Download PDF: Haulotte Forklift SIGMA 16 - SIGMA 46 Maintenance Manual

SIGMA 16 - SIGMA 46 - SIGMA 16 PRO - SIGMA 46 PRO

Maintenance Book

Maintenance Book

SIGMA 16 - SIGMA 46 SIGMA 16 PRO - SIGMA 46 PRO

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CONTENTS

A Responsibilities and commitments 1 - Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2 - Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.1 - Owner's responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.1.1 -

Product modification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.2 - Technician's responsability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 - HAULOTTE® commitments . . . . . . . . . . . . . . . 10 3.1 - HAULOTTE Services®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.2 - Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.3 - Product information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.3.1 -

Implementing manufacturer safety campaigns. . . . . . . . . . . . . . 11

4 - Conditions of warranty . . . . . . . . . . . . . . . . . . 11

B Safety

CONTENTS

1 - General safety rules . . . . . . . . . . . . . . . . . . . . . 13 1.1 - Uncontrolled movement Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.2 - Electric Shock Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1.3 - Explosion / Fire Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2 - Safety rules energy source motorization . . . . 16 2.1 - General safety and specific interventions on energy storage . . . . . . . 16

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C Familiarization 1 - HAULOTTE Activ'Screen 2 . . . . . . . . . . . . . . . 17 2 - List of actuators and sensors . . . . . . . . . . . . . 23 2.1 - Sensors and actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3 - Consumables (Oils...) . . . . . . . . . . . . . . . . . . . . 27 3.1 3.2 3.3 3.4 3.5 -

Hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Gear motor oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Cylinder storage oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4 - Movement speed . . . . . . . . . . . . . . . . . . . . . . . 31

D Inspection and maintenance schedule 1 - Inspection program . . . . . . . . . . . . . . . . . . . . . 33 2 - Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . 33 3 - Preventive maintenance . . . . . . . . . . . . . . . . . 34 4 - Periodic inspection . . . . . . . . . . . . . . . . . . . . . 38 5 - Major inspection . . . . . . . . . . . . . . . . . . . . . . . . 40

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Machine sheets MP0001 - Wheel tightening procedure . . . . . . . . . . . . . 41 MP0006 - Hydraulic oil filter replacement . . . . . . . . . . 43 MP0011 - Wear pad check . . . . . . . . . . . . . . . . . . . . . . . 47 MP0013 - Hydraulic tank level . . . . . . . . . . . . . . . . . . . . 49 MP0014 - Emptying the hydraulic tank. . . . . . . . . . . . . 53 MP0015 - Load cell tightness check . . . . . . . . . . . . . . . 57 MP0016 - Rotary cylinder tightness check. . . . . . . . . . 61 MP0019 - Torque tightening of the slew ring . . . . . . . . 65 MP0027 - Steering system greasing . . . . . . . . . . . . . . . 71 MP0028 - Greasing the pads . . . . . . . . . . . . . . . . . . . . . 75 MP0043 - Draining the wheel reducer. . . . . . . . . . . . . . 79 MP0044 - Greasing the turntable rotation gearbox . . . 85 MP0049 - Battery electrolyte level. . . . . . . . . . . . . . . . . 89 MP0051 - Rotary cylinder tightness check. . . . . . . . . . 93 MP0052 - Check the electric motor's carbon brushes 95 MS0285 - Maintenance implementation . . . . . . . . . . . . 99 MS0360 - Placing the machine in maintenance

configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

E

CONTENTS

Electric and hydraulic diagrams 1 - Electric diagram . . . . . . . . . . . . . . . . . . . . . . . 108 2 - Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . 118

F Records 1 - Intervention register . . . . . . . . . . . . . . . . . . . . 121

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Responsibilities and commitments 1-

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/modifications to the aerial work platform must be approved by HAULOTTE®.

This manual provides the owner, operator and field service technician all necessary and detailed informations on preventive maintenance to be carried out on their machine.

It is recommended that only trained personnel should perform these operations.

We would particularly like to draw your attention to : • Compliance with safety instruction (machine, use, environment).

• Use of the equipment within the performance limits.

This maintenance book is specific to the HAULOTTE® products listed on the cover page of this manual.

It is the on-site maintenance technician's duty to carry out the regular maintenance work recommended

by HAULOTTE®.

This maintenance work is essential for correct machine operation.

If regular maintenance is not carried out, this may : • Jeopardize operator safety.

• Reduce machine reliability and shorten its service life.

• Cause machine malfunction.

• Void the warranty.

In order to guarantee optimal maintenance, we recommend that you use HAULOTTE® expert technicians with genuine spare parts, documentation and the required tools.

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S y m b o l 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®) Recommended tools Number of persons required Safety Appropriate workwear Safety shoes Gloves Safety goggles Face shield

N.B. :

8

Additional technical information

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Responsibilities 2.1 -

OWNER'S RESPONSIBILITY 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 decals can be ordered from HAULOTTE Services® The owner (or hirer) is responsible for applying the local regulations regarding maintenance of the machine.

2.1.1 - Product modification Without the written permission from HAULOTTE®, modifying a HAULOTTE® product is a Safety concern.

Any modification may violate Haulotte design parameters, local regulations and industry standards.

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

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.

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HAULOTTE® commitments 3.1 -

HAULOTTE SERVICES® HAULOTTE Services® is at your service in all 5 continents of the world via an extensive network of its own trained technicians, who are ready to respond to your every need.

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 : • To ensure the preventive maintenance of your equipment and optimize your total cost of ownership (TCO).

• To repair your machine or to improve its performance and for all spare parts orders (Spare Parts Catalogue, www.easy-spare-parts.com), the only guarantee of perfect operation.

3.2 -

TRAINING Would you like to train your teams to operate and/or maintain your machine HAULOTTE®? Contact your subsidiary.

The HAULOTTE® training courses help your teams to improve their skills.

Our trainers are experts in pedagogy, at the cutting edge of HAULOTTE® products and the latest technological innovations.

3.3 -

PRODUCT INFORMATION In a constant concern to improve the reliability and safety of its machines, HAULOTTE® provides the following documents from the site www.e-technical-information.com : • 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.

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- Responsibilities and commitments 3.3.1 - Implementing manufacturer safety campaigns It is essential to implement the safety campaigns issued by the manufacturer. All of these campaigns are accessible on our website.

Connect to our website : www.haulotte.com

Never market (or sell) a machine without first having carried out all of the safety campaigns.

4-

Conditions of warranty Our warranty conditions and extension contracts are now available on the websites of our sales network : www.haulotte.com

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Notes

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- Safety

Safety 1-

General safety rules Before performing any maintenance interventions, place the machine in maintenance configuration : •

Section MS0285 - Turntable rotation locking

•

Section MS0360 - Placing the machine in maintenance configuration

1.1 -

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.

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ELECTRIC SHOCK HAZARDS The machine is not electrically insulated and does not provide protection from contact or proximity to electrically charged conductors.

Always position the lift at a safe distance from electrically charged conductors to ensure that no part of the machine is within an unsafe area.

Respect the local rules and the minimum safety distance from power lines.

M i n i m u m

s a f e

a p p r o a c h

Electric voltage

d i s t a n c e s

Minimum safety distance Mètre

0 - 300 V 300 V - 50 kV 50 - 200 kV 200 - 350 kV 350 - 500 kV 500 - 750 kV 750 - 1000 kV

Feet Avoid contact

3 5 6 8 11 14

10 15 20 25 35 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 weld on the machine without first disconnecting the battery terminals.

• Do not wash electrical components with a high pressure washer.

• 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.

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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 touch hot components.

• Do not work in an explosive or flammable atmosphere / environment.

• 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.

• Do not bridge the battery terminals with metallic objects.

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2-

Safety rules energy source motorization 2.1 -

GENERAL SAFETY AND SPECIFIC INTERVENTIONS ON ENERGY STORAGE MS0360 - Placing the machine in maintenance configuration.

If you need to perform an operation on LIVE circuits (for voltage and/or current measurement, for example) without locking out the machine, make sure that you have : • The level of competence required to perform an operation while this machine is LIVE and/or voltage and current values present on this machine.

• Appropriate electrical training and certification required by the legislation of the country in which the machine is being used.

• Authorisation.

Risk of electrification or electrocution : • Voltage > 60 volts or a capacity > 180 Ah in direct current.

• Voltage > 25 volts in alternating current.

Before any intervention on the electrical circuit, or for any work near a LIVE part, the machine bust be locked out by an authorised and properly trained person.

After it is locked out, and before any intervention on the electrical power circuit, wait 5 minutes for the voltage to drop to 0 Volt. Using a voltage absence tester, make sure that the voltage is definitely at 0 Volt.

• The use of this form implies that its user has been trained on this type of equipment.

• 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...

• 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.

• Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE® are described in this sheet.

Only an authorised and qualified technician is permitted to work on the machines HAULOTTE®.

• 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.

Reminder of voltages and currents present on the machine : • 12 volts VDC (DC version) • 48 volts VDC (DC version) • 110 volts VAC (AC Version) • 220 volts VAC (AC Version) • 400 volts VAC (AC Version) • Capacities > 180 Ah (For example, 6 Volts - 357 Ah semi-traction batteries in C5 or 435 Ah in C20)

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Familiarization 1-

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.

C o n t r o l s Icon

a n d

i n d i c a t o r s

Description

Function

Access code entered is incorrect

Access code NIV 1 (Will be visible - depending on the machine)

C o n t r o l s Icon

a n d

i n d i c a t o r s

Description

Function

The machine can be personalized with a user identification code. Personalization is only possible with NIV 1 : 1250 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 Operator PIN code entered is correct Operator PIN code entered is incorrect

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Description

Function

E-Stop at platform control box has been pushed in (de-energized). The machine will switch off after several seconds. In an emergency, use this mode.

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).

• The machine is NOT in overload state.

• Ground control box is NOT selected/energized.

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.

The maintenance tool icon turns RED when the next Maintenance use scheduled maintenance must be carried out in under 25 hours.

Analog Gauge - Battery charging indicator

Analog Gauge - Battery charging indicator (Machine is charging)

The battery discharge indicator turns from GREEN to RED when the battery status is less than 20%

: Charging : Battery charged The alarm icon blinks in case of : • Machine failure • Failure detected • Machine overloaded • Machine on excessive slope Another icon will be displayed to show the machine's status, the failure or the malfunction

Alarm

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Description

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Beacon

The icon is ON when the flashing light is switched on

Auto beacon

Flashing light control is in automatic mode.

Activ' Lighting System

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

Activ' Lighting System

The function is off. To switch it on, go to the 'Settings' menu

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i n d i c a t o r s Function

Platform control selected

Selector switch is in platform control box position

Ground control selected

Selector switch is in ground control box position

Tilt

The machine is elevated , and is on a slope greater than the permitted slope. Depending on the machine configuration, machine raise and extend functions may be slowed or prevented.

Overload

The platform is overloaded. Remove the excessive load to or below the rated capacity, to restore functions. In case of an emergency, to rescue the operator in platform, use the Overriding system.

F12.01 bus CAN fault

CAN network fault between the screen and the rest of the machine

Screen software obsolete

Screen software update essential Contact HAULOTTE Services®

Diagnostic in progress

The HaulotteDiag console is connected to the machine

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Description

Function

Activ' Shield Bar disable

The secondary safety system is 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 ( 21 ) to the ground control Activ' Shield Bar triggered

box

position to take 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.

C o n t r o l s Icon

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i n d i c a t o r s

Description

Function

Movement restricted due to critical The battery level is critical. Battery recharge is mandatory. battery level

Battery level low

Recharge batteries.

Battery charge complete

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a n d

Description

i n d i c a t o r s Function Low battery water level : • You must first fully recharge the batteries and then refill the batteries with demineralized water • When the water level is low, high risk of batteries damage

Low battery water level

Low Water level tank : • Refill the water battery tank with demineralized water

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Warning next recharge must be a full recharge by plugging the machine electrical socket to external source of power to prevent damage on the batteries

45 hours without full recharge

Machine elevation blocked. You must full recharge by plugging the machine electrical socket to external source of power. Risk of damage on the batteries.

Too hot to charge

The battery temperature is too high. Charging them now would cause damage.

Too cold to charge

The battery temperature is too low. Charging them now would cause damage.

High temperature

In order to protect your machine, it is currently on a derating mode.

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List of actuators and sensors 2.1 -

SENSORS AND ACTUATORS S e n s o r s

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Name EL905 EL906 EL907 HA901 HL901 HL910 A HL910 B HL911 HL912 A HL912 B HL912 C HL912 D HL913 KA2 KA3 KA8 KA9 KA911 KM803 SL901 SL911 SN900 SP800 SP801 SQ421 SQ520 SQ530 SQ800 SQ902 4001160870

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Function Light - Activ' Shield Bar system activated Activ' Lighting System - Counterweight light Activ' Lighting System Boom light Buzzer - Turret buzzer Light - Activ' Shield Bar detected Activ' Lighting System - Turret light Activ' Lighting System - Turret light Activ' Lighting System - Ground control box light Activ' Lighting System - Platform control box light Activ' Lighting System - Platform control box light Activ' Lighting System - Platform light Activ' Lighting System - Platform light Activ' Lighting System - Under basket light Power inverter relay Stand-by relay Flashing light relay Horn relay Relay - Centralized battery refilling Power contactor Battery level sensor Sensor - Low Water level tank Twilight sensor Sensor - Strain gauges Sensor - Strain gauges Detector - Arm down Detector - Boom down Detector - Telescope retracted Tilt sensor Detector - Activ' Shield Bar detector E 04.22

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Name SR150 SR720 SR721 ST302 ST303 ST305 SV300 YV150 L YV150 R YV250 L YV250 R YV420 D YV420 U YV421 D YV520 D YV520 U YV530 I YV530 O YV620 D YV620 U YV650 L YV650 R YV720 D YV720 U YV750 L YV750 R YV800 YV900 YV904 YV905

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Function Sensor - Steering angle Sensor - Tilt - 10° Sensor - Tilt + 10° Sensor - Drive motor temperature Sensor - Drive motor temperature Temperature sensor on pump Drive motor speed sensor Valve - Steering left side valve Valve - Steering right side valve Valve - Left turntable rotation Valve - Right turntable rotation Valve - Arm descent Valve - Arm raise Valve - Arm descent Valve - Boom descent Valve - Boom raise Valve - Telescope retracted Valve - Telescope extension Valve - Jib lowering Valve - Jib raising Valve - Jib rotation left side Valve - Jib rotation right side Valve - Basket compensation descent Valve - Basket compensation lift Valve - Basket rotation to the left Valve - Basket rotation to the right Valve - LS Valve Valve - Platform movements Valve - Split outflow Valve - Pump outflow

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Consumables (Oils...)

3.1 -

HYDRAULIC OIL Hydraulic oils must comply with the following requirements : • Oil filterability must be compatible with absolute filters 5 µ.

• COmpatibility with elastomers (polyurethane, NBR, VITON, etc.).

• Have properties such as : • Antifoam and deaeration • Anti-wear, anti-shear and antioxydant • Rust and corrosion inhibitors (copper)

Biodegradable oils may be used if they comply with the following requirements : • HEES type biodegradable oil only according to standards ISO 15380 and VDMA 24568 The recommended viscosity grades depending on the environmental conditions are as follows : N.B.-:-REFER TO

- CONSUMABLES

Viscosity grade

HV32

HV32 Arctic

Ambient temperature

Between - 15° C (- 9° F) and + 40° C (+ 104° F)

Between - 35° C (- 31° F) and + 35° C (+ 95° F)

Hydraulic oil temperature

Between - 15° C (- 9° F) and + 80° C (+ 176° F)

Between - 35° C (- 31° F) and + 80° C (+ 176° F)

Standards Viscosity at + 40° C (+ 104° F)

ISO 3104

32 +/- 3 cst

32 +/- 3 cst

Viscosity at + 100° C (+ 260° F)

ISO 3104

> 6 cst

> 8 cst

Viscosity Index

ISO 2909

> 150

> 250

Flashpoint

ISO 2592

> 205° C (> 401° F)

> 125° C (> 257° F)

Pour point

ISO 3016

< - 40 ° C (< - 40° F)

< - 50 ° C (< - 58° F)

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GEAR MOTOR OIL The recommended oil is EP type, the characteristics of which comply with standards MIL-L-2105 and API GL5.

N.B.-:-REFER TO

- CONSUMABLES

Mineral

Synthetic

Normal operating condition

SAE 80W/90

SAE 75W/90

Harsh operating condition

SAE 85W/140

SAE 80W/140 - SAE 75W/140

3.3 -

CYLINDER STORAGE OIL If a cylinder is not used, the surface of the cylinder rod may be exposed to a corrosive environment (Example : When new equipment is stored before shipping. ).

1 time per month, apply oil diluted in a solvent (Recommendations : UNIL OPAL PROTECT SHX 12).

Procedure : • Wash the machine completely to remove any trace of harsh environmental pollution. Clean the cylinder rods, which are sensitive to corrosion, using clean water.

• Perform a dynamic test. For each cylinder perform a movement from stop to stop ( 3 times each movement).

• Dry the cylinder rods.

• Grease the cylinder rods with protective oil (See recommendations) • Verify absence of any oil leaks.

N.B.-:-REFER TO

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- Familiarization 3.4 -

GREASE N.B.-:-REFER TO

- CONSUMABLES

Grease for telescope

Shell gadus S2 V220AC 2 grease

Polyplex Bardahl grease

Nature of the lubricating oil

Semisynthetic

Mineral oil

Semisynthetic

Appearance

Viscous grease

Semi-solid

Semi-solid

Thickening nature

Lithium

Lithium / Calcium

Complex lithium

Color

Ivory

Red

Blue

1

2

2

- 40 at 140

- 20 at 120

- 20 at 160

Units

Standards

Grade NLGI Operating temperature

°C

Viscosity of the basic oil at 40° C / 104° F

mm² / s

ISO 3104

25

220

140

Viscosity of the basic oil at 100°C / 212° F

mm² / s

ISO 3104

-

18

14,5

Penetration at 25° C / 77° F

0,1 mm

ISO 2137

310 - 340

277

265 - 295

Drop point

°C / °F

ISO 2176

> 180

175

> 250

> 315

-

> 315

0,91

0,9

0,9

Welding 4 ball test

kg

Density at 20° C / 68° F

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- Familiarization 3.5 -

CONSUMABLES

Consumable

HAULOTTE® code

Quantity

Hydraulic filter cartridge

4001135500

1

Driving reducer - Hydraulic oil :

4000530610

1 l(0.22 gal US) by reducer

1 l(0.22 gal US)

Driving reducer - Hydraulic oil :

2420801370

1 l(0.22 gal US) by reducer

20 l(5.3 gal US)

Driving reducer - Hydraulic oil :

2420801380

1 l(0.22 gal US) by reducer

209 l(55.2 gal US)

Hydraulic circuit - Hydraulic oil (HV32) :

4000596020

18 l(5 gal US)

209 l(55.2 gal US)

Hydraulic circuit - Hydraulic oil (HV32 Arctic) :

4000096350

18 l(5 gal US)

20 l(5,3 gal US)

Hydraulic circuit - Hydraulic oil (HV32 Arctic) :

2505002640

18 l(5 gal US)

209 l(55.2 gal US)

Telescopic boom grease

4000813570

1 kg / 2,20 lbs

Telescopic boom grease

4000813560

5 kg / 11,02 lbs

Extreme-pressure lithium grease GADUS

2326005400

0,4 l(0.1 gal US)

Extreme-pressure lithium grease BARDAHL

4000561720

0,4 l(0.1 gal US)

Demineralized Water

4000813550

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5 l(1.3 gal US)

Packaging

5 l(1.3 gal US)

USA / GB

SIGMA 16 - SIGMA 46 - SIGMA 16 PRO - SIGMA 46 PRO

C

- Familiarization

4-

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.

SIGMA 16 SIGMA 46

Micro drive speed Low drive speed High drive speed Maximum towing speed Time for telescopic boom extension Time for telescopic boom retraction Time for raising boom Time for descent boom Left / right turntable 180 ° rotation time Rotation time from left / right turntable stop point to stop point Jib rotation time from left/right stop point to stop point Time for arm lifting Time for descent arm Time for jib lifting Time for jib descent Time for raising compensation Time for lowering compensation Forward high-speed drive Reverse high-speed drive Forward micro-speed drive Reverse micro-speed drive Stop point to stop point steering

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SIGMA 16 PRO SIGMA 46 PRO

0,5 km/h (0.30 mph) 2,0 km/h (1.24 mph) 5 km/h (3.10 mph) 5 km/h (3.10 mph) 11 s - 15 s 11 s - 15 s 26 s - 30 s 26 s - 30 s 41 s - 49 s 19 s - 25 s N/A 18 s - 22 s 34 s - 38 s 30 s - 34 s 28 s - 32 s 28 s - 32 s 13 s - 17 s 13 s - 17 s 5 km/h (3.10 mph) 5 km/h (3.10 mph) 0,5 km/h (0.30 mph) 0,5 km/h (0.30 mph) 4s-6s

USA / GB

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C

- Familiarization

Notes

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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

Before each hire Owner Before each use or each Operator change of user At intervals Owner recommended

by HAULOTTE® Before sale

Owner

Annually ( 1 year) (*)

Owner

After 10 years then every 5 years

Owner

Stakeholder

Type

Documentation

On-site technician

Daily inspection

Operator's manual

Operator

Daily inspection

Operator's manual

Preventive maintenance

Maintenance Book

Periodic inspection

Maintenance Book

Periodic inspection

Maintenance Book

Major inspection

Maintenance Book

On-site technician, qualified HAULOTTE Services® technician On-site technician, qualified HAULOTTE Services® technician On-site technician, qualified HAULOTTE Services® technician Qualified technician HAULOTTE Services®

(*) Or according to local regulations.

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.

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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.

S y m b o l m e a n i n g s Oil change

To check by test

Tightening

Levelling

Visual inspection

Functional adjustments / Checks / Cleaning

L e v e l

1

Page or associated procedure

First 50H

-

F i r s t

5 0 H

Corrected

M a i n t e n a n c e

NOK

P r e v e n t i v e

OK

Systematic replacement

First 50H

Lubrication-Lubrication

Comments

Chassis assembly : Wheel, reducer, steering, wheel pivot

Page or associated procedure

1

-

E v e r y

Corrected

Every 2 weeks

L e v e l

NOK

M a i n t e n a n c e

OK

P r e v e n t i v e

MP0001

Every 2 weeks

Tighten the wheel nuts

2

w e e k s

Comments

Batteries Check the electrolyte level of the battery/batteries

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1

Page or associated procedure

-

E v e r y

6

Corrected

Every 6 months or 250H

L e v e l 2 5 0 H

NOK

M a i n t e n a n c e o r

OK

P r e v e n t i v e

Every 6 months or 250H

- Inspection and maintenance schedule m o n t h s

Comments

Chassis assembly : Wheel, reducer, steering, wheel pivot Tighten the wheel nuts

MP0001

Check the wheel reducer level

MP0002

Grease the bushings and pins Grease the steering system

MP0027

Check that the ground strap is present and in good condition

Slew ring Tighten the slew ring

MP0019

Grease the turntable slew ring

MP0044

Hydraulic : oils, filters and hoses Check the hydraulic oil level

MP0013

Arm, boom Grease the pads

MP0028

Jib Tighten the rotary cylinder

MP0016

Platform Tighten the mounting on the platform support, the platform floor and the platform access

Batteries Perform a long charge Check the tightening of the terminals (Batteries - Variator Electric motor)

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Page or associated procedure

2

-

E v e r y

1

Corrected

Every 1 year or 500H

L e v e l 5 0 0 H

OK

M a i n t e n a n c e

Every 1 year or 500H

P r e v e n t i v e

NOK

- Inspection and maintenance schedule y e a r

o r

Comments

Batteries Check the condition of the battery terminals, cables(Corrosion, not damaged)

Hydraulic : oils, filters and hoses Replace the hydraulic filter

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D

- Inspection and maintenance schedule E v e r y

Corrected

-

NOK

Page or associated procedure

Every 2 years or 1000H

2

OK

M a i n t e n a n c e L e v e l o r 1 0 0 0 H

Every 2 years or 1000H

P r e v e n t i v e

2

y e a r s

Comments

Chassis assembly : Wheel, reducer, steering, wheel pivot Check the bushings and pins - Replacement if necessary

MS0002

Drain the wheel reducer

MP0043

Slew ring Check the slew ring clearance

MP0018

Hydraulics : Oil, filters and pressure checks Drain the hydraulic oil

MP0014

Arm, boom Check the pads-Replacement if necessary

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MP0011

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- Inspection and maintenance schedule

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.

Corrected

NOK

OK

Page or associated procedure

Periodic

Periodic

Use the detailed program below.

Comments

Chassis assembly : Wheel, reducer, steering, wheel pivot Check state of tires/tyres and inflations

Batteries Check the condition of the battery

Turntable Test the operation of the turntable locking system

Hydraulic : oils, filters and hoses Check the hoses, blocks and pumps, fittings, cylinders and the tank for the absence of leaks, deformations and damage

Platform Test the closure and locking of access platform Check that the harness anchor points are not cracked or damaged

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Corrected

NOK

OK

Page or associated procedure

Periodic

Periodic

- Inspection and maintenance schedule

Comments

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 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 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

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- Inspection and maintenance schedule

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 sheets

N.B.-:-THE LIST OF MAINTENANCE SHEETS IS NOT EXHAUSTIVE. OTHER SHEETS MAY BE SENT UPON REQUEST. CONTACT HAULOTTE SERVICES®.

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Chassis

Wheel tightening procedure MP0001 Chassis Wheel tightening procedure

1-

Concerned machines • SIGMA 16 - SIGMA 46 - SIGMA 16 PRO - SIGMA 46 PRO

2-

Concerned area

3-

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.

• 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...

• 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.

• Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE® are described in this sheet.

4-

Risk prevention M e a n s

o f

p r o t e c t i o n

Appropriate workwear

t o b e u s e d t h e r a n g e

w h e n

i m p l e m e n t i n g

Gloves

Safety shoes

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Chassis

Wheel tightening procedure MP0001 5-

You will need • "DO NOT OPERATE" tag • Personal protective equipment • Standard tool kit • Torque wrench

• Place barriers around the perimeter of the work area

1 person

6-

Procedure • Position the machine on a flat and firm surface, clear of obstructions (beware of power lines).

• Put the machine in stowed position, boom and arm fully retracted and lowered. Jib is in transportation position and telescope is retracted.

• Mark out the work area (barriers, cones, marking tape).

• Restrict access to the area (restricted access sign).

• 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.

Wheel / Reduction gear : • Check the tightening torque of the 8 studs : 150 N.m (110 lbf.ft).

7-

Additional operations • Clean the work area.

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Hydraulic oil filter replacement MP0006 Chassis Hydraulic oil filter replacement

1-

Concerned machines • SIGMA 16 - SIGMA 46 - SIGMA 16 PRO - SIGMA 46 PRO

2-

Concerned area

3-

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.

• 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...

• 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.

• Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE® are described in this sheet.

• 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.

4-

Risk prevention M e a n s

o f

p r o t e c t i o n

Appropriate workwear

t o b e u s e d t h e r a n g e

w h e n

i m p l e m e n t i n g

Gloves

Safety shoes

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Chassis

Hydraulic oil filter replacement MP0006 5-

You will need • Filter replacement every year or every 1000 h • "DO NOT OPERATE" tag • Personal protective equipment • Wrench • Bolts • Collection tray 1 l(0.22 gal US)

• Place barriers around the perimeter of the work area

1 person

6-

Consumables H y d r a u l i c Reference

o i l Part number HAULOTTE®

Hydraulic filter cartridge

7-

4001135500

Procedure • Position the machine on a flat and firm surface, clear of obstructions (beware of power lines).

• Put the machine in stowed position, boom and arm fully retracted and lowered.

• Mark out the work area (barriers, cones, marking tape).

• Restrict access to the area (restricted access sign).

• 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.

• Turn the turret 90° to improve accessibility.

• Open the frame cover.

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Hydraulic oil filter replacement MP0006 • Unscrew the cap from the filter 1.

N.B.-:-TORQUE HUB : 50 N.M (36.8 FT.LBF).

• Screw the M6 screw into the threaded hole.

• Remove the filter cartridge and replace it with a new one.

• Close the cap 1.

• Wipe away any run-off and check that the system has no leaks.

N.B.-:-PERFORM THE OPERATION WHEN THE OIL IS AT AMBIENT TEMPERATURE.

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Hydraulic oil filter replacement MP0006

Notes

46

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Upper boom

Wear pad check MP0011 Upper boom Wear pad check

1-

Concerned machines • SIGMA 16 - SIGMA 46 - SIGMA 16 PRO - SIGMA 46 PRO

2-

Concerned area

3-

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.

• 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...

• 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.

• Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE® are described in this sheet.

4-

Risk prevention M e a n s

o f

p r o t e c t i o n

Appropriate workwear

t o b e u s e d t h e r a n g e

w h e n

i m p l e m e n t i n g

Gloves

Safety shoes

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Upper boom

Wear pad check MP0011 5-

You will need • "DO NOT OPERATE" tag • Personal protective equipment • Standard tool kit • Stepladder

• Place barriers around the perimeter of the work area

1 person

6-

Procedure • 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).

Front pads : • Carefully extend the tube.

• Check the wear on the 8 wear pads : • If the chamfers ( 1 ) are visible on the pads, the pad is compliant.

• If the chamfers are not visible on the pads, replace the pads (Service and Repair Manual).

Rear pads : • Check the wear on the 2 upper pads : • If the chamfers ( 1 ) are visible on the pads, the pad is compliant.

• If the chamfers are not visible on the pads, replace the pads (Service and Repair Manual).

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Chassis

Hydraulic tank level MP0013 Chassis Hydraulic tank level

1-

Concerned machines • SIGMA 16 - SIGMA 46 - SIGMA 16 PRO - SIGMA 46 PRO

2-

Concerned area

3-

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.

• 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...

• 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.

• Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE® are described in this sheet.

• 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.

4-

Risk prevention M e a n s

o f

p r o t e c t i o n

Appropriate workwear

t o b e u s e d t h e r a n g e

w h e n

i m p l e m e n t i n g

Gloves

Safety shoes

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Chassis

Hydraulic tank level MP0013 5-

You will need • "DO NOT OPERATE" tag • Personal protective equipment • Standard tool kit • Rags • Funnel

• Place barriers around the perimeter of the work area

1 person

6-

Consumables Consumable

HAULOTTE® code

Packaging

HV32 Hydraulic oil

4000596020

Barrel : 209 l(55.2 gal US)

HV32 Arctic Hydraulic oil

4000096350

20 l(5.3 gal US) bucket

HV32 Arctic Hydraulic oil

2505002640

Barrel : 209 l(55.2 gal US)

7-

Procedure • Position the machine on a flat and firm surface, clear of obstructions (beware of power lines).

• Put the machine in stowed position, boom and arm fully retracted and lowered. Jib is in transportation position and telescope is retracted.

• Mark out the work area (barriers, cones, marking tape).

• Restrict access to the area (restricted access sign).

• 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.

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Chassis

Hydraulic tank level MP0013 • Check the hydraulic oil level on the gauge placed on the side of the chassis.

• The oil level should be between the minimum ( B ) and maximum ( A ) levels.

• If the level is below the minimum level ( B ) : Refill the hydraulic oil reservoir ( tank).

8-

MP0014 - Emptying the hydraulic

Additional operations • Clean the work area.

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Chassis

Hydraulic tank level MP0013

Notes

52

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Chassis

Emptying the hydraulic tank MP0014 Chassis Emptying the hydraulic tank

1-

Concerned machines • SIGMA 16 - SIGMA 46 - SIGMA 16 PRO - SIGMA 46 PRO

2-

Concerned area

3-

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.

• 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...

• 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.

• Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE® are described in this sheet.

• 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.

4-

Risk prevention M e a n s

4001160870

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t o b e u s e d t h e r a n g e

w h e n

i m p l e m e n t i n g

Appropriate workwear

Gloves

Safety shoes

Safety goggles

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Chassis

Emptying the hydraulic tank MP0014 5-

You will need • "DO NOT OPERATE" tag • Personal protective equipment • Standard tool kit • Funnel • Hose • Oil collection pan • Rags

• Place barriers around the perimeter of the work area

1 person

6-

Consumables Consumable

HAULOTTE® code

Packaging

HV32 Hydraulic oil

4000596020

Barrel : 209 l(55.2 gal US)

HV32 Arctic Hydraulic oil

4000096350

20 l(5.3 gal US) bucket

HV32 Arctic Hydraulic oil

2505002640

Barrel : 209 l(55.2 gal US)

7-

Procedure • Position the machine on a flat and firm surface, clear of obstructions (beware of power lines).

• Put the machine in stowed position, boom and arm fully retracted and lowered.

• Mark out the work area (barriers, cones, marking tape).

• Restrict access to the area (restricted access sign).

• 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.

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Chassis

Emptying the hydraulic tank MP0014 • Turn the turret 90° to improve accessibility.

• Open the frame cover.

• Place a recipient under the hydraulic oil tank ( 1 ).

• Remove the drain plug under the tank and allow the oil to fully drain out.

N.B.-:-REMOVE THE FILLING CAP TO FACILITATE DRAINING (2).

• Tighten the drain plug .

• Refill the hydraulic oil reservoir 2.

N.B.-:-DO NOT FILL TO THE MAXIMUM LEVEL , AS THE OIL COULD LEAK OUT.

• Run several cycles with the machine and ensure that the oil is between the minimum and maximum level.

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Chassis

Emptying the hydraulic tank MP0014 8-

Additional operations • Clean any oil traces.

• Clean the work area.

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Platform

Load cell tightness check MP0015 Platform Load cell tightness check

1-

Concerned machines • SIGMA 16 - SIGMA 46 - SIGMA 16 PRO - SIGMA 46 PRO

2-

Concerned area

3-

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.

• 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...

• 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.

• Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE® are described in this sheet.

4-

Risk prevention M e a n s

o f

p r o t e c t i o n

Appropriate workwear

t o b e u s e d t h e r a n g e

w h e n

i m p l e m e n t i n g

Gloves

Safety shoes

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57

Platform

Load cell tightness check MP0015 5-

You will need • "DO NOT OPERATE" tag • Standard tool kit • Torque wrench

• Place barriers around the perimeter of the work area

1 person

6-

Procedure • Position the machine on a flat and firm surface, clear of obstructions (beware of power lines).

• Put the machine in stowed position, boom and arm fully retracted and lowered. Jib is in transportation position and telescope is retracted.

• Mark out the work area (barriers, cones, marking tape).

• Restrict access to the area (restricted access sign).

• 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.

Check the tightness of the platform-side load cell : • Check the tightening torque on the 4 screws : Torque wrench for 215 Nm (159 ft.lbs). 24 mm (0.94 in) pin with extension.

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Platform

Load cell tightness check MP0015 Check the tightness of the jib-side load cell : • Check the tightening torque on the 4 screws : Torque wrench for 215 Nm (159 ft.lbs). 24 mm (0.94 in) socket.

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Platform

Load cell tightness check MP0015

Notes

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Platform

Rotary cylinder tightness check MP0016 Platform Rotary cylinder tightness check

1-

Concerned machines • SIGMA 16 - SIGMA 46 - SIGMA 16 PRO - SIGMA 46 PRO

2-

Concerned area

3-

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.

• 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...

• 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.

• Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE® are described in this sheet.

4-

Risk prevention M e a n s

o f

p r o t e c t i o n

Appropriate workwear

t o b e u s e d t h e r a n g e

w h e n

i m p l e m e n t i n g

Gloves

Safety shoes

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61

Platform

Rotary cylinder tightness check MP0016 5-

You will need • "DO NOT OPERATE" tag • Standard tool kit • Torque wrench • Spanner 30 mm • Torque multiplier

• Place barriers around the perimeter of the work area

1 person

6-

Procedure • Position the machine on a flat and firm surface, clear of obstructions (beware of power lines).

• Put the machine in stowed position, boom and arm fully retracted and lowered. Jib is in transportation position and telescope is retracted.

• Mark out the work area (barriers, cones, marking tape).

• Restrict access to the area (restricted access sign).

• 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.

N.B.-:-USE A SPANNER AND A TORQUE SPANNER FOR TIGHTENING. • Place the 30 mm flat wrench on the central nut of the rotary cylinder 1.

• Place the torque wrench equipped with a 30 mm socket at the bottom of the central screw of the rotary cylinder 2.

• Check the torque of the rotatory cylinder central nut is at 550 Nm (405 ft.lbf).

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Platform

Rotary cylinder tightness check MP0016 • Visually inspect the 8 screws on the rotary cylinder.

N.B.-:-DO NOT TIGHTEN USING A TORQUE WRENCH AS THE SCREWS ARE TIGHTENED WITH THREADLOCKER.

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Platform

Rotary cylinder tightness check MP0016

Notes

64

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Turntable

Torque tightening of the slew ring MP0019 Turntable Torque tightening of the slew ring

1-

Concerned machines • SIGMA 16 - SIGMA 46 - SIGMA 16 PRO - SIGMA 46 PRO

2-

Concerned area

3-

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.

• 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...

• 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.

• Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE® are described in this sheet.

4-

Risk prevention M e a n s

4001160870

o f

p r o t e c t i o n

t o b e u s e d t h e r a n g e

w h e n

i m p l e m e n t i n g

Appropriate workwear

Gloves

Safety shoes

Face shield

E 04.22

USA / GB

65

Turntable

Torque tightening of the slew ring MP0019 5-

You will need • Voltage absence tester • "DO NOT OPERATE" tag • Handling equipment • Standard tool kit • Chocks (2,5 m(8 ft2 in)) • Torque wrench

• Place barriers around the perimeter of the work area

1 person

6-

Procedure • Position the machine on a flat and firm surface, clear of obstructions (beware of power lines).

• Put the machine in stowed position, boom and arm fully retracted and lowered. Jib is in transportation position and telescope is retracted.

• Mark out the work area (barriers, cones, marking tape).

• Restrict access to the area (restricted access sign).

• 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.

6.1 -

TIGHTENING THE CHASSIS / SLEW RING • Raise the boom to put the chock under the axis of the arm.

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Turntable

Torque tightening of the slew ring MP0019 • Place the chock under the axis of the arm.

• Lower the arm until it rests on the chock.

• Adjust the torque wrench at 215 N.m (159 ft.lbf).

• Tighten the nuts .

• The wrench must click when the torque is correct.

• Raise a little the boom.

• Remove the chock.

• Fold up fully the boom.

6.2 -

TIGHTENING THE TURNTABLE / SLEW RING • Press the emergency stop button on the turntable (button in position OFF).

The battery charger must be disconnected during the whole period of the recording.

• Turn off the circuit breaker.

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Turntable

Torque tightening of the slew ring MP0019 • Unlock the 2 latches on each side of the battery tray.

• Remove the cover.

• If equipped, disconnect the 2 quick plug from the centralized water filling system.

N.B.-:-WHEN DISCONNECTING THE CABLE FROM THE BATTERY, START WITH THE NEGATIVE TERMINAL, AND WHEN CONNECTING THEM, START WITH THE POSITIVE TERMINAL FIRST. • First disconnect the negative connection cable ( A ) with an insulating 14 mm wrench.

• Then disconnect the positive connection cable ( B ).

• Place insulation caps on the battery terminals.

• Push the cables in the chassis hole.

• Unlock the 2 latches on each side of the battery tray.

• Remove the cover.

• First disconnect the negative connection cable ( A ) with an insulating 14 mm wrench.

• Then disconnect the positive connection cable ( B ).

• Place insulation caps on the battery terminals.

• Push the cables in the chassis hole.

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Turntable

Torque tightening of the slew ring MP0019 • Place a handling device with a palet under the battery pack.

• Slighly, grow up the device until it support the battery pack.

• Unscrew the 4 screws without removing them.

• Lift the battery pack slightly with the handling equipment.

• Remove the battery pack.

• Adjust the torque wrench at 215 N.m (159 ft.lbf).

• Tighten the nuts .

• The wrench must click when the torque is correct.

• Approach battery pack.

• If needed, remove the lower screw on each side in order to aim at the threaded holes.

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Turntable

Torque tightening of the slew ring MP0019 • Lower the battery pack then remove the handling device.

• Tighten the battery pack at a torque of 190 N.m (140 ft.lbf).

• First connect the positive connection cable A with an insulating 14 mm wrench • Then connect the negative connection cable ( B ).

• Place insulation caps on the battery terminals.

• If equipped, connect the 2 quick plug ( C ) from the centralized water filling system.

• Place the cover in the correct position on the batteries.

• Lock the 2 latches on each side of the battery tray.

• Close the machine covers.

• First connect the positive connection cable ( A ) with an insulating 14 mm wrench.

• Then connect the negative connection cable ( B ).

• Place insulation caps on the battery terminals.

• Place the cover in the correct position on the batteries.

• Lock the 2 latches on each side of the battery tray.

• Close the machine covers.

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Chassis

Steering system greasing MP0027 Chassis Steering system greasing

1-

Concerned machines • SIGMA 16 - SIGMA 46 - SIGMA 16 PRO - SIGMA 46 PRO

2-

Concerned area

3-

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.

• 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...

• 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.

• Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE® are described in this sheet.

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Chassis

Steering system greasing MP0027 4-

Risk prevention M e a n s

5-

o f

p r o t e c t i o n

t o b e u s e d t h e r a n g e

w h e n

i m p l e m e n t i n g

Appropriate workwear

Gloves

Safety shoes

Safety goggles

You will need • Personal protective equipment • Standard tool kit • "DO NOT OPERATE" tag • Grease pump / Grease gun

• Place barriers around the perimeter of the work area

1 person

6-

Consumables Consumable

HAULOTTE® code

Packaging

Extreme-pressure lithium grease

2326005400

Cartridge : 0,4 l(0.1 gal US)

Extreme-pressure lithium grease

4000561720

Cartridge : 0,4 l(0.1 gal US)

7-

Procedure • Position the machine on a flat and firm surface, clear of obstructions (beware of power lines).

• Put the machine in stowed position, boom and arm fully retracted and lowered. Jib is in transportation position and telescope is retracted.

• Mark out the work area (barriers, cones, marking tape).

• Restrict access to the area (restricted access sign).

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Chassis

Steering system greasing MP0027 • 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.

Grease the wheel pivot : • Use extreme pressure grease.

• Grease the articulation between the wheel pivot and the chassis : • Remove the 2 caps.

• Grease the 2 points with the grease gun : Pump until a resistance is felt or greasing flowing out.

• Clean the 2 greasing points.

• Close the caps.

Grease the steering connecting rod : • Use extreme pressure grease.

• Grease the steering connecting rod : • Remove the cap.

• Grease the point with the grease gun. Pump until a resistance is felt or greasing flowing out.

• Clean the greasing point.

• Close the cap.

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Chassis

Steering system greasing MP0027

Notes

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Upper boom

Greasing the pads MP0028 Upper boom Greasing the pads

1-

Concerned machines • SIGMA 16 - SIGMA 46 - SIGMA 16 PRO - SIGMA 46 PRO

2-

Concerned area

3-

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.

• 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...

• 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.

• Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE® are described in this sheet.

4-

Risk prevention M e a n s

4001160870

o f

p r o t e c t i o n

t o b e u s e d t h e r a n g e

w h e n

i m p l e m e n t i n g

Appropriate workwear

Gloves

Safety shoes

Safety goggles

E 04.22

USA / GB

75

Upper boom

Greasing the pads MP0028 5-

You will need • "DO NOT OPERATE" tag • Personal protective equipment • Brush with long handle

• Place barriers around the perimeter of the work area

1 person

6-

Consumable Consumable

HAULOTTE® code

Packaging

Telescopic boom grease

4000813560

5 kg(11 lb) can

Telescopic boom grease

4000813570

1 kg(2.2 lb) can

7-

Procedure • Position the machine on a flat and firm surface, clear of obstructions (beware of power lines).

• Put the machine in stowed position, boom and arm fully retracted and lowered. Jib is in transportation position and telescope is retracted.

• Mark out the work area (barriers, cones, marking tape).

• Restrict access to the area (restricted access sign).

• 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.

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Upper boom

Greasing the pads MP0028 • Clean the boom : • Extend the boom fully.

• Clean the 4 sides of the boom with a clean cloth.

• Grease the boom : • Use telescopic boom grease.

• Grease the 4 sides of the boom with the brush.

• Retract / Extend the boom to spread the grease.

• Clean the excess on the pads.

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Upper boom

Greasing the pads MP0028

Notes

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Chassis

Draining the wheel reducer MP0043 Chassis Draining the wheel reducer

1-

Concerned machines • SIGMA 16 - SIGMA 46 - SIGMA 16 PRO - SIGMA 46 PRO

2-

Concerned area

3-

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.

• 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...

• 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.

• Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE® are described in this sheet.

4-

Risk prevention M e a n s

4001160870

o f

p r o t e c t i o n

t o b e u s e d t h e r a n g e

w h e n

i m p l e m e n t i n g

Appropriate workwear

Gloves

Safety shoes

Safety goggles

E 04.22

USA / GB

79

Chassis

Draining the wheel reducer MP0043 5-

You will need • Personal protective equipment • Standard tool kit • "DO NOT OPERATE" tag • Wooden wedge (10000 kg(22050 lb)) • Handling device (1000 kg(2205 lb)) • Lifting device (floor crane or similar) 10000 kg(22050 lb) capacity minimum • Funnel • Oil collection pan • Rags

• Place barriers around the perimeter of the work area

1 person

6-

Consumables Consumable

Driving reducer - Hydraulic oil Driving reducer - Hydraulic oil Driving reducer - Hydraulic oil

7-

HAULOTTE® code

Quantity

Packaging

4000530610 2420801370 2420801380

1 l(0.22 gal US) by reducer 1 l(0.22 gal US) by reducer 1 l(0.22 gal US) by reducer

Can : 1 l(0.22 gal US) Can : 20 l(5.3 gal US) Barrel : 209 l(55.2 gal US)

Procedure • Position the machine on a flat and firm surface, clear of obstructions (beware of power lines).

• Put the machine in stowed position, boom and arm fully retracted and lowered. Jib is in transportation position and telescope is retracted.

• Mark out the work area (barriers, cones, marking tape).

• Restrict access to the area (restricted access sign).

• 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.

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Chassis

Draining the wheel reducer MP0043 • Lift the machine up with a lifting device.

• Put the wooden wedges under the frame.

• Put the machine on wedges.

• Unscrew the wheel nuts.

• Place a handling device to support the wheel.

• Remove the last nut.

• Pull back the assembly wheel-forklift.

• Place a recovery tank under the wheel reducer.

• Open the filling ( 1 ) and draining ( 2 ) caps.

• Let the oil drain out.

• Close the draining cap ( 1 ).

• Clean any oil traces.

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Chassis

Draining the wheel reducer MP0043 • Open the levelling cap ( 3 ).

• With a funnel, fill 1 l (0.22 gal US) of preconized oil.

• The level is correct when oil flows by the levelling hole.

• Close the filling cap ( 2 ) and the levelling cap ( 3 ) • Clean the work area.

• Using a handling device place back the wheel.

• Manually screw wheel nuts.

• Using a torque wrench, tighten in a crosswise sequence the wheel nuts at the torque of 150 N.m (110 lbf.ft).

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Chassis

Draining the wheel reducer MP0043 • Lift the machine up with a lifting device.

• Remove the wooden wedges under the frame.

• Place the machine on the floor.

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Chassis

Draining the wheel reducer MP0043

Notes

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Turntable

Greasing the turntable rotation gearbox MP0044 Turntable Greasing the turntable rotation gearbox

1-

Concerned machines • SIGMA 16 - SIGMA 46 - SIGMA 16 PRO - SIGMA 46 PRO

2-

Concerned area

3-

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.

• 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...

• 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.

• Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE® are described in this sheet.

• Beware of the risk of burns; the hydraulic system operates at high temperatures.

4-

Risk prevention M e a n s

4001160870

o f

p r o t e c t i o n

t o b e u s e d t h e r a n g e

w h e n

i m p l e m e n t i n g

Appropriate workwear

Gloves

Safety shoes

Safety goggles

E 04.22

USA / GB

85

Turntable

Greasing the turntable rotation gearbox MP0044 5-

You will need • Personal protective equipment • Standard tool kit • "DO NOT OPERATE" tag • Grease pump • Brush

• Place barriers around the perimeter of the work area

1 person

6-

Consumables Consumable

HAULOTTE® code

Packaging

Extreme-pressure lithium grease

2326005400

Cartridge : 0,4 l(0.1 gal US)

Extreme-pressure lithium grease

4000561720

Cartridge : 0,4 l(0.1 gal US)

7-

Procedure • Position the machine on a flat and firm surface, clear of obstructions (beware of power lines).

• Put the machine in stowed position, boom and arm fully retracted and lowered. Jib is in transportation position and telescope is retracted.

• Mark out the work area (barriers, cones, marking tape).

• Restrict access to the area (restricted access sign).

• 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.

• Grease the rotation worn screw.

• Use extreme pressure grease.

• Grease the rotation worn screw : • Remove the 3 caps.

• Grease the points with the grease gun : Pump until a resistance is felt or greasing flowing out.

• Clean the 3 greasing points.

• Close the caps.

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Turntable

Greasing the turntable rotation gearbox MP0044 • Grease the rotation bearing : • Use extreme pressure grease.

• Grease the rotation bearing : • Raise the arm, secure by placing a chock under the axis of the lift cylinder.

• Inside the slew ring : • Remove the 2 caps.

• Grease the points with the grease gun : Pump until a resistance is felt or greasing flowing out.

• Clean the greasing point.

• Close the caps.

• Grease the slew ring theeth : • Use extreme pressure grease.

• Grease the theeth all around the slew ring with the brush.

In order to grease the slew ring well, pivot the turntable several times to access all of the teeth.

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Turntable

Greasing the turntable rotation gearbox MP0044

Notes

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Chassis

Battery electrolyte level MP0049 Chassis Battery electrolyte level

1-

Concerned machines • SIGMA 16 - SIGMA 46 - SIGMA 16 PRO - SIGMA 46 PRO

2-

Concerned area

3-

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.

• 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...

• 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.

• Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE® are described in this sheet.

• 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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Chassis

Battery electrolyte level MP0049 4-

Risk prevention M e a n s

5-

o f

p r o t e c t i o n

t o b e u s e d t h e r a n g e

w h e n

i m p l e m e n t i n g

Appropriate workwear

Gloves

Safety shoes

Face shield

You will need • "DO NOT OPERATE" tag • Personal protective equipment • Standard tool kit • Centralized circuit filling fit • Demineralized Water

• Place barriers around the perimeter of the work area

1 person

6-

Consumable Consumable

Option EASY : • Demineralized Water • Quick plug

Option AUTO : • Demineralized Water

7-

HAULOTTE® code

Packaging

4000813550 4000717150

5 l(1.3 gal US)

4000813550

5 l(1.3 gal US)

Procedure • Position the machine on a flat and firm surface, clear of obstructions (beware of power lines).

• Put the machine in stowed position, boom and arm fully retracted and lowered. Jib is in transportation position and telescope is retracted.

• Mark out the work area (barriers, cones, marking tape).

• Restrict access to the area (restricted access sign).

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Chassis

Battery electrolyte level MP0049 • 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.

• Place the machine in maintenance configuration. Refer to Placing the machine in maintenance configuration.

7.1 -

MS0360

PROCEDURE TO FILL THE BATTERIES MANUALLY (OPTION EASY) • Check the batteries are fully charged.

• Unlock the 2 latches on each side of the battery tray.

• Remove the cover.

• On each battery, remove the 3 caps and check demineralized water level.

N.B.-:-THE WATER LEVEL MUST BE ABOVE THE METAL ELEMENTS • Fill the batteries with distilled water.

• Proceed in the same way for the other compartment.

• Refit the cover.

• Lock the 2 latches on each side of the battery tray.

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Chassis

Battery electrolyte level MP0049 7.2 -

PROCEDURE TO FILL THE BATTERIES AUTOMATICALLY (OPTION AUTO) • Unlock the latche.

• Rotate the metal plate.

• Unscrew the water tank cap.

• Fill the tank with appropriate water.

• Screw the water tank cap.

• Rotate the metal plate.

• Lock the latche.

8-

Additional operations • Clean the work area.

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Jib

Rotary cylinder tightness check MP0051 Jib Rotary cylinder tightness check

1-

Concerned machines • SIGMA 16 - SIGMA 46 - SIGMA 16 PRO - SIGMA 46 PRO

2-

Concerned area

3-

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.

• 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...

• 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.

• Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE® are described in this sheet.

4-

Risk prevention M e a n s

o f

p r o t e c t i o n

Appropriate workwear

t o b e u s e d t h e r a n g e

w h e n

i m p l e m e n t i n g

Gloves

Safety shoes

4001160870

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93

Jib

Rotary cylinder tightness check MP0051 5-

You will need • "DO NOT OPERATE" tag • Standard tool kit • Torque wrench • Spanner 36 mm • Torque multiplier

• Place barriers around the perimeter of the work area

1 person

6-

Procedure • Position the machine on a flat and firm surface, clear of obstructions (beware of power lines).

• Put the machine in stowed position, boom and arm fully retracted and lowered. Jib is in transportation position and telescope is retracted.

• Mark out the work area (barriers, cones, marking tape).

• Restrict access to the area (restricted access sign).

• 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.

N.B.-:-USE A SPANNER AND A TORQUE SPANNER FOR TIGHTENING. • Place the 36 mm flat wrench on the central nut of the rotary cylinder 1.

• Place the torque wrench equipped with a 36 mm socket at the bottom of the central screw of the rotary cylinder 2.

• Check the torque of the rotatory cylinder central nut is at 800 Nm (590 ft.lbf).

• Visually inspect the 8 screws on the rotary cylinder.

N.B.-:-DO NOT TIGHTEN USING A TORQUE WRENCH AS THE SCREWS ARE TIGHTENED WITH THREADLOCKER.

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Check the electric motor's carbon brushes MP0052 Chassis Check the electric motor's carbon brushes

1-

Concerned machines • SIGMA 16 - SIGMA 46 - SIGMA 16 PRO - SIGMA 46 PRO

2-

Concerned area

3-

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.

• 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...

• 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.

• Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE® are described in this sheet.

4-

Risk prevention M e a n s

o f

p r o t e c t i o n

Appropriate workwear

t o b e u s e d t h e r a n g e

w h e n

i m p l e m e n t i n g

Gloves

Safety shoes

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Check the electric motor's carbon brushes MP0052 5-

You will need • "DO NOT OPERATE" tag • Standard tool kit

• Place barriers around the perimeter of the work area

1 person

6-

Procedure • Position the machine on a flat and firm surface, clear of obstructions (beware of power lines).

• Put the machine in stowed position, boom and arm fully retracted and lowered. Jib is in transportation position and telescope is retracted.

• Mark out the work area (barriers, cones, marking tape).

• Restrict access to the area (restricted access sign).

• 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).

• Stow the machine.

• Orientate the turntable to 90 °.

• 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.

• Place the machine in maintenance configuration. Refer to configuration.

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MS0360 Placing the machine in maintenance

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Chassis

Check the electric motor's carbon brushes MP0052 • Remove the cover.

• Pull back the spring.

N.B.-:-DON'T REMOVE THE SPRING FROM ITS HOOK.

• Remove the coal brush from its bracket.

• Check the length of the coal brush.

N.B.-:-REPLACE THE COAL BRUSH WHEN THE LENGTH IS LESS THAN 17 MM.

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Check the electric motor's carbon brushes MP0052 • Unscrew the bolt ( 1 ).

• Remove the coal brush.

• Clean the motor from carbon dust by using compressed air.

Re-installation : • Screw the bolt of the new coal brush.

• Place the coal brush in the bracket.

• Put back the spring on the coal brush.

• Refit the cover.

N.B.-:-PERFORM THIS OPERATION FOR EACH COAL BRUSH.

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Maintenance implementation MS0285 Turntable Maintenance implementation

1-

Placing in configuration 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.

Turntable rotation lock pin engaged

Placing 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.

Turntable rotation lock pin disengaged

Placing in operating configuration :

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Remove the turntable rotation locking pin.

6.

Pull the E-stop button.

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Maintenance implementation MS0285

Notes

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Placing the machine in maintenance configuration MS0360 Chassis Placing the machine in maintenance configuration

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.

• 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...

• 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.

• Only risks linked specifically to activities relating to the disassembly and assembly of the machine HAULOTTE® are described in this sheet.

• 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.

• 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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Placing the machine in maintenance configuration MS0360 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

t o b e u s e d t h e r a n g e

w h e n

i m p l e m e n t i n g

Appropriate workwear

Gloves

Safety shoes

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 • "DO NOT OPERATE" tag • Standard tool kit • 14 mm insulated open-end wrench (HAULOTTE® code : 4000710390) • Insulated torque wrench of 11,5 Nm (HAULOTTE® code : 4000710380) • Insulated pin of 14 mm (HAULOTTE® code : 4000710370)

• Place barriers around the perimeter of the work area

1 person

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Placing the machine in maintenance configuration MS0360 5-

Placing the machine in maintenance configuration • 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).

• Stow the machine.

• Restrict access to the area (restricted access sign).

• Switch off the ignition and remove the key ( 1 ) from the ignition.

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Placing the machine in maintenance configuration MS0360 • Place a do not operate tag at the start/stop switch location to inform personnel that the equipment is being worked on.

• Turn off the circuit breaker (Opened position).

• Open circuit: handle vertical.

• Closed circuit: handle horizontal.

• Unlock the 2 latches on each side of the battery tray.

• Remove the cover.

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Placing the machine in maintenance configuration MS0360 N.B.-:-WHEN DISCONNECTING THE CABLE FROM THE BATTERY, START WITH THE NEGATIVE TERMINAL, AND WHEN CONNECTING THEM, START WITH THE POSITIVE TERMINAL FIRST. For each battery compartment : • First disconnect the negative connection cable ( A ) with an insulating 14 mm wrench.

• Then disconnect the positive connection cable ( B ).

• Place insulation caps on the battery terminals.

• Push the cables in the chassis hole.

6-

Putting in use position • Carry out the operations in the reverse order.

• First connect the positive connection cable ( A ) with an insulating 14 mm wrench.

• Then connect the negative connection cable ( B ).

• Apply contact grease to the cable lugs before reconnecting them.

• Use the insulated torque wrench and apply a torque of 11,5 Nm to the battery nuts.

• Position the insulation caps correctly on the battery terminals.

• Activate the circuit breaker (Closed circuit: handle horizontal).

• Remove the "DO NOT USE" label from the ground control box.

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Placing the machine in maintenance configuration MS0360

Notes

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SIGMA 16 - SIGMA 46 - SIGMA 16 PRO - SIGMA 46 PRO

E

- Electric and hydraulic diagrams

Electric and hydraulic diagrams N.B.-:-T

O ENSURE THAT YOU ALWAYS HAVE THE LATEST VERSION OF OUR ELECTRICAL AND HYDRAULIC DIAGRAMS, PLEASE LOG ON TO OUR WEBSITE : HTTPS://WWW.E-TECHNICAL-INFORMATION.COM

h t t p s : / / w w w . e - t e c h n i c a l - i n f o r m a t i o n . c o m

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F

- Records

1 - Intervention register Records 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.

Date

4001160870

Type of intervention

E 04.22

Number of hours

Intervenor

HAULOTTE Services® intervention number

USA / GB

121

SIGMA 16 - SIGMA 46 - SIGMA 16 PRO - SIGMA 46 PRO

F

- Records

Date

122

Type of intervention

4001160870

Number of hours

E 04.22

Intervenor

HAULOTTE Services® intervention number

USA / GB