Haulotte HS15E - HS4390E Maintenance Manual - PDF DOWNLOAD

HS15E - HS4390E - HS15E PRO - HS4390E PRO HS18E - HS5390E - HS18E PRO - HS5390E PRO

Maintenance Manual

Maintenance Manual

HS15E - HS4390E HS15E PRO - HS4390E PRO HS18E - HS5390E HS18E PRO - HS5390E PRO USA

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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 the thermal engine . . . . 16 2.2 - General safety and specific interventions on energy storage . . . . . . . 17

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Maintenance Manual

C Familiarization 1 - HAULOTTE Activ'Screen 2 . . . . . . . . . . . . . . . . . 19 2 - List of actuators and sensors . . . . . . . . . . . . . . 28 2.1 - Sensors and actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3 - Consumables (Oils...) . . . . . . . . . . . . . . . . . . . . . 33 3.1 3.2 3.3 3.4 3.5 3.6 -

Engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Axle, Gearbox and reducer oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Cylinder storage oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4 - Movement speed . . . . . . . . . . . . . . . . . . . . . . . . . 37

D Inspection and maintenance schedule 1 - Inspection program . . . . . . . . . . . . . . . . . . . . . . . 39 2 - Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 39 3 - Preventive maintenance . . . . . . . . . . . . . . . . . . . 40 3.1 - Engine maintenance - Option Range Extender . . . . . . . . . . . . . . . . . . 43

4 - Periodic inspection . . . . . . . . . . . . . . . . . . . . . . . 45 5 - Major inspection . . . . . . . . . . . . . . . . . . . . . . . . . 47

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Maintenance Manual

Machine sheets MP0001 - Wheel tightening procedure . . . . . . . . . . . . . . . 49 MP0002 - Wheel reducer level procedure . . . . . . . . . . . . . 53 MP0006 - Hydraulic oil filter replacement . . . . . . . . . . . . . 57 MP0008 - Front axle locking function check. . . . . . . . . . . 61 MP0011 - Wear pad check . . . . . . . . . . . . . . . . . . . . . . . . . 65 MP0012 - Platform overload check . . . . . . . . . . . . . . . . . . 69 MP0013 - Hydraulic tank level . . . . . . . . . . . . . . . . . . . . . . 73 MP0014 - Emptying the hydraulic tank . . . . . . . . . . . . . . . 77 MP0017 - Checking the platform . . . . . . . . . . . . . . . . . . . . 83 MP0024 - Checking the bushings and pins . . . . . . . . . . . 87 MP0027 - Steering system greasing . . . . . . . . . . . . . . . . . 91 MP0043 - Draining the wheel reducer . . . . . . . . . . . . . . . . 95 MP0045 - Oil the stabiliser pads . . . . . . . . . . . . . . . . . . . 101 MP0046 - Grease axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 MP0048 - Draining the axles and transfer box . . . . . . . . 109 MP0049 - Centralized battery refilling . . . . . . . . . . . . . . . 115 MP0050 - Brake release check procedure. . . . . . . . . . . . 119 MP0053 - Check the operation of the safety valves . . . . 125 MS0163 - Lock-out procedure . . . . . . . . . . . . . . . . . . . . . 167

CONTENTS

MS0314 - Maintenance implementation . . . . . . . . . . . . . 175

Machine sheets Option Range Extender MP0003 - Procedure for checking the level of

engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 MP0004 - Replacing the engine oil filter / Drain the

engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 MP0005 - Diesel filter replacement . . . . . . . . . . . . . . . . . 189 MP0010 - Air filter replacement . . . . . . . . . . . . . . . . . . . . 195 MS0238 - Links to engine manufacturer manuals -

Fuel-powered machines . . . . . . . . . . . . . . . . . . . . . . . . . 199

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Maintenance Manual

E Electric and hydraulic diagrams 1 - Electric diagram. . . . . . . . . . . . . . . . . . . . . . . . . 202 2 - Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . 214

F Records 1 - Intervention register . . . . . . . . . . . . . . . . . . . . . 217

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- Responsibilities and commitments

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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- Responsibilities and commitments Symbol Symbol

Description Danger : Risk of injury or death Caution : Risk of material damage Prohibition relating to work safety and quality Reminder to use good practice or follow pre-operation checks Cross-reference to another part of the manual Cross-reference to another manual Cross-reference to repair (contact HAULOTTE Services®) Recommended tools Number of persons required Safety Appropriate workwear

Safety shoes

Gloves

Safety goggles

Face shield N.B. :

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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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- Responsibilities and commitments

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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 MS0163 - Lock-out procedure

•

Section MS0314 - Maintenance implementation

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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- Safety 1.2 -

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

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

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

Minimum safe approach distances

Electric voltage

Minimum safety distance Mètre

0 - 300 V

Feet Avoid contact

300 V - 50 kV

3

10

50 - 200 kV

5

15

200 - 350 kV

6

20

350 - 500 kV

8

25

500 - 750 kV

11

35

750 - 1000 kV

14

45

N.B.-:-THIS TABLE IS APPLICABLE, EXCEPT WHEN THE LOCAL REGULATIONS ARE MORE STRICT. Do not operate the machine : • Do not operate the machine when close to live power lines, consider the movement of the machine and the sway of the electric power lines particularly in windy conditions.

• Do not operate the machine during lightning, thunderstorms, snow/ ice or any weather condition that could compromise operator safety.

• Do not operate the machine during lightning or storms.

• Do not use the machine as a welding earth.

• Do not 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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- Safety 1.3 -

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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- Safety

2-

Safety rules energy source motorization 2.1 -

GENERAL SAFETY AND SPECIFIC INTERVENTIONS ON THE THERMAL ENGINE The technician should take all steps to protect themselves or others against all risks of injury inherent in his intervention.

The technician should ensure that suitable PPE (personal protective equipment) for the job is used, and check the particular conditions of environment in which the material can be found (see safety information specific to the operation site).

• Turn off the ignition, remove the key, open the battery switch before working on the engine.

• Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (-) battery terminal.

Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a do not operate tag at the start/stop switch location to inform personnel that the equipment is being worked on.

• The hot engine parts can cause injury and burns. Before performing maintenance on the engine, cool the engine and parts.

• By touching a functioning engine, there is a risk of burns from contact with hot parts, and injuries by the rotating parts.

• To avoid any risk of accident, using compressed air (example : blowing air filter), always wear a headband and goggles.

• The hot coolant, steam and alkalis can cause injury. At the operating temperature, the engine coolant is hot and under pressure. Do not open the cap of the expansion chamber before letting the circuit cool.

• The radiator and all the pipes going to the heaters or engine contain hot coolant or steam. Contact can cause severe burns.

The engine exhaust gases contain harmful combustion products. Always start and run the engine in a well ventilated area. In an enclosed area, evacuate the exhaust outside.

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GENERAL SAFETY AND SPECIFIC INTERVENTIONS ON ENERGY STORAGE

MS0163 - Lock-out procedure.

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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- Safety

Notes

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- Familiarization

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.

HAULOTTE Activ'Screen 2

HAULOTTE Activ'Screen 2 – If Range Extender option is connected

Machine switched on from the lower control console

Machine switched on from the upper control console

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- Familiarization Controls and indicators Icon

Description

Function

Access code entered is incorrect

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

Controls and indicators Icon

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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- Familiarization Controls and indicators Icon

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Description

Function

Single-phase

The single-phase charge socket is connected to an electricity network

Three-phase

The three-phase charge socket is connected to an electricity network

Range Extender connection

The Range Extender is connected to the machine

Engine preheating

Engine preheating in progress. Please wait a few seconds.

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Description

Function

Emergency mode not active

This is for emergency use. It is active only when the upper Emergency Stop or Load Sensing System is activated.

Emergency mode valid

Emergency Mode, use only to rescue trapped or incapacited operator. Press and hold this Emergency Button AND the movement button required.

Maintenance use

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

Battery charge status

Battery charge status gauge

Electric mode

Switched to Electric Mode and the machine will runs on batteries only. No emission

Auto mode

Switched to ECO Mode and the machine will automatically manage engine and electric inputs

Engine mode

Switched to Engine Mode, and the machine will runs with the engine and battery will keep chargin

High fuel level

Sufficient fuel level

Low fuel level

To avoid damaging the motor, please refuel the machine

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- Familiarization Icon

Description

Function Alarm icon is flashing slowly If there is either an active or detected machine failure, or if the machine is in an overload or tilt is active.

When the Alarm symbol is displayed, there will also be a symbol displayed to show either the type of machine state, or machine failure that corresponds.

Alarm

• Flashes when the machine starts at the same time as the

Overload indicator

icon

• Is blinking if overriding is active : • If there is a fault, an error code will be displayed on the Activ' Screen • Or Hydraulic oil temperature icon is active on the Activ' Screen • Or Engine pressure icon is active on the Activ' Screen • Or Engine stop icon is active on the Activ' Screen • Or Overload machine status is active on the Activ' Screen • Flashes when the machine starts at the same time as

the icon Engine warning indicator / Engine pre• Is blinking if overriding is active Warning icon is ON if : heating • Engine warning icon will be displayed on the Activ' Screen • Or Tilt machine status will be displayed on the Activ' Screen • Or Engine is pre-heating

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Description

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.

Machine is charging

The machine is recharged from the on-board generator.

Board

Completely recharge the machine at least once every 7 days with the mains charger in order to optimize battery life (charging must start when the charge level is below 90 % to be effective).

Diagnostic in progress

The HaulotteDiag console is connected to the machine

Screen software obsolete

Screen software update essential Contact HAULOTTE Services®

F12.01 bus CAN fault

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

Movement restricted due to critical battery level

The battery level is critical. Battery recharge is mandatory. To keep working, use the Engine mode or ECO mode to recharge the battery.

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Description

Function

Working light

The icon is ON when the work light is switched on

Activ' Lighting System

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

Activ' Lighting System

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

Controls and indicators Icon

Description

Activ' Shield Bar disable

Function

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 Activ' Shield Bar triggered

control box key selector ( 21 ) to the ground control 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 )

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Description

Function

Battery accelerated recharge

The machine recharges itself

Battery charge complete

Charge finished and complete

Battery level low

Use the engine mode or ECO mode to recharge the battery or connect the machine to a power outlet

Controls and indicators Icon

26

Description

Function

With "Battery saving" activation

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, so elevation will be blocked

Without "Battery saving" activation

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 water level tank

Low water level in the battery, yrefill the tank with demineralized water. Make a full recharge. If the level of water is not correct, high risk of batteries damage. Elevation will be blocked.

35 hours without full recharge

Warning next recharge must be a full recharge by plugging the machine electrical socket to external source of power. If not, risk of damage on the batteries and the machine will be blocked.

43 hours without full recharge

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

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

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- Familiarization Controls and indicators Icon

4001153170

Description

Function

Drive disabled by charger

To avoid damaging the charger, all drive fonctions are disabled

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.

Movement restricted due to critical battery level

The battery level is critical. Battery recharge is mandatory. To keep working, use the Engine mode or ECO mode to recharge the battery.

Range Extender disconnected

The Range Extender is connected. AUTO and FORCED mode are not available

Range Extender unavailable

AUTO and FORCED Mode are not available due to the Range Extender being disconnected

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2-

List of actuators and sensors 2.1 -

SENSORS AND ACTUATORS Sensors and actuators - 1

28

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- Familiarization Sensors and actuators - 2

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- Familiarization Sensors and actuators - 3

30

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- Familiarization

Name

Function

EL906

Activ' Lighting System - Chassis light - Front

EL907

Activ' Lighting System - Chassis light - Rear

EL908

Activ' Lighting System - Platform light

EL909

Activ' Lighting System - Platform light

HA901

Buzzer

HL910 A

Activ' Lighting System - Ladder light - Right-hand side

HL910 B

Activ' Lighting System - Ladder light - Left side

HL910 C

Activ' Lighting System - Platform light

HL910 D

Activ' Lighting System - Platform light

HL910 E

Activ' Lighting System - Platform light

HL910 F

Activ' Lighting System - Platform light

HL911

Activ' Lighting System - Ground control box light

HL912

Activ' Lighting System - Platform control box light

KA3

Stand-by relay

KA4

Range Extender starter

KA6

Wake up relay

KA8

Flashing light relay

KA9

Horn relay

KM803

Power contactor

SG701

Front left strain gauge

SG702

Rear left strain gauge

SG703

Rear right strain gauge

SG704

Front right strain gauge

SG705

Instrumented load sensor

SL901

Battery water level

SL911

Low water tank level

SN900

Twilight sensor

SP101

Pressure sensor

SP102

Pressure sensor

SP103

Pressure sensor

SP104

Pressure sensor

SP110

Brake release pressure sensor

SP111

Pressure sensor

SP114

Pressure sensor

SP802

Pressure sensor

SQ101

Retracted position detector

SQ102

Retracted position detector

SQ103

Retracted position detector

SQ104

Retracted position detector

SQ423

Arm down detector

SQ800

Tilt sensor

SQ902

Activ’ Shield Bar Scissors detector

SQ904

Docking sensor

SR130

Oscillating axle inclination angle sensor

SR420

Arm angle (batteries side)

SR421

Arm angle (lower controls side)

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- Familiarization Name

Function

ST304

Motor temperature sensor

ST305

Motor temperature sensor

ST900 (or ST903)

32

Hydraulic oil temperature - Extreme ambiance

SV304

Motor speed sensor

SV305

Motor speed sensor

YV100

Differential lock valve

YV101

Oscillating axle

YV102

Brake release valve

YV104

Oscillating axle

YV105

Brake release valve

YV116

Control electro valve

YV117

Control electro valve

YV118

Control electro valve

YV119

Control electro valve

YV123

Outrigger valve

YV123 I

Outriggers retraction valve

YV123 O

Outriggers extension valve

YV150 L

Steering left side valve

YV150 R

Steering right side valve

YV420 U

Arm raise valve

YV420 D

Arm descent valve

YV421 D

Arm descent valve

YV811

Control electro valve

YV814

Control electro valve

YV901

Pressure control valve

YV902

Flow control valve

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- Familiarization

3-

Consumables (Oils...)

3.1 -

ENGINE OIL The correct SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start-up, and the maximum ambient temperature during engine operation.

Refer to Table "Engine Oil Viscosity" (minimum temperature) in order to determine the required oil viscosity for starting a cold engine.

Refer to Table "Engine oil Viscosity" (maximum temperature) in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated.

Generally, use the highest viscosity oil that is available to meet the requirement for the temperature at start-up.

N.B.-:-REFER TO

- CONSUMABLES Engine oil viscosity

Ambient temperature

Viscosity index

Above 25 °C(77 °F)

SAE 30 SAE 10W30 SAE 15W40

From -10 °C(14 °F) to 25 °C(77 °F)

SAE 10W30 SAE 15W40

Below -10 °C(14 °F)

SAE 10W30

Classification API Fuel type

Engine oil classification API CJ-4 or CK-4 (If the engine oil is used with a high sulfur level, change the engine oil at shorter intervals, approximately half)

High sulfur fuel ≤ [0.05% (500 ppm)] Sulfur content < 0.50% (5000 ppm)

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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)

3.3 -

AXLE, GEARBOX AND REDUCER OIL The recommended oil for the transmission components must comply with the UTTO standard (Universal Tractor Transmission Oil) in order to correspond to the manufacturer's requirements.

N.B.-:-REFER TO

- CONSUMABLES Characteristics Units

Kinematic viscosity at 40°C

mm²/s (cSt)

84

Kinematic viscosity at 100°C

mm²/s (cSt)

10,5

Viscosity index

108

Pour point

°C

–27

Oil type : Elf SF3, Total Dynatrans FR, ATF DEXTRON 3.

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- Familiarization 3.4 -

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

3.5 -

- CONSUMABLES

GREASE N.B.-:-REFER TO

- CONSUMABLES Grease for telescope

Shell gadus S2 V220AC 2 grease

Polyplex Bardahl grease

Nature of the lubricating oil

Semi-synthetic

Mineral oil

Semi-synthetic

Appearance

Units

Standards

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

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 3.6 -

CONSUMABLES

Consumable

HAULOTTE® code

Quantity

Packaging

Hydraulic oil filter

2427002910

Hydraulic circuit - Hydraulic oil (HV32)

4000596020

78 l(20.6 gal US)

20 l(5.3 gal US)

Hydraulic circuit - Hydraulic oil (HV32)

2505002640

78 l(20.6 gal US)

209 l(55.2 gal US)

Hydraulic circuit - Hydraulic oil (Organic option) HS15E - HS4390E - HS15E PRO HS4390E PRO

4001095340

78 l(20.6 gal US)

209 l(55.2 gal US)

Hydraulic circuit - Hydraulic oil (Organic option) HS18E - HS5390E HS18E PRO - HS5390E PRO

4001095370

78 l(20.6 gal US)

209 l(55.2 gal US)

Oil for transfer box

4001118660

2 l(0.52 gal US)

5 l(1.3 gal US)

Axle differential housing oil

4001095970

5 l(1.3 gal US)

25 l(6.6 gal US)

Oil for wheel reducer

4001095970

0,9 l(0.23 gal US) by reducer

25 l(6.6 gal US)

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

5 l(1.3 gal US)

Option Range Extender Consumable

HAULOTTE® code

Quantity

Packaging

Air filter

4001105180

1

Oil filter

4001105190

1

Engine fuel filter

4001105210

1

Engine oil - 15W40

4000530600

6,7 l(1.77 gal US)

1.5 l(0.33 gal US)

Engine oil - 15W40

2420801360

6,7 l(1.77 gal US)

20 l(5.3 gal US)

Engine oil - 10W40

4000531300

6,7 l(1.77 gal US)

20 l(5.3 gal US)

Engine oil - Winter option - 5W40

4000010660

6,7 l(1.77 gal US)

60 l(15.85 gal US)

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- 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.

HS15E - HS4390E

HS15E PRO - HS4390E PRO

Micro drive speed

0,5 km/h (0.31 mph)

Low drive speed

1,7 km/h (1.06 mph)

Medium-speed driving

2,5 km/h (1.55 mph)

High drive speed

5 km/h (3.11 mph)

Time for lifting at maximum height

55 s - 65 s

Time for lowering to minimum height

45 s - 55 s

Steering

4s-5s

Stabiliser retraction

19 s - 22 s

Stabiliser extension

34 s - 38 s

HS18E - HS5390E

HS18E PRO - HS5390E PRO

Micro drive speed

0,5 km/h (0.31 mph)

Low drive speed

1,7 km/h (1.06 mph)

Medium-speed driving

2,5 km/h (1.55 mph)

High drive speed

5 km/h (3.11 mph)

Time for lifting at maximum height

65 s - 75 s

Time for lowering to minimum height

55 s - 65 s

Steering

4s-5s

Stabiliser retraction

19 s - 22 s

Stabiliser extension

34 s - 38 s

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Notes

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- Inspection and maintenance schedule

Inspection and maintenance schedule 1-

Inspection program The machine must be inspected at regular intervals in accordance with the requirements set out in the country of use and at least once a year. The purpose of the inspection is to detect any defect which could lead to an accident during routine use of the machine.

Inspections and maintenance must be carried out by a qualified company or person chosen by the owner of the machine.

The results of these visits must be recorded in a safety register created by the owner. This register as well as the list of competent repair persons must made available to the work inspector, government inspector and company safety committee at any time.

Frequency

Person-in-charge

Stakeholder

Type

Documentation

Before each hire

Owner

On-site technician

Daily inspection

Operator's manual

Before each use or each change of user

Operator

Operator

Daily inspection

Operator's manual

At intervals recommended

by HAULOTTE®

Owner

On-site technician, qualified HAULOTTE Services® technician

Preventive maintenance Maintenance Book

Before sale

Owner

On-site technician, qualified HAULOTTE Services® technician

Periodic inspection

Maintenance Book

Annually ( 1 year) (*)

Owner

On-site technician, qualified HAULOTTE Services® technician

Periodic inspection

Maintenance Book

After 10 years then every 5 years

Owner

Qualified technician HAULOTTE Services®

Major inspection

Maintenance Book

(*) 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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- Inspection and maintenance schedule

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.

Symbol meanings Oil change

To check by test

Tightening

Levelling

Visual inspection

Functional adjustments / Checks / Cleaning

Lubrication-Lubrication

Systematic replacement

NOK

Corrected

OK

Comments

Corrected

Page or associated procedure

First 50H

First 50H

Preventive Maintenance Level 1 - First 50H

Comments

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

MP0001

Hydraulic : oils, filters and hoses Replace the hydraulic filter

MP0006

Every 2 weeks

Page or associated procedure

Every 2 weeks

Preventive Maintenance Level 1 - Every 2 weeks

OK

NOK

Battery Check battery level

MP0049

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- Inspection and maintenance schedule

OK

NOK

Corrected

Page or associated procedure

Every 6 months or 250H

Every 6 months or 250H

Preventive Maintenance Level 1 - Every 6 months or 250H

Comments

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

MP0001

Grease the steering system

MP0027

Oil the stabiliser pads

MP0045

Grease the axles

MP0046

Check the operation of the safety valves : • oscillating axle safety valves (If equipped) • Outrigger safety valves • Scissor lift lowering safety valves (HS18E HS5390E - HS18E PRO - HS5390E PRO)

MP0053

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

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

MP0013

Lower arm Clean the pads slide

Platform Clean the platform extension

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- Inspection and maintenance schedule

OK

NOK

Corrected

Page or associated procedure

Comments

Corrected

Every 1 year or 500H

Every 1 year or 500H

Preventive Maintenance Level 2 - Every 1 year or 500H

Comments

Chassis assembly : Wheel, reducer, steering, wheel pivot Check the level of the axle, gearbox and wheel gears Drain the axle, transfer box and wheel reduction gears*

MP0002 MP0043/MP0048

Hydraulic : oils, filters and hoses Replace the hydraulic filter

MP0006

* Only the first year then every 2 years or 1000H.

Every 2 years or 1000H

Page or associated procedure

2 year(s) or 1000H

Preventive Maintenance Level 2 - Every 2 years or 1000H

OK

NOK

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

MP0024

Check the stabiliser pads - Replacement if necessary

MP0011

Drain the axle, transfer box and wheel reduction gears

MP0043/MP0048

Lower arm Check the pads - Replacement if necessary

MP0011

Hydraulic : oils, filters and hoses Drain the hydraulic oil

MP0014

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- Inspection and maintenance schedule 3.1 -

ENGINE MAINTENANCE - OPTION RANGE EXTENDER The information contained in our manual is to be complemented by the information found in the engine manufacturer's maintenance manual, which can be found on the link in the associated maintenance sheet MS0238.

NOK

Corrected

OK

Comments

Corrected

Page or associated procedure

First 50H

First 50H

Preventive Maintenance Level 1 - First 50H

Comments

Range Extender Engine Replace the oil filter

MP0004

Drain the engine oil

MP0004

Page or associated procedure

Every 200H

Every 200H

Preventive Maintenance Level 1 - Every 200H

OK

NOK

Range Extender Engine Clean the oil filter Clean the air filter Drain the engine oil

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- Inspection and maintenance schedule

Page or associated procedure

OK

NOK

Corrected

Every 400H

Every 400H

Preventive Maintenance Level 1 - Every 400H

Comments

Range Extender Engine Replace the fuel filter

MP0005

Check the fuel hoses - Replace if necessary Replace the engine oil filter

MP0004

Replace the air filter

MP0010

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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.

OK

NOK

Corrected

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

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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Page or associated procedure

OK

NOK

Corrected

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

MP0008

Test the operation of the Activ’ Shield Bar Scissors (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 Test the overriding system

46

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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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- Inspection and maintenance schedule

Notes

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Chassis

Wheel tightening procedure

MP0001 Chassis Wheel tightening procedure

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E 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

Wheel tightening procedure

MP0001 4-

Risk prevention Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

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

50

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Chassis

Wheel tightening procedure

MP0001 6-

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

• Put the machine in stowed position.

• 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 : 320 N.m (236 lbf.ft).

7-

Additional operations • Clean the work area.

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Chassis

Wheel tightening procedure

MP0001

Notes

52

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Chassis

Wheel reducer level procedure

MP0002 Chassis Wheel reducer level procedure

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E 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

Wheel reducer level procedure

MP0002 4-

Risk prevention Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

5-

You will need • "DO NOT OPERATE" tag • Personal protective equipment • Standard tool kit • 1 syringe for oil filling • Rags

• Place barriers around the perimeter of the work area

1 person

6-

Consumables Consumable

Oil for wheel reducer

54

4001153170

HAULOTTE® code

Quantity

Packaging

4001095970

0,9 l(0.23 gal US) by reducer

Can : 25 l(6.6 gal US)

E 10.22

USA / GB

Chassis

Wheel reducer level procedure

MP0002 7-

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

• Put the machine in stowed position.

• 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.

• Lift the machine using the stabiliser cylinders.

• To release the brakes - Refer to procedure.

MP0050 - Brake release check

• Turn the wheel while moving forward slowly to fit the filler cap ( 1 ) horizontally.

• Open the cap (1).

• It is level when the oil overflows from the hole ( 1 ).

• If not, add oil via the cap ( 1 ) using the syringe until oil flows through the hole ( 1 ).

• Close the caps and wipe up any oil that has spilled on the floor.

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Chassis

Wheel reducer level procedure

MP0002 • Locate the brake release valve YV150 at the back of the machine.

• To enable the brake, turn the valve YV105 counter clockwise.

• Raise the stabilisers.

8-

Additional operations • Clean any oil traces.

• Clean the work area.

56

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Chassis

Hydraulic oil filter replacement

MP0006 Chassis Hydraulic oil filter replacement

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E 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.

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Chassis

Hydraulic oil filter replacement

MP0006 4-

Risk prevention Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

5-

You will need • Filter replacement every year or every 1000 h • Hydraulic filter cartridge - 2427002910 • "DO NOT OPERATE" tag • Personal protective equipment • Wrench • Collection tray 1 l(0.22 gal US)

• Place barriers around the perimeter of the work area

1 person

58

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Chassis

Hydraulic oil filter replacement

MP0006 6-

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

• Put the machine in stowed position.

• 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.

• Open the hydraulic compartment door.

• Place a container under the filter.

• Loosen the oil filter support with the wrench.

• Unscrew the support by hand.

• Set aside the support.

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Chassis

Hydraulic oil filter replacement

MP0006 • Remove the filter and discard.

• Change the hydraulic oil filter.

• Mount the support and screw by hand at first.

• Tighten the support with the wrench.

• Wipe out the possible oil on the support.

60

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Chassis

Front axle locking function check

MP0008 Chassis Front axle locking function check

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E 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

Front axle locking function check

MP0008 4-

Risk prevention Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

5-

You will need • Personal protective equipment

• 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.

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

• Lift the machine using the stabiliser cylinders.

• Check the 2 wheels are not on the ground.

• The oscillating axle are automatically locked.

62

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Chassis

Front axle locking function check

MP0008 • Keep lowering the front outriggers only.

• Place a piece of wood of 10 cm (3.9 in) high.

• Raise completely the ( 4 ) outriggers.

• Once all outriggers are raised, do a translation.

• Check the rear wheel drop to the ground.

• The oscillating axle unlocks automatically when a translation is performed.

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Chassis

Front axle locking function check

MP0008

Notes

64

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Platform / Chassis

Wear pad check

MP0011 Platform / Chassis Wear pad check

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E 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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Platform / Chassis

Wear pad check

MP0011 4-

Risk prevention Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

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

66

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Platform / Chassis

Wear pad check

MP0011 6-

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

• Put the machine in stowed position.

• 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.

Pads on platform side : • Check the wear on the 2 pads between the arms and the platform ( 1 ).

• If the chamfers are visible on the pads, the pad is compliant.

• If the chamfers are not visible on the pads, replace the pads.

• Check that the pad slides are clean and in good condition : • Clean where applicable.

Pads on chassis side : • Check the wear on the 2 pads between the arms and the chassis ( 2 ).

• If the chamfers ( 3 ) are visible on the pads, the pad is compliant.

• If the chamfers are not visible on the pads, replace the pads.

• Check that the pad slides are clean and in good condition : • Clean where applicable.

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Platform / Chassis

Wear pad check

MP0011 Pads on platform side : • Check the weighing gauge pads ( 4 ) located under the platform.

• There are 2 gauges in the front and 2 gauges in the back of the machine (each gauge has 2 pads).

• Check the wear on the 8 wear pads.

• If the chamfers are visible on the pads, the pad is compliant.

• If the chamfers are not visible on the pads, replace the pads.

• Check that the pad slides are clean and in good condition : • Clean where applicable.

68

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Platform

Platform overload check

MP0012 Platform Platform overload check

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E 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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Platform

Platform overload check

MP0012 4-

Risk prevention Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

5-

You will need • Personal protective equipment • "DO NOT OPERATE" tag • Standard tool kit • Lifting equipment adapted and suitable for placing and removing the load from the platform • 750 kg (1653.47 lbs) load

• Place barriers around the perimeter of the work area

1 person

70

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Platform

Platform overload check

MP0012 6-

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

• Put the machine in stowed position.

• 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.

• Push the machine to the location beneath where aerial working is required.

• Start the machine.

• Use an external weight lifting device to place 100% of the nominal weight 750 kg (1653.47 lbs) in the center of the platform.

• From the ground control box : • Lift the platform.

• Check that there is no overload alarm

• Remove the weight from the platform.

• Use an external weight lifting device to place 105% of the nominal weight 787.5 kg (1736.14 lbs) in the center of the platform.

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Platform

Platform overload check

MP0012 • Check the overload / fault indicator light is ON.

• Check the overload alarm is displayed on the Activ' Screen.

• Remove all load from the platform.

72

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Chassis

Hydraulic tank level

MP0013 Chassis Hydraulic tank level

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E 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.

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Chassis

Hydraulic tank level

MP0013 4-

Risk prevention Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

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

Hydraulic oil (HV32)

74

4001153170

HAULOTTE® code

Quantity

Packaging

4000596020

78 l(20.6 gal US)

20 l(5.3 gal US) bucket

E 10.22

USA / GB

Chassis

Hydraulic tank level

MP0013 7-

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

• Put the machine in stowed position.

• 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 filling level of the hydraulic tank.

• The oil level should be between the minimum and maximum levels.

• If not the case, use the following refill procedure.

• Unscrew both screws ( 1 ) and remove the top cover plate 2.

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Chassis

Hydraulic tank level

MP0013 • Open the hydraulic tank cap to refill the oil level.

• Use a funnel and refill the tank with HV32 hydraulic oil to the right level.

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

• Refit and tighten the tank cap .

• Replace the top cover plate ( 2 ) and tighten both screws ( 1 ).

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

8-

Additional operations • Clean the work area.

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Chassis

Emptying the hydraulic tank

MP0014 Chassis Emptying the hydraulic tank

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E 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.

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77

Chassis

Emptying the hydraulic tank

MP0014 4-

Risk prevention Means of protection to be used when implementing the range

5-

Appropriate workwear

Gloves

Safety shoes

Safety goggles

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

Hydraulic oil (HV32)

78

4001153170

HAULOTTE® code

Quantity

Packaging

4000596020

78 l(20.6 gal US)

20 l(5.3 gal US)

E 10.22

USA / GB

Chassis

Emptying the hydraulic tank

MP0014 7-

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

• Put the machine in stowed position.

• 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.

• Unscrew both screws ( 1 ) and remove the top cover plate ( 2 ).

• Locate the drain hose beneath the hydraulic tank.

• Unscrew the bolt ( 3 ) slightly.

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Chassis

Emptying the hydraulic tank

MP0014 • Place the oil recovery device under the drain hose.

• Remove the bolt ( 3 ) completely to let the hydraulic oil flow.

• Check the hydraulic oil level going down on the level indicator.

• Allow the oil to run out.

• Refit and tighten the drain hose bolt ( 3 ).

• Remove the oil recovery device.

• Clean the drain hose.

• Fill the tank with new oil.

• Open the hydraulic tank cap to refill the oil level.

80

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Chassis

Emptying the hydraulic tank

MP0014 • Use a funnel and refill the tank with HV32 hydraulic oil to the right level.

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

• Check the hydraulic oil level going up and reach more than half of the level indicator.

• Refit and tighten the tank cap .

• Replace the top cover plate ( 2 ) and tighten both screws ( 1 ).

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

8-

Additional operations • Clean any oil traces.

• Clean the work area.

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Chassis

Emptying the hydraulic tank

MP0014

Notes

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Platform

Checking the platform

MP0017 Platform Checking the platform

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E 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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Platform

Checking the platform

MP0017 4-

Risk prevention Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

5-

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

• Place barriers around the perimeter of the work area

1 person

84

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Platform

Checking the platform

MP0017 6-

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

• Put the machine in stowed position.

• 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 pins are tightened on both sides of the platform.

• Check that the sliding rail is in good condition and working properly.

• Check the bolts on both sides are tightened.

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Platform

Checking the platform

MP0017

Notes

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Scissors

Checking the bushings and pins

MP0024 Scissors Checking the bushings and pins

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E 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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Scissors

Checking the bushings and pins

MP0024 4-

Risk prevention Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

5-

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

• Place barriers around the perimeter of the work area

1 person

88

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Scissors

Checking the bushings and pins

MP0024 6-

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

• Put the machine in stowed position.

• 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 condition of the pins.

• Check the absence of radial gap > 0,5 mm (19690 µ in) on the pins.

• Check the absence of shaving in periphery of the pins.

Criteria of replacement : Replace as soon as the anomaly indicated above appears.

• Check the bolts are all tightened.

• Raise the platform to reveal all the middle pins.

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Scissors

Checking the bushings and pins

MP0024 • Check all pins are tightened on both sides of the arm.

• Check the pins inside the arm are all tightened.

90

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Chassis

Steering system greasing

MP0027 Chassis Steering system greasing

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E 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 Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

5-

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)

92

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Chassis

Steering system greasing

MP0027 7-

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

• Put the machine in stowed position.

• 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.

• Place the machine in maintenance configuration.

• Lift the machine using the stabiliser cylinders.

On each of the steering wheels : • Grease the articulation between the wheel pivot and the chassis.

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Chassis

Steering system greasing

MP0027 • Grease the wheel pivot - Top view : • 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.

Grease the wheel pivot - Bottom view : • 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

Draining the wheel reducer

MP0043 Chassis Draining the wheel reducer

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E 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.

4001153170

E 10.22

USA / GB

95

Chassis

Draining the wheel reducer

MP0043 4-

Risk prevention Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

5-

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

• Place barriers around the perimeter of the work area

1 person

6-

Consumables Consumable

Oil for wheel reducer

96

4001153170

HAULOTTE® code

Quantity

Packaging

4001095970

0,9 l(0.23 gal US) by reducer

Can : 25 l(6.6 gal US)

E 10.22

USA / GB

Chassis

Draining the wheel reducer

MP0043 7-

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

• Put the machine in stowed position.

• 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.

• Lift the machine using the stabiliser cylinders.

• To release the brakes - Refer to procedure.

MP0050 - Brake release check

• Turn the wheel manually to position the drain plug at the bottom of the verticle axis ( 1 ).

• Position the oil collection tray under the plug ( 1 ).

• Loosen the filling cap ( 1 ).

• Allow the oil to run out ; To make the flow easier, the oil should still be hot.

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Chassis

Draining the wheel reducer

MP0043 • Turn the wheel while moving forward slowly to fit the filler cap ( 1 ) horizontally.

• Add the oil via the hole ( 1 ) using a funnel with a hose until the oil flows from the hole.

• Quantity: 0,9 l (0.23 gal US).

• Close the caps and wipe up any oil that has spilled on the floor.

• Locate the brake release valve YV150 at the back of the machine.

• To enable the brake, turn the valve YV105 counter clockwise.

• Raise the stabilisers.

98

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Chassis

Draining the wheel reducer

MP0043 8-

Additional operations • Clean any oil traces.

• Clean the work area.

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USA / GB

99

Chassis

Draining the wheel reducer

MP0043

Notes

100

4001153170

E 10.22

USA / GB

Stabilisers

Oil the stabiliser pads

MP0045 Stabilisers Oil the stabiliser pads

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E 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.

4001153170

E 10.22

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101

Stabilisers

Oil the stabiliser pads

MP0045 4-

Risk prevention Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

5-

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)

102

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Stabilisers

Oil the stabiliser pads

MP0045 7-

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

• Put the machine in stowed position.

• 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.

• Place the machine in maintenance configuration.

• Lift the machine using the stabiliser cylinders.

On each of the 4 pads : • 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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103

Stabilisers

Oil the stabiliser pads

MP0045

Notes

104

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Chassis

Grease axle

MP0046 Chassis Grease axle

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E 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.

4001153170

E 10.22

USA / GB

105

Chassis

Grease axle

MP0046 4-

Risk prevention Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

5-

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)

106

4001153170

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Chassis

Grease axle

MP0046 7-

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

• Put the machine in stowed position.

• 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.

• Place the machine in maintenance configuration.

• Lift the machine using the stabiliser cylinders.

Grease the 2 axles (rear and front) : • 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

Grease axle

MP0046 Grease the transmission rod : • Grease the point with the grease gun. Pump until a resistance is felt or greasing flowing out.

• Clean the greasing point.

108

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Chassis

Draining the axles and transfer box

MP0048 Chassis Draining the axles and transfer box

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E 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.

4001153170

E 10.22

USA / GB

109

Chassis

Draining the axles and transfer box

MP0048 4-

Risk prevention Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

5-

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

• Place barriers around the perimeter of the work area

1 person

6-

Consumable Consumable

HAULOTTE® code

Quantity

Packaging

Oil for transfer box

4001118660

2 l(0.52 gal US)

Can : 5 l(1.3 gal US)

Axle differential housing oil

4001095970

5 l(1.3 gal US)

Can : 25 l(6.6 gal US)

Transfer box

• Marking ( 1 ) : Oil filler cap / Oil level check.

• Marking ( 2 ) : Oil drain plug.

110

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Chassis

Draining the axles and transfer box

MP0048 7-

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

• Put the machine in stowed position.

• 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.

• Lift the machine using the stabiliser cylinders.

Draining the axles : • Position the oil collection tray under the plug .

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Chassis

Draining the axles and transfer box

MP0048 • Remove the filling cap ( 1 ).

• Loosen the drain plug ( 2 ).

• Allow the oil to run out ; To make the flow easier, the oil should still be hot.

• Refit and tighten the drain out ( 2 ).

• Remove the oil recovery device.

• Add the oil via the hole ( 1 ) using a funnel with a hose until the oil flows from the hole.

112

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Chassis

Draining the axles and transfer box

MP0048 • Refit and tighten the drain out ( 1 ).

8-

Additional operations • Clean any oil traces.

• Clean the work area.

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113

Chassis

Draining the axles and transfer box

MP0048

Notes

114

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Chassis

Centralized battery refilling

MP0049 Chassis Centralized battery refilling

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E 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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115

Chassis

Centralized battery refilling

MP0049 4-

Risk prevention Means of protection to be used when implementing the range

5-

Appropriate workwear

Gloves

Safety shoes

Safety goggles

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

• Place barriers around the perimeter of the work area

1 person

6-

Consumable Consumable

HAULOTTE® code

Packaging

Option EASY : • Demineralized Water • Quick plug

4000717150

5 l(1.3 gal US)

Option AUTO : • Demineralized Water

4000813550

5 l(1.3 gal US)

116

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Chassis

Centralized battery refilling

MP0049 7-

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

• Put the machine in stowed position.

• 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.

7.1 -

PROCEDURE TO FILL THE BATTERIES MANUALLY (OPTION EASY) • Unplug the charging device.

• Check the batteries are fully charged.

• Plug the quick plug and start pumping until batteries are fully filled.

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Chassis

Centralized battery refilling

MP0049 7.2 -

PROCEDURE TO FILL THE BATTERIES AUTOMATICALLY (OPTION AUTO) • Unplug the charging device.

• Check the batteries are fully charged.

• Fill the can with demineralized water.

8-

Additional operations • Clean the work area.

118

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Chassis

Brake release check procedure

MP0050 Chassis Brake release check procedure

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E 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.

4001153170

E 10.22

USA / GB

119

Chassis

Brake release check procedure

MP0050 4-

Risk prevention Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

5-

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

• Place barriers around the perimeter of the work area

1 person

120

4001153170

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USA / GB

Chassis

Brake release check procedure

MP0050 6-

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

• Put the machine in stowed position.

• 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.

• Lower the 2 rear outriggers to raise the back of the machine so both wheels are not on the ground.

• Locate the brake release valve YV105 at the back of the machine.

• Slightly loosen the screw and turn the cover.

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121

Chassis

Brake release check procedure

MP0050 • Push and turn clockwise to disengage the break release valve.

Hydraulic block : • Insert the lever ( 1 ) in the return bend of the pump ( 2 ).

• Actuate lever ( 1 ) sideways until a constant resistance force is felt (10 to 20 actions on the lever ( 1 ) are usually required).

• Check the machine brakes are released.

• Push and turn counterclockwise the YV105 valve to engage the breaks.

122

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Chassis

Brake release check procedure

MP0050 • Close the cover and tighten the screw.

• Raise the stabilisers.

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USA / GB

123

Chassis

Brake release check procedure

MP0050

Notes

124

4001153170

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USA / GB

Chassis

Check the operation of the safety valves

MP0053 Chassis Check the operation of the safety valves

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E 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.

4001153170

E 10.22

USA / GB

125

Chassis

Check the operation of the safety valves

MP0053 4-

Risk prevention Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

5-

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

• Place barriers around the perimeter of the work area

1 person

6-

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

• Put the machine in stowed position.

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

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

Check the outrigger safety valves : • Switch on the contact key.

126

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Chassis

Check the operation of the safety valves

MP0053 • Press the Home button ( 1 ).

• Enter the level 2 code using the arrows ( 2 ).

• Log in using the level 2 code.

• Select the menu : Machine settings.

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127

Chassis

Check the operation of the safety valves

MP0053 • Select the menu : Calibration.

• Go into the menu : Outrigger safety valve test.

128

4001153170

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Chassis

Check the operation of the safety valves

MP0053 • Launch the valve check.

• Satisfy the pre-requisites : • Hydraulic oil temperature > 20° C.

• If this is the case, validate and move on to the next step.

• If this is not the case, use the machine to heat the oil, then restart the procedure.

4001153170

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129

Chassis

Check the operation of the safety valves

MP0053 • Place the platform control box near to the ground control box.

• Turn the ground control box selector key to platform control box position.

• Set the machine to the requested configuration from the platform control box : • Rear right outrigger extended.

• The other outriggers retracted.

At the ground control box : • When the conditions are fulfilled, all the dots change to green.

• Automatic progression to the next step.

130

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Chassis

Check the operation of the safety valves

MP0053 • Press the enable switch ( 1 ) and hold it down for 30 seconds.

• When the conditions are fulfilled, all the dots change to green.

• Automatic progression to the next step.

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131

Chassis

Check the operation of the safety valves

MP0053 • No errors on YV118.

• Validate to continue.

• Set the machine to the requested configuration from the platform control box : • Rear left outrigger extended.

• The other outriggers retracted.

132

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Chassis

Check the operation of the safety valves

MP0053 At the ground control box : • When the conditions are fulfilled, all the dots change to green.

• Automatic progression to the next step.

4001153170

E 10.22

USA / GB

133

Chassis

Check the operation of the safety valves

MP0053 • Press the enable switch ( 1 ) and hold it down for 30 seconds.

• When the conditions are fulfilled, all the dots change to green.

• Automatic progression to the next step.

134

4001153170

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Chassis

Check the operation of the safety valves

MP0053 • No errors on YV117.

• Validate to continue.

• Set the machine to the requested configuration from the platform control box : • Front left outrigger extended.

• The other outriggers retracted.

4001153170

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135

Chassis

Check the operation of the safety valves

MP0053 At the ground control box : • When the conditions are fulfilled, all the dots change to green.

• Automatic progression to the next step.

136

4001153170

E 10.22

USA / GB

Chassis

Check the operation of the safety valves

MP0053 • Press the enable switch ( 1 ) and hold it down for 30 seconds.

• When the conditions are fulfilled, all the dots change to green.

• Automatic progression to the next step.

4001153170

E 10.22

USA / GB

137

Chassis

Check the operation of the safety valves

MP0053 • No errors on YV116.

• Validate to continue.

• Set the machine to the requested configuration from the platform control box : • Front right outrigger extended.

• The other outriggers retracted.

138

4001153170

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Chassis

Check the operation of the safety valves

MP0053 At the ground control box : • When the conditions are fulfilled, all the dots change to green.

• Automatic progression to the next step.

4001153170

E 10.22

USA / GB

139

Chassis

Check the operation of the safety valves

MP0053 • Press the enable switch ( 1 ) and hold it down for 30 seconds.

• When the conditions are fulfilled, all the dots change to green.

• Automatic progression to the next step.

140

4001153170

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Chassis

Check the operation of the safety valves

MP0053 • No errors on YV119.

• Validate to continue.

4001153170

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141

Chassis

Check the operation of the safety valves

MP0053 At the ground control box : • Press the enable switch ( 1 ) and hold it down for 32 seconds.

142

4001153170

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Chassis

Check the operation of the safety valves

MP0053 • No errors on the YV123 solenoid valve of the hydraulic unit.

• Validate to continue.

• Operate the centralised selector SA120 to lower the outriggers for 35 seconds.

4001153170

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143

Chassis

Check the operation of the safety valves

MP0053 • When the conditions are fulfilled, all the dots change to green.

• Automatic progression to the next step.

• No errors on the YV123 I/O solenoid valve of the hydraulic unit.

• Validate to continue.

144

4001153170

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Chassis

Check the operation of the safety valves

MP0053 • The procedure is complete.

• The valves are operational.

• Raise the stabilisers.

• Switch off the machine.

• Move on to the next test.

4001153170

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145

Chassis

Check the operation of the safety valves

MP0053 7-

Oscillating axle safety valves - For HS15 E PRO - HS4390 E PRO HS18 E PRO - HS5390 E PRO machine only Check the oscillating axle safety valves : • Switch on the contact key.

146

4001153170

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Chassis

Check the operation of the safety valves

MP0053 • Press the Home button ( 1 ).

• Enter the level 2 code using the arrows ( 2 ).

• Log in using the level 2 code.

• Select the menu : Machine settings.

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147

Chassis

Check the operation of the safety valves

MP0053 • Select the menu : Calibration.

• Go into the menu : Oscillating axle safety valve test.

148

4001153170

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Chassis

Check the operation of the safety valves

MP0053 • Launch the valve check.

• Satisfy the pre-requisites : • Hydraulic oil temperature > 20° C.

• If this is the case, validate and move on to the next step.

• If this is not the case, use the machine to heat the oil, then restart the procedure.

4001153170

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149

Chassis

Check the operation of the safety valves

MP0053 At the ground control box : • Press the enable switch ( 1 ) to decompress the oscillating cylinders.

• If this operation is not sufficient to activate the condition ( 2 ), perform a drive movement to decompress the oscillating axle cylinders.

• When the conditions are fulfilled, all the dots change to green.

• Automatic progression to the next step.

150

4001153170

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Chassis

Check the operation of the safety valves

MP0053 • Place the platform control box near to the ground control box.

• Turn the ground control box selector key to platform control box position.

From the platform control box : • Extend the front outriggers.

• Place a wedge greater than or equal to 50 mm under the front left wheel.

• Raise the stabilisers.

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151

Chassis

Check the operation of the safety valves

MP0053 • When the conditions are fulfilled, all the dots change to green.

• Automatic progression to the next step.

152

4001153170

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Chassis

Check the operation of the safety valves

MP0053 • Press the enable switch ( 1 ) and hold it down for 30 seconds.

• When the conditions are fulfilled, all the dots change to green.

• Automatic progression to the next step.

4001153170

E 10.22

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153

Chassis

Check the operation of the safety valves

MP0053 • No errors on YV101.

• Validate to continue.

154

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Chassis

Check the operation of the safety valves

MP0053 • Press the enable switch ( 1 ) and hold it down for 30 seconds.

• When the conditions are fulfilled, all the dots change to green.

• Automatic progression to the next step.

4001153170

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155

Chassis

Check the operation of the safety valves

MP0053 • No errors on YV811.

• Validate to continue.

From the platform control box : • Extend the front outriggers.

• Place a wedge greater than or equal to 50 under the front right wheel.

156

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Chassis

Check the operation of the safety valves

MP0053 • Raise the stabilisers.

• When the conditions are fulfilled, all the dots change to green.

• Automatic progression to the next step.

4001153170

E 10.22

USA / GB

157

Chassis

Check the operation of the safety valves

MP0053 • Press the enable switch ( 1 ) and hold it down for 30 seconds.

• When the conditions are fulfilled, all the dots change to green.

• Automatic progression to the next step.

158

4001153170

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Chassis

Check the operation of the safety valves

MP0053 • No errors on YV104.

• Validate to continue.

4001153170

E 10.22

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159

Chassis

Check the operation of the safety valves

MP0053 • Press the enable switch ( 1 ) and hold it down for 30 seconds.

• When the conditions are fulfilled, all the dots change to green.

• Automatic progression to the next step.

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Check the operation of the safety valves

MP0053 • No errors on YV814.

• Validate to continue.

• The procedure is complete.

• The valves are operational.

• Extend the front outriggers.

• Remove the chock.

• Retract the front outriggers.

• Perform a drive movement to decompress the oscillating axle cylinders.

• Move on to the next test.

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Check the operation of the safety valves

MP0053 8-

Scissor lift lowering safety valves • After checking the oscillating axle safety valves • Go into the menu : Scissor lift safety valves.

• Launch the valve check.

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Check the operation of the safety valves

MP0053 • Satisfy the pre-requisites : • Hydraulic oil temperature > 20° C.

• If this is the case, validate and move on to the next step.

• If this is not the case, use the machine to heat the oil, then restart the procedure.

• Set the machine to the requested configuration from the platform control box : • The scissor arms are folded.

• All the outriggers are retracted.

• Turn the key switch to the ground control box position.

At the ground control box : • When the conditions are fulfilled, all the dots change to green.

• Automatic progression to the next step.

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Check the operation of the safety valves

MP0053 From the ground control box : • Unfold the scissor arms until the arms reach an angle of > 14°.

• Approximately 4 metres high.

• When the conditions are fulfilled, all the dots change to green.

• Automatic progression to the next step.

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Check the operation of the safety valves

MP0053 From the ground control box : • Slightly fold the scissor arms to achieve an arm angle of < 13°.

• Once the action has been performed, wait 10 seconds for the indicator to turn green.

• When the conditions are fulfilled, all the dots change to green.

• Automatic progression to the next step.

• A 600-second then 300-second timer starts.

• Allow this operation to run automatically.

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Check the operation of the safety valves

MP0053 • The procedure is complete.

• The valves are operational.

• Stow the machine.

• Move on to the next test.

For the 3 procedures, if the valves are faulty, immediately contact HAULOTTE Services®.

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Lock-out procedure

MS0163 Chassis Lock-out procedure

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E PRO

2-

Concerned area

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Lock-out procedure

MS0163 3-

Warning This procedure describes the required steps for locking out the machine if you need to perform an operation WITHOUT POWER : • On electrical circuits and/or electrical components.

• On hydraulic, mechanical components located in the electrical environment.

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®.

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

• The pressure in the hydraulic system is very important. It can cause accidents. Relieve the pressure before beginning any work and never search for oil leaks using your hands.

• The engine exhaust gases contain harmful combustion products. Always start and run the engine in a well ventilated area. In a closed room, ensure the exhaust gases are evacuated to the outside.

• Do not wear any metal jewellery (rings, watches, chains, etc.) when working on the batteries.

• ONLY use insulated tools when working on or near batteries or electrical connections.

• Do not produce sparks or flames or smoke near the battery.

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Lock-out procedure

MS0163 3.1 -

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) : Capacity in Amp Hours (Ah)

4-

5 hours

10 hours

20 hours

100 hours

357

400

435

483

Risk prevention Means of protection to be used when implementing the range 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 : .

5-

You will need Lock-out kit - 4001070150 : • Lock-out padlock - 4000710070 • Lock-out chock - 4001069760 • Voltage absence tester • "DO NOT OPERATE" tag • Standard tool kit

• Place barriers around the perimeter of the work area

1 person

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Lock-out procedure

MS0163 6-

Procedure The battery charger must be disconnected during the lock-out procedure and throughout the lock-out period.

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

Put a "DO NOT USE" decal near the start/stop button to inform personnel that work is currently in progress on the equipment • Switch off the ignition and remove the ignition key.

N.B.-:-THE BATTERY CHARGER MUST NOT BE CONNECTED TO THE MAINS WHEN BEING LOCKED OUT AND THE FOR ENTIRE LOCK-OUT DURATION.

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Lock-out procedure

MS0163 • Open battery compartments.

• Disconnect the plug to the power circuit.

After it is locked out, and before any intervention on the electrical power circuit, wait 5 mn minutes for the voltage to drop to 0 Volt.

• Using the voltage absence tester, check that the voltage is 0 Volts at the socket between the ( + ) and ( - ).

• Lock-out chock ( 1 ).

• Padlock ( 2 ).

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Lock-out procedure

MS0163 • Place the lock-out chock ( 1 ) above the plug ( 3 ).

• Insert and lock the padlock ( 2 ).

• Attach a Lock-out sheet to the machine's ground control box.

• Write the machine's serial number on the Lock-out sheet.

The lock-out procedure is complete.

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Lock-out procedure

MS0163 7-

Unlocking procedure • Remove the padlock (2).

• Remove the lock-out chock (1).

• Connect the plug to the power circuit.

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Lock-out procedure

MS0163

Notes

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Scissors

Maintenance implementation

MS0314 Scissors 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.

The maintenance prop must be in place before any maintenance operation of the arm is begun.

Placing the machine in operational configuration (Maintenance use) : • Lift scissor arms to a sufficient height to tilt the stand.

• Tilt the stand to the vertical position. A mechanical locking click sound occurs.

• The stand should remain in the vertical position.

• Lower the scissor arms.

• Scissor arm pivoting rod should rest on the V groove of the stand.

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Scissors

Maintenance implementation

MS0314 Placing the machine in the operational position (Excluding maintenance) : • Lift scissor arms to a sufficient height to tilt the stand.

• Press the unlocking button on the maintenance stand .

• Tilt the stand to the horizontal position.

• Lower the scissor arms.

Machine sheets - Option Range Extender

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Range Extender

Procedure for checking the level of engine oil

MP0003 Range Extender Procedure for checking the level of engine oil

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E PRO

2-

Concerned area

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Range Extender

Procedure for checking the level of engine oil

MP0003 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.

• The engine exhaust gases contain harmful combustion products. Always start and run the engine in a well ventilated area. In a closed room, ensure the exhaust gases are evacuated to the outside.

• Be sure to stop the engine before checking and changing the engine oil and the oil filter cartridge.

• Do not touch muffler or exhaust pipes while they are hot; Severe burns could result.

• Always stop the engine and allow it to cool before conducting inspections, maintenance, or for a cleaning procedure.

• Contact with engine oil can damage your skin.

• If you come in contact with engine oil, wash it off immediately.

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Range Extender

Procedure for checking the level of engine oil

MP0003 4-

Risk prevention Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

5-

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

• Place barriers around the perimeter of the work area

1 person

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Range Extender

Procedure for checking the level of engine oil

MP0003 6-

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

• Put the machine in stowed position.

• 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 engine oil level before starting or more than 5 minutes after stopping the engine.

• Remove the oil level gauge, wipe it clean and reinstall it.

• Remove the gauge again.

• Check the engine oil level withing the indicated lines.

• Screw back and tighten the oil level gauge.

• Close the Range Extender door.

7-

Additional operations • Clean the work area.

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Range Extender

Replacing the engine oil filter / Drain the engine oil

MP0004 Range Extender Replacing the engine oil filter / Drain the engine oil

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E PRO

2-

Concerned area

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Range Extender

Replacing the engine oil filter / Drain the engine oil

MP0004 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.

• The engine exhaust gases contain harmful combustion products. Always start and run the engine in a well ventilated area. In a closed room, ensure the exhaust gases are evacuated to the outside.

• Be sure to stop the engine before checking and changing the engine oil and the oil filter cartridge.

• Do not touch muffler or exhaust pipes while they are hot; Severe burns could result.

• Always stop the engine and allow it to cool before conducting inspections, maintenance, or for a cleaning procedure.

• Contact with engine oil can damage your skin.

• If you come in contact with engine oil, wash it off immediately.

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Range Extender

Replacing the engine oil filter / Drain the engine oil

MP0004 4-

Risk prevention Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

5-

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

• Place barriers around the perimeter of the work area

1 person

6-

Consumables Consumable

HAULOTTE® code

Quantity

Engine oil filter

4001105190

1

Engine oil - 15W40

4000530600

6,7 l(1.77 gal US)

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Range Extender

Replacing the engine oil filter / Drain the engine oil

MP0004 7-

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

• Put the machine in stowed position.

• 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.

• Open the Range Extender door.

• Place a oil recovery device in place.

• Use a flat screwdriver to remove the drain hose passing hole cap ( 1 ).

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Range Extender

Replacing the engine oil filter / Drain the engine oil

MP0004 • Insert the drain hose ( 2 ) through the hole ( 3 ).

• Use 2 flat keys to unscrew slightly the drain bolt ( 4 ).

• Remove the gauge.

• Allow the oil to run out.

• Use an elbow wrench to release the oil filter screw.

• Unscrew completely by hand and remove the screw.

• Use a flat screwdriver to remove the oil filter from its location.

• Replace the engine oil filter.

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Range Extender

Replacing the engine oil filter / Drain the engine oil

MP0004 • Place the new engine oil filter into its hole ( 5 ).

• Use a screwdriver to align the screw hole.

• Replace the screw and check its alignment.

• Use an elbow wrench to tighten the screw.

• Use 2 flat keys to tighten the drain bolt.

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Range Extender

Replacing the engine oil filter / Drain the engine oil

MP0004 • Put the drain hose ( 2 ) to its original location.

• Reconnect the drain hole cap ( 1 ).

• Add the oil via the hole ( 6 ) using a funnel with a hose.

• Oil quantity : 1,5 l (0.33 gal US).

• Screw back and tighten the oil level gauge.

• Remove the gauge again.

• Check the engine oil level withing the indicated lines.

• Screw back and tighten the oil level gauge.

• Close the Range Extender door.

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Range Extender

Replacing the engine oil filter / Drain the engine oil

MP0004 8-

Additional operations • Clean any oil traces.

• Clean the work area.

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Range Extender

Diesel filter replacement

MP0005 Range Extender Diesel filter replacement

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E PRO

2-

Concerned area

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Range Extender

Diesel filter replacement

MP0005 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.

• The engine exhaust gases contain harmful combustion products. Always start and run the engine in a well ventilated area. In a closed room, ensure the exhaust gases are evacuated to the outside.

• Be sure to stop the engine before checking and changing the engine oil and the oil filter cartridge.

• Do not touch muffler or exhaust pipes while they are hot; Severe burns could result.

• Always stop the engine and allow it to cool before conducting inspections, maintenance, or for a cleaning procedure.

• Contact with engine oil can damage your skin.

• If you come in contact with engine oil, wash it off immediately.

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Range Extender

Diesel filter replacement

MP0005 4-

Risk prevention Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

5-

You will need • "DO NOT OPERATE" tag • Personal protective equipment • Standard tool kit • Flat pliers • Rags • Fuel filter - 4001105210

• Place barriers around the perimeter of the work area

1 person

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Range Extender

Diesel filter replacement

MP0005 6-

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

• Put the machine in stowed position.

• 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.

• Open the Range Extender door.

• Turn the fuel intake valve ( 1 ) to closed position.

• Place un absorbent towel beneath the fuel filter ( 2 ).

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Range Extender

Diesel filter replacement

MP0005 • Use a flat pliers to release the lower hose clip ( 3 ).

• Pull the lower hose downwards to release.

• Use a flat pliers to release the upper hose clip ( 4 ).

• Turn and pull the filter downwards to remove the filter.

Replace the fuel filter : • Mount the new fuel filter with the internal spring on top.

• Push the filter upwards into the upper hose.

• Use a flat pliers to place the upper hose clip in place.

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Range Extender

Diesel filter replacement

MP0005 • Insert the filter into the lower hose.

• Use a flat pliers to place the lower hose clip in place.

• Turn the fuel intake valve ( 1 ) to open position.

• Start the engine manually several times to fill the filter up.

• Close the Range Extender door.

7-

Additional operations • Clean the work area.

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Range Extender

Air filter replacement

MP0010 Range Extender Air filter replacement

1-

Concerned machines • HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E - HS18E PRO - HS5390E 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.

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Range Extender

Air filter replacement

MP0010 4-

Risk prevention Means of protection to be used when implementing the range Appropriate workwear

Gloves

Safety shoes

5-

You will need • "DO NOT OPERATE" tag • Personal protective equipment • Standard tool kit • Air filter - 4001105180

• Place barriers around the perimeter of the work area

1 person

196

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Range Extender

Air filter replacement

MP0010 6-

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

• Put the machine in stowed position.

• 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.

• Open the Range Extender door.

• Unscrew and remove the filter cover screw ( 1 ).

• Remove the air filter cover ( 2 ).

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Range Extender

Air filter replacement

MP0010 • Remove the filtering element ( 3 ).

• Replace the filter.

• Place the air filter cover back.

• Tighten the air filter cover screw.

• Close the Range Extender door.

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Links to engine manufacturer manuals - Fuel-powered machines

MS0238 Chassis Links to engine manufacturer manuals - Fuel-powered machines

1-

Links to engine manufacturer manuals - Fuel-powered machines For online reference and to download engine maintenance manuals for HAULOTTE® machines, go to : https://www.e-technical-information.com : • Username : Haulotte-Manuals • Password : manuals

2-

KUBOTA V1505 – D1105 E3 Engine : • In french : Manuel d'atelier 9Y111-00543 • In english : Workshop manual 9Y111-00126 V1505 – D1105 E4 Engine : • In french : Manuel d'atelier 9Y111-14251 • In english : Workshop manual 9Y111-07841 D1803 CRTE5 - STAGE V Engine : • In french : Manuel de l'opérateur 1J783-8915-7FRA • In english : Operator's manual 1J783-8915-7ENG • In french : Manuel d'atelier 9Y311-00022 • In english : Workshop manual 9Y311-00032 V2403 CR Engine : • In french : Manuel d'atelier 9Y111-10985 • In english : Workshop manual 9Y111-07825 V2403M Engine : • In french : Manuel d'atelier 9Y111-02584 • In english : Workshop manual 9Y111-02574 V2607 CR E4 Engine : • In french : Manuel d'atelier 9Y111-11034 • In english : Workshop manual 9Y111-06744 V2607 MT E3 Engine : • In french : Manuel d'atelier 9Y111-01726 • In english : Workshop manual 9Y111-01036 WG1605 Engine : • In french : Manuel atelier moteur réf 4000208650 • In english : Workshop manual engine ref 4000208650

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Chassis

Links to engine manufacturer manuals - Fuel-powered machines

MS0238 WG2503 Engine : • In french : Manuel d'atelier 9Y111-10902 • In english : Workshop manual 9Y111-09142 WG3800 Engine : • In french : Manuel d'atelier 9Y111-13101 • In english : Workshop manual 9Y111-13091 WG972 Engine : • In french : Manuel d'atelier 9Y111-03190 • In english : Workshop manual 9Y111-03180

3-

PERKINS 403J-17 Engine : • In english : Operator's manual PERKINS engine type 403J-17 1104D Engine : • In french : Manuel de l'opérateur Moteur PERKINS 1104D-44T • In english : Operator's manual PERKINS engine type 1104D-44T

4-

DEUTZ TCD 2,2 L3 Engine : • In french : Manuel de l'opérateur 03125369 • In english : Operator's manual 03125367 TCD 2,9 L4 Engine : • In french : Manuel de l'opérateur 03124630_10_2013 • In english : Operator's manual 03124628 en

5-

KOHLER KDI 3404 TCR Engine : • In french : ED0053030060 UM_KDI_3404TCR_REV_00_FR_HD • In english : ED0053030050 UM_KDI_3404TCR_REV_00_EN_HD KDI 1903 TC - STAGE V Engine : • In english : ED0053029490_UM_KDI_1903_2504TCR_REV_19_1_EN • In french : ED0053029710_UM_KDI_1903_2504TCR_REV_19_1_FR

6-

YANMAR Range Extender P6000 : • In english : Yanmar Operation Manual EN0016

200

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HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E HS18E PRO - HS5390E 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

https://www.e-technical-information.com

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HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E HS18E PRO - HS5390E PRO

E

- Electric and hydraulic diagrams

1-

Electric diagram Fast Charge - Range Extender CE - 4001012330 H - folio 02

202

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HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E HS18E PRO - HS5390E PRO

E

- Electric and hydraulic diagrams Power supply - Charger 48V - 4001012330 H - folio 03

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HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E HS18E PRO - HS5390E PRO

E

- Electric and hydraulic diagrams Lower part - PCB - 4001012330 H - folio 04

204

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HS15E - HS4390E - HS15E PRO - HS4390E PRO - HS18E - HS5390E HS18E PRO - HS5390E PRO

E

- Electric and hydraulic diagrams Inverter - 4001012330 H - folio 05

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2-

Hydraulic diagram HS15E - HS4390E - HS15E PRO HS4390E PRO - HS18E - HS5390E HS18E PRO - HS5390E PRO 4000509890 A - 1/2

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- Records

Records 1-

Intervention register The intervention register keeps a record of maintenance and repair work carried out inside or outside the maintenance programme.

N.B.-:-I N THE CASE OF A HAULOTTE SERVICES® INTERVENTION, THE QUALIFIED TECHNICIAN MUST INDICATE THE HAULOTTE SERVICES® INTERVENTION NUMBER. Date

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Number of hours

Intervenor

HAULOTTE Services® intervention number

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217

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- Records

Date

218

Type of intervention

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Number of hours

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Intervenor

HAULOTTE Services® intervention number

USA / GB