
Incoherence between boom position sensors : Limit switch angle sensor ( SQ521) is
16 b4 active with both P1 position detectors in active state
--> SQ521=ON & SQ590=ON & SQ591=ON
394 4000866050 E 10.18 USA / GB


Sensors
Telescope retracted, horizontal boom :
Extend the boom (nearly 1m) :
--> SQ533=ON & SQ531=OFF & SQ590= & SQ590=
Extend the boom (nearly 8m) :
Extend the boom (nearly 8m+)
Extend the boom (nearly 8m++) :
Extend the boom to high end :
--> SQ533=OFF & SQ531=OFF & SQ590=OFF & SQ590=OFF
Retract the boom (nearly 8m++) :
Retract the boom (nearly 8m+) :
Retract the boom (nearly 8m) :
Retract the boom (nearly 1m) :
F07.11 --> SQ533=ON & SQ531=OFF & SQ590= & SQ591=
Telescope Length Telescope retracted, boom down :
SQ531 / SQ533 / --> SQ533=ON & SQ531=OFF & SQ590=OFF & SQ591=OFF
SQ590 / SQ591
state.
Incoherence between telescope position sensors : Falling edge on limit switch telescope
sensor ( SQ533) out of the allowed zone (in front of telescope zone magnet detector
1 b0 SQ531)
--> SQ533= & SQ531=OFF
Incoherence between telescope position sensors : Raising edge on limit switch
telescope sensor ( SQ533) out of the allowed zone (in front of telescope zone magnet
2 b1 detector SQ531)
--> SQ533= & SQ531=OFF
Incoherence between telescope position sensors : Raising edge on telescope zone
D magnet detector SQ531 not in allowed zone (limit switch sensor SQ533 inactive) during
4 b2 boom raise or telescope extend
--> SQ531= & SQ533=OFF & (CTRL[Telescope]=O | CTRL[Boom]=U)
Incoherence between telescope position sensors : Falling edge on telescope zone
magnet detector SQ531 not in allowed zone (limit switch sensor SQ533 active) during
8 b3 boom descent
--> SQ531= & SQ533=ON & & (CTRL[Telescope]=O | CTRL[Boom]=U)
Incoherence between telescope position sensors : Limit switch angle sensor ( SQ533) is
16 b4 inactive with both P1 position detectors in active state
--> SQ533=OFF & SQ590=ON & SQ591=ON
4000866050 E 10.18 USA / GB 395


Sensors
Incoherence between basket tilt sensors : SR721/SR720.
Check position sensors with basket tilt = 0°.
F07.15 SR721=OFF & SR720=0FF
Compensation pos. D Check position sensors with basket tilt > 10°.
SR721 / SR720 SR721=ON & SR720=OFF
Check position sensors with basket tilt <-10°.
SR721=OFF & SR720=ON
Telescope retracted, horizontal boom :
state.
Incoherence between position sensors : Boom limit switch and folded position
1 b0
--> SQ590=ON & SQ521=ON & SQ533=ON
2 b1
--> SQ590=ON & SQ521=ON & SQ533=OFF
4 b2
--> SQ590=ON & SQ521=OFF & SQ533=OFF
Incoherence between position sensors : Boom magnet detector and telescope magnet
F07.17 8 b3 detector and folded position
Incoherence --> SQ590=OFF & SQ591=ON & SQ523=OFF & SQ531=ON
position 2 Incoherence between position sensors : Boom magnet detector and telescope magnet
16 b4 detector and folded position
--> SQ590=ON & SQ591=OFF & SQ523=OFF & SQ531=ON
D
--> SQ590=OFF & SQ591=ON & SQ523=ON & SQ531=OFF
--> SQ590=ON & SQ591=OFF & SQ523=ON & SQ531=OFF
--> SQ590=OFF & SQ591=ON & SQ523=ON & SQ531=ON
--> SQ590=ON & SQ591=OFF & SQ523=ON & SQ531=ON
F07.30
Incoherence between engine pressure signal and engine state : engine is not running
Engine oil pressure N
and SP300 in ON position (engine running)
SP300
F07.31
D+ N Engine is not running and DPLUS signal is active
D+
Drive hydraulic circuit pressure sensor is out of normal operative range
F07.37 D 1 b0
--> SP160F < 200mV | SP160F > 4800mV
Drive press. Sensor
Drive hydraulic circuit pressure sensor is out of normal operative range
SP160F / SP160B D 2 b1
--> SP160B < 200mV | SP160F > 4800mV
Open circuit on fuel level sensor (only for analog fuel level sensor type) :
D 1 b0 Check fuel level sensor SL300
F07.39 --> SL300 > 500 ohms & CONFIG[FuelLevelSensorType] = Analog
Fuel level sensor
Short circuit to ground on fuel level sensor (only for analog fuel level sensor type) :
SL300
D 2 b1 Check fuel level sensor SL300
--> SL300 = 0 ohms & CONFIG[FuelLevelSensorType] = Analog
396 4000866050 E 10.18 USA / GB


Supplies
Detected ECU voltage difference --> Difference between U106 (SPU) and U104
(basket B2)
F08.04
• Check U100, U104 and U106 supply voltage
Calc. Input Supply D
• Check fuses
U104 / U106
• Check supply voltage coherence between all ECU (more than 2000 V far during the
first 4 seconds after start)
Failure on regulated 5 V output of U104 ECU (basket slave node ) supplying the
joysticks. --> 5 V output is measured out the range [4.5;5.5]V and 5 V output not failing
D 1 b0 • Check fuses
F08.05 • Check the harness (check short circuit to power supply, to ground supply, open
Calc. Input Supply circuit…)
U106 5V regul Failure on regulated 5 V output of U104 ECU (basket slave node ) supplying the
joysticks. --> Detected failure on 5 V output
D 2 b1
• Switch OFF/ON the machine, check the failure has gone (probable cause: internal
failure of the ECU)
Supplies’ input detected as unplugged on connectors : Check the CN1.B connectors for
1 b0 U106 ECU :
--> 12VD1<5.00V & 12VF1<5.00V
Supplies’ input detected as unplugged on connectors : Check the CN2.A connectors for
2 b1 U106 ECU :
--> 12VD2<5.00V & 12VF2<5.00V
F08.08
Unplugged
D 4 b2 U106 ECU :
connector --> 12VD3<5.00V & 12VF3<5.00V
Connectors / Fuses
Supplies’ input detected as unplugged on connectors : Check the CN3.A connectors for
8 b3 U106 ECU :
--> 12VD4<5.00V & 12VF4<5.00V
16 b4 U106 ECU :
--> 12VD5<5.00V
4000866050 E 10.18 USA / GB 397


Engine
F09.01
Engine overheat
Water temperature D
--> T2s(ST300 & T15s(VAR[Engine]=RUNNING))
Engine overheat
F09.02
Engine oil pressure
Oil pressure D
--> T6s(SP300 & T15s(VAR[Engine]=RUNNING))
Engine pressure
F09.07
Available with Tier III variable RPM electronic engine and Tier III dual fuel engine,
Amber warning
D warning lamp received from engine ECU
lamp • Check DIAGNOSTIC => FUNCTIONS => Engine => Failure SPN
Check engine
F09.08 Available with Tier III variable RPM electronic engine and Tier III dual fuel engine, stop
Red stop lamp D lamp code received from engine ECU
Check engine • Check DIAGNOSTIC => FUNCTIONS => Engine => Failure SPN
F09.10 Alternator failure (alternator not charging battery): only for future TIV versions/ Tier III
D+ D variable ECU electronic engines
Engine alternator --> T2s(CTRL[Engine]=RUNNING & (DPLUS=OFF | 12VP<12.00V)

Functions
While driving in micro speed, measured current for YV160F or YV160B proportional
F10.01 D electrovalves is too high : --> VAR[MachinePosition]≠P1 & (YV160F[current]> 900 μA
| YV160B[current] > 900 μA)
While driving in micro speed, pressure is detected in the hydraulic high speed circuit :
--> VAR[MachinePosition]≠P1 & SP100=OFF
--> VAR[MachinePosition]=P1 & CTRL[DriveSpeed]=High & CTRL[Drive]≠N &
F10.02 D SP100=ON
Check high speed circuit (YV686), check SP692 sensor (15b) :
• Case 001 = probably hydraulic failure, or SP692 disconnected
• Case 002 = probably SP692 failure (shunt, wrong calibration adjusting pressure)
Engine RPM is too high during driving in micro speed :
F10.03 D
--> VAR[EngineSpeed] > 2550RPM & CTRL[Drive]≠N & VAR[UnfoldedMachine] = 1
398 4000866050 E 10.18 USA / GB


Functions
Digital output's failure : Lower control box buzzer
F11.06
--> HA901=FAIL
Buzzer N
Upper panel's buzzer is not tested (impedance off buzzer component is too low, seen as
HA901
failing even if not failing)
F11.08 Absolute pressure difference in drive circuit is greater than 20bar, except if machine is
Drive press. Incoh. D
driving or steering is active (because they cause the pressure difference to raise)
SP160F / SP160B / --> ABS(VAR[DrivePressureDiff]) > 20 bar & 5s(CTRL[Drive] = Neutral &
Drive pump CTRL[Steering] = Neutral)

Internal faults
CAN network failure detected with turret B2 ECU (U100)
Machine not supplied, with multimeter, check the resistance between 1001 (CAN high)
and 1002 (CAN low) is nearly 60 ohms (if 0 ohm or 120 ohm : failure, check RES
F12.01 1 b0
TERM connection for all ECUs)
CAN Fault D Check ECU supplies line
Check wires Check address connections for each B2 ECU (CN106.18/CN106.19/CN106.20)
2 b1 CAN network failure detected with keyboard switches ECU (U107)
4 b2 CAN network failure detected with onboard screen ECU (U101)
F12.02
E2P Read/Write Internal failure of SPU: access to EEPROM (read or write)
Error Restart machine
Change U106 ECU
ID of software loaded into machine is different from the ID stored into EEPROM: all
1 b0 machine parameters have been reset and must then be set again (speeds, ramps,
options, configs, access code level 2, failure counters and calibration data)
2 b1 Detected changes in machine speeds and ramps
F12.04 4 b2 Detected changes in machine options
E2P Param Reset D
8 b3 Detected changes in machine configuration
Check SETTINGS
16 b4 Detected changes in machine maintenances
32 b5 Detected changes in machine daily logs
64 b6 Detected changes in machine events counters
128 b7 Detected changes in machine events logs
4000866050 E 10.18 USA / GB 399


Internal faults
Machine’s model is not set
1 b0
Set machine model (HT23RTJO - HT23RTJPRO)
Country not set
2 b1
Set country (USA/AUS/STD/RUS)
Serial number not set
4 b2
Set machine serial number
Some speed or ramp parameters are not set
8 b3
Set all speed and ramp parameter
Some options are not set
16 b4
Set machine options (Buzzer, Flashing light, Fleet management, Activ' Shield Bar)
Some configurations are not set
32 b5
Set all machine's options (Engine)
Activ' Shield Bar option is active while Activ' Shield Bar system version is set to "Not
mounted"
Set the Activ' Shield Bar system configuration to the version conforming with the type of
hardware on the machine
F12.05
D
Machine not set
64 b6
V2Version
400 4000866050 E 10.18 USA / GB


Switches
Detected failure on upper console switches : Two directions active at the same time for
1 b0 steering rocker switch
--> SM902L=ON & SM902R=ON
Detected failure on upper console switches : Two directions active at the same time for jib
2 b1 switch
--> SA621U=ON & SA621D=ON
F13.02 Detected failure on upper console switches : Two directions active at the same time for
Platform switches D 4 b2 platform rotation switch
Sw:2 dir active --> SA751U=ON & SA751D=ON
8 b3 platform level switch
--> SA721U=ON & SA721D=ON
16 b4 steering mode switch
--> SA101C=ON & SA101S=ON
Neutral detection failure at machine's power-on for lower console switches : Turntable
1 b0
rotate switch is active
Neutral detection failure at machine's power-on for lower console switches : Boom switch
2 b1
is active
Neutral detection failure at machine's power-on for lower console switches : Telescope
4 b2
switch is active
Neutral detection failure at machine's power-on for lower console switches : Jib switch is
8 b3
active
Neutral detection failure at machine's power-on for lower console switches : Platform
16 b4
level switch is active
Neutral detection failure at machine's power-on for lower console switches : Engine start/
F13.10 32 b5
stop switch is active
Switches neutral A
Neutral detection failure at machine's power-on for lower console switches : Enable
Sw: Lower box 64 b6
switch is active
Neutral detection failure at machine's power-on for lower console switches : DPF switch
128 b7
is active
Neutral detection failure at machine's power-on for lower console switches : Overriding
256 b8
switch is active
Neutral detection failure at machine's power-on for lower console switches : Platform
512 b9
rotation switch is active
102 Neutral detection failure at machine's power-on for lower console switches : Horn switch
b10
4 is active
204 Neutral detection failure at machine's power-on for lower console switches : Beacon
b11
8 switch is active
4000866050 E 10.18 USA / GB 401


Switches
Neutral detection failure at machine's power-on for upper console switches : Jib switch is
1 b0
active
Neutral detection failure at machine's power-on for upper console switches : Platform
2 b1
rotation switch is active
Neutral detection failure at machine's power-on for upper console switches : Platform
4 b2
level switch is active
Neutral detection failure at machine's power-on for upper console switches : Steering
F13.11 8 b3
rocker switch is active
Switches neutral 2 A
Neutral detection failure at machine's power-on for upper console switches : Engine start/
Sw: Upper box 16 b4
stop switch is active
Neutral detection failure at machine's power-on for upper console switches : Emergency
32 b5
pump switch is active
Neutral detection failure at machine's power-on for upper console switches : Horn switch
64 b6
is active
Neutral detection failure at machine's power-on for upper console switches : Foot Switch
128 b7
is active

CAN J1939
Problem detected in J1939 CAN
Machine not supplied, with multimeter, check the resistance between 2001 (CAN high)
F15.06 and 2002 (CAN low) is nearly 60 ohms (if 0 ohm or 120 ohm : failure, check RES
D
CANBus Cycle Unit TERM connection for all ECUs)
Check ECU supplies line
Check CAN connection for Display and/or engine
402 4000866050 E 10.18 USA / GB

Notes
4000866050 E 10.18 USA / GB 403


3- Legend
3.1 - PCB TURRET
Location on the machine
404 4000866050 E 10.18 USA / GB


Location
4000866050 E 10.18 USA / GB 405

406 4000866050 E 10.18 USA / GB


Marking Description
FU1 Fuse -10 A - Engine shutdown
FU2 Fuse - 20A - Starter
FU3 Not used
FU4 Fuse - 25A - Generator
FU5 Fuse - 30A - General
FU6 Not used
FU7 Fuse - 15A - ECU
FU8 Fuse - 20A - Option
FU9 Fuse - 20A - Attachments
FU10 Not used
FU11 Fuse - 7.5A - + Permanent
FU12 Not used
FU13 Fuse - 20A - Power
FU14 Not used
FU15 Not used
FU16 Not used
FU17 Not used
FU18 Not used
FU19 Fuse - 5A - Emergency stop and selectors
KA1 Relay - 1RT - 12V - Engine shutdown
KA2 Relay - 1RT - 12V
KA3 Solenoid valve
KA4 General
KA5 Relay - 1RT - 12V - Engine speed
KA9 Relay - 1RT - 12V - Horn
KMG Relay - 1T - 12V/70A - Main relay
KMP Relay - 1T - 12V/70A - Power
4000866050 E 10.18 USA / GB 407


4- Electric diagram
Engine part - Tiers 3 - 4000421620H - folio 2
408 4000866050 E 10.18 USA / GB


Turntable part - PCB - 4000421620H - folio 3
4000866050 E 10.18 USA / GB 409


Turntable part - SPU 1/3 + CLUSTER - 4000421620H - folio 4
410 4000866050 E 10.18 USA / GB


Turntable part - SPU 2/3 - 4000421620H - folio 5
4000866050 E 10.18 USA / GB 411


Turntable part - SPU 3/3 - 4000421620H - folio 6
412 4000866050 E 10.18 USA / GB


Cage part - Noeud B - B Node 1/2 - 4000421620H - folio 7
4000866050 E 10.18 USA / GB 413


Cage part - Noeud B - B Node 2/2 - 4000421620H - folio 8
414 4000866050 E 10.18 USA / GB


Engine part - Tiers 4 - 4000421620H - folio 9
4000866050 E 10.18 USA / GB 415


Engine part-Petrol/gas 4000421620H - folio 10
416 4000866050 E 10.18 USA / GB


Options 4000421620H - folio 11
4000866050 E 10.18 USA / GB 417


System architecture 4000421620H - folio 12
418 4000866050 E 10.18 USA / GB

Notes
4000866050 E 10.18 USA / GB 419


5- Hydraulic diagram
Turntable jib boom PVG 4 sides - 1/2
420 4000866050 E 10.18 USA / GB


Turntable jib boom PVG 4 sides - 2/2
4000866050 E 10.18 USA / GB 421


Frame and driving - 1/2
422 4000866050 E 10.18 USA / GB


Frame and driving - 2/2
4000866050 E 10.18 USA / GB 423


Direction chassis - 1/2
424 4000866050 E 10.18 USA / GB


Direction chassis - 2/2
4000866050 E 10.18 USA / GB 425


Option - 1/2
426 4000866050 E 10.18 USA / GB


Option - 2/2
4000866050 E 10.18 USA / GB 427

Notes
428 4000866050 E 10.18 USA / GB

F - Records
Records
1- Intervention register
The intervention register keeps a record of maintenance and repair work carried out inside or outside the
maintenance programme.
N.B.-:-I N THE CASE OF A HAULOTTE SERVICES® INTERVENTION, THE QUALIFIED TECHNICIAN MUST
INDICATE THE HAULOTTE SERVICES® INTERVENTION NUMBER.
Number of HAULOTTE Services®

Date Type of intervention Intervenor
hours intervention number
4000866050 E 10.18 USA / GB 429

F - Records
430 4000866050 E 10.18 USA / GB

F - Records
4000866050 E 10.18 USA / GB 431

F - Records
432 4000866050 E 10.18 USA / GB

F - Records
4000866050 E 10.18 USA / GB 433

F - Records
434 4000866050 E 10.18 USA / GB

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Maintenance Book

HT23RTJ PRO - HT23RTJ PRO SW - HT67RTJ PRO

4000866050 E 10.18 USA / GB

2 4000866050 E 10.18 USA / GB

3.2 - Warranty period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

MS0028 - Procedure of dismantling /

MS0224 - Remove/Re-install jib cylinder . . . . . . . . . . 263

4000866050 E 10.18 USA / GB 7

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®)

N.B. : Additional technical information

8 4000866050 E 10.18 USA / GB

Color Title Description

Danger : Indicates a hazardous situation which if not avoided,

Warning : Indicates a hazardous situation which if not avoided,

Caution : Failure to comply could result in minor or moderate

Notice : Indicates practices not related to personal injury.

Procedure : Indicates a maintenance operation.

4000866050 E 10.18 USA / GB 9

10 4000866050 E 10.18 USA / GB

1.1 - MAINTENANCE IMPLEMENTATION

1. Place the machine on firm, level ground.

4000866050 E 10.18 USA / GB 11

1.2 - UNCONTROLLED MOVEMENT HAZARD

Be aware of uncontrolled movement and always respect the following :

12 4000866050 E 10.18 USA / GB

Minimum safe approach distances

Electric voltage Minimum safety distance

Do not operate the machine :

4000866050 E 10.18 USA / GB 13

N.B.-:-ACID IS NEUTRALIZED WITH SODIUM BICARBONATE AND WATER.

14 4000866050 E 10.18 USA / GB

2.1 - OWNER'S RESPONSABILITY

Additional copies can be ordered from HAULOTTE Services®.

2.2 - TECHNICIAN'S RESPONSABILITY

Only authorized and qualified operators may operate HAULOTTE® machines.

2.3 - HAULOTTE SERVICES®

4000866050 E 10.18 USA / GB 15

These improvements will be shared via the following documents :

2.6 - AFTER SALES SERVICE

2.7 - PRODUCT INFORMATION

If you desire a modification to the product, submit a request in writing to HAULOTTE.

16 4000866050 E 10.18 USA / GB

3.1 - WARRANTY ACCEPTANCE

3.2 - WARRANTY PERIOD

Spare parts are covered by a 6 month warranty.

3.3 - CONDITIONS OF WARRANTY

4000866050 E 10.18 USA / GB 17

3.4 - WARRANTY CONDITIONS

18 4000866050 E 10.18 USA / GB

4000866050 E 10.18 USA / GB 19

HT23RTJ O - HT23RTJ O SW - HT67RTJ O - HT23RTJ PRO - HT23RTJ PRO SW - HT67RTJ PRO

20 4000866050 E 10.18 USA / GB

4000866050 E 10.18 USA / GB 21

22 4000866050 E 10.18 USA / GB

Marking Description Function

By pressing on : Tilt the platform towards the front of the

By pressing on : Tilt the platform towards the back of the

By pressing on : Jib lifting