Haulotte Forklift SIGMA 16 - SIGMA 46 SIGMA 16 PRO - SIGMA 46 PRO Service and Repair Manual

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

Service and Repair Manual

Service and Repair Manual

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

4001160950

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

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Service and Repair Manual

CONTENTS

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

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

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

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

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

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

B Safety

CONTENTS

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

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

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Service and Repair Manual

C Familiarization 1 - HAULOTTE Activ'Screen 2 . . . . . . . . . . . . . . . 17 2 - List of actuators and sensors . . . . . . . . . . . . . 24 2.1 - Sensors and actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3 - Consumables (Oils...)Oils... . . . . . . . . . . . . . . . 29 3.1 3.2 3.3 3.4 3.5 -

Hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Gear motor oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Cylinder storage oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4 - Movement speed . . . . . . . . . . . . . . . . . . . . . . . 33

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Service and Repair Manual

Machine sheets MS0001 - Structural part inspection . . . . . . . . . . . . . . . 34 MS0002 - Pins and bearing inspection . . . . . . . . . . . . . 39 MS0003 - Cylinder inspection . . . . . . . . . . . . . . . . . . . . 43 MS0004 - Braking test procedure . . . . . . . . . . . . . . . . . 47 MS0133 - Universal plug . . . . . . . . . . . . . . . . . . . . . . . . 49 MS0285 - Maintenance implementation . . . . . . . . . . . . 53 MS0334 - Removal - Replacement of the platform . . . 55 MS0335 - Remove - Replace load cell. . . . . . . . . . . . . . 61 MS0336 - Remove/Re-install jib cylinder . . . . . . . . . . . 67 MS0337 - Remove/Re-install rotary actuator . . . . . . . . 73 MS0338 - Remove/Re-install jib cylinder . . . . . . . . . . . 79 MS0339 - Removal - Replacement of the jib

and platform . . . . . . . . . . . . . . . . . . . . . . . . . . 87 MS0340 - Remove/Re-install input compensation

cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 MS0341 - Remove/Re-install output compensation

cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 MS0342 - Remove - Replace telescope cylinder . . . . 107 MS0344 - Removing the boom lifting cylinder. . . . . . 121 MS0345 - Remove - Replace arm cylinder . . . . . . . . . 131 MS0346 - Remove - Replace counterweight . . . . . . . 139 MS0347 - Remove - Reinstall the hydraulic rotation

motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 MS0348 - Removal - Replacement of the electro-pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 MS0349 - Removal - Replacement of the steering

cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 MS0350 - Remove - Replace the boom/jib/box

CONTENTS

assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 MS0351 - Remove - Replace arm assembly . . . . . . . . 175 MS0352 - Removal - Replacement of the electric brake on the gear motor . . . . . . . . . . . . . . . . . . . . 187 MS0353 - Removal - Replacement of on-board

charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 MS0354 - Removal - Replacement of the gear motor 199 MS0355 - Removal - Replacement of semi-traction batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 MS0356 - Removal - Replacement of battery compartments . . . . . . . . . . . . . . . . . . . . . . . 213 MS0357 - Removal - Replacement of the drive controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 MS0358 - Removing / Replacing the pads . . . . . . . . . 225 MS0359 - Remove/re-install the harness BUS CAN . 243 MS0360 - Placing the machine in maintenance configuration . . . . . . . . . . . . . . . . . . . . . . . . 253

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D Trouble shooting 1 - Trouble shooting . . . . . . . . . . . . . . . . . . . . . . 259 1.1 1.2 1.3 1.4 1.4.1 -

Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 Failures list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 List of failures per category . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

2 - Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 2.1 -

PCB Turret. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

E Electric and hydraulic diagrams 1 - Electric diagram . . . . . . . . . . . . . . . . . . . . . . . 288 2 - Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . 298

F Records 1 - Intervention register . . . . . . . . . . . . . . . . . . . . 301

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A - 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.

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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A - Responsibilities and commitments S y m b o l Symbol

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

N.B. :

Additional technical information N.B.-:-THE FOLLOWING SAFETY ADVISORIES ARE USED THROUGHOUT THIS MANUAL TO INDICATE SPECIFIC HAZARDS WHEN OPERATING OR MAINTAINING THE TELEHANDLER.

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A - Responsibilities and commitments 2-

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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A - Responsibilities and commitments 3-

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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A - 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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A - Responsibilities and commitments Notes

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B - Safety Safety

1-

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

Section MS0285 - Turntable rotation locking

•

Section MS0360 - Placing the machine in maintenance configuration

1.1 -

UNCONTROLLED MOVEMENT HAZARD Be aware of uncontrolled movement and always respect the following : • Maintain clearance from high voltage lines.

• Maintain clearance from generators, radar, electromagnetic fields.

• Never expose the batteries or electrical components to water (high pressure washer, rain).

• Never tow the machine over extended distances.

• In case of a machine breakdown, it is possible to tow short distance to load it onto a trailer.

• Never leave the hydraulic cylinders fully extended before switching off the machine, or when stationary for an extended period of time.

• Retract and lower the boom to the stowed position rotate the turntable so that the boom is between the non-steering wheels.

• Select a safe parking location, on a firm level surface, clear of obstruction and traffic.

• Ensure all compartments are closed and secured.

• Chock the wheels.

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B - 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.

M i n i m u m

s a f e

a p p r o a c h

Electric voltage

d i s t a n c e s

Minimum safety distance Mètre

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

Feet Avoid contact

3 5 6 8 11 14

10 15 20 25 35 45

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

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

• Do not operate the machine during lightning or storms.

• Do not use the machine as a welding earth.

• Do not weld on the machine without first disconnecting the battery terminals.

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

• The machine must not be used while charging the batteries.

• When using the platform AC power line, ensure it is protected with a circuit breaker.

Keep away from the machine if it contacts energized power lines. Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut off.

In the event of accidental contact with a high voltage line, wait for the power to the line be de-energized before attempting to operate the machine.

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B - 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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B - Safety 2-

Safety rules energy source motorization 2.1 -

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

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

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

• Authorisation.

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

• Voltage > 25 volts in alternating current.

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

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

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

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

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

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C - 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.

C o n t r o l s Icon

a n d

i n d i c a t o r s

Description

Function

Access code entered is incorrect

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

C o n t r o l s Icon

a n d

i n d i c a t o r s

Description

Function

The machine can be personalized with a user identification code. Personalization is only possible with NIV 1 : 1250 access.

Machine properties display : Soft version, machine serial number, adjustment parameters.

Possible change of parameters : Language, fault display format, brightness setting, time, and some options availables.

Operator PIN code not yet entered

Operator PIN code entered is correct

Operator PIN code entered is incorrect

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C - Familiarization C o n t r o l s Icon

a n d

i n d i c a t o r s

Description

Function

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

Emergency mode is activated when : • The E-Stop at platform control box is pushed in (de-energized).

• The machine is in overload state.

• Ground control box is selected/energized.

• The emergency overriding button is activated.

Emergency mode is deactivated when : • The E-Stop at platform control box is pulled out (energized).

• The machine is NOT in overload state.

• Ground control box is NOT selected/energized.

Emergency mode has been used and activation of its function saved in the memory of the machine. A HAULOTTE® certified technician is required to reset the Emergency Mode system.

Maintenance use

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

Analog Gauge - Battery charging indicator

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

Analog Gauge - Battery charging indicator (Machine is charging)

: Charging : Battery charged

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

Alarm

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C - Familiarization C o n t r o l s Icon

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Description

a n d

i n d i c a t o r s Function

Beacon

The icon is ON when the flashing light is switched on

Auto beacon

Flashing light control is in automatic mode.

Activ' Lighting System

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

Activ' Lighting System

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

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C - Familiarization C o n t r o l s Icon

20

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Description

i n d i c a t o r s Function

Platform control selected

Selector switch is in platform control box position

Ground control selected

Selector switch is in ground control box position

Tilt

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

Overload

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

F12.01 bus CAN fault

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

Screen software obsolete

Screen software update essential Contact HAULOTTE Services®

Diagnostic in progress

The HaulotteDiag console is connected to the machine

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C - Familiarization C o n t r o l s Icon

a n d

i n d i c a t o r s

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 control box key selector ( 21 ) to the ground Activ' Shield Bar triggered

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 )

must be pressed

and held.

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C - Familiarization C o n t r o l s Icon

a n d

i n d i c a t o r s

Description

Function

Movement restricted due to critical battery level

The battery level is critical. Battery recharge is mandatory.

Battery level low

Recharge batteries.

Battery charge complete

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C - Familiarization C o n t r o l s Icon

a n d

Description

i n d i c a t o r s Function Low battery water level :

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 : • Refill the water battery tank with demineralized water

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35 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

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

Too hot to charge

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

Too cold to charge

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

High temperature

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

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C - Familiarization 2-

List of actuators and sensors 2.1 -

SENSORS AND ACTUATORS S e n s o r s

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C - Familiarization S e n s o r s

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C - Familiarization S e n s o r s

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

C - Familiarization Name EL905 EL906 EL907 HA901 HL901 HL910 A HL910 B HL911 HL912 A HL912 B HL912 C HL912 D HL913 KA2 KA3 KA8 KA9 KA911 KM803 SL901 SL911 SN900 SP800 SP801 SQ421 SQ520 SQ530 SQ800 SQ902 SR150 SR720 SR721 ST302 ST303 ST305 SV300 YV150 L YV150 R YV250 L YV250 R YV420 D YV420 U YV421 D YV520 D YV520 U YV530 I YV530 O YV620 D YV620 U YV650 L 4001160950

Function Light - Activ' Shield Bar system activated Activ' Lighting System - Counterweight light Activ' Lighting System Boom light Buzzer - Turret buzzer Light - Activ' Shield Bar detected Activ' Lighting System - Turret light Activ' Lighting System - Turret light Activ' Lighting System - Ground control box light Activ' Lighting System - Platform control box light Activ' Lighting System - Platform control box light Activ' Lighting System - Platform light Activ' Lighting System - Platform light Activ' Lighting System - Under basket light Power inverter relay Stand-by relay Flashing light relay Horn relay Relay - Centralized battery refilling Power contactor Battery level sensor Sensor - Low Water level tank Twilight sensor Sensor - Strain gauges Sensor - Strain gauges Detector - Arm down Detector - Boom down Detector - Telescope retracted Tilt sensor Detector - Activ' Shield Bar detector Sensor - Steering angle Sensor - Tilt - 10° Sensor - Tilt + 10° Sensor - Drive motor temperature Sensor - Drive motor temperature Temperature sensor on pump Drive motor speed sensor Valve - Steering left side valve Valve - Steering right side valve Valve - Left turntable rotation Valve - Right turntable rotation Valve - Arm descent Valve - Arm raise Valve - Arm descent Valve - Boom descent Valve - Boom raise Valve - Telescope retracted Valve - Telescope extension Valve - Jib lowering Valve - Jib raising Valve - Jib rotation left side E 04.22

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

C - Familiarization Name YV650 R YV720 D YV720 U YV750 L YV750 R YV800 YV900 YV904 YV905

28

Function Valve - Jib rotation right side Valve - Basket compensation descent Valve - Basket compensation lift Valve - Basket rotation to the left Valve - Basket rotation to the right Valve - LS Valve Valve - Platform movements Valve - Split outflow Valve - Pump outflow

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C - Familiarization 3-

Consumables (Oils...)

3.1 -

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

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

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

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

- CONSUMABLES

Viscosity grade

HV32

HV32 Arctic

Ambient temperature

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

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

Hydraulic oil temperature

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

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

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

ISO 3104

32 +/- 3 cst

32 +/- 3 cst

Viscosity at + 100° C (+ 260° F)

ISO 3104

> 6 cst

> 8 cst

Viscosity Index

ISO 2909

> 150

> 250

Flashpoint

ISO 2592

> 205° C (> 401° F)

> 125° C (> 257° F)

Pour point

ISO 3016

< - 40 ° C (< - 40° F)

< - 50 ° C (< - 58° F)

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

C - Familiarization 3.2 -

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

N.B.-:-REFER TO

- CONSUMABLES

Mineral

Synthetic

Normal operating condition

SAE 80W/90

SAE 75W/90

Harsh operating condition

SAE 85W/140

SAE 80W/140 - SAE 75W/140

3.3 -

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

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

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

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

• Dry the cylinder rods.

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

N.B.-:-REFER TO

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C - Familiarization 3.4 -

GREASE N.B.-:-REFER TO

- CONSUMABLES

Grease for telescope

Shell gadus S2 V220AC 2 grease

Polyplex Bardahl grease

Nature of the lubricating oil

Semisynthetic

Mineral oil

Semi-synthetic

Appearance

Viscous grease

Semi-solid

Semi-solid

Thickening nature

Lithium

Lithium / Calcium

Complex lithium

Color

Ivory

Red

Blue

Grade NLGI

1

2

2

- 40 at 140

- 20 at 120

- 20 at 160

Units

Standards

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

Welding 4 ball test

kg

> 315

-

> 315

0,91

0,9

0,9

Density at 20° C / 68° F

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

C - Familiarization 3.5 -

CONSUMABLES

Consumable

HAULOTTE® code

Quantity

Hydraulic filter cartridge

4001135500

1

Driving reducer - Hydraulic oil :

4000530610

1 l(0.22 gal US) by reducer

1 l(0.22 gal US)

Driving reducer - Hydraulic oil :

2420801370

1 l(0.22 gal US) by reducer

20 l(5.3 gal US)

Driving reducer - Hydraulic oil :

2420801380

1 l(0.22 gal US) by reducer

209 l(55.2 gal US)

Hydraulic circuit - Hydraulic oil (HV32) :

4000596020

18 l(5 gal US)

209 l(55.2 gal US)

Hydraulic circuit - Hydraulic oil (HV32 Arctic) :

4000096350

18 l(5 gal US)

20 l(5,3 gal US)

Hydraulic circuit - Hydraulic oil (HV32 Arctic) :

2505002640

18 l(5 gal US)

209 l(55.2 gal US)

Telescopic boom grease

4000813570

1 kg / 2,20 lbs

Telescopic boom grease

4000813560

5 kg / 11,02 lbs

Extreme-pressure lithium grease GADUS

2326005400

0,4 l(0.1 gal US)

Extreme-pressure lithium grease BARDAHL

4000561720

0,4 l(0.1 gal US)

Demineralized Water

4000813550

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5 l(1.3 gal US)

Packaging

5 l(1.3 gal US)

USA / GB

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

C - Familiarization 4-

Movement speed To allow checking operation, refer to the following table about originally time per movement. If the values measured by test are not equal to the following : • Do not use the machine.

• Setting updating is needed.

Always check speed movement from the ground control box.

SIGMA 16 - SIGMA 46

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

SIGMA 16 PRO - SIGMA 46 PRO

0,5 km/h (0.30 mph) 2,0 km/h (1.24 mph) 5 km/h (3.10 mph) 5 km/h (3.10 mph) 11 s - 15 s 11 s - 15 s 26 s - 30 s 26 s - 30 s 41 s - 49 s 19 s - 25 s N/A

18 s - 22 s 34 s - 38 s 30 s - 34 s 28 s - 32 s 28 s - 32 s 13 s - 17 s 13 s - 17 s 5 km/h (3.10 mph) 5 km/h (3.10 mph) 0,5 km/h (0.30 mph) 0,5 km/h (0.30 mph) 4s-6s

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

C - Familiarization General data Structural part inspection

Notes

34

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General data

Structural part inspection MS0001 1-

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.

2-

Risk prevention M e a n s

o f

p r o t e c t i o n

Appropriate workwear

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

w h e n

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

Gloves

Safety shoes

3-

You will need • Standard tool kit

4001160950

• Place barriers around the perimeter of the work area

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General data

Structural part inspection MS0001 4-

Control and maintenance To guarantee the integrity of the machine, it is necessary to carry out periodical controls on the mechanical structure such as defines hereafter.

4.1 -

DAILY INSPECTION All the accessible structural part without disassembling must be subjected to a fast visual inspection.

If anomalies are noted, according to the list below, a reinforced control will have to be carried out to judge conformity of the part : • Absence of foreign body to the articulations and slides.

• Absence of deformation and visible damage.

• Absence of crack, broken welding, oxidation, glare of painting.

• Absence of excessive gap to the articulations and slides.

• Check that locking device are not damaged and are functional.

• No screws or missing part loosened or unscrew.

• Anchorage points firmly fixed and not damaged.

The list of part to check are define Section Familiarization.

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General data

Structural part inspection MS0001 4.2 -

MAJOR INSPECTION All structural part listed Section Familiarization must be disassembled and all weldsmust be review using non-destructive checks Section D - Inspection and maintenance schedule.

The criteria quoted above are applicable.

The main items to be inspected are : • Boss welds on chassis, turret, arms, booms and jib.

• Booms and arms welds.

E x a m p l e

In the event of suspicion of crack, a cleaning and a sweating are to be carried out to guarantee the integrity of the part before reassembly.

Check presence and torque of each bolts and screw used to assembly part listed in Section Familiarization.

Refer to spare part catalog for additional information if needed.

Some screws are not reusable and must be systematically changed (ex: screws from the gear ring).

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General data

Structural part inspection MS0001 4.3 -

FUNCTIONAL TESTS The following tests must be performed periodically • An important technical intervention.

Section D - Inspection and maintenance schedule :

• An accident resulting from a failure of a major component.

The following tests must be realized by a qualified staff under secure conditions.

The results of the tests must be entirely documented.

To avoid the swing of the machine during the test, it is imperative that a device of reserve (chain, not of anchoring) is used during the test.

4.4 -

DYNAMIC TESTS The machine must be place on level and firm ground.

With 100% of the maximum allowed load, operate from ground control box (or emergency control box) all the movements ; the platform floor must reach a height of about 1 above the ground.

The functional tests must show the following facts : • The machine carried out all the movements without jolts while supporting the load.

• All the security device function correctly.

• Authorized maximum speeds of operation are not exceeded.

Refer to the user manual for the description of the safety device and technical characteristics to be reached.

4.5 -

STRUCTURAL TEST The following test shows that the structure of the machine is in conformity with the safety requirements.

The machine must be place on level and firm ground.

With 100% of the maximum allowed load, operate from ground control box (or emergency control box) all the movements ; the platform floor must reach a height of about 1 above the ground : • Measure the distance between the ground and the basket (or of the platform).

• Leave the machine in static during 15 mnn.

• Measure the distance between the ground and the basket (or of the platform).

If the difference between two measurements does not exceed 4 cm (1.575 in) : the test is validated.

If the difference between two measurements exceeds 4 cm (1.575 in), to contact HAULOTTE Services® or to carry out the additional tests described below.

MS0003 - § 3.2 Cylinder inspection.

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General data

Pins and bearing inspection MS0002 General data Pins and bearing inspection

1-

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.

2-

Risk prevention M e a n s

o f

p r o t e c t i o n

Appropriate workwear

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

w h e n

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

Gloves

Safety shoes

3-

You will need • Standard tool kit

4001160950

• Place barriers around the perimeter of the work area

E 04.22

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39

General data

Pins and bearing inspection MS0002 4-

Control and maintenance Inspection of the pins, stop pins, bushings and bearings must be carried out according to the recommendations Section D - Inspection and maintenance schedule : • Fast visual inspection without disassembling

Section D - Inspection and maintenance schedule :

• Check the presence of the pins and visible stops pins without disassembling.

• Check the presence of the screws.

• Check absence of deformations, cracks or breakage of pins and/or stops pins.

• Check absence of heavy abrasion, wear or oxidation of the pins, stops pins.

• Reinforced visual inspection with disassembling of certain elements to reach the bushes or bearing Inspection and maintenance schedule : In addition to the above cited criteria, verify the following :

Section D -

• Check the presence and the position of the bushes and bearings.

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

• Check the absence of heavy abrasion, wear or oxidation of the bushes and bearing.

• Check the absence of deformations, cracks or breakage of the bushes and bearing.

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

• Complete disassembling of the pins, bushes and bearing Section D - Inspection and maintenance schedule : In complement of the inspections above cited, it is necessary to check : • For the stages :

• Check the presence of material of friction.

• For the bearings :

• After disassembling, protect the bearing from pollution and shocks.

• Clean the bearing with a suitable solvent.

• Check the absence of shaving in the housing of the bearing and/or the bearing.

• Check the absence of heavy abrasion, wear, oxidation, deformations of the balls (or rollers) and the ball races.

The periodicity can evolve under the following conditions

Section D - Inspection and maintenance schedule :

• Abnormal noise during movements of the structure.

• Prolonged storage of the machine ( 6 months).

• Specific storage and use Environment (strong moisture and salinity of the air).

5-

Criteria of replacement The pins, stop pins, bushes and bearing must be replaced as soon as one of the anomalies quoted above is noted.

Bearing and bushes must be imperatively changed at the end of 10 years of use.

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General data

Pins and bearing inspection MS0002 6-

Procedure of reassembly 6.1 -

PINS AND BUSHES When reassembling bearings and pins ensure that : • Lightly lubricate the housing into which the bearing is to be installed.

• Insert the bearing using a bearing drift, preferably out of mild steel.

• The bearing, the bearing drift and the bearing housing must be correctly aligned during the assembly process.

• The recommended values for the bearing drift are given on the diagram below : R e c o m m e n d e d

V a l u e s

C

A

D E

B F

G

Marking A B C D E F G

Description At least 0,5 times the nominal diameter Make a chamfer Nominal diameter of the bearing - 0,2 / - 0,3 mm (-7874 µ in / -11810 µ in) Bearing drift Diameter of the bearing guide - 0,20 / - 0,25 mm (-7874 µ in / -9843 µ in) Bearing Housing

• After inserting the bearing, lubricate and fit the pin.

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General data

Pins and bearing inspection MS0002 6.2 -

BEARINGS For the reassembly of bearings, respect the following stages : • Clean boring and/or the pins to remove all the foreign bodies.

• Slightly lubricate boring and/or pins.

• Lubricate the ring of the bearing slightly.

• To fit bearing in a boring: take support on the external ring of the bearing.

• To fit bearing on an axis: take support on the interior ring of the bearing.

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General data

Cylinder inspection MS0003 General data Cylinder inspection

1-

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.

2-

Risk prevention M e a n s

o f

p r o t e c t i o n

Appropriate workwear

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

w h e n

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

Gloves

Safety shoes

3-

You will need • Standard tool kit

4001160950

• Place barriers around the perimeter of the work area

E 04.22

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General data

Cylinder inspection MS0003 4-

Control and maintenance 4.1 -

VISUAL INSPECTIONS The hydraulic actuating cylinders must be subjected to visual inspections periodic all the 250 hours or 6 months such as defined below : • Absence of leakage.

• Absence of deformations, visible damage , cracks on the body and fixing of the cylinder.

• Absence of rust and shock on the rod.

• Absence of foreign objects on all surfaces.

• Absence of missing or loosened part (bolt, nut, connection, flexible device, etc).

4.2 -

FUNCTIONAL TESTS To guarantee an optimal level of performance and safety, functional tests must be realized all the 250 hours or 6 months.

The periodicity can evolve under the following conditions : • Anomaly noted during visual inspection.

• Abnormal noise during movements of the structure.

• Prolonged storage of the machine ( 6 months).

• Specific storage and use Environment (strong moisture and salinity of the air).

Generic Control : • Position a load equal to the rated capacity on the cage (or platform).

• Raise the cage (or the platform) using the ground control box. To activate the cylinder to be tested, proceed as follows : • Lift Arm hydraulic cylinder : Lift the arm to approximately half full height. The telescopic boom should be fully extended and in the horizontal position. (For machines fitted with).

• Boom lifting cylinder or Jib cylinder : Lift the concerned equipment (boom or jib) of approximately half way. Extend the telescope to its maximum.

• Telescoping cylinder : Lift the boom to its maximum angle and telescope approximately 50 cm (19.69 in).

• Measure the distance between the floor of the cage (or of the platform) and the ground.

• Leave the machine in this condition for 15 mn (minutes).

• Measure the distance between the floor of the cage (or of the platform) and the ground.

• If the difference between two measurements does not exceed 4 cm (1.575 in) : the test validates correct operation.

• If the difference between two measurements exceeds 4 cm (1.575 in), contact HAULOTTE Services® or carry out the additional tests described below.

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General data

Cylinder inspection MS0003 Control cylinder by cylinder : • Position a load equal to the rated capacity on the cage (or platform).

• Perform the movement of the concern cylinder to half of its stroke.

• Fix the cylinder with a comparator : • Attach the body of the comparator on the cylinder rod.

• The needle of the comparator must be in contact with the end of the casing of the cylinder.

• The target is to measure the creep of the cylinder rod.

• If the creep of the cylinder rod is higher than the values indicated in the table below, replace the cylinder.

Type of cylinders

Maximum drift authorised due to an internal leak of the cylinder

Lift cylinder arm or boom (Machine with working heights > 26 m(85 ft4 in))

After 10 mn, creep < 0,2 mm (7874 µ in)

After 60 mn, creep < 1 mm (0.039 in)

Outriggers cylinder, Oscillating axle locking, Lift cylinder arm or boom (Machine with range-limiting system)

After 10 mn, creep < 0,5 mm (0.01196 in)

After 60 mn, creep < 2,5 mm (0.098 in)

Lift cylinder arm or boom, Telescoping, Compensation, ...

After 10 mn, creep < 1 mm (0.039 in)

After 60 mn, creep < 6 mm (0.236 in)

Steering cylinder

After 10 mn, creep < 1,5 mm (0.059 in)

After 60 mn, creep < 9 mm (0.354 in)

These tests must be made in conditions of equivalent temperatures.

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General data

Cylinder inspection MS0003 4.3 -

MAJOR INSPECTION A thorough inspection of the structural parts must be realized all the 5000 h or 10 years with disassembling of the element to check the entirety of the welding. Each Cylinder must be disassembled and must be review using non-destructive checks.

The criteria quoted above are applicable : • Absence of deformation and visible damage.

• Absence of crack, broken welding, oxidation, glare of painting.

Check : 1.

46

Pipe weld connection.

2.

Rod weld connection.

3.

Ring.

4.

Rod.

5.

Piston.

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General data

Braking test procedure MS0004 General data Braking test procedure

1-

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.

2-

Risk prevention M e a n s

o f

p r o t e c t i o n

Appropriate workwear

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

w h e n

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

Gloves

Safety shoes

3-

You will need • Standard tool kit

4001160950

• Place barriers around the perimeter of the work area

E 04.22

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47

General data

Braking test procedure MS0004 4-

Test procedure The brake system is a significant component of the safety of the machine. The following tests must be performed periodically Section D - Inspection and maintenance schedule.

High speed : • On a flat ground or slightly inclined (always lower than the authorized slope: see plate manufacturer).

• Trace on the ground, a line being used as reference mark of stop.

• Roll moving front until reaching maximum speed : • Between 3 km/h (1.9 mph) and 6,5 km/h (4,039 mph) according to the machines.

• Release the manipulator as soon as the wheels axles are on the level of the traced reference mark.

• Stopped machine, measure the distance between the wheel axles and traced reference mark on the ground : • If the distance lies between 0.2 m (0ft 8in) and 2,7 m (8 ft 11 in), the test is validated.

• If not, Contact HAULOTTE Services® to repair the system.

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Turntable

Universal plug MS0133 Turntable Universal plug

1-

You will need • The tracker with its cable.

• A clamp to strip the wires.

• A clamp to crimp the wires.

• Place barriers around the perimeter of the work area

1 person

2-

Procedure Step 1 : • Disconnect the plug 2.

• Remove the caps on the plug.

Step 2 : • Pick up the pins in the plastic bag.

• Strip the wires of the tracker.

• Crimp the wires with the pins with a crimping clamp.

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Turntable

Universal plug MS0133 Step 3 : • Take the wedgelock off the plug.

• Thread the wires in the positions regarding the information.

C1

Universal connector

Pin 1

+ permanent battery

Pin 2

GND (0 V)

Pin 3

+ battery voltage

Pin 4

• Machine with engine : Engine ON information.

• Electrical machine : Movement and driving information.

Pin 5

Power ON information

Pin 6 Pin 7

Movement information (Flashing light option activation)

Pin 8

Driving information

Pin 9

CAN 1 H

Pin 10

CAN 1 L

Pin 11

CAN 2 H

Pin 12

CAN 2 L N.B.-:-R EFER TO THE INSTRUCTIONS PROVIDED WITH THE TRACKER FOR THE WIRES CORRESPONDENCE .

DEPENDING OF THE TYPE OF UNIT, A RESISTANCE (200 OHMS, 1 W) MUST BE INTEGRATED BETWEEN SIGNAL AND GROUND.

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Turntable

Universal plug MS0133 Step 4 : • Put the wedgelock back on the plug to fix the pins.

Step 5 : • Reconnect the plugs.

• Mount the tracker.

• The tracking device is operational.

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Turntable

Universal plug MS0133

Notes

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Turntable

Maintenance implementation MS0285 Turntable Maintenance implementation

1-

Placing in configuration Your safety and the safety of the people around are essential.

Make sure the work area is clean in order to not to pollute the system of the machine.

Before performing any maintenance interventions, place the machine in maintenance configuration.

Turntable rotation lock pin engaged

Placing the machine in maintenance configuration : 1.

Place the machine on firm, level ground.

2.

Stow the machine completely.

3.

Push the E-stop button to cut off the electricity supply.

4.

Insert the turntable rotation locking pin.

Turntable rotation lock pin disengaged

Placing in operating configuration :

4001160950

5.

Remove the turntable rotation locking pin.

6.

Pull the E-stop button.

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53

Turntable

Maintenance implementation MS0285

Notes

54

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Platform

Removal - Replacement of the platform MS0334 Platform Removal - Replacement of the platform

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

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

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

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

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55

Platform

Removal - Replacement of the platform MS0334 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield — In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

56

You will need • "DO NOT OPERATE" tag • Personal protective equipment • Standard tool kit • Lifting and handling equipment(bridge crane, crane, etc) • Torque wrench for 40 - 215 Nm (29 - 159 lbs-ft) • Circlips pliers • Hose clamps • Cable tie gun

• Place barriers around the perimeter of the work area

• Platform assembly mass : 131 kg (289 lbs)

1 person

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Platform

Removal - Replacement of the platform MS0334 5-

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

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

• Stow the machine.

• Fit the platform on a handling device.

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

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

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

• Turn off the circuit breaker.

• Disconnect the terminal from the negative terminal (-) then from the positive terminal (+).

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57

Platform

Removal - Replacement of the platform MS0334 • Put the machine in stowed position, boom and arm fully retracted and lowered.

• Locate the position of the Foot Switch on the floor (mark the position of it on the floor).

• Remove the three screws that hold the pedal to the floor.

• Remove the plate ( 1 ).

• Open the plastic collar ( 2 ) using a screwdriver.

• Cut the polyamide ties holding the cable and the control box wiring harness.

• Put the pedal on the outside the platform.

• Disconnect the 2 plugs positioned under the platform control panel.

• Remove all of the plastic ties and place the plugs on the outside of the platform.

58

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Platform

Removal - Replacement of the platform MS0334 • If the machine is fitted with the Activ' Lighting System option, disconnect the light under the platform and place the plug outside the platform.

• Remove the circlip ( 1 ).

• Remove the washer ( 2 ).

• Remove the pin ( 3 ).

• Remove the screws ( 1 ).

• Gently move the platform backwards using the handling equipment.

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Platform

Removal - Replacement of the platform MS0334 6-

Re-installation • To refit it, proceed in the opposite order to removal.

• Fit the screws ( 1 ).

• Apply torque in 3 times.

• Apply the following torques : • 70 Nm (51.6 lbs-ft) • 140 Nm (103.2 lbs-ft) • 215 Nm (158.5 lbs-ft) N.B.-:-TIGHTEN THE SCREWS CROSSWISE.

7-

Additional operations • Check that the weighing system is working properly.

• Calibrate the load cell : Refer to

PI 563Calibrations.

• Clean off any residual oil or grease.

• Clean the work area.

In compliance with the country's laws, have the machine approved by an accredited organization.

60

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Platform

Remove - Replace load cell MS0335 Platform Remove - Replace load cell

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

• 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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61

Platform

Remove - Replace load cell MS0335 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield — In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

You will need • "DO NOT OPERATE" tag • Standard tool kit • Torque wrenches for torque of 40 Nm / 215 Nm • 24 mm / 1 in socket • Palettes for placement under the platform (about 700 mm / 28 in) • Forklift • Circlips pliers • Collars

• Place barriers around the perimeter of the work area

1 person

62

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Platform

Remove - Replace load cell MS0335 5-

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

• Stow the machine.

• Fit the platform on a handling device.

• Mark out the work area.

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

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

• Turn off the circuit breaker.

• Disconnect the terminal from the negative terminal (-) then from the positive terminal (+).

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Platform

Remove - Replace load cell MS0335 • Remove a circlip, the washer and then the pin between the platform and the link piece.

• If the machine is fitted with the Activ' Lighting System option, disconnect the light under the platform and place the plug outside the platform.

• Loosen the 4 screws connecting the platform support to the gauge.

• Open the plastic collar ( 1 ) using a screwdriver.

• Open the metal support ( 2 ) to facilitate separation of the platform and load cell

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Platform

Remove - Replace load cell MS0335 • Pull slightly on the platform assembly to free access to the stress gauge.

• Disconnect the stress gauge plug.

• Loosen the 4 screws that hold the strain gage onto the connecting element.

• Remove the strain gage.

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Platform

Remove - Replace load cell MS0335 6-

Re-installation • If the cell has been replaced, note the traceability number.

• Remount in reverse order to removal.

• When re-installing the cell on the link piece, ensure the cell is fitted the right way round (A label indicates the top). Place the label marked TOP at the top. PLATFORM marking on the platform side and BOOM on the boom side. Check there are no foreign bodies (even small) between the cell and the brackets.

• Apply the following torques : • 70 Nm • 140 Nm • 215 Nm N.B.-:-TIGHTEN THE SCREWS CROSSWISE. N.B.-:-USE A TORQUE WRENCH WITH AN OPEN END WRENCH FITTING TO TIGHTEN THE JIB SIDE. • Apply contact grease for the connector .

7-

Additional operations • Clean the work area.

• Calibrate the load cell : Refer to

PI 563Calibrations.

• Make a few movements and ensure that the overload is working correctly.

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Jib

Remove/Re-install jib cylinder MS0336 Jib Remove/Re-install jib cylinder

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

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

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

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

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Jib

Remove/Re-install jib cylinder MS0336 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield – In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

68

You will need • "DO NOT OPERATE" tag • Personal protective equipment • Standard tool kit • Pin diameter 20 mm / 0,80 in, length 500 mm / 20 in • Palettes for placement under the platform (about 700 mm / 28 in) • Torque wrench for 44 Nm • 290 kg / 640 lbs load for static test • Hammer • ORFS seal kit : 2505000470 • ORFS plug kit : 2505001600

• Place barriers around the perimeter of the work area

• Weight of the jib cylinder : 16,3 kg / 36 lbs

1 person

4001160950

E 04.22

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Jib

Remove/Re-install jib cylinder MS0336 5-

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

• Stow the machine.

• Fit the platform on a handling device.

• Mark out the work area.

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

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

• Turn off the circuit breaker.

• Disconnect the terminal from the negative terminal (-) then from the positive terminal (+).

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69

Jib

Remove/Re-install jib cylinder MS0336 • Disconnect the solenoid valve YV620D on the cylinder flange.

On each side of the pin, cylinder rod side : • Remove the end-play take up screw and smooth clevis then extract the pin on the platform side (Using a 15 mm / 0,60 in wrench).

• Allow the cylinder to hang down in order to access the hydraulic hoses more easily.

• Locate, disconnect and plug the hoses supplying the jib cylinder.

70

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Jib

Remove/Re-install jib cylinder MS0336 On each side of the pin, platform side : • Remove the end-play take up screw and smooth clevis then extract the pin on the platform side (Using a 15 mm / 0,60 in wrench).

• Use a pin of diameter 20 mm / 0,80 in and length 500 mm / 20 in to knock out the cylinder pin.

• Leave the cylinder pin in the link piece and the second jib arm.

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Jib

Remove/Re-install jib cylinder MS0336 • Support the jib cylinder, then remove the extraction pin in order to gently remove the cylinder.

6-

Re-installation • If you are installing a new cylinder, note the traceability number.

• Perform the operations in the reverse order of dismantling.

• Remember to refit the pin stop screws. Install the screws with threadlock.

• Tighten the screws to the recommended torque : 44 Nm (32.45 lb.ft).

• Grease the pins, the seals, and the bored holes.

• Check that the seals are on the connections before reconnecting the hoses.

• To avoid the hoses twisting when they are connected to the rigid tubes, hold them firmly when tightening the couplings.

During reinstallation, pay attention to the hoses and cables.

7-

Additional operations • From the ground control box, operate the cylinder to flush out the hydraulic circuit.

• Check that there is no leak of oil at the removing connections.

• Perform a static test by putting 290 kg / 640 lbs on the platform. Machine unfolded, 15 mn after checking the performance of its parts : • Jib cylinder.

• Boom lifting cylinder.

• Boom telescopic cylinder.

• Input jib leveling cylinder.

In compliance with the country's laws, have the machine approved by an accredited organization.

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Platform

Remove/Re-install rotary actuator MS0337 Platform Remove/Re-install rotary actuator

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

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

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

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

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

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Platform

Remove/Re-install rotary actuator MS0337 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield — In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

74

You will need • "DO NOT OPERATE" tag • Standard tool kit • Lifting equipment(bridge crane, crane, etc) - Minimum capacity 500 kg(1100 lb) • Strap • Palettes for placement under the platform (about 700 mm / 28 in) • ORFS seal kit : 2505000470 • ORFS plug kit : 2505001600 • Mallet and pin diameter 20 mm / 1 in length 300 mm / 12 in minimum • Torque wrench for 44 Nm , and 57 Nm • Torque wrench for 550 Nm • Grease • Oil collection pan

• Place barriers around the perimeter of the work area

• Weight of rotary cylinder : 19,5 Kg / 43 lbs

1 person

4001160950

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USA / GB

Platform

Remove/Re-install rotary actuator MS0337 5-

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

• Stow the machine.

• Fit the platform on a handling device.

• Mark out the work area.

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

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

• Turn off the circuit breaker.

• Disconnect the terminal from the negative terminal (-) then from the positive terminal (+).

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Platform

Remove/Re-install rotary actuator MS0337 • Locate, disconnect and plug the hoses that supply the cylinder.

• Open the plastic ( 1 ) and metal ( 2 ) support of the cable duct to access the cylinder screws ( 3 ).

• Loosen the central screw ( 1 ) using a 30 mm wrench.

Tightening at a torque of 550 Nm (405.65 lb.ft).

• Remove the 8 screws that hold the cylinder to the connecting piece. Use an 8 mm 6-side wrench.

• Remove the central screw.

• Remove the platform.

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Platform

Remove/Re-install rotary actuator MS0337 • Remove the 2 pin stop screws and the smooth clevises between the bottom tie rods of the jib and rotation cylinder.

• Pull out the pin.

• Let the jib tie rods hang.

• Attach the rotation cylinder with a sling.

• Tighten the sling from the bridge crane.

• Remove the 2 pin stop screws and the smooth clevises between the top tie rods of the jib and the rotation cylinder.

• Pull out the pin.

• Remove the cylinder.

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Platform

Remove/Re-install rotary actuator MS0337 6-

Re-installation • If you are installing a new cylinder, note the traceability number.

• Perform the operations in the reverse order of dismantling.

• Replace the adjustment wedges.

• Grease the pins, the seals, and the bored holes.

• Remember to refit the pin stop screws. Install the screws with threadlock.

• Tighten the rotary cylinder central nut to a torque of 500 Nm (368.78 lb.ft).

• Tighten the 8 rotary cylinder screws to the torque of 57 Nm (42 lb.ft).

• Check that the seals are on the connections before reconnecting the hoses.

• Hold the hoses to ensure that they don't turn while tightening the connections (risk of seal damage). This will avoid the hoses twisting when they are connected to the rigid tubes.

During reinstallation, pay attention to the hoses and cables.

7-

Additional operations • Clean off any residual oil or grease.

• Rotate the platform a few times.

• Ensure that there are no hydraulic leaks.

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Jib

Remove/Re-install jib cylinder MS0338 Jib Remove/Re-install jib cylinder

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

• 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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Jib

Remove/Re-install jib cylinder MS0338 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield — In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

80

You will need • "DO NOT OPERATE" tag • Standard tool kit • Lifting equipment(bridge crane, crane, etc) - Minimum capacity 1000 kg(2205 lb) • Forklift • 1000 kg(2205 lb) ratchet strap, 3 m(9 ft10 in) in length • Palettes for placement under the platform (about 700 mm / 28 in) • ORFS seal kit : 2505000470 • ORFS plug kit : 2505001600 • Mallet and pin diameter 20 mm / 1 in length 300 mm / 12 in minimum • Torque wrench for 44 N.m , and 57 N.m • 800 Nm torque wrench with 36 mm sleeve • Grease • Oil collection pan

• Place barriers around the perimeter of the work area

• Weight of the jib cylinder : 32 Kg / 70.5 lbs

1 person

4001160950

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Jib

Remove/Re-install jib cylinder MS0338 5-

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

• Stow the machine.

• Fit the platform on a handling device.

• Mark out the work area.

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

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

• Turn off the circuit breaker.

• Disconnect the terminal from the negative terminal (-) then from the positive terminal (+).

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81

Jib

Remove/Re-install jib cylinder MS0338 • Using handling equipment, place a weight of 500 kg(1103 lb) centrally on the platform.

• Sling the jib on the pin of the link piece and the top tie rods.

• Slightly tension the assembly.

• Locate, disconnect and plug the hoses supplying the jib cylinder.

• Remove the metal support ( 1 ) of the cable duct to access the cylinder screws.

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Jib

Remove/Re-install jib cylinder MS0338 • Loosen the central screw ( 1 ) using a 36 mm wrench.

Tightening at a torque of 800 Nm. • Remove the 8 screws that hold the cylinder to the connecting piece. Use an 12 mm 6-side wrench.

• Remove the central screw.

• Move the platform clear using a pallet truck.

• Attach a strap between the jib pin and the platform.

• Tighten the strap.

• Slowly release the bridge crane.

• The jib should remain in place.

• Screw 2 rings on the jib rotation cylinder.

• Using handling equipment, attach the jib rotation cylinder with a sling.

• Tighten the sling.

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Jib

Remove/Re-install jib cylinder MS0338 • Remove the 2 pin stop screws and the smooth clevises from the pins of the jib rotation cylinder.

• Remove the pin between the compensation cylinder and the rotation cylinder.

• Carefully remove the compensation cylinder and place it on a chock or a cloth inside the boom section.

• Using handling equipment, pull on the cylinder so that it remains in a vertical position.

• Remove the pin between the boom section and the rotation cylinder.

• Remove the rotation cylinder.

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Jib

Remove/Re-install jib cylinder MS0338 6-

Re-installation • If you are installing a new cylinder, note the traceability number.

• Perform the operations in the reverse order of dismantling.

• Refit the adjustment shims on the rotation cylinder.

• Grease all the pins, seals, and bore holes.

• Remember to refit the pin stop screws. Install the screws with threadlock.

• Tighten to a torque of 44 Nm (32.45 lb.ft).

• Tighten the rotary cylinder central nut to a torque of 800 Nm (590.05 lb.ft).

• Use medium-strength threadlock and tighten the 8 screws of the rotation cylinder to a torque of 99 Nm (73.01 lb.ft).

• Check that the seals are on the connections before reconnecting the hoses.

• To avoid the hoses twisting when they are connected to the rigid tubes, hold them firmly when tightening the couplings.

• During reinstallation, pay attention to the hoses and cables.

7-

Additional operations • Rotate the platform a few times • Ensure that there are no hydraulic leaks.

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Jib

Remove/Re-install jib cylinder MS0338

Notes

86

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Jib and platform

Removal - Replacement of the jib and platform MS0339 Jib and platform Removal - Replacement of the jib and platform

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

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

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

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

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E 04.22

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87

Jib and platform

Removal - Replacement of the jib and platform MS0339 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield — In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

88

You will need • "DO NOT OPERATE" tag • Personal protective equipment • Standard tool kit • Palettes for placement under the platform (about 200 mm / 8 in) • Lifting and handling equipment(bridge crane, crane, etc) – capacity 1000 kg / 2205 lbs.

• Forklift • Pin diameter 20 mm / 0,80 in, length 500 mm / 20 in • Oil collection pan • 290 kg / 640 lbs load for static test • Torque wrench for 44 Nm • Grease • Hammer • ORFS seal kit : 2505000470 • ORFS plug kit : 2505001600

• Place barriers around the perimeter of the work area

• Weight of jib and platform : 270 Kg / 595.2 lbs

2 persons

4001160950

E 04.22

USA / GB

Jib and platform

Removal - Replacement of the jib and platform MS0339 5-

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

• Stow the machine.

• Fit the platform on a handling device.

• Mark out the work area.

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

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

• Turn off the circuit breaker.

• Disconnect the terminal from the negative terminal (-) then from the positive terminal (+).

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Jib and platform

Removal - Replacement of the jib and platform MS0339 • Disconnect the plug CAN. • Cut the hose clamps.

• Put down the plug outside the platform.

• Open the hose clamp ( 1 ).

• Loosen the ( 2 ) harness' retention bracket.

• If the machine is fitted with a 220 V socket in the platform ( 3 ), disconnect it.

• Remove the sheath ( 4 ).

CAN cable ( 1 ) and the

220 V cable ( 2 ) from the

• Thread the wiring harness through the jib, removing the screw clamps.

• If the machine is fitted with a 220 V socket in the platform, remove it too.

• Leave the wiring harness attached to the end of the boom.

• Remove the protection plate in front of the block by removing the 4 screws.

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Jib and platform

Removal - Replacement of the jib and platform MS0339 • Disconnect the solenoid valves and leave them with the jib.

• Reduce the pressure in the hydraulic lines before removing the hoses.

• Identify, disconnect and plug the 2 hoses supplying the jib rotation cylinder ( 1 ).

• Leave them to hang with the block.

• Identify, disconnect and plug the 2 hoses supplying the platform rotation cylinder at the link piece ( 2 ).

• Leave them to hang with the block.

• Identify, disconnect and plug the 2 hoses supplying the jib cylinder on the block ( 3 ).

• Open the hose clamp ( 4 ).

• Leave them to hang with the jib.

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Jib and platform

Removal - Replacement of the jib and platform MS0339 • Slide the platform and jib unit.

• Remove the 2 pin stop screws and the smooth clevises from the pins of the jib rotation cylinder.

• Remove the pin between the compensation cylinder and the rotation cylinder.

• Carefully remove the compensation cylinder and place it on a chock or a cloth inside the boom section.

• Check that the sling is taught to hold the jib cylinder.

• Remove the pin between the boom section and the rotation cylinder.

• Remove the jib platform assembly using a pallet truck and the bridge crane.

• Make a wedge under the jib arms. A minimum wedging height of A : 200 mm / 8 in is required.

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Jib and platform

Removal - Replacement of the jib and platform MS0339 6-

Re-installation • Perform the operations in the reverse order of dismantling.

• Grease the pins, the seals, and the bored holes.

• Remember to refit the pin stop screws. Install the screws with threadlock.

• Tighten the screws to the recommended torque : 44 Nm (32.45 lb.ft).

• Check that the seals are on the connections before reconnecting the hoses.

• Hold the hoses to ensure that they don't turn while tightening the connections (risk of seal damage). This will avoid the hoses twisting when they are connected to the rigid tubes.

During reinstallation, pay attention to the hoses and cables.

7-

Additional operations • Clean off any residual oil or grease.

• Clean the work area.

• From the ground control panel, manoeuvre the platform and jib compensation to purge the circuit.

• Check that there is no leak of oil at the removing connections.

• Top up the hydraulic oil if necessary (machine in stowed position).

• Perform a static test by putting 290 kg / 640 lbs on the platform. Machine unfolded, 15 mn after checking the performance of its parts : • Jib cylinder.

• Boom lifting cylinder.

• Boom telescopic cylinder.

• Input jib leveling cylinder.

In compliance with the country's laws, have the machine approved by an accredited organization.

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Jib and platform

Removal - Replacement of the jib and platform MS0339

Notes

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Upper boom

Remove/Re-install input compensation cylinder MS0340 Upper boom Remove/Re-install input compensation cylinder

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

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

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

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

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Upper boom

Remove/Re-install input compensation cylinder MS0340 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield — In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

96

You will need • Personal protective equipment • Standard tool kit • "DO NOT OPERATE" tag • Standard tool box • Palettes for placement under the platform (about 200 mm / 8 in) • Lifting and handling equipment(bridge crane, crane, etc) – capacity 100 kg / 220 lbs • Ratchet strap - 1000 mm / 39 in • Pin diameter 20 mm / 0,80 in, length 500 mm / 20 in • Torque wrench for 44 Nm • Grease • Hammer • 290 kg / 640 lbs load for static test • Oil collection pan • ORFS seal kit : 2505000470 • ORFS plug kit : 2505001600

• Place barriers around the perimeter of the work area

• Weight of the receiver cylinder assembly : 24 kg / 53 lbs

1 person

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Upper boom

Remove/Re-install input compensation cylinder MS0340 5-

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

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

• Stow the machine.

• Fit the platform on a handling device.

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

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

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

• Turn off the circuit breaker.

• Disconnect the terminal from the negative terminal (-) then from the positive terminal (+).

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Upper boom

Remove/Re-install input compensation cylinder MS0340 • Remove the flap on the boom section ( 1 ) and the protection cover on the ON/OFF block ( 2 ).

• Identify the hoses on the hydraulic block.

• Gently loosen the fittings.

• As soon as a trickle of oil appears, let it flow out. When there is no longer any residual pressure, disconnect the hoses and plug the connectors.

• Remove the 2 pin stop screws and the smooth clevises from the pins of the jib rotation cylinder.

• Remove the pin between the compensation cylinder and the rotation cylinder.

• Carefully remove the compensation cylinder and place it on a chock or a cloth inside the boom section.

• Do not remove the top pin between the jib rotation cylinder and the boom.

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Upper boom

Remove/Re-install input compensation cylinder MS0340 • Attach a sling to the cylinder.

• Tension the handling device.

• Remove the pin stop screw and the smooth clevis.

• Knock out the pin using a metal pin on the opposite side of the block.

• Pull the cylinder out of the boom using handling equipment.

• Remove the cylinder.

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Upper boom

Remove/Re-install input compensation cylinder MS0340 6-

Re-installation • If you are installing a new cylinder, note the traceability number.

• Perform the operations in the reverse order of dismantling.

• Remember to refit the pin stop screws. Install the screws with threadlock.

• Tighten the screws to the recommended torque : 44 Nm (32.45 lb.ft).

• Grease the pins, the seals, and the bored holes.

• Check that the seals are on the connections before reconnecting the hoses.

• To avoid the hoses twisting when they are connected to the rigid tubes, hold them firmly when tightening the couplings.

During reinstallation, pay attention to the hoses and cables.

7-

Additional operations • From the lower control box, operate the platform compensation functions to flush out the hydraulic circuit.

• Check that there is no leak of oil at the removing connections.

• Perform a static test by putting 290 kg / 640 lbs on the platform. Machine unfolded, 15 mn after checking the performance of its parts : • Input jib leveling cylinder.

• Jib cylinder.

• Boom lifting cylinder.

• Boom telescopic cylinder.

In compliance with the country's laws, have the machine approved by an accredited organization.

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Upper boom

Remove/Re-install output compensation cylinder MS0341 Upper boom Remove/Re-install output compensation cylinder

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

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

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

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

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Upper boom

Remove/Re-install output compensation cylinder MS0341 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield – In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

102

You will need • Personal protective equipment • Standard tool kit • "DO NOT OPERATE" tag • Standard tool box • Palettes for placement under the platform (about 700 mm / 27 in) • Lifting and handling equipment(bridge crane, crane, etc) – capacity 100 kg / 220 lbs • Strap - 100 kg / 220 lbs • Pin diameter 20 mm / 0,80 in, length 500 mm / 20 in • Torque wrench for 44 Nm • Grease • Hammer • 290 kg / 640 lbs load for static test • Oil collection pan • ORFS seal kit : 2505000470 • ORFS plug kit : 2505001600

• Place barriers around the perimeter of the work area

• Output compensation cylinder : 22,3 Kg / 49.16 lbs

1 person

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Upper boom

Remove/Re-install output compensation cylinder MS0341 5-

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

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

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

• Lift the arm.

• Fit the platform onto a chock.

• Position a chock under the arm.

• The pin ( 1 ) must pass over the counterweight.

• Set the machine down on the chocks.

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

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Upper boom

Remove/Re-install output compensation cylinder MS0341 • Place a do not operate tag at the start/stop switch location to inform personnel that the equipment is being worked on.

• Turn off the circuit breaker.

• Disconnect the terminal from the negative terminal (-) then from the positive terminal (+).

• Remove the 6 plate's fastening screws that give access to the output compensation cylinder.

• Locate the 2 hoses leading to the compensation receiver cylinder.

• Gently loosen the fittings.

• Place an absorbent cloth under the cylinder to avoid any oil leaks inside the machine.

• As soon as a trickle of oil appears, let it flow out. When there is no longer any residual pressure, disconnect the hoses and plug the connectors.

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Upper boom

Remove/Re-install output compensation cylinder MS0341 • Remove the pin stop screw and the smooth clevis.

• Extract the pin between the compensation cylinder and the boom using a metal pin.

• Carefully set down the cylinder outside the access hole.

• Attach a sling to the cylinder.

• Tension the handling device.

• Remove the pin stop screw and the smooth clevis.

• Pull out the pin.

• Lift the handling equipment.

• Extract the cylinder.

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Upper boom

Remove/Re-install output compensation cylinder MS0341 • Remove the cylinder.

6-

Re-installation • If you are installing a new cylinder, note the traceability number.

• Perform the operations in the reverse order of dismantling.

• Remember to refit the pin stop screws. Install the screws with threadlock.

• Tighten the screws to the recommended torque : 44 Nm (32.45 lb.ft).

• Grease the pins, the seals, and the bored holes.

• Check that the seals are on the connections before reconnecting the hoses.

• To avoid the hoses twisting when they are connected to the rigid tubes, hold them firmly when tightening the couplings.

During reinstallation, pay attention to the hoses and cables.

7-

Additional operations • From the lower control box, operate the platform compensation functions to flush out the hydraulic circuit.

• Check that there is no leak of oil at the removing connections.

• Perform a static test by putting 290 kg / 640 lbs on the platform. Machine unfolded, 15 mn after checking the performance of its parts : • Output jib compensation cylinder • Input jib leveling cylinder.

• Jib cylinder.

• Boom lifting cylinder.

• Boom telescopic cylinder.

In compliance with the country's laws, have the machine approved by an accredited organization.

106

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Upper boom

Remove - Replace telescope cylinder MS0342 Upper boom Remove - Replace telescope cylinder

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

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

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

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

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Upper boom

Remove - Replace telescope cylinder MS0342 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield — In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

108

You will need • The telescopic cylinder : 4000703310 • "DO NOT OPERATE" tag • Standard tool kit • Circlips pliers • Hammer • ORFS seal kit : 2505000470 • ORFS plug kit : 2505001600 • Palettes for placement under the platform (about 700 mm / 28 in) • 2 axes with diameter of 20 mm (0,79 in), length of 500 mm (19.6 in) • Torque wrench for 44 Nm (32.45 lbs-ft) • Lifting and handling equipment(bridge crane, crane, etc) : capacity 1000 kg(2205 lb) • 1 strap, length 3 m (9 ft 84 in), capacity 1000 kg (2204 lbs) • Grease • Oil collection pan

• Place barriers around the perimeter of the work area

• Telescoping cylinder weight : 30,8 Kg / 67.9 lbs

1 person

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Upper boom

Remove - Replace telescope cylinder MS0342 5-

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

• Lower the top arm.

• Place a wedge ( 1 ) under the arm .

• Lower the arm until it rests on the chock.

• The pin ( 2 ) must pass over the counterweight ( 3 ).

• Fully extend the telescoping boom.

• Set the platform ( 1 ) on chocks ( 2 ) 700 mm (27.56 in) high.

• Position chocks ( 3 ) to make the machine safe.

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Upper boom

Remove - Replace telescope cylinder MS0342 • Fit a pin ( 1 ) to stop the tube.

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

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

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

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

• Turn off the circuit breaker.

• Disconnect the terminal from the negative terminal (-) then from the positive terminal (+).

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Upper boom

Remove - Replace telescope cylinder MS0342 Cylinder rod side : • Remove the circlip ( 1 ).

• Remove the pin ( 2 ).

Cylinder body side : • Remove the 6 pins ( 1 ).

• Remove the plate ( 2 ).

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Upper boom

Remove - Replace telescope cylinder MS0342

• Place an absorbent cloth under the cylinder to avoid any oil leaks inside the machine.

• Identify the 2 telescope cylinder supply hoses ( 1 - 2 ).

• Gently loosen the fittings.

• As soon as the oil begins to flow, stop the release and let the pressure drop.

• Disconnect the 2 telescope cylinder supply hoses ( 1 - 2 ).

• Perform the same operation on the hydraulic block.

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Upper boom

Remove - Replace telescope cylinder MS0342 • Plug the openings after disassembly.

• Perform the same operation on the hydraulic block.

• Remove the pin stop screw ( 1 ).

• Remove the pin ( 2 ).

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Upper boom

Remove - Replace telescope cylinder MS0342 • Remove the pin ( 1 ).

• Carefully tip the cylinder ( 1 ) outside the access opening.

• Attach the cylinder ( 1 ) with a sling and slightly tighten the sling ( 2 ).

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Upper boom

Remove - Replace telescope cylinder MS0342 • Remove the pin stop screw ( 1 ).

• Remove the pin ( 2 ).

• Remove the pin ( 3 ).

• Use suitable handling equipment.

• Remove the cylinder ( 4 ).

• Remove the cylinder ( 4 ).

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Upper boom

Remove - Replace telescope cylinder MS0342

• Place an absorbent cloth under the cylinder to avoid any oil leaks inside the machine.

• Identify the 2 telescope cylinder supply hoses ( 1 - 2 ).

• Gently loosen the fittings.

• As soon as the oil begins to flow, stop the release and let the pressure drop.

• Disconnect the 2 telescope cylinder supply hoses ( 1 - 2 ).

• Perform the same operation on the hydraulic block.

• Plug the openings after disassembly.

• Disconnect the sensor ( 3 ) SQ530.

• Remove the pin stop screw ( 1 ).

• Remove the pin ( 2 ).

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Upper boom

Remove - Replace telescope cylinder MS0342 • Use suitable handling equipment.

• Attach the cylinder ( 1 ) with a sling and slightly tighten the sling ( 2 ).

• Remove the pin ( 1 ).

• Carefully put down the cylinder inside the boom section.

• Attach the cylinder ( 1 ) with a sling (Sling the body-side of the cylinder passing it through the rear door).

• Use suitable handling equipment. Gradually pull the cylinder from the rear.

• Do not fully extend the cylinder.

• Carefully put down the cylinder inside the boom section.

• Slide the sling ( 2 ) as far as the centre of gravity of the cylinder ( 1 ).

• Remove the cylinder ( 1 ) (Extend the cylinder, ensuring the hoses are not damaged).

N.B.-:-CENTER OF GRAVITY : A = 1390 MM / 4 FT 7 IN

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Upper boom

Remove - Replace telescope cylinder MS0342 6-

Re-installation • If you are installing a new cylinder, note the traceability number.

• Extend the cylinder rod ( 1 ) to a length of 1560 mm / 5 ft 1 in.

• Grease the pins, the seals, and the bored holes.

• Install and grease the front guiding pads.

• Refit the sensor ( 1 ) and its plate ( 2 ) inside the new cylinder ( 3 ).

• Perform the operations in the reverse order of dismantling.

• Remember to refit the pin stop screws. Install the screws with threadlock.

• Tighten the screws to the recommended torque : 44 Nm (32.45 lb.ft).

• Grease the pins, the seals, and the bored holes.

• Check that the seals are on the connections before reconnecting the hoses.

• Hold the hoses to ensure that they don't turn while tightening the connections (risk of seal damage). This will avoid the hoses twisting when they are connected to the rigid tubes.

• Connect the sensor SQ530 and attach the wiring harness to the attachment point provided using a collar.

• Re-install the circlip and ensure that it's correctly seated in the groove.

• Remove the pin immobilising the tube.

During reinstallation, pay attention to the hoses and cables.

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Upper boom

Remove - Replace telescope cylinder MS0342 7-

Additional operations • Clean off any residual oil or grease.

• From the ground control box, run the platform compensation and telescoping functions in order to flush out the hydraulic system.

• Check that there is no leak of oil at the removing connections.

• Top up the hydraulic oil if necessary (machine in stowed position).

• Check that there are no SQ530 sensor errors on the screen.

• Perform a static test by putting 290 kg / 640 lbs on the platform.

• Machine unfolded, 15 mn after checking the performance of its parts : • Boom lifting cylinder • Boom telescopic cylinder • Input jib leveling cylinder • Jib cylinder • Oscillating axle cylinder • Clean the work area.

In compliance with the country's laws, have the machine approved by an accredited organization.

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Upper boom

Remove - Replace telescope cylinder MS0342

Notes

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Upper boom

Removing the boom lifting cylinder MS0344 Upper boom Removing the boom lifting cylinder

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

• 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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Upper boom

Removing the boom lifting cylinder MS0344 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield — In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

122

You will need • "DO NOT OPERATE" tag • Standard tool kit • Wooden shims • Height wedge 1110 mm / 44 in (support to be positioned between the arm and the ground) • Height wedge 600 mm / 24 in (support to be positioned between the arm and the counterweight) • Height wedge 500 mm / 20 in (support to be positioned under the boom) • Height wedge 20 mm / 0,8 in (support to be positioned under the cylinder) • ORFS seal kit : 2505000470 • ORFS plug kit : 2505001600 • Lifting equipment(bridge crane, crane, etc) - Minimum capacity 1000 kg(2205 lb) • 1 strap, length 3 m (9 ft 84 in), capacity 1000 kg (2204 lbs) • Ratchet strap • Mallet and pin diameter 20 mm / 1 in length 500 mm / 20 in minimum • Torque wrench for 44 Nm • Grease • Oil collection pan • 290 kg / 639 lbs load for static test

• Place barriers around the perimeter of the work area

• Weight of the lifting cylinder assembly : 38 Kg / 83.8 lbs

1 person

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Upper boom

Removing the boom lifting cylinder MS0344 5-

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

• Lower the top arm.

• Place a wedge ( 1 ) under the arm .

• Lower the arm until it rests on the chock.

• The pin ( 2 ) must pass over the counterweight ( 3 ).

• Position the chocks ( 1 ) between the arm and the ground.

• Lift the boom to free up access to the cylinder. The pin ( 2 ) should pass over the arm.

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Upper boom

Removing the boom lifting cylinder MS0344 • Attach slings to the boom.

• Tension the handling device.

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

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

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

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Upper boom

Removing the boom lifting cylinder MS0344 • Place a do not operate tag at the start/stop switch location to inform personnel that the equipment is being worked on.

• Turn off the circuit breaker.

• Disconnect the terminal from the negative terminal (-) then from the positive terminal (+).

• Remove the pin stop screw and the smooth clevis.

• Position a chock ( 1 ) under the cylinder body.

• Extract the pin ( 2 ).

• Place the cylinder body on the chock.

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Upper boom

Removing the boom lifting cylinder MS0344 • Switch the machine on.

• From the ground control box, retract the cylinder rod.

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

N.B.-:-T HE FOLLOWING OPERATIONS ALLOW THE BRIDGE CRANE TO BE RELEASED IF OTHER HANDLING EQUIPMENT IS NOT AVAILABLE TO SLING THE LIFT CYLINDER :

• Position a chock ( 1 ) between the boom and the arm.

• Hold the chock ( 1 ) in place using a strap ( 2 ).

• Lower the boom until it is resting on the chock.

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Upper boom

Removing the boom lifting cylinder MS0344 • Identify the hoses.

• Gently loosen the fittings.

• Place an absorbent cloth under the cylinder to avoid any oil leaks inside the machine.

• As soon as a trickle of oil appears, let it flow out. When there is no longer any residual pressure, disconnect the hoses and plug the connectors.

• Perform the same operation on the hydraulic block.

• Attach the cylinder ( 1 ) with a sling and slightly tighten the sling ( 2 ).

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Upper boom

Removing the boom lifting cylinder MS0344 • Remove the pin stop screw and the smooth clevis.

This pin is the link between the arm tie rods, the boom lift cylinder and the link piece. Do not completely extract the pin.

• Mark a line on the extraction rod at 360 mm / 14 in.

• Remove the pin ( 1 ).

Do not extract the pin more than a maximum of 385 mm / 15 in.

• Remove the pin extraction rod.

• Use handling equipment to lift the cylinder and move towards the platform.

• Guide the cylinder to remove it.

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Removing the boom lifting cylinder MS0344 • Remove the cylinder.

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Upper boom

Removing the boom lifting cylinder MS0344 6-

Re-installation • If you are installing a new cylinder, note the serial number.

• Perform the operations in the reverse order of dismantling.

• Remember to refit the pin stop screws. Install the screws with threadlock.

Tightening at a torque of 44 Nm (32.45 lb.ft).

• Grease the pins, the seals, and the bored holes.

• Check that the seals are on the connections before reconnecting the hoses.

• Hold the hoses to ensure that they don't turn while tightening the connections (risk of seal damage). This will avoid the hoses twisting when they are connected to the rigid tubes.

• During reinstallation, pay attention to the hoses and cables.

• Remove the pin immobilising the tube.

7-

Additional operations • Clean off any residual oil or grease.

• Perform boom lifting movements.

• Ensure that there are no hydraulic leaks.

• Check the level of the hydraulic oil reservoir. Top up the oil if necessary.

• Perform a static test by putting 290 kg(639 lb) on the platform. Machine unfolded, 15 mn after checking the performance of its parts : • Lift cylinder.

In compliance with the country's laws, have the machine approved by an accredited organization.

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Lower arm

Remove - Replace arm cylinder MS0345 Lower arm Remove - Replace arm cylinder

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

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

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

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

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Lower arm

Remove - Replace arm cylinder MS0345 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield – In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

132

You will need • Arm cylinder : 4000717190 • "DO NOT OPERATE" tag • Standard tool kit • Wooden shims • Height wedge 1110 mm / 44 in (support to be positioned between the arm and the ground) • Height wedge 600 mm / 24 in (support to be positioned between the arm and the counterweight) • Height wedge 20 mm / 0,8 in (support to be positioned under the cylinder) • ORFS seal kit : 2505000470 • ORFS plug kit : 2505001600 • Hammer • Lifting equipment(bridge crane, crane, etc) - Minimum capacity 1000 kg(2205 lb) • 1 strap, length 3 m (9 ft 84 in), capacity 1000 kg (2204 lbs) • Ratchet strap • Mallet and pin diameter 20 mm / 1 in length 500 mm / 20 in minimum • Torque wrench for 44 Nm • Grease • Oil collection pan • 290 kg / 639 lbs load for static test

• Place barriers around the perimeter of the work area

• Arm cylinder weight : 83 Kg / 183 lbs

1 person

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Remove - Replace arm cylinder MS0345 5-

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

• Lift the arm.

• Position a chock under the arm.

• Lower the boom to the lowest point.

• Retract the telescoping boom.

• Position the chocks ( 1 ) between the arm and the ground.

• Set the machine down on the chocks.

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

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

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

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Lower arm

Remove - Replace arm cylinder MS0345 • Place a do not operate tag at the start/stop switch location to inform personnel that the equipment is being worked on.

• Turn off the circuit breaker.

• Disconnect the terminal from the negative terminal (-) then from the positive terminal (+).

Remove the side covers : • Unscrew the lock nut ( 1 ).

• Loosen the screw ( 2 ).

• Pull the cover upwards and remove it.

• Attach the cylinder ( 1 ) with a sling and slightly tighten the sling ( 2 ).

• Remove the pin stop screw and the smooth clevis.

• Remove the pin ( 1 ).

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Lower arm

Remove - Replace arm cylinder MS0345 • Use the handling equipment to carefully place the cylinder in the centre of the arm.

• Turn the cylinder rod ( 1 ) so that the pin is vertical.

• Disconnect the solenoid valves YV420D ( 1 ) and YV421D ( 2 ).

• Cut the collars between the cylinder and the wiring harness.

• Identify the 3 hoses on the cylinder.

• Gently loosen the fittings.

• Place an absorbent cloth under the cylinder to avoid any oil leaks inside the machine.

• As soon as a trickle of oil appears, let it flow out. When there is no longer any residual pressure, disconnect the hoses and plug the connectors.

• As soon as a trickle of oil appears, let it flow out.

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Lower arm

Remove - Replace arm cylinder MS0345 • Completely remove the hoses.

• Seal the hoses and connections on the cylinder.

• Move the hoisting strap to tie the cylinder at the center of gravity : A = 890 mm / 2 ft 91 in.

• Put a small amount of tension on the strap.

• Remove the pin stop screw and the smooth clevis.

• Remove the pin ( 1 ).

• Slightly lift the cylinder so that it can be moved.

• Push the cylinder towards the counterweight between the arms in order to remove the cylinder on the rod side.

• Put the cylinder on the wooden pallet.

• Pull out the cylinder by the rod, then pull the cylinder out completely between the arm and the tie rod.

• Remove the cylinder.

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Lower arm

Remove - Replace arm cylinder MS0345 6-

Re-installation • If you are installing a new cylinder, note the traceability number.

• Refit the flange on the new cylinder.

• Perform the operations in the reverse order of dismantling.

• Grease the pins, the seals, and the bored holes.

• Remember to refit the pin stop screws. Install the screws with threadlock.

• Tighten the screws to the recommended torque : 44 Nm (32.45 lb.ft).

• Check that the seals are on the connections before reconnecting the hoses.

• To avoid the hoses twisting when they are connected to the rigid tubes, hold them firmly when tightening the couplings.

During reinstallation, pay attention to the hoses and cables.

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Lower arm

Remove - Replace arm cylinder MS0345 7-

Additional operations • Clean off any residual oil or grease.

• Clean the work area.

• From the ground control box, operate the cylinder to flush out the hydraulic circuit.

• Check that there is no leak of oil at the removing connections.

• Perform a static test by putting 290 kg / 640 lbs on the platform. Machine unfolded, 15 mn after checking the performance of its parts : • Output jib compensation cylinder • Input jib leveling cylinder.

• Jib cylinder.

• Boom lifting cylinder.

• Boom telescopic cylinder.

In compliance with the country's laws, have the machine approved by an accredited organization.

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Turntable

Remove - Replace counterweight MS0346 Turntable Remove - Replace counterweight

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

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

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

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

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Turntable

Remove - Replace counterweight MS0346 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield — In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

140

You will need • Standard tool kit • 1 wooden chock with a thickness of 1100 mm / 43 in • 1 wooden chock, length 400 mm / 16 in • Torque wrench • 2 hoisting strap(s) for 3 T / 6615 lbs at a length of 3 m / 9 ft 10 in • Lifting and handling equipment(bridge crane, crane, etc)Capacity : 3 T

• Place barriers around the perimeter of the work area

• Weight of counterweight : 2650 kg / 5843 lbs

1 person

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Turntable

Remove - Replace counterweight MS0346 5-

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

• Lift the arm ( 1 ) so that it is not in contact with the counterweight ( 2 ).

• Lower the boom to the lowest point.

• Retract the telescope to the maximum point.

• Position the chocks ( 1 ) between the arm and the ground.

• Set the machine down on the chocks.

• Mark out the work area.

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Turntable

Remove - Replace counterweight MS0346 • Switch off the ignition and remove the key ( 1 ) from the ignition.

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

• Turn off the circuit breaker.

• Disconnect the terminal from the negative terminal (-) then from the positive terminal (+).

If machine equipped with the option Activ' Lighting System : • Remove the 3 screws that hold the plate ( 1 ) on the counterweight.

• Remove the screws ( 2 ).

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Turntable

Remove - Replace counterweight MS0346 • Disconnect the spotlight. Disconnect the connector ( 1 ).

• Disconnect the beacon light. Disconnect the connector ( 2 ).

• Disconnect the twilight sensor. Disconnect the connector ( 3 ).

• On each side connector ( 2 ).

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Turntable

Remove - Replace counterweight MS0346 • Unscrew the turntable rotation stop pin ( 1 ) using a 36 mm / 1.42 in wrench.

• Secure the counterweights using the rings with 2 3 T / 6615 lbs straps, 3 m / 9 ft 10 in long, and carefully tension the bridge.

• Open the side cover on the hydraulic compartment side.

• Using a 36 mm / 1.42 in wrench, unscrew then remove the screw ( 1 ).

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Turntable

Remove - Replace counterweight MS0346 Check the tension of the bridge and its alignment • Open the side cover on side Activ' Screen.

• Using a 36 mm / 1.42 in wrench, unscrew then remove the screws ( 1 ).

• Gently lower the axle then retract the counterweight.

• Remove the counterweight.

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Turntable

Remove - Replace counterweight MS0346 6-

Re-installation • Perform the operations in the reverse order of dismantling.

Counterweight tightening torque : 320 Nm / 236 lbs-ft.

7-

Additional operations • Clean the work area.

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Turntable

Remove - Reinstall the hydraulic rotation motor MS0347 Turntable Remove - Reinstall the hydraulic rotation motor

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

• 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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Turntable

Remove - Reinstall the hydraulic rotation motor MS0347 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield — In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

You will need • Torque wrench 105 Nm • Spanner 24 mm • Key BTR 10 mm • ORFS seal kit : 2505000470 • ORFS plug kit : 2505001600

• Place barriers around the perimeter of the work area

1 person

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Turntable

Remove - Reinstall the hydraulic rotation motor MS0347 5-

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

• Stow the machine.

• Fit the platform on a handling device.

• Mark out the work area.

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

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

• Turn off the circuit breaker.

• Disconnect the terminal from the negative terminal (-) then from the positive terminal (+).

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Turntable

Remove - Reinstall the hydraulic rotation motor MS0347 • Identify the hoses.

• Gently loosen the fittings.

• Place an absorbent cloth under the hoses to avoid any oil leaks inside the machine.

• As soon as a trickle of oil appears, let it flow out. When there is no longer any residual pressure, disconnect the hoses and plug the connectors.

• Perform the same operation on the hydraulic block.

• Unscrew the 2 screws from the engine using a BTR 10 mm wrench.

• Pull the motor towards the rear to free the shaft.

• Remove the hydraulic motor.

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Turntable

Remove - Reinstall the hydraulic rotation motor MS0347 6-

Re-installation • Perform the operations in the reverse order of dismantling.

• If the motor has been replaced, remove and retain its traceability number.

• Check state and presence of the seals on hydraulic motor.

• Be aware of the position of the pin when reinstalling the hydraulic motor. If the pin is not correctly positioned, turn the screw located on the other side of the wormscrew in order to line up the key with its position :

• Reassemble and tighten the 2 screws to a torque of 105Nm using a torque wrench.

• Check for the presence of seal on connections.

• Maintain hoses so they do not turn when tightening fittings.

7-

Additional operations • From the ground control box, rotate the turntable to bleed the hydraulic circuit

• Ensure that there are no hydraulic leaks.

• Check the level of the hydraulic oil reservoir. Top up the oil if necessary.

• Clean the work area.

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Turntable

Remove - Reinstall the hydraulic rotation motor MS0347

Notes

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Turntable

Removal - Replacement of the electro-pump unit MS0348 Turntable Removal - Replacement of the electro-pump unit

1-

Concerned area

2-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield — In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

3-

You will need • Personal protective equipment • Standard tool kit • ORFS seal kit : 2505000470 • ORFS plug kit : 2505001600 • A bridge or handling device 1000 kg / 2205 lbs • 1 x sling 3 m / 9 ft 10 in, 1000 kg / 2205 lbs minimum • 1 lifting ring, capacity 1000 kg / 2205 lbs, length 200 mm / 7.9 in, diameter M8

• Place barriers around the perimeter of the work area

Weight of the electro-pump unit : 50 kg / 110 lbs

1 person

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Turntable

Removal - Replacement of the electro-pump unit MS0348 4-

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

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

• Stow the machine.

• Orientate the turntable to 90 °.

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

MS0360 Placing the machine in maintenance

• Remove the 3 fastening screws ( 1 ) from the protective cover ( 2 ).

• Remove the cover ( 2 ).

• Remove the 2 power cables ( 1 ) and ( 2 ) on the motor.

• Disconnect the cable ( 3 ) from the temperature sensor .

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Turntable

Removal - Replacement of the electro-pump unit MS0348 • Disconnect the solenoid valves (1) - YV905, (2) - YV800 and (3) YV150R, (4) - YV150L.

N.B.-:-PLACE AN ABSORBENT CLOTH UNDER THE HOSES TO AVOID ANY OIL LEAKS INSIDE THE MACHINE • Locate, disconnect and plug the hydraulic unit hoses.

• Identify the hoses on the hydraulic block.

• Gently loosen the fittings.

• As soon as the oil begins to flow, stop the release and let the pressure drop.

• Completely remove the hoses.

• Plug the hose(s) and the hydraulic block .

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Turntable

Removal - Replacement of the electro-pump unit MS0348 • Fit and screw up a lifting ring ( 1 ).

• Attach the assembly with a sling to a bridge crane or handling equipment.

• Remove the 2 pins ( 1 ).

• Slightly tighten the sling ( 1 ).

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Turntable

Removal - Replacement of the electro-pump unit MS0348 • Remove the electro-pump unit.

5-

Re-installation • To refit it, proceed in the opposite order to removal.

• Check that the seals are on the connections before reconnecting the hoses.

• To avoid the hoses twisting when they are connected to the rigid tubes, hold them firmly when tightening the couplings.

• During reinstallation, pay attention to the hoses and cables.

6-

Additional operations • Unlock the machine. Refer to

MS0360 Placing the machine in maintenance configuration.

• Perform several complete movements of all the machine's functions(Perform a function test).

• Ensure that there are no hydraulic leaks.

• Check the level of the hydraulic oil reservoir.

• Top up the hydraulic oil if necessary (machine in stowed position).

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Turntable

Removal - Replacement of the electro-pump unit MS0348

Notes

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Chassis

Removal - Replacement of the steering cylinder MS0349 Chassis Removal - Replacement of the steering cylinder

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

• 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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Chassis

Removal - Replacement of the steering cylinder MS0349 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield — In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

160

You will need • "DO NOT OPERATE" tag • Standard tool kit • ORFS plug kit : 2505001600 • ORFS seal kit : 2505000470 • Torque wrench for 100 Nm • Steering cylinder : 133B158580

• Place barriers around the perimeter of the work area

• Weight of steering cylinder : 14,7 Kg / 32.4 lbs

1

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Chassis

Removal - Replacement of the steering cylinder MS0349 5-

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

• Stow the machine.

• Turn the turret 90 ° to improve accessibility.

• Mark out the work area.

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

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

• Turn off the circuit breaker.

• Disconnect the terminal from the negative terminal (-) then from the positive terminal (+).

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Chassis

Removal - Replacement of the steering cylinder MS0349 • Unscrew the 3 attaching the front centre cover.

• Remove the central cover.

• Unscrew the 3 screws attaching the front centre panel.

• Remove the panel.

• Identify the hoses.

• Gently loosen the fittings.

• Place an absorbent cloth under the hoses to avoid any oil leaks inside the machine.

• As soon as a trickle of oil appears, let it flow out. When there is no longer any residual pressure, disconnect the hoses and plug the connectors.

• Perform the same operation on the hydraulic block.

• Remove the pin stop screw and the smooth clevis.

• Remove the pin .

• Perform the same operation on each side of the machine.

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Chassis

Removal - Replacement of the steering cylinder MS0349 • Unscrew the 4 screws ( 1 ) between the cylinder and the chassis.

• Remove the cylinder via the access hatch.

• Remove the cylinder

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Chassis

Removal - Replacement of the steering cylinder MS0349 6-

Re-installation • If you are installing a new cylinder, note the traceability number.

• If the pin has come off with the cylinder : • Recover it and refit the pin (as shown) when refitting the new cylinder

• Perform the operations in the reverse order of dismantling.

• Reassemble and tighten the 2 screws to a torque of 99 Nm using a torque wrench.

N.B.-:-START BY BRINGING THE PIN UP TO THE SCREW. • Remember to refit the pin stop screws Install the screws with threadlock (Tightening at a torque of 10 Nm (7.37 lb.ft)).

• Grease the pins, the seals, and the bored holes.

• Check for the presence of seal on connections.

• Maintain hoses so they do not turn when tightening fittings.

7-

Additional operations • From the top control box, perform drive movements to bleed the hydraulic circuit.

• Ensure that there are no hydraulic leaks.

• Check the level of the hydraulic oil reservoir. Top up the oil if necessary.

• Clean the work area.

164

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Upper boom

Remove - Replace the boom/jib/box assembly MS0350 Upper boom Remove - Replace the boom/jib/box assembly

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

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

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

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

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Upper boom

Remove - Replace the boom/jib/box assembly MS0350 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield — In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

166

You will need • "DO NOT OPERATE" tag • Standard tool kit • ORFS seal kit : 2505000470 • ORFS plug kit : 2505001600 • Lifting and handling equipment(bridge crane, crane, etc) : capacity 3000 kg(6615 lb) • 2 slings 3000 kg (6615 lb) - 3 m (9 ft 84 in) • Hammer • Pin diameter 20 mm / 0,79 in, length 300 mm / 12 in • Torque wrench for 44 Nm (32.45 lbs-ft) • Grease • Oil collection pan • 290 kg / 639 lbs load for static test

• Place barriers around the perimeter of the work area

• Weight of boom/jib/platform assembly : 600 Kg / 1323 lbs

2 persons

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Upper boom

Remove - Replace the boom/jib/box assembly MS0350 5-

Removal • Remove the platform. Refer to

MS0334 Removal - Replacement of the platform.

The platform is removed.

• Raise the boom.

• The pin ( 1 ) should pass over the arm.

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

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

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

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Upper boom

Remove - Replace the boom/jib/box assembly MS0350 • Place a do not operate tag at the start/stop switch location to inform personnel that the equipment is being worked on.

• Turn off the circuit breaker.

• Disconnect the terminal from the negative terminal (-) then from the positive terminal (+).

• Using a coloured felt pen, mark the location of the wiring harness where it enters and leaves the cable holder chain.

N.B.-:-THIS WILL ENABLE THEM TO BE CORRECTLY REPOSITIONED WHEN RE-INSTALLING.

• Open each link of the cable holder chain using a screwdriver.

• Remove the cable bundle from the cable chain.

• Remove the 2 cable supports located under the boom.

• Pass the wiring harness down as far as the foot of the boom.

• Refit the 2 supports once the wiring harness has been removed.

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Upper boom

Remove - Replace the boom/jib/box assembly MS0350 • Remove the collar at the foot of the boom.

• Remove the harness.

• Remove the 6 plate's fastening screws that give access to the output compensation cylinder.

• Locate the 2 hoses leading to the compensation receiver cylinder.

• Gently loosen the fittings.

• Place an absorbent cloth under the cylinder to avoid any oil leaks inside the machine.

• As soon as a trickle of oil appears, let it flow out. When there is no longer any residual pressure, disconnect the hoses and plug the connectors.

• Completely remove the hoses.

• Perform the same operation on the hydraulic block.

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Upper boom

Remove - Replace the boom/jib/box assembly MS0350 • Identify the 2 telescope cylinder supply hoses ( 1 - 2 ).

• Gently loosen the fittings.

• Place an absorbent cloth under the cylinder to avoid any oil leaks inside the machine.

• As soon as a trickle of oil appears, let it flow out. When there is no longer any residual pressure, disconnect the hoses and plug the connectors.

• Completely remove the hoses.

• Perform the same operation on the hydraulic block.

• Disconnect the sensor (3) SQ530.

• Identify the hoses on the boom.

• Gently loosen the fittings.

• Place an absorbent cloth under the cylinder to avoid any oil leaks inside the machine.

• As soon as a trickle of oil appears, let it flow out. When there is no longer any residual pressure, disconnect the hoses and plug the connectors.

• Completely remove the hoses.

• Perform the same operation on the hydraulic block.

• Bring the telescope cylinder hoses and the 3 hoses which go towards the chassis to the rear of the boom.

• Attach the 2 compensation cylinder hoses to the side of the boom.

170

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Upper boom

Remove - Replace the boom/jib/box assembly MS0350 • Remove the pin stop screw and the smooth clevis.

• Extract the pin between the compensation cylinder and the boom using a metal pin.

• Carefully set down the cylinder outside the access hole.

• Attach the boom with a sling on the platform side.

• Tighten the sling around the boom.

• Remove the pin stop screw and the smooth clevis of the boom lift cylinder pin.

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Upper boom

Remove - Replace the boom/jib/box assembly MS0350 • Position a chock ( 1 ) under the cylinder body.

• Extract the pin ( 2 ).

• Place the cylinder body on the chock.

• Using handling equipment, carefully set down the boom on the arms

Attach slings to the boom : • Move backwards : • Pass a 3000 kg (6615 lb) - 3 m (9 ft 84 in) sling around the boom.

• Move forward : • Pass a 3000 kg (6615 lb) - 3 m (9 ft 84 in) sling around the telescope.

N.B.-:-MAKE AN EXTRA TURN WITH THIS SLING TO FIND THE POINT OF EQUILIBRIUM OF THE BOOM.

• Align the bridge and tension the straps.

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Upper boom

Remove - Replace the boom/jib/box assembly MS0350 • Remove the pin stop screw and the smooth clevis.

• Extract the pin, adjusting the tension of the bridge to find the position where the pin can be removed more easily.

• Remove the boom and set it on strong and stable supports.

• Place a chock ( 1 ) between the support and the boom to avoid resting on the cable supports • Attach the boom.

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Upper boom

Remove - Replace the boom/jib/box assembly MS0350 6-

Re-installation • Perform the operations in the reverse order of dismantling.

• Grease the pins, the seals, and the bored holes.

• Remember to refit the pin stop screws. Install the screws with threadlock.

• Tighten the screws to the recommended torque : 44 Nm (32.45 lb.ft).

• Check that the seals are on the connections before reconnecting the hoses.

• Hold the hoses to ensure that they don't turn while tightening the connections (risk of seal damage). This will avoid the hoses twisting when they are connected to the rigid tubes.

During reinstallation, pay attention to the hoses and cables.

• Re-install the platform. Refer to

7-

MS0334 Removal - Replacement of the platform.

Additional operations • Clean off any residual oil or grease.

• Top up the hydraulic oil if necessary (machine in stowed position).

• From the ground control box, perform complete movements of the boom, compensation, jib and platform : • Check the articulation of the hoses.

• Check the articulation of the wire harnesses.

• Check that there are no SQ530 sensor errors on the screen.

• Check that there is no leak of oil at the removing connections.

• Top up the hydraulic oil if necessary (machine in stowed position).

• Perform a static test by putting 290 kg / 640 lbs on the platform.

• Machine unfolded, 15 mn after checking the performance of its parts : • Boom lifting cylinder • Boom telescopic cylinder • Output jib compensation cylinder • Input jib leveling cylinder • Jib cylinder In compliance with the country's laws, have the machine approved by an accredited organization.

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Lower arm

Remove - Replace arm assembly MS0351 Lower arm Remove - Replace arm assembly

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

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

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

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

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Lower arm

Remove - Replace arm assembly MS0351 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield — In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

176

You will need • "DO NOT OPERATE" tag • ORFS seal kit : 2505000470 • ORFS plug kit : 2505001600 • Personal protective equipment • Standard tool kit • Hammer • Torque wrench for 44 Nm / 32.5 lbs-ft • Oil collection pan • Grease • Pin diameter 20 mm / 0.79 in, length 500 mm / 20 in • 2 ratcheting straps that support 1000 kg / 2205 lbs at a length of 2 m / 6 ft 56 in • 2 hoisting strap(s) for 2000 kg / 4410 lbs at a length of 3 m / 9 ft 10 in • A bridge or handling device 2000 kg / 4410 lbs • 1 wooden chock, length 400 mm / 15.7 in

• Place barriers around the perimeter of the work area

• Arm assembly weight : 753 Kg / 1660 lbs

1 person

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Lower arm

Remove - Replace arm assembly MS0351 5-

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

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

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

• Remove the basket. Refer to

MS0334 Removal - Replacement of the platform.

• Remove the counterweight. Refer to • Remove the boom. Refer to

MS0346 Remove - Replace counterweight.

MS0350 Remove - Replace boom assembly.

• Remove the compensation output cylinder. Refer to

MS0341 Remove/Re-install output compensation cylinder.

The platform, boom and counterweight are removed • Position a wooden chock ( 1 ), length 400 mm / 15.7 in between the arm elements ( 2 ).

• Fold and bring the arm elements ( 2 ) to rest on the chock ( 1 ).

• Mark out the work area.

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

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Lower arm

Remove - Replace arm assembly MS0351 • Place a do not operate tag at the start/stop switch location to inform personnel that the equipment is being worked on.

• Turn off the circuit breaker.

• Disconnect the terminal from the negative terminal (-) then from the positive terminal (+).

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Lower arm

Remove - Replace arm assembly MS0351

• Identify the hose(s) ( 1 ) on the hydraulic block .

• Ensure that the coloured collars are present to identify the position of the hoses ( 1 ) on the hydraulic block .

• Place an absorbent cloth under the hoses to avoid any oil leaks inside the machine.

• Gently loosen the fittings.

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Lower arm

Remove - Replace arm assembly MS0351

Do not unscrew and remove the hoses which are connected to the hydraulic tank • Do not unscrew and remove the hoses ( 1 ).

• Do not unscrew and remove the coupling ( 2 ).

Do not unscrew and remove the hoses which are connected to the turntable rotation function • Do not unscrew and remove the hoses ( 1 ).

• Do not unscrew and remove the tubes ( 2 ).

• As soon as the oil begins to flow, stop the release and let the pressure drop.

• Completely remove the hoses.

• Plug the hoses and unions.

On the ground control box side, disconnect the plugs : • Marking CN6-01.

• Marking CN6-02.

• Marking CN02.

• Cut the 220 V cable hose clamps.

• Bring the harnesses to the back of the arm.

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Lower arm

Remove - Replace arm assembly MS0351 • Mark the passage of the hoses through the collars.

• Remove the collars ( 1 ) retaining the hoses on the chassis .

• Bring the hoses to the back of the arm.

• Using a 1000 kg / 2205 lbs ratchet strap, of 2 m / 6 ft 56 in in length, strap the lower arm and the upper arm.

• Tighten the strap.

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Lower arm

Remove - Replace arm assembly MS0351 • Remove the pin stop screw ( 1 ) and the smooth clevis ( 2 ) from each tie rod(On each side of the machine).

• Strap the tie rods to the link piece using a ratcheting strap supporting 1000 kg / 2205 lbs at a length of 2 m / 6 ft 56 in.

• Put a small amount of tension on the strap.

• Remove the pin ( 3 )(On each side of the machine).

• Tighten the strap.

• At the rear, refit the boom pin ( 1 ) with the pin stop smooth clevis assembly ( 2 ).

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Lower arm

Remove - Replace arm assembly MS0351 • Secure the arm ( 1 ) with 2 lifting strap(s) ( 2 ), capacity 2000 kg / 4410 lbs, length 3 m / 9 ft 10 in for each strap.

• Align the bridge and add tension to it.

• Remove the pin stop screw ( 1 ) and the smooth clevis ( 2 ).

• Remove the pin ( 3 ).

N.B.-:-SLIGHTLY TIGHTEN OR RELEASE USING THE BRIDGE CRANE TO FIND AN IDEAL POSITION TO REMOVE THE PIN ( 3 )

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Lower arm

Remove - Replace arm assembly MS0351

• Use handling equipment to carefully remove the arm ( 1 ).

• Place the assembly on a flat surface while ensuring the assembly's stability.

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Lower arm

Remove - Replace arm assembly MS0351 6-

Re-installation • Perform the operations in the reverse order of dismantling.

• Grease the pins, the seals, and the bored holes.

• Remember to refit the pin stop screws. Install the screws with threadlock.

• Tighten the screws to the recommended torque : 44 Nm (32.45 lb-ft).

• Check that the seals are on the connections before reconnecting the hoses.

• Hold the hoses to ensure that they don't turn while tightening the connections (risk of seal damage). This will avoid the hoses twisting when they are connected to the rigid tubes During reinstallation, pay attention to the hoses and cables.

• Reinstall the counterweight. Refer to • Re-install the boom. Refer to

MS0346 Remove - Replace counterweight.

MS0350 Remove - Replace boom assembly.

• Refit the compensation output cylinder. Refer to • Re-install the platform. Refer to

7-

MS0341 Remove/Re-install output compensation cylinder.

MS0334 Removal - Replacement of the platform.

Additional operations • Clean off any residual oil or grease.

• Check the hydraulic oil level.

• Perform complete movements of the arm, boom, compensation, jib and platform from the ground control box : • Check the articulation of the hoses.

• Check the articulation of the wire harnesses.

• Check that the ILS SQ530 sensor changes status on the ground control box screen.

• Check that there is no leak of oil at the removing connections.

• Perform a static test by putting 290 kg / 640 lbs on the platform. Machine unfolded, 15 mn after checking the performance of its parts : • Lift Arm hydraulic cylinder.

• Boom lifting cylinder.

• Boom telescopic cylinder.

• Input jib leveling cylinder.

• Output jib compensation cylinder.

• Jib cylinder.

In compliance with the country's laws, have the machine approved by an accredited organization.

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Lower arm

Remove - Replace arm assembly MS0351

Notes

186

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Chassis

Removal - Replacement of the electric brake on the gear motor MS0352 Chassis Removal - Replacement of the electric brake on the gear motor

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

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

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Chassis

Removal - Replacement of the electric brake on the gear motor MS0352 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield - In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

188

You will need • Electric brake - 4001115650 • "DO NOT OPERATE" tag • Standard tool kit • Torque wrench for 24 Nm • Grease • Hose clamps

• Place barriers around the perimeter of the work area

• Weight of the brake : 88 Kg / 194 lbs

1 person

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Chassis

Removal - Replacement of the electric brake on the gear motor MS0352 5-

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

• Mark out the work area.

• Place the machine in its folded position.

• Turn the turntable through 90° to access the chassis cover.

• Switch off the ignition and remove the ignition key.

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

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

MS0360 -

• Unscrew and remove the 6 screws.

• Remove cover from chassis.

• Use a line to mark the position of the brake assembly in relation to the engine.

N.B.-:-THE MARK MUST BE TRANSFERRED TO THE NEW ELECTRIC BRAKE.

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Chassis

Removal - Replacement of the electric brake on the gear motor MS0352 • Disconnect the YB100 sensor (right brake) or YB101 sensor (left brake).

• Unscrew and remove the 3 screws.

• Pull the electric brake.

• Remove the electric brake.

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Chassis

Removal - Replacement of the electric brake on the gear motor MS0352 6-

Brake adjustment

Marking

Description

Marking

Description

1

Ring

6

Hub

2

Coil

7

Fastening screw

3

Anchor

8

Adjustment screw

4

Disc brake

9

Spring pusher

5

Flange

10

Spring

• Unscrew the fastening screw ( 7 ) by one turn.

Move the adjustment screws ( 8 ) : • If you turn in one direction the clearance ( E ) will increase, in the opposite direction the play decreases ( E ).

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Chassis

Removal - Replacement of the electric brake on the gear motor MS0352 • Tighten the fastening screw ( 7 ) to a torque of 24 Nm.

• Check the clearance ( E ) again with a gauge.

• Perform this action on the 3 fastening screws.

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Chassis

Removal - Replacement of the electric brake on the gear motor MS0352 7-

Re-installation • Remount in reverse order to removal.

• Tighten the 3 electric brake screws to the torque of 24 Nm. • Apply contact grease to the sockets before reconnecting them.

• Refit the seal correctly between the brake and the electric motor.

8-

Additional operations • Unlock the machine. Refer to

MS0360 Placing the machine in maintenance configuration.

• Perform a drive function test.

• Ensure the brakes are working properly.

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Chassis

Removal - Replacement of the electric brake on the gear motor MS0352

Notes

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Electricity

Removal - Replacement of on-board charger MS0353 Electricity Removal - Replacement of on-board charger

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

• 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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195

Electricity

Removal - Replacement of on-board charger MS0353 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield - In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

196

You will need • Charger - 4001095580 • "DO NOT OPERATE" tag • Standard tool kit • Torque wrench for 10 Nm • 6 mm Allen wrench

• Place barriers around the perimeter of the work area

• Approximate weight of a charger : 1,4 Kg / 3.08 lbs

1 person

4001160950

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USA / GB

Electricity

Removal - Replacement of on-board charger MS0353 5-

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

• Mark out the work area.

• Place the machine in its folded position.

• Turn the turntable through 90° to access the chassis cover.

• Switch off the ignition and remove the ignition key.

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

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

MS0360 -

• Unscrew and remove the 6 screws.

• Remove cover from chassis.

Unplug the 3 plugs from the charger : • Marking ( 1 ) : 220 V mains power plug.

• Marking ( 2 ) : CAN sheet.

• Marking ( 3 ) : 72 V sheet.

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Electricity

Removal - Replacement of on-board charger MS0353 • Marking ( 1 ) : 220 V mains power plug : • Remove the white latch ( 4 ).

• Press the push button ( 5 ).

• Disconnect the plug.

• Unscrew the 2 plate support screws.

• Remove the plate and charger assembly ( 6 ).

• Undo the 4 screws .

• Remove the charger.

6-

Re-installation • Remount in reverse order to removal.

• Tighten the charger screws to a torque of 10 Nm. • Apply contact grease to the sockets before reconnecting them.

7-

Additional operations • Unlock the machine. Refer to

MS0360 Placing the machine in maintenance configuration.

• Ensure the charger is working properly.

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Chassis

Removal - Replacement of the gear motor MS0354 Chassis Removal - Replacement of the gear motor

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

• 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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199

Chassis

Removal - Replacement of the gear motor MS0354 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield - In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

200

You will need • Gear motor SIGMA 16 - 4001135370 • Gear motor SIGMA 16 PRO - 4001135370 • Contact grease • "DO NOT OPERATE" tag • Standard tool kit • Lifting and handling equipment(bridge crane, crane, etc) • 1 ratcheting straps that support 1000 kg / 2205 lbs at a length of 2 m / 6 Ft 7 in.

• 2 hoisting strap(s) for 4000 kg / 8818 lbs at a length of 3 m / 9 Ft 10 in • 1 hoisting strap(s) for 1000 kg / 2205 lbs at a length of 1 m / 3 Ft 3 in • Torque wrench for 80 Nm • Torque wrench for 100 Nm • Torque wrench for 170 Nm

• Place barriers around the perimeter of the work area

• Weight of the reduction gear : 50 Kg / 110.2 lbs

1 person

4001160950

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USA / GB

Chassis

Removal - Replacement of the gear motor MS0354 5-

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

• Mark out the work area.

• Stow the machine.

• Switch off the ignition and remove the ignition key.

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

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

MS0360 -

• Unscrew and remove the 6 screws.

• Remove cover from chassis.

• Sling the machine using 2 slings, capacity 4000 kg / 8818 lbs, length 3 m / 9 Ft 10 in and handling equipment.

• Lift the machine.

• Place the machine on resistant and stable wedges.

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Chassis

Removal - Replacement of the gear motor MS0354 • Strap the wheel with the ratchet strap ( 2 ).

N.B.-:- 1000 KG / 2205 LBS RATCHET STRAP, 2 M / 6 FT 7IN IN LENGTH. • Thread strap ( 1 ) through strap ( 2 ) to slide the wheel.

N.B.-:- 1000 KG / 2205 LBS LIFT STRAP, 1 M / 3 FT 3 IN IN LENGTH. • Tighten the strap.

• Tighten the sling from the bridge crane.

• Loosen then remove the wheel nuts.

• Remove the wheel.

202

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Chassis

Removal - Replacement of the gear motor MS0354 • Remove the 3 power cables U, V and W on the motor : • Marking ( 1 ) : U .

• Marking ( 2 ) : V. • Marking ( 3 ) : W.

• Identify the cables on the board ( 4 ) then mark the cables to facilitate refitting.

• Disconnect the YB100 sensor (right brake) or YB101 sensor (left brake) (5).

• Disconnect the plug SV300 (right reducer) or SV301 (left reducer) (6).

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Chassis

Removal - Replacement of the gear motor MS0354 • Sling the gear.

• Tension the handling device.

• Remove the screws between the chassis and the reducer.

• Leave 2 screws in place to hold the assembly in position.

• Ensure that the sling is supporting the assembly properly.

• Remove the last screws between the chassis and the reducer.

• Use handling equipment to extract the gearmotor from the chassis.

204

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Chassis

Removal - Replacement of the gear motor MS0354 • Remove the gear motor.

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Chassis

Removal - Replacement of the gear motor MS0354 6-

Re-installation • Remount in reverse order to removal.

• If the reduction gear has been replaced, note its traceability number.

• Ensure that the reducer vent is positioned facing upwards.

• Tighten the 8 screws between the chassis and the reducer to a torque of 100 Nm.

• Tighten the screws crosswise.

• Tighten the 8 wheel nuts to the torque of : • 80 Nm • 170 Nm

• Apply contact grease to the sockets before reconnecting them.

Respect the cable routing.

• Hold the power cables so that they do not turn during refitting.

7-

Additional operations • Unlock the machine. Refer to

MS0360 Placing the machine in maintenance configuration.

• Perform drive movements from the top control box • Ensure the drive function and the brakes are working properly.

206

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Chassis

Removal - Replacement of semi-traction batteries MS0355 Chassis Removal - Replacement of semi-traction batteries

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

• 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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Removal - Replacement of semi-traction batteries MS0355 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield — In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

208

You will need • "DO NOT OPERATE" tag • Standard tool kit • Battery - 2901010690 • 14 mm - 4000710390 insulated open-end wrench • Insulated torque wrench of 11,5 Nm - 4000710380 • Insulated pin of 14 mm - 4000710370 • Demineralised water (if required to cover the battery plates)

• Place barriers around the perimeter of the work area

• Weight of a battery : 55 Kg / 122 lbs

2 persons

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Chassis

Removal - Replacement of semi-traction batteries MS0355 5-

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

• Mark out the work area.

• Stow the machine.

• Switch off the ignition and remove the ignition key.

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

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

MS0360 -

• On each side of the battery compartment, move the 2 hooks on the cover to the open position.

• Remove the top cover.

• Unscrew the 2 screws located on each side of the battery compartment front panel.

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Chassis

Removal - Replacement of semi-traction batteries MS0355 • Pull the sheet upwards to release it from the lower fastening notches.

• Remove the 2 screws and remove the battery locking plate.

• Identify the battery to be replaced.

• Remove the main power terminals in the following order : The negative terminal ( B- ) then the positive terminal ( B+ ).

• Place insulation caps on the battery terminals.

• If the machine has them, unscrew each yellow cap ( 1 ) from the centralised filling system battery and replace with a white cap ( 2 ).

210

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Removal - Replacement of semi-traction batteries MS0355 • Remove the support ( 3 ) between the 2 batteries.

• Remove the battery using the handles provided.

Keep batteries upright.

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Removal - Replacement of semi-traction batteries MS0355 6-

Re-installation • Remount in reverse order to removal.

• Before positioning the new batteries in the compartment, check that each cell's plates are covered by the electrolyte as a minimum.

N.B.-:-THE LEVEL IS CHECKED WHEN THE BATTERY IS CHARGED.

• Leave the caps in place while handling the battery.

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

Connect the positive first, then the negative.

• Tighten the battery nuts to a torque of 11,5 Nm using an insulated torque wrench.

• Position the insulation caps correctly on the battery terminals.

• Reassemble the sheet on the front side of the compartment.

• Position the top cover.

• Lock the top cover.

7-

Additional operations • Unlock the machine. Refer to

MS0360 Placing the machine in maintenance configuration.

• Carry out a complete battery charging cycle on the mains supply.

• After charging, complete the battery level using the centralized filling device.

212

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Removal - Replacement of battery compartments MS0356 Chassis Removal - Replacement of battery compartments

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

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

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Chassis

Removal - Replacement of battery compartments MS0356 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield - In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

214

You will need • Battery : 2901010690 • "DO NOT OPERATE" tag • Standard tool kit • 14 mm - 4000710390 insulated open-end wrench • Insulated pin of 14 mm - 4000710370 • Insulated torque wrench of 11,5 Nm - 4000710380 • 190 Nm torque wrench with 22 mm sleeve • Lifting and handling equipment(bridge crane, crane, etc) : capacity 1000 kg(2205 lb) • Demineralized Water

• Place barriers around the perimeter of the work area

• Weight of battery compartment : 264 Kg / 582 lbs • Weight of a battery : 55 Kg / 122 lbs

1 person

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Removal - Replacement of battery compartments MS0356 5-

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

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

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

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

• Switch off the ignition and remove the ignition key.

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

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

MS0360 -

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

• Remove the cover.

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

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

• Then disconnect the positive connection cable B. • Place insulation caps on the battery terminals.

• Push the cables in the chassis hole.

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Removal - Replacement of battery compartments MS0356 • Place a handling device with a palet under the battery pack.

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

• Unscrew the 4 screws without removing them.

• Lift the battery pack slightly with the handling equipment.

• Remove the battery pack.

• The battery compartment is removed.

216

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Removal - Replacement of battery compartments MS0356 6-

Re-installation • Carry out the operations in the reverse order.

• Before positioning the new batteries in the compartment, check that each cell's plates are covered by the electrolyte as a minimum.

N.B.-:-THE LEVEL IS CHECKED WHEN THE BATTERY IS CHARGED.

• Refit the cables as follows :

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Chassis

Removal - Replacement of battery compartments MS0356 • Install the centralised filling system as follows :

• Tighten the battery compartment fastening bolts at a torque of 190 Nm with a 22 mm pin.

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

Connect the positive first, then the negative. Do this for every battery.

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

• Position the insulation caps correctly on the battery terminals.

7-

Additional operations • Unlock the machine. Refer to

MS0360 Placing the machine in maintenance configuration.

• Fully recharge the batteries.

• Check the level.

• Top up the oil if necessary.

218

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Removal - Replacement of the drive controller MS0357 Electricity Removal - Replacement of the drive controller

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

• 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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Electricity

Removal - Replacement of the drive controller MS0357 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield - In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

You will need • Contact grease • "DO NOT OPERATE" tag • Standard tool kit • Torque wrench for 14 Nm

• Place barriers around the perimeter of the work area

1 person

220

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Electricity

Removal - Replacement of the drive controller MS0357 5-

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

• Mark out the work area.

• Place the machine in its folded position.

• Turn the turntable through 90° to access the chassis cover.

• Switch off the ignition and remove the ignition key.

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

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

MS0360 -

• Unscrew and remove the 6 screws.

• Remove cover from chassis.

• Locate the cables before disassembly.

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Electricity

Removal - Replacement of the drive controller MS0357 Identify the indicator on each cable in relation to the variator before removing them : • ACE0 variator • Marking ( 1 ) : W. • Marking ( 2 ) : B-.

• Marking ( 3 ) : B+.

• Marking ( 4 ) : V. • Marking ( 5 ) : U. • Marking ( 6 ) : Male ACE0 plug.

• Unscrew the 5 cables and remove them.

• Unplug the ACE0 plug.

Identify the indicator on each cable in relation to the variator before removing them : • COMBIAC0 variator • Marking ( 1 ) : V. • Marking ( 2 ) : B-.

• Marking ( 3 ) : B-.

• Marking ( 4 ) : W. • Marking ( 5 ) : P-.

• Marking ( 6 ) : Male COMBIAC0 plug.

• Marking ( 7 ) : U. • Unscrew the 6 cables and remove them.

• Unplug the COMBIAC0 plug.

For each unit : • Undo the 4 screws .

222

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Removal - Replacement of the drive controller MS0357 • Remove the units.

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Electricity

Removal - Replacement of the drive controller MS0357 6-

Re-installation • Remount in reverse order to removal.

Make sure that the controller is facing the right direction.

Clean electrical plugs before reassembly.

• Apply contact grease to the sockets before reconnecting them.

• Tighten the controller's electrical plug screws to the torque of 14 Nm. • Reposition insulation caps correctly.

7-

Additional operations • Unlock the machine. Refer to

MS0360 Placing the machine in maintenance configuration.

• Update the controller settings : • Switch the machine on. On power-up the F12.10 fault code appears (internal parameter default).

• Switch off the machine and wait between 3 and 5 seconds.

• Switch the machine back on, the fault code must no longer be displayed.

N.B.-:-IF THE FAULT CODE PERSISTS, CHECK COMPATIBILITY OF THE SOFTWARE VERSION. CONTACT HAULOTTE SERVICES®.

• Perform a drive function test.

224

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Wear pads

Removing / Replacing the pads MS0358 Wear pads Removing / Replacing the pads

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

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

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

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

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Wear pads

Removing / Replacing the pads MS0358 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield — In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

You will need • "DO NOT OPERATE" tag • Personal protective equipment • Standard tool kit • ORFS seal kit : 2505000470 • ORFS plug kit : 2505001600 • 16 friction pads : 164P323990 • Greasing the pads : 2326005410 • Lifting and handling equipment(bridge crane, crane, etc) • Torque wrench for 25 Nm (18.4 lbs/ft) • 1 hoisting strap(s) for 2000 kg / 4410 lbs at a length of 2 m / 6 ft 56 in

• Place barriers around the perimeter of the work area

1 person

226

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Wear pads

Removing / Replacing the pads MS0358 5-

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

• Stow the machine.

• Telescope slightly out.

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

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

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

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

• Turn off the circuit breaker.

• Disconnect the terminal from the negative terminal (-) then from the positive terminal (+).

Removal-Upper pads :

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Wear pads

Removing / Replacing the pads MS0358 • Remove the screws ( 1 ).

• Remove the pads ( 1 ) and wedges adjustment ( 2 ).

228

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Wear pads

Removing / Replacing the pads MS0358 Removal-Lower pads : • Remove the 2 upper pads.

• Sling the telescope ( 1 ) at the end.

• Tension the bridge to raise the telescope box so that the pads can be pulled out.

• Remove the screws ( 1 ).

• Remove the pads ( 2 ) and wedges adjustment ( 3 ).

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Wear pads

Removing / Replacing the pads MS0358 Re-installation-Lower pads : Re-installation is a reversal of the removal procedure, with the following important points : • Grease the surface of the new pads and ensure that the adjustment wedges are reset identically.

• Install the screws with threadlock.

• Tighten the pad screws to a torque of 25 Nm (18.4 lbs/ft).

• Slowly release the sling ( 1 ) and set the telescope tube on the lower pads ( 2 ).

230

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Wear pads

Removing / Replacing the pads MS0358 Removal-Side pads : • Remove the screws ( 1 )( 4 on each side).

• Remove the pads ( 1 ) and wedges adjustment ( 2 ).

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Wear pads

Removing / Replacing the pads MS0358 Re-installation-Side pads : Re-installation is a reversal of the removal procedure, with the following important points : • Grease the surface of the new pads and ensure that the adjustment wedges are reset identically.

• Fit the pad ( 1 ).

• Fit the screw ( 1 )(Install the screws with threadlock).

• Insert and fit the thickness shim ( 2 ).

232

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Wear pads

Removing / Replacing the pads MS0358 • Fit the screw ( 1 )(Install the screws with threadlock).

• Tighten the pad screws to a torque of 25 Nm (18.4 lbs/ft).

N.B.-:-PROCEED IN THE SAME WAY TO FIT THE OTHER SIDE PADS

Re-installation-Upper pads : Re-installation is a reversal of the removal procedure, with the following important points : • Grease the surface of the new pads and ensure that the adjustment wedges are reset identically.

• Install the screws with threadlock.

• Tighten the pad screws to a torque of 25 Nm (18.4 lbs/ft).

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Wear pads

Removing / Replacing the pads MS0358 6-

Rear pads replacement Removal-Upper rear pads(only) : • Position the machine on a flat and firm surface, clear of obstructions (beware of power lines).

• Stow the machine.

• Retract the telescoping boom.

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

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

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

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

• Turn off the circuit breaker.

• Disconnect the terminal from the negative terminal (-) then from the positive terminal (+).

234

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Wear pads

Removing / Replacing the pads MS0358 • Sling the telescope ( 1 ) at the end.

• Tension the bridge to raise the telescope box so that the pads can be pulled out.

• Remove the 4 fastening screws from the upper pads.

• Remove the pads ( 1 ) and wedges adjustment .

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Wear pads

Removing / Replacing the pads MS0358 Re-installation-Upper rear pads (only) : Re-installation is a reversal of the removal procedure, with the following important points : • Grease the surface of the new pads and ensure that the adjustment wedges are reset identically.

• Install the screws with threadlock.

• Tighten the pad screws to a torque of 25 Nm (18.4 lbs/ft).

236

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Wear pads

Removing / Replacing the pads MS0358 Removal-Rear pads(All) : • Position the machine on a flat and firm surface, clear of obstructions (beware of power lines).

• Stow the machine.

• Retract the telescoping boom.

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

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

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

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

• Turn off the circuit breaker.

• Disconnect the terminal from the negative terminal (-) then from the positive terminal (+).

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Wear pads

Removing / Replacing the pads MS0358 • Remove the jib and platform assembly. Refer to

MS0339 .

• Place an absorbent cloth under the cylinder to avoid any oil leaks inside the machine.

• Identify the 2 telescope cylinder supply hoses ( 1 - 2 ).

• Gently loosen the fittings.

• As soon as the oil begins to flow, stop the release and let the pressure drop.

• Disconnect the 2 telescope cylinder supply hoses ( 1 - 2 ).

• Perform the same operation on the hydraulic block.

• Plug the openings after disassembly.

• Disconnect the sensor ( 3 ) SQ530.

• Remove the pin stop screw ( 1 ).

• Remove the pin ( 2 ).

238

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Wear pads

Removing / Replacing the pads MS0358 • Use suitable handling equipment.

• Attach the cylinder ( 1 ) with a sling and slightly tighten the sling ( 2 ).

• Remove the pin ( 1 ).

• Carefully put down the cylinder inside the boom section.

• Remove the front pads(procedure above).

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Wear pads

Removing / Replacing the pads MS0358

• Sling the telescope ( 1 ) using a lifting strap of ( 2 ).

• Move the lifting strap ( 2 ) to secure the telescope at its centre of gravity ( A ).

• Slowly withdraw the telescope ( 1 ) N.B.-:- A = 1050 MM / 3 FT 5 IN FROM THE WELD

• Place the telescope ( 1 ) on a suitable support.

240

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Wear pads

Removing / Replacing the pads MS0358 Rear pads replacement : • Unscrew and remove the 8 pads ( 2 on each side).

Re-installation is a reversal of the removal procedure, with the following important points : • Grease the surface of the new pads and ensure that the adjustment wedges are reset identically.

• Install the screws with threadlock.

• Tighten the pad screws to a torque of 25 Nm (18.4 lbs/ft).

• Perform the operations in the reverse order of dismantling.

• Remember to refit the pin stop screws. Install the screws with threadlock.

• Tighten the screws to the recommended torque : 44 N.m (32.45 lb.ft).

• Grease the pins, the seals, and the bored holes.

• Check that the seals are on the connections before reconnecting the hoses.

• Hold the hoses to ensure that they don't turn while tightening the connections (risk of seal damage). This will avoid the hoses twisting when they are connected to the rigid tubes.

• Connect the sensor SQ530 and attach the wiring harness to the attachment point provided using a collar.

During reinstallation, pay attention to the hoses and cables.

7-

Additional operations • From the ground control box, operate the telescope function several times.

• Ensure there are no jerky movements, jamming or other elements which could lead to abnormal operation of the machine.

• Clean the work area.

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Wear pads

Removing / Replacing the pads MS0358

Notes

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Upper boom

Remove/re-install the harness BUS CAN MS0359 Upper boom Remove/re-install the harness BUS CAN

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

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

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

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

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Upper boom

Remove/re-install the harness BUS CAN MS0359 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield — In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

You will need • Personal protective equipment • Contact grease • Standard tool kit

• Place barriers around the perimeter of the work area

1 person

244

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Upper boom

Remove/re-install the harness BUS CAN MS0359 5-

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

MS0360 Placing the machine in maintenance

• Disconnect the CAN1 - (1) plug from the platform control box and cut the plastic collars .

• Put down the plug outside the platform.

• Open the plastic collar ( 1 ) using a screwdriver.

• Loosen the ( 2 ) harness' retention bracket.

• Release the wiring harness so as not to damage it.

• If the machine is fitted with a 220 V socket in the platform ( 3 ), disconnect it.

• Remove the harness from the sheath ( 4 ).

• Thread the wiring harness through the jib, removing the screw clamps.

• If the machine is fitted with a 220 V socket in the platform , disconnect it.

• The wiring harness BUS CAN is now free as far as the end of the boom .

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Upper boom

Remove/re-install the harness BUS CAN MS0359 • Using a coloured felt pen, mark the location of the wiring harness where it enters and leaves the cable holder chain.

• This will enable them to be correctly repositioned when re-installing.

• Open each link of the cable holder chain using a screwdriver.

• Remove the cable bundle from the cable chain.

• Remove the 2 cable supports located under the boom.

• Pass the wiring harness down as far as the foot of the boom.

• Remove the plastic collars .

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Upper boom

Remove/re-install the harness BUS CAN MS0359 • Open the hose clamp ( 1 ).

N.B.-:-LENGTH BETWEEN THE COLLAR AT THE FOOT OF THE BOOM AND THE FIRST COLLAR OF THE UPPER ARM : 1280 MM / 4 FT 2 IN.

• With a coloured felt pen, mark the position of the wiring harness between the 2 collars ( 1 ).

• Remove the collar(s) ( 1 ).

• Remove the plastic collars located in the tube(s).

• Bring the wiring harness(es) to the rear of the arm .

N.B.-:-LENGTH BETWEEN THE COLLAR(S) ( 1 ) : 2600 MM / 8 FT 6 IN.

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Upper boom

Remove/re-install the harness BUS CAN MS0359 • Pass the cable through the arm link piece .

• Remove the plastic collars .

N.B.-:-LENGTH BETWEEN THE COLLAR ( 1 ) OF THE UPPER ARM AND THE ENTRANCE OF THE TUBE ( 2 ) OF THE LOWER ARM : 1300 MM / 4 FT 3 IN.

• Remove the plastic collars ( 1 ).

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Upper boom

Remove/re-install the harness BUS CAN MS0359 • Free the wiring harness ( 1 ) from the lower arm .

N.B.-:-L ENGTH BETWEEN THE END OF THE TUBE ( 2 ) AND THE COLLAR ( 3 ) : 950 MM / 3 FT 1 IN.

• Using a coloured felt pen, mark the location of the wiring harness where it enters and leaves the collar ( 1 ).

• This will enable them to be correctly repositioned when re-installing.

• Open the hose clamp ( 1 ).

• Release the wiring harness ( 2 ) so as not to damage it.

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Upper boom

Remove/re-install the harness BUS CAN MS0359 • Disconnect the plugs from the harness (1) - BUS CAN CN06-1 / CN06-2.

• Extract the wiring harness ( 2 ) via the orifice of the turntable located behind the screen.

• If the machine is fitted with a (1) - 220 V socket in the platform, remove it too.

• Place the plugs inside a plastic bag for protection so as not to contaminate the connectors.

250

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Upper boom

Remove/re-install the harness BUS CAN MS0359 6-

Re-installation • To refit it, proceed in the opposite order to removal.

• Place the old wiring harness next to the new and transfer the marks previously made on the old wiring harness to it.

• Follow the initial harness routing.

• Put contact grease on the connectors and the platform control panel socket.

• Connect the plugs.

• Attach the cables.

7-

Additional operations • Unlock the machine. Refer to

MS0360 Placing the machine in maintenance configuration.

• From the ground control box, perform complete movements of the jib, telescope extension and retraction and arm and boom lifting.

• Attach the wiring harnesses with polyamide ties, ensuring that the routing is correct.

• From the ground control box, ensure that the all of the machine's movements are working properly.

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Upper boom

Remove/re-install the harness BUS CAN MS0359

Notes

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

1-

Concerned area

2-

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

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

• It is important that the person working on the machine is familiar with all of the safety information contained in the user manual.

• Generally speaking, the user must comply with regulatory obligations in force, particularly those relating specifically to working alone, co-activity and manual load handling...

• The user must have all the permits/authorizations required to work (fire permit, etc.) and comply with the specific safety instructions at the intervention site.

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

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

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

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

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

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

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Placing the machine in maintenance configuration MS0360 3-

Risk prevention M e a n s

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Face shield — In accordance with standard NF EN 166 / EN 170

Specific protective measures to be used for the stage concerned : • Risk of electric arc. Face shield and insulating gloves must be worn for the steps with these images : .

4-

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

• Place barriers around the perimeter of the work area

1 person

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Placing the machine in maintenance configuration MS0360 5-

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

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

• Stow the machine.

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

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Placing the machine in maintenance configuration MS0360 • Switch off the ignition and remove the key ( 1 ) from the ignition.

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

• Turn off the circuit breaker (Opened position).

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Placing the machine in maintenance configuration MS0360 • Open circuit: handle vertical.

• Closed circuit: handle horizontal.

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

• Remove the cover.

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

• Then disconnect the positive connection cable ( B ).

• Place insulation caps on the battery terminals.

• Push the cables in the chassis hole.

6-

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

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

• Then connect the negative connection cable ( B ).

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

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

• Position the insulation caps correctly on the battery terminals.

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

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

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Placing the machine in maintenance configuration MS0360

Notes

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D - Trouble shooting Trouble shooting

1-

Trouble shooting 1.1 -

RECOMMENDATIONS If a malfunction occurs, check the following points : • Sufficient hydraulic oil in the tank.

• Batteries are charging.

• Control box E-stop push-buttons are pulled out.

• The control box selector key is set to platform or ground control box.

• Control box relays are engaged.

• Fuse status.

• Ground control box solenoid valve status.

If the malfunction persists, consult the troubleshooting table to identify the problem.

IF you cannot identify the problem, contact HAULOTTE Services®.

1.2 -

DESCRIPTION The FAILURES function describes the requirements relative to failures : monitoring, information recording, information reading.

1.3 -

REQUIREMENTS

Requirements

Definition

FAIL_xx_001

An ACTIVE failure ( A ) signals that the failure is stive active A DETECTED failure ( D ) signals the cause of the failure has been valid one at least power on, but is inactive A code CODE is linked to failures which have several causes of activation to identify the one of activation (if many conditions are active the code are added) At power on, the failure log and failure counter are not changed for a failure which was already active at power off The failure log and failure counter are changed for a failure which internal code is changed

FAIL_xx_002 FAIL_xx_003 FAIL_xx_004 FAIL_xx_005

N.B.-:- VAR[ACTIVEFAILURE] = 1 IF ONE OR MORE OF THE FOLLOWING FAILURES ARE IN ACTIVE STATE

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D - Trouble shooting 1.4 -

FAILURES LIST With Activ’screen, it is possible to visualize the defects in "FAILURES".

• For any type A (ACTIVE) failure code, it will appear on display in lower control and the warning light will flicker on upper controls (see below).

• For any type D (DETECTED) failure code, it will also appear on display in lower control and the warning light will flicker on upper controls. In order to reset this failure which has been detected and no more active, it will be necessary to fold the machine until full stowed position, and then switch OFF then ON again the main power.

• For any type N failure code, it means that this alarm will never appear on display.

The notification of failures on the lights and displays of the machine is managed in the following way : •

the failure is notified only if it is active

•

the failure is notified if it has been detected after the power on, even if it is not active anymore

•

the failure is notified if it has been detected after the power on, even if it is not active anymore

Explanation on the column C of the table of failures : • An internal code (column C) with 5 digits, visible only on the console, allows specifying the trigger conditions of the failure.

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D - Trouble shooting • Each trigger condition is associated with a single code number (16 possible single codes in decimal format corresponding to a single bit in binary format) :

Individual code Decimal

Binary

Bit

1

0000000000000001

0

2

0000000000000010

1

4

0000000000000100

2

8

0000000000001000

3

16

0000000000010000

4

32

0000000000100000

5

64

0000000001000000

6

128

0000000010000000

7

256

0000000100000000

8

512

0000001000000000

9

1024

0000010000000000

10

2048

0000100000000000

11

4096

0001000000000000

12

8192

0010000000000000

13

16384

0100000000000000

14

32768

1000000000000000

15

If several conditions are active at the same time, single codes are added to form the resulting code displayed.

For example, if the conditions of single code 1 and 2 are active, the resulting code posted will be 3 ( 1 +2 = 3 into decimal or 0000000000000011 in binary format).

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D - Trouble shooting On newest models, the binary code appears directly on screen. In case of multiple failures, the binary codes will scroll on screen (B2, B7, ...).

E x a m p l e

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D - Trouble shooting Definition Machine failures are checked only if power is ON for more than 3s : • D3s(VAR[PowerOn]=1) The notification (N) of failures on the lights and displays of the machine is managed in the following way (See Lights and Buzzers function) : • A: the failure is notified only if it is active • B: the failure is notified if it has been detected after the power on, even if it is not active anymore • C: the failure is never notified (it is visible only with the console) In all cases, active and detected failures are always visible with the console.

An internal code (column C) with 5 digits, visible only on the console, allows specifying the trigger conditions of the failure. Each trigger condition is associated with a single code number (16 possible single codes in decimal format corresponding to a single bit in binary format).

If several conditions are active at the same time, single codes are added to form the resulting code displayed. For example, if the conditions of single code 1 and 2 are active, the resulting code posted will be 3 ( 1+2 = 3 into decimal or 0000000000000011 in binary format).

Failures related to slave ECU outputs ( F04 for upper movements electrovalves) require the following conditions to be triggered : • A failure due to an open circuit OC can appear or disappear only if the output is inactive • A failure due to a short circuit (SC) to GND or VBAT can appear or disappear only if the output is active Failures related to master ECU PWM HSD outputs ( F02 for contactors, F03 for relays and F04 for electrovalves) require the following conditions to be triggered : • A failure due to an open circuit (OC) or short circuit to VBAT(SC+) or power supply error (PSE) can appear or disappear if the output is active or inactive • A failure due to an over current to GROUND(SC-) or a low current (LC) can appear or disappear only if the output is active Failures related to master ECU DIGITAL HSD outputs ( F02 for contactors, F03 for relays and F04 for electrovalves) require the following conditions to be triggered : • A failure due to an open circuit (OC) or short circuit to VBAT(SC+) can appear or disappear if the output is inactive • A failure due to an over current to GROUND(SC-) or a low current (LC) can appear or disappear only if the output is active • A failure due to a power supply error (PSE) can appear or disappear if the output is active or inactive Failures related to master ECU DIGITAL LSD outputs ( F02 for contactors, F03 for relays and F04 for electrovalves) require the following conditions to be triggered : • A failure due to an open circuit (OC) or over current to GROUND(SC-) can appear or disappear if the output is inactive • A failure due to a short circuit to VBAT(SC+) can appear or disappear only if the output is active Failures related to master ECU DIGITAL PVG outputs ( F02 for contactors, F03 for relays and F04 for electrovalves) require the following conditions to be triggered : • A failure due to a short circuit to VBAT(SC+) can appear or disappear only if the output is active • A failure due to an over current to GROUND(SC-) can appear or disappear if the output is active • A failure due to a power supply error (PSE) can appear or disappear if the output is active or inactive A failure active at power off does not increment the counter or the log if it is still active at the next power up.

The counter of an active failure is incremented when its internal code changes and the failure is again recorded into the log with the new code.

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D - Trouble shooting 1.4.1 - List of failures per category

Failures

Bit

Dec

Description Contactors

F02.03 Main Contactor

b0

1

• Incoherence between the emergency stop status and the presence of ECU power supply : Emergency stop is pushed but there is still power ( KMG or KMP potentially stuck).

F02.04 Power Contactor

b0

1

• Power contactor failure (open or short circuit) --> KM803.

Bit

Dec

Failures

Description Relays • Beacon relay failure (open or short circuit) --> KA8.

F03.05 Flashing light relay

b0

1

F03.06 Horn Relay

b0

1

• Horn relay failure (open or short circuit) --> KA9.

F03.07 Standby timer reloads relay

b0

1

• Standby timer reloads relay failure (open or short circuit) --> KA3.

F03.11 Generator relay

b0

1

• Generator relay failure (open or short circuit) --> KA2.

F03.15 Water refill pump control relay

b0

1

• Automatic refill pump control relay failure --> KA911.

Bit

Dec

Failures

Description Electrovalves

F04.01 Steering valve F04.02 Platform level valve F04.03 Turntable orientation valve F04.04 Arm valve

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b0

1

• Digital electrovalve failure for steering left movement --> YV150L.

b1

2

• Digital electrovalve failure for steer right movement --> YV150R.

b0

1

• Proportional electrovalve failure for platform level movement --> YV900.

b1

2

• Digital electrovalve failure for platform level raise movement --> YV720U.

b2

4

• Digital electrovalve failure for platform level descent movement --> YV720D.

b0

1

• Digital electrovalve failure for turret rotation left movement --> YV250L.

b1

2

• Digital electrovalve failure for turret rotation right movement --> YV250R.

b0

1

• Digital electrovalve failure for arm raise movement --> YV420U.

b1

2

• Digital electrovalve failure for arm descent movement --> YV420D.

b2

4

• Digital electrovalve failure for arm descent movement --> YV421D.

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D - Trouble shooting Failures

Bit

Dec

Description Electrovalves

F04.05 Boom valve

b0

1

• Digital electro valve failure for boom raise movement --> YV520U.

b1

2

• Digital electro valve failure for boom descent movement --> YV520D.

F04.06 Boom telescope valve

b0

1

• Digital electro valve failure for boom telescope extend movement --> YV530O.

b1

2

• Digital electro valve failure for boom telescope retract movement --> YV530I.

F04.07 Jib valve

b0

1

• Digital electrovalve failure for jib raise movement --> YV620U.

b1

2

• Digital electro valve failure for jib descent movement --> YV620D.

F04.08 Platform rotation valve

b0

1

• Proportional electrovalve failure for platform rotation movement --> YV900.

b1

2

• Digital electrovalve failure for platform rotation left movement --> YV750L.

b2

4

• Digital electrovalve failure for platform rotation right movement --> YV750R.

b0

1

• Proportional electrovalve failure for jib rotation movement --> YV900.

b1

2

• Digital electrovalve failure for jib rotation left movement --> YV650L.

b2

4

• Digital electrovalve failure for jib rotation right movement --> YV650R.

b0

1

• Digital electrovalve failure when a movement is active (failure state is updated only when a movement is active, because YV800 status always shows a false failure when no movement is active).

b1

2

• Digital electrovalve ground failure when a movement is active (failure state is updated only when a movement is active, because YV800G status always shows a false failure when no movement is active).

F04.46 Flow control valve

b0

1

• Proportional electrovalve failure for flow control --> YV905.

F04.47 Split outflow valve

b0

1

• Proportional electrovalve failure for split outflow --> YV904.

F04.09 Jib rotation valve

F04.44 Safety movement

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D - Trouble shooting Failures

Bit

Dec

Description Joysticks

Not triggered if failure F08.05 is active.

F05.01 Drive Joystick

b0

1

• Drive joystick failure SM902Y: Out of range [0.2 ; 4.8]V.

b1

2

• Drive joystick failure SM902Y: Analogue signal and out of neutral incoherence.

Not triggered if failure F08.05 is active.

F05.04 Boom Joystick

b0

1

• Boom joystick failure SM900Y: Out of range [0.2 ; 4.8]V.

b1

2

• Boom joystick failure SM900Y: Analogue signal and out of neutral incoherence.

Not triggered if failure F08.05 is active.

F05.05 Turntable Joystick

b0

1

• Turntable joystick failure SM900X: Out of range [0.2 ; 4.8]V.

b1

2

• Turntable joystick failure SM900X: Analogue signal and out of neutral incoherence.

F05.11 Joystick Neutral

b0

1

• No detection of drive joystick's neutral position at machine start up.

F05.12 Joystick Neutral 2

b0

1

• No detection of Turntable orientation / Boom joystick neutral position at machine power on.

Bit

Dec

Failures

Description Load management system

F06.01 Load management system not calibrated

b0

1

• Load Management System not calibrated.

b0

1

• Gauge out of range - SP800.

b1

2

• Gauge out of range - SP801.

F06.04 Load cells incoherence

b0

1

• SP800 and SP801 measured weight difference are more than 80kg far (and gauges are not out of range). The check is done only if there are no movements (static) and if none of the gauges are out of range (no failure F06.03).

F06.05 Overload low power

b0

1

• Low power for strain gauges detected (lower than 8.5V).

F06.03 Load cells out of range

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D - Trouble shooting Failures

Bit

Dec

Description Load management system

b0

1

• Overvoltage on sensor 1 : Sensor and/or electronic card failure.

• Replace weighing unit.

b1

2

• Overvoltage on sensor 2 : Sensor and/or electronic card failure.

• Replace weighing unit.

b2

4

• Low voltage on sensor 1 : Battery voltage too low or electronic card failure.

• Check the battery voltage (minimum 8V) ; • Replace weighing unit.

b3

8

• Low voltage on sensor 2 : Battery voltage too low.

• Electronic card failure : • Check the battery voltage (minimum 8V) ; • Replace weighing unit.

b4

16

• Sensor 1: Loss of signal : Internal wiring failure, sensor failure or card failure.

• Replace weighing unit.

32

• Sensor 2: Loss of signal : Internal wiring failure, sensor failure or card failure.

• Check the load in the basket ; • Check if the basket is bearing against something ; • Replace weighing unit.

64

• Sensor 1 out of range : Excessive mechanical stress, sensor and/or unit failure or sensor assembly.

• Check the load in the basket ; • Check if the basket is bearing against something ; • Replace weighing unit.

b7

128

• Sensor 2 out of range : Excessive mechanical stress, sensor and/or unit failure or sensor assembly.

• Check the load in the basket ; • Check if the basket is bearing against something ; • Replace weighing unit.

b8

256

• Sensor 1: Signal dispersion: Sensor mechanical slip.

• Check weighing system ; • Perform a new advanced calibration.

b9

512

• Sensor 2: Signal dispersion: Sensor mechanical slip.

• Check weighing system ; • Perform a new advanced calibration.

1024

• Sensor 1 displacement: Sensor disconnected of the unit.

• Check weighing system ; • Perform a new advanced calibration.

• Replace weighing unit.

2048

• Sensor 2 displacement: Sensor disconnected of the unit.

• Check weighing system ; • Perform a new advanced calibration.

• Replace weighing unit.

b5

F06.06 Weighing sensors

b6

b10

b11

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D - Trouble shooting Failures

Bit

Dec

Description Load management system

b0

1

• Weighing system memory erroneous: Electronic card failure.

• Replace weighing unit.

b1

2

• Dynamic correction out of service: Accelerometer failure.

• Weighing active without this correction.

• Replace weighing unit.

4

• Information received from the weighing system not refreshed: CAN bus connection or card failure.

• Check weighing system unit connection (CAN bus) ; • Check harness state ; • Replace weighing unit.

8

• Low temperature threshold reached: Ambient temperature too low or temperature sensor failure.

• Return to proper temperature conditions ; • Replace weighing unit.

b4

16

• High temperature threshold reached: Ambient temperature too high or temperature sensor failure.

• Return to proper temperature conditions ; • Replace weighing unit.

b5

32

• Temperature information incoherent: Temperature sensor failure.

• Replace weighing unit.

b6

64

• Too many shocks detected.

b0

1

• Measured weight has been detected above 700kg.

b0

1

• Measured load on SP800 gauge is below -40kg for more than 2s.

b1

2

• Measured load on SP801 gauge is below -40kg for more than 2s.

b2

F06.07 Weighing system b3

F06.08 Strong overload F06.09 Negative load

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D - Trouble shooting Failures

Bit

Dec

Description Sensors

F07.03 Boom angle sensor

b0

1

• Voltage failure of SQ520 sensor, above 6V: possibly short circuit to VBAT.

F07.06 Arm angle sensor

b0

1

• Voltage failure of SQ421 sensor, above 6V: possibly short circuit to VBAT.

F07.10 Telescope length sensor

b0

1

• Voltage failure of SQ531 sensor, above 6V: possibly short circuit to VBAT.

F07.15 Platform level position sensor

b0

1

• Incoherence between platform level detectors: SR720 and SR721.

F07.33 Wheels turn angle sensor

b0

1

• Analog signal of steering angle sensor is out of range (only if calibrated).

b0

1

• Open circuit: SN900 > 4800mV.

b1

2

• Short circuit: SN900 > 100mV.

b0

1

• Tilt sensor is not calibrated.

b0

1

• Checksum failure.

b1

2

• Fault detected on X - axis.

b2

4

• Fault detected on Y - axis.

b3

8

• Supply voltage < 8V.

b4

16

• Supply voltage > 28V.

b5

32

• Temperature > 90°C.

b0

1

• Battery temperature sensor error (ST309).

F07.40 Twilight sensor F07.44 Tilt sensor not calibrated

F07.46 Tilt sensor error

F07.52 Battery temperature sensor

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D - Trouble shooting Failures

Bit

Dec

Description Supplies

F08.04 ECU input supply

b0

1

• Supply voltage of master ECU 106 greater than supply voltage of slave ECU 104: more than 2V for 1s.

b1

2

• Supply voltage of master ECU U106 too high: more than 20V.

b2

4

• Supply voltage of slave ECU U104 too high: more than 20V.

b0

1

• Regulated 5V output of U104 ECU platform slave node supplying the joysticks is out of range [4.5; 5.5]V.

b1

2

• Detected failure on regulated 5V output of U104 ECU (Platform slave node) supplying the joysticks.

b0

1

• Supplies’ input detected as unplugged on connectors: 12VD1 /12VF1.

b1

2

• Supplies’ input detected as unplugged on connectors: 12VD2 /12VF2.

b2

4

• Supplies’ input detected as unplugged on connectors: 12VD3 /12VF3.

b3

8

• Supplies’ input detected as unplugged on connectors: 12VD4 /12VF4.

b4

16

• Supplies’ input detected as unplugged on connectors: 12VD5.

b0

1

• Failure of front angle sensor SR150.

b1

2

• Front angle sensor is out of range (Short circuit) - SR150.

b2

4

• Front angle sensor is out of range (Open circuit) - SR150.

b0

1

• Charger failure (check charger internal failure code in reference).

F08.05 ECU output supply

F08.08 Unplugged connector

F08.12 Wheel angle sensor

F08.13 Charger

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D - Trouble shooting Failures

Dec

Description Supplies

F08.13 Charger

1

LOGIC FAILURE #1

2

BMS OFFLINE

3

WATCHDOG

6

MISSING PHASE

7

OVERCURRENT

8

HIGH TEMPERATURE

9

MISMATCH VOLTAGE

16

LOGIC FAILURE #2

17

FLASH CHECKSUM

18

EEPROM KO

21

LOGIC FAILURE #3

23

POWER FAILURE #1

24

WRONG INPUT VOLTAGE

25

SHORTED OUTPUT

26

WRONG MARKER EEP

27

NO MAINS

28

LOW TEMPERATURE

29

CLK BATTERY OFF

31

NODES MISMATCH

33

MASTER NOT FOUND

37

FIRMWARE MISMATCH

40

BMS OVERVOLTAGE

41

CLEAR EEPROM REQUEST

43

ADR INPUTS FAILURE

56

EVSE ERROR

57

EVSE NOT FOUND

59

FIRMWARE NOT VALID

60

WRONG PROTOCOL

65

ADDRESS CLAIM FAILED

This failure is checked only if wake-up 1 by key (WUI1) or wake-up 2 by charger (WUI2) is active.

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D - Trouble shooting Failures

Bit

Dec

Description Supplies

F08.16 Charge dialog

b0

1

• Charger identification failed.

b1

2

• Charger authentification failed.

This failure is checked only if wake-up 2 by charger (WUI2) is active.

F08.18 Charge timeout

Failures

b0

1

• Phase 1 of battery charge has timed out.

b1

2

• Phase 2 of battery charge has timed out.

b2

4

• Desulfation phase of battery has timed out.

Bit

Dec

Description Functions

F10.14 Steering angle calibration

F10.17 Lights

F10.21 Battery water refill system F10.22 Battery water refill needed

b0

1

• Steering angle sensor not calibrated.

b0

1

• Short circuit detected on turret lights.

b1

2

• Short circuit detected on counter weight lights.

b2

4

• Short circuit detected on boom lights.

b3

8

• Short circuit detected on basket lights.

b0

1

• Detector SL911 indicates low level in automatic refill tank.

b1

2

• Battery water refill needed: Charge complete detected - but one of the temperature of motors, inverters or battery (ST309) is too cold (? 3°C).

b0

1

• Battery water level is low.

Tank water level is not low but battery water level is low.

F10.24 Incoherence between water level in refill tank and water level in batteries

272

4001160950

Check the functional state of refill system components : b0

1

• Check ambient temperature is beyond 3°.

• Check battery state of charge is beyond 95%.

• Check refill system circuit pipes: no leakage, no blockage.

• Check functional state of refill tank electric pumps.

• Check refill tank water level detector and the presence of demineralized water in the tank (SL911).

E 04.22

USA / GB

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

D - Trouble shooting Failures

Bit

Dec

Description Securities

F11.06 Buzzer

Failures

b0

1

• Buzzer failure (HA901) : Open circuit.

Bit

Dec

Description Internal faults

F12.01 CAN fault

b0

1

• CAN failure detected with platform ECU (U104) and wake-up 1 by key (WUI1) is active.

b1

2

• CAN failure detected with membrane switch controller (U107) and wake-up 1 by key (WUI1) or wake-up 2 by charger (WUI2) is active.

b2

4

• CAN failure detected with Activ’Screen (U101) and wake-up 1 by key (WUI1) or wake-up 2 by charger (WUI2) is active.

b3

8

• CAN failure detected with rear right drive inverter (COMBI-ACE0) and wake-up 1 by key (WUI1) is active.

b4

16

• CAN failure detected with rear left drive inverter (ACE0) and wake-up 1 by key (WUI1) is active.

b5

32

• CAN frame not received from tilt sensor or stagnant transmission and wake-up 1 by key (WUI1) is active.

b6

64

• CAN failure detected with charger and wake-up 2 by key (WUI1) is active.

This failure is checked only if wake-up 1 by key (WUI1) or wake-up 2 by charger (WUI2) is active.

F12.02 Read/write error in EEPROM

F12.04 Parameters reset into EEPROM

4001160950

b0

1

• Internal failure of SPU: access to EEPROM (read or write).

b1

2

• Internal failure of SPU: EEPROM stack full.

b0

1

• Detected change in software machine identification: all the settings forced to default values (ramps, speeds, options, machine configuration and erase of calibration).

b1

2

• Detected changes in machine speeds and ramps: Settings forced to default values.

b2

4

• Detected changes in machine options: Settings forced to default values.

b3

8

• Detected changes in machine configuration: Settings forced to default values.

b4

16

• Detected changes in machine maintenances: Settings forced to default values.

b5

32

• Detected changes in machine daily logs: Settings forced to default values.

b6

64

• Detected changes in machine events counters: Settings forced to default values.

b7

128

• Detected changes in machine events logs: Settings forced to default values.

E 04.22

USA / GB

273

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

D - Trouble shooting Failures

Bit

Dec

Description Internal faults

F12.05 Machine not set

F12.08 ECU fault (Master)

F12.10 Wrong internal parameters

274

4001160950

b0

1

• Machine model is not set.

b1

2

• Country not set.

b2

4

• Serial number not set.

b3

8

• Some speed or ramp parameters are not set.

b4

16

• Some options are not set.

b5

32

• Machine components are not set.

b6

64

• Activ'Shield Bar version is not set.

b0

1

• Wrong master ECU reference ( SPU-7066 ).

b0

1

• Parameters have changed on the rear right inverter.

b1

2

• Wrong software version on the rear right inverter.

b2

4

• Be careful: debug mode, the parameters are not checked on the rear right inverter.

b3

8

• Wrong status of the rear right inverter.

b4

16

• Parameters have changed on the rear left inverter.

b5

32

• Wrong software version on the rear left inverter.

b4

64

• Be careful: debug mode, the parameters are not checked on the rear left inverter.

b7

128

• Wrong status of the rear left inverter.

E 04.22

USA / GB

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

D - Trouble shooting Failures

Bit

Dec

Description Internal faults

Invalid identification (ID) used during a request of diagnostic system (screen or diag console). The value indicates the wrong request :

F12.16 Internal error of diagnostic system (REQUEST)

4001160950

4

• Maintenance log

6/7

• Events log

193

• Failure

196

• Machine parameter (speed or ramp)

197

• Machine calibration

198

• Option

199

• Country

200

• Machine configuration

201

• Machine Model

205

• Security settings

206

• Machine state

207

• Inputs/Outputs

209

• Internal function

210

• Internal cut-out

211

• Machine maintenance

212

• Event counters

213

• Internal version

E 04.22

USA / GB

275

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

D - Trouble shooting Failures

Bit

Dec

Description Internal faults

Invalid identification ( ID ) used during a set of diagnostic system (screen or diag console). The value indicates the wrong set :

F12.17 Internal error of diagnostic system (SET)

276

4001160950

4

• Maintenance log

6/7

• Events log

193

• Failure

196

• Machine parameter (speed or ramp)

197

• Machine calibration

198

• Option

199

• Country

200

• Machine configuration

201

• Machine Model

205

• Security settings

206

• Machine state

207

• Inputs/Outputs

209

• Internal function

210

• Internal cut-out

211

• Machine maintenance

212

• Event counters

213

• Internal version

E 04.22

USA / GB

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

D - Trouble shooting Failures

Bit

Dec

Description Switches

F13.02 Upper control switches

F13.10 Neutral switches (turret control box)

4001160950

b0

1

• Detected failure on arm lifting switch: SA421: 2 directions active at the same time.

b1

2

• Detected failure on boom telescoping switch: SA531: 2 directions active at the same time.

b2

4

• Detected failure on jib switch: SA621: 2 directions active at the same time.

b3

8

• Detected failure on jib rotation switch: SA651: 2 directions active at the same time.

b4

16

• Detected failure on platform level switch: SA721: 2 directions active at the same time.

b5

32

• Detected failure on platform rotation switch: SA751: 2 directions active at the same time.

b6

64

• Detected failure on steering rocker switch: SM902: 2 directions active at the same time.

b7

128

• Detected failure on Activ'Lighting System switch: SA910: 2 directions active at the same time.

b0

1

• Neutral position not detected after power on for turntable orientation switch SA250.

b1

2

• Neutral position not detected after power on for arm lifting switch SA420.

b2

4

• Neutral position not detected after power on for boom lifting switch SA520.

b3

8

• Neutral position not detected after power on for boom telescoping switch SA530.

b4

16

• Neutral position not detected after power on for jib switch SA620.

b5

32

• Neutral position not detected after power on for jib rotation switch SA650.

b6

64

• Neutral position not detected after power on for platform level switch SA720.

b7

128

• Neutral position not detected after power on for platform rotation switch SA750.

b8

256

• Neutral position not detected after power on for enable switch SA905EN.

b9

512

• Neutral position not detected after power on for overriding switch SA801.

b10

1024

• Neutral position not detected after power on for horn switch SB907.

b11

2048

• Neutral position not detected after power on for beacon switch SA903.

b12

4096

• Neutral position not detected after power on for unbraking switch SA103.

E 04.22

USA / GB

277

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

D - Trouble shooting Failures

Bit

Dec

Description Switches

F13.11 Neutral switches 2 (platform control box)

Failures

b0

1

• Neutral position not detected after power on for boom telescoping switch SA531.

b1

2

• Neutral position not detected after power on for jib switch SA621.

b2

4

• Neutral position not detected after power on for platform rotation switch SA751.

b3

8

• Neutral position not detected after power on for platform level switch SA721.

b4

16

• Neutral position not detected after power on for steering rocker switch SM902.

b5

32

• Neutral position not detected after power on for arm lifting switch SA421.

b6

64

• Neutral position not detected after power on for jib rotation switch SA651.

b7

128

• Neutral position not detected after power on for horn switch SA907.

b8

256

• Neutral position not detected after power on for enable switch SB800.

b9

512

• Neutral position not detected after power on for Activ'Lighting System switch SA910.

Bit

Dec

Description J1939 CAN

F15.06 CAN bus cycle unit

278

4001160950

b0

1

• Timeout detected on J1939 CAN_HG (1001/1002).

b1

2

• Timeout detected on J1939 CAN_2.0 (2001/2002).

b2

4

• Overrun of the transmit queue on J1939 CAN_HG (1001/1002).

b3

8

• Overrun of the transmit queue on J1939 CAN_2.0 (2001/2002).

E 04.22

USA / GB

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

D - Trouble shooting Failures

Bit

Dec

Description Electrical Motor (drive)

b0

1

• Overheat of rear right motor (triggered when temperature above 149°C and reset when temperature below 144°C).

b1

2

• Overheat of rear left motor (triggered when temperature above 149°C and reset when temperature below 144°C).

b2

4

• Overheat of rear right controller (triggered when temperature aove 84°C and reset when temperature below 79°C).

b3

8

• Overheat of rear left controller (triggered when temperature above 84°C and reset when temperature below 79°C).

b4

16

• ZAPI overheat failure on rear right motor.

b5

32

• ZAPI overheat failure on rear left motor.

b6

64

• ZAPI internal overheat failure on rear right drive inverter.

b7

128

• ZAPI internal overheat failure on rear left drive inverter.

b0

1

• Encoder issue on Rear Right Motor.

b1

2

• Encoder issue on Rear Left Motor.

b2

4

• Rear right motor is stalled, or its encoder is not working.

b3

8

• Rear left motor is stalled, or its encoder is not working.

b0

1

• Main contactor stuck opened on rear right motor.

b1

2

• Main contactor stuck opened on rear left motor.

b2

4

• Wrong voltage on pin 10 of the rear right inverter.

b3

8

• Wrong voltage on pin 10 of the rear left inverter.

b4

16

• COMBI-ACE0: Power capacitors voltage does not increase at start-up.

b5

32

• ACE0: Power capacitors voltage does not increase at start-up.

b6

64

• The rear right controller detects an overvoltage or under voltage on B+.

b7

128

• The rear left controller detects an overvoltage or under voltage on B+.

b0

1

• Electro brake issue on rear right motor (Open circuit).

b1

2

• Electro brake issue on rear left motor (Open circuit)

b2

4

• Electro brake issue on rear right motor (Short circuit).

b3

8

• Electro brake issue on rear left motor (Short circuit).

F16.05 Thermal sensor issue

b0

1

• Issue on the temperature sensor on rear right motor.

b1

2

• Issue on the temperature sensor on rear left motor.

F16.06 Untreated ZAPI code

b0

1

• A not decoded ZAPI failure is present on rear right inverter.

b1

2

• A not decoded ZAPI failure is present on rear left inverter.

F16.01 Motor overheat

F16.02 Motor speed issue

F16.03 Drive Motor supply failure

F16.04 Brake issue

4001160950

E 04.22

USA / GB

279

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

D - Trouble shooting Failures

Bit

Dec

Description Electrical Motor (drive)

F16.07 Motor failure

F16.08 Internal issue

F16.09 Unable to stop the machine

1

• Rear right: Motor output voltage is lower than expected while running.

b1

2

• Rear left: Motor output voltage is lower than expected while running.

b2

4

• Rear right: Motor output voltage is higher than expected while running.

b3

8

• Rear left: Motor output voltage is higher than expected while running.

b4

16

• Rear right: One of the motor phases is open.

b5

32

• Rear left: One of the motor phases is open.

b6

64

• The current on the power part of the front right inverter is incoherent.

b7

128

• The current on the power part of the front left inverter is incoherent.

b0

1

• Internal failure of the rear right drive inverter.

b1

2

• Internal failure of the rear left drive inverter.

b2

4

• Wrong internal parameters (right inverter).

b3

8

• Wrong internal parameters (left inverter).

• The machine has not been able to reach null speed so emergency braking has been activated.

• COMBI-ACE0: Hardware overcurrent protection.

F16.10 Motor failure

280

b0

• ACE0: Hardware overcurrent protection.

4001160950

E 04.22

USA / GB

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

D - Trouble shooting Failures

Bit

Dec

Description Electrical Motor (pump)

F17.12 Motor overheat

4001160950

b0

1

• Overheat of pump motor (> 95°C).

E 04.22

USA / GB

281

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

D - Trouble shooting 2-

Legend 2.1 -

PCB TURRET L o c a t i o n

o n

Marking 1 2 3

282

t h e

m a c h i n e

Description Activ’Screen Keyboard switches Fuses relays card ( PCB)

4001160950

E 04.22

USA / GB

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

D - Trouble shooting L o c a t i o n

4001160950

E 04.22

USA / GB

283

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

D - Trouble shooting

284

4001160950

E 04.22

USA / GB

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

D - Trouble shooting F u s e s

a n d

r e l a y s

Marking

Description

FU2 FU3 FU4 FU5 FU6 FU7 FU8 FU9 FU34 FU101 FU102 FU103 FUP1 FUP2 FUP3 KA2 KA3 KA4 KA6 KA7 KA8 KA9 KA10 KA12 KA911

Protection of invertor option on platform (20A) Power stand-by for electric models (15A) Not used for electric models (25A) Protection of main supply logic circuit (30A) Not used for electric models (25A) Protection of power supply line V ECU SPU and UCB card Option flashing light (20 A) Power supply for accessories (20A) Protection of load sensors (1A) Protection converter (30A) Protection circuit key selection on variators Protection circuit supply and valves for both inverters Main power circuit (400A) Protection of inverter COMBIACE0 (300A) Protection of inverter ACE0 (200A) Invertor option on platform (192) Power stand-by for electric models (170) Not used for electric models Relay for battery charge CAN + Activ screen (20) Not used for electric models Option flashing light (194) Horn (187) Activ' Lighting System option (915) Main key circuit (144) Battery water filling pump (110) Stand-by relay ( 172 ), cut all power on main line after 4 hours if machine is still energised without action and E-stop not pushed Power relay (Keeps power a few seconds after KMG) (144) Main line contactor (144) Main power line contactor (144)

KMEV KMP KMG KM803

4001160950

E 04.22

USA / GB

285

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

D - Trouble shooting Notes

286

4001160950

E 04.22

USA / GB

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

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

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

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

4001160950

E 04.22

USA / GB

287

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

E - Electric and hydraulic diagrams 1-

Electric diagram E l e c t r i c i t y

288

4001160950

p a r t

-

4 0 0 0 7 1 1 2 5 0

E 04.22

F

f o l i o

0 2

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E - Electric and hydraulic diagrams L o w e r

4001160950

p a r t

-

E 04.22

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-

4 0 0 0 7 1 1 2 5 0

F

f o l i o

USA / GB

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289

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

E - Electric and hydraulic diagrams I n v e r t e r

290

4001160950

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F

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0 4

USA / GB

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E - Electric and hydraulic diagrams S P U

4001160950

1 / 3

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E 04.22

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f o l i o

USA / GB

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291

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E - Electric and hydraulic diagrams S P U

292

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E - Electric and hydraulic diagrams S P U

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3 / 3

E 04.22

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E - Electric and hydraulic diagrams C a g e

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p a r t - N o d e

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1 / 2

E 04.22

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f o l i o

0 8

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

E - Electric and hydraulic diagrams C a g e

4001160950

p a r t - N o d e

E 04.22

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2 / 2

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E - Electric and hydraulic diagrams O p t i o n

296

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-

4 0 0 0 7 1 1 2 5 0

E 04.22

F

f o l i o

1 0

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E - Electric and hydraulic diagrams S y s t e m

4001160950

a r c h i t e c t u r e

E 04.22

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4 0 0 0 7 1 1 2 5 0

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f o l i o

USA / GB

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297

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

E - Electric and hydraulic diagrams 2-

Hydraulic diagram S I G M A 1 6

298

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S I G M A 1 6

P R O

E 04.22

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E - Electric and hydraulic diagrams S I G M A 1 6

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E - Electric and hydraulic diagrams Notes

300

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E 04.22

USA / GB

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

F - Records Records 1-

Intervention register

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

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

Date

4001160950

Type of intervention

E 04.22

Number of hours

Intervenor

HAULOTTE Services® intervention number

USA / GB

301

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

F - Records Date

302

Type of intervention

4001160950

Number of hours

E 04.22

Intervenor

HAULOTTE Services® intervention number

USA / GB