MB Ha20rtj Usa E05.21

Maintenance Book
HA20RTJ - HA20RTJ O - HA20RTJ PRO -

HA61RTJ O - HA61RTJ PRO
MAINTENANCE BOOK
HA20RTJ - HA20RTJ O -
HA20RTJ PRO -
HA61RTJ O - HA61RTJ PRO
USA
4001055090 E 05.21 USA / GB

HA20RTJ - HA20RTJ O - HA20RTJ PRO - HA61RTJ O - HA61RTJ PRO
2 4001055090 E 05.21 USA / GB

Maintenance Book
CONTENTS
Preface -
Foreword
1 - Symbols and colors . . . . . . . . . . . . . . . . . . . . . 10
Safety
1 - General safety rules . . . . . . . . . . . . . . . . . . . . . 13
1.1 - Maintenance implementation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 - Uncontrolled movement Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 - Electric Shock Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 - Explosion / Fire Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2 - Maintenance and repair training . . . . . . . . . . . 17
2.1 - Owner's responsability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 - Technician's responsability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3 - HAULOTTE Services®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4 - Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5 - Product modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.6 - After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CONTENTS
2.7 - Product information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3 - Conditions of warranty . . . . . . . . . . . . . . . . . . 18
3
Maintenance Book
Familiarization
1 - Primary machine components . . . . . . . . . . . . 20
1.1 - Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2 - Ground control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.2 - HAULOTTE Activ'Screen 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.3 - Platform control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.3.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.3.2 - Display Panel (LED'S 101 - 117). . . . . . . . . . . . . . . . . . . . . . . . 51
2 - List of actuators and sensors . . . . . . . . . . . . . 54
2.1 - Sensors and actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3 - Power source - Engine specifications . . . . . . 56
3.1 - General safety and specific interventions on motor. . . . . . . . . . . . . . . . 56
3.2 - General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.3 - Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4 - Consumables (Oils - Fuels - Engine oil -
Coolant level...) . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.1 - Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.1.1 - Other fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.2 - Engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.3 - Hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.4 - Gear motor oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.5 - Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.6 - Cylinder storage oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.7 - Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.8 - Marine protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5 - Machine specifications . . . . . . . . . . . . . . . . . . 64
5.1 - Movement speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Inspection and
maintenance
schedule
1 - Inspection program . . . . . . . . . . . . . . . . . . . . . 65
2 - Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . 65
3 - Preventive maintenance . . . . . . . . . . . . . . . . . 66
4 - Periodic inspection . . . . . . . . . . . . . . . . . . . . . 72
5 - Major inspection . . . . . . . . . . . . . . . . . . . . . . . . 74
4
Maintenance Book
Machine sheet
MS0001 - Structural part inspection . . . . . . . . . . . . . . . 75
MS0002 - Pins and bearing inspection . . . . . . . . . . . . . 79
MS0003 - Cylinder inspection . . . . . . . . . . . . . . . . . . . . 83
MS0004 - Braking test procedure . . . . . . . . . . . . . . . . . 87
MS0005 - Torque Values . . . . . . . . . . . . . . . . . . . . . . . . 89
MS0009 - Fuel tank - Filling-up . . . . . . . . . . . . . . . . . . . 95
MS0020 - Hoses inspection - Replacement . . . . . . . . . 97
MS0026 - Dismantling / Reassembling wheels reducer99
MS0028 - Procedure of dismantling / reassembling
hydraulic rotary actuators . . . . . . . . . . . . . . . . . . . . . 117
MS0029 - KUBOTA diesel engine. . . . . . . . . . . . . . . . 135
MS0055 - Wheel replacement . . . . . . . . . . . . . . . . . . . 151
MS0057 - Overload system . . . . . . . . . . . . . . . . . . . . . 155
MS0058 - Ramps and speeds adjustment . . . . . . . . . 163
MS0063 - Sensor ILS adjustment . . . . . . . . . . . . . . . . 167
MS0064 - Pressure adjustment . . . . . . . . . . . . . . . . . . 173
MS0066 - Check and replacing the pads . . . . . . . . . . 175
MS0067 - Remove - Replace counterweight . . . . . . . 183
MS0068 - Remove - Replace arm assembly . . . . . . . . 189
MS0069 - Remove - Replace telescope cylinder . . . . 205
MS0070 - Remove - Replace arm cylinder . . . . . . . . . 215
MS0071 - Remove - Replace boom assembly . . . . . . 225
MS0074 - Remove - Replace Boom cylinder . . . . . . . 235
MS0075 - Boom and arm pads adjustment . . . . . . . . 241
CONTENTS
MS0076 - Remove - Replace turret/platform CAN BUS

wiring harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
MS0077 - Remove - Replace load cell. . . . . . . . . . . . . 253
MS0078 - Remove/Re-install rotary actuator . . . . . . . 261
MS0079 - Remove/Re-install output compensation
cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
MS0080 - Remove/Re-install input compensation
cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
MS0081 - Remove/Re-install jib cylinder . . . . . . . . . . 281
MS0082 - Remove/Re-install wheel reduction gear. . 285
MS0083 - Remove/Re-install slip ring (electric rotary
coupling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
MS0133 - Universal plug . . . . . . . . . . . . . . . . . . . . . . . 305
MS0238 - Links to engine manufacturer manuals -
Fuel-powered machines . . . . . . . . . . . . . . . . . . . . . . 307
5
Maintenance Book
MP0001 - Wheel tightening procedure . . . . . . . . . . . . 309

MP0001 - Wheel tightening procedure . . . . . . . . . . . . 309
MP0002 - Wheel reducer level procedure. . . . . . . . . . 317
MP0002 - Wheel reducer level procedure. . . . . . . . . . 317
MP0003 - Procedure for checking the level of engine
oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
MP0004 - Replacing the engine oil filter. . . . . . . . . . . 329
MP0005 - Diesel filter replacement . . . . . . . . . . . . . . . 333
MP0006 - Hydraulic oil filter replacement . . . . . . . . . 337
MP0007 - Procedure for checking engine belt tension341
MP0008 - Front axle locking function check . . . . . . . 345
MP0010 - Air filter replacement . . . . . . . . . . . . . . . . . . 349
MP0011 - Wear pad check . . . . . . . . . . . . . . . . . . . . . . 353
MP0013 - Hydraulic tank level . . . . . . . . . . . . . . . . . . . 357
MP0014 - Emptying the hydraulic tank. . . . . . . . . . . . 359
MP0015 - Load cell tightness check . . . . . . . . . . . . . . 363
MP0016 - Rotary cylinder tightness check. . . . . . . . . 365
MP0017 - Checking the platform . . . . . . . . . . . . . . . . . 369
MP0018 - Slew ring clearance check . . . . . . . . . . . . . 373
MP0019 - Torque tightening of the slew ring . . . . . . . 381
MP0020 - Emptying the diesel tank. . . . . . . . . . . . . . . 385
MP0021 - Draining the cooling circuit . . . . . . . . . . . . 389
MP0023 - Starter battery inspection . . . . . . . . . . . . . . 393
MP0024 - Checking the bushings and pins . . . . . . . . 397
MP0025 - Checking the condition of belts . . . . . . . . . 401
MP0026 - Checking and cleaning the fuel filter . . . . . 403
MP0027 - Steering system greasing . . . . . . . . . . . . . . 405
MP0028 - Greasing the pads . . . . . . . . . . . . . . . . . . . . 407
MP0029 - Jib cylinder lubrication . . . . . . . . . . . . . . . . 409
MP0030 - Cleaning of air cleaner element . . . . . . . . . 411
MP0031 - Coolant level. . . . . . . . . . . . . . . . . . . . . . . . . 413
MP0032 - Replace the belt . . . . . . . . . . . . . . . . . . . . . . 415
MP0036 - Drain the engine oil . . . . . . . . . . . . . . . . . . . 417
MP0037 - Greasing the cage rotation cylinder. . . . . . 421
MP0043 - Draining the wheel reducer. . . . . . . . . . . . . 423
MP0043 - Draining the wheel reducer. . . . . . . . . . . . . 423
MP0044 - Greasing the turntable rotation gearbox . . 431
6
Maintenance Book
Trouble shooting
and diagram
1 - Trouble shooting . . . . . . . . . . . . . . . . . . . . . . 433
1.1 - Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
1.2 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
1.3 - Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
1.4 - Failures list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
1.4.1 - List of failures per category . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
2 - Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
2.1 - PCB Turret. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
3 - Electric diagram . . . . . . . . . . . . . . . . . . . . . . . 454
4 - Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . 466
Records
1 - Intervention register . . . . . . . . . . . . . . . . . . . . 475
CONTENTS
7
Maintenance Book
8
A - Preface - Foreword
Preface - Foreword
You have just purchased a HAULOTTE® product and we would like to thank you for your business.
The Aerial Work Platform is a mechanical device primarily designed and manufactured with the intent to position people
with the necessary tools and material to overhead elevated temporary workplaces. All other uses or alterations/modifi-
cations to the aerial work platform must be approved by HAULOTTE®.
This manual shall be considered a permanent component of the machine and shall be kept with the aerial work platform
in the designated Manual Holder, at all times.
Safe operation of this product can only be assured if you follow the operating instructions contained in this manual are
followed. To ensure proper and safe use of this equipment, it is strongly recommended that only trained and authorized
personnel operate and maintain the aerial work platform.
We would particularly like to draw your attention to 2 essential points :

• Compliance with safety instruction (machine, use, environment).
• Use of the equipment within the performance limits.
With regard to the designation of our equipment, we stress that this is purely for commercial purposes and not to be con-
fused with the technical specifications. Only the specifications in this manual should be used to study the suitability of
the equipment for the intended use.
This maintenance and repairs book is specific to the HAULOTTE® products listed on the cover page of this manual. The
maintenance book is intended for the on-site maintenance technician.
It is the on-site maintenance technician's duty to carry out the regular maintenance work recommended by HAULOTTE
Services®.
This maintenance work is essential for correct machine operation.
If regular maintenance is not carried out, this may :

• Void the warranty.
• Cause machine malfunction.
• Reduce machine reliability and shorten its service life.
• Jeopardize operator safety.
To ensure that the regular maintenance requirements are fully satisfied, contact HAULOTTE Services®.
HAULOTTE Services® technicians are specially trained to carry out extensive repairs, interventions or adjust-
ments on the safety systems or elements of HAULOTTE® machines. They carry genuine HAULOTTE spare parts
and tools as required, and also provide fully documented reports on all work completed.
4001055090 E 05.21 USA / GB 9

1- Symbols and colors
Symbols and colors are used to alert the operator of safety precautions and/or to highlight important safety
information.
The following safety symbols are used throughout this manual to indicate specific hazards and the hazard
severity level when operating or maintaining the Aerial Work Platform.
Symbol
Symbol Description
Danger : Risk of injury or death
Caution : Risk of material damage
Prohibition relating to work safety and quality
Reminder to use good practice or follow pre-operation checks
Cross-reference to another part of the manual
Cross-reference to another manual
Cross-reference to repair (contact HAULOTTE Services®)
Maintenance sheet
Recommended tools
Recommended part
Safety
N.B. : Additional technical information
10 4001055090 E 05.21 USA / GB

Decals
Color Title Description
Danger : Indicates a hazardous situation which if not avoided,

WILL result in death or serious injury.
Warning : Indicates a hazardous situation which if not avoided,

COULD result in death or serious injury.
Caution : Failure to comply could result in minor or moderate

injury.
Notice : Indicates practices not related to personal injury.
Procedure : Indicates a maintenance operation.
N.B.-:-THE FOLLOWING SAFETY ADVISORIES ARE USED THROUGHOUT THIS MANUAL TO INDICATE SPECIFIC
HAZARDS WHEN OPERATING OR MAINTAINING THE TELEHANDLER.
4001055090 E 05.21 USA / GB 11

Notes
12 4001055090 E 05.21 USA / GB

B - Safety
Safety
1- General safety rules
1.1 - MAINTENANCE IMPLEMENTATION
Your safety and the safety of the people around are essential.
Make sure the work area is clean in order to not to pollute the system of the machine.
Before performing any maintenance interventions, place the machine in maintenance

configuration.
1. Place the machine on firm, level ground.

2. Stow the machine completely.
3. Push the E-stop button to cut off the electricity supply.
4. Insert the turntable rotation locking pin.
Never leave the hydraulic cylinders fully extended before switching off the machine, or when stationary
for an extended period of time. Keep the elements of the machine in configuration of maintenance
thanks to mechanics devices.
Report that the machine is under maintenance by tagging the platform and ground control boxes.
4001055090 E 05.21 USA / GB 13

B - Safety
Note :
• Using the machine during maintenance is strictly forbidden.
• Do not climb onto the covers.
• The handling of parts must be carried out using appropriate equipment (Chains, Lifting slings, Lifting
anchors).
• Plug the end of any hoses removed, and cap any open ports to prevent contamination during
maintenance.
Return the machine to operating configuration after maintenance has been completed :
1. Remove the turntable rotation locking pin.
2. Pull the E-stop button.
1.2 - UNCONTROLLED MOVEMENT HAZARD
Be aware of uncontrolled movement and always respect the following :

• Maintain clearance from high voltage lines.
• Maintain clearance from generators, radar, electromagnetic fields.
• Never expose the batteries or electrical components to water (high pressure washer, rain).
• Never tow the machine over extended distances.
• In case of a machine breakdown, it is possible to tow short distance to load it onto a trailer.
• Never leave the hydraulic cylinders fully extended before switching off the machine, or when
stationary for an extended period of time.
• Retract and lower the boom to the stowed position rotate the turntable so that the boom is between
the non-steering wheels.
• Select a safe parking location, on a firm level surface, clear of obstruction and traffic.
• Ensure all compartments are closed and secured.
• Chock the wheels.
14 4001055090 E 05.21 USA / GB

B - Safety
1.3 - ELECTRIC SHOCK HAZARDS
The machine is not electrically insulated and does not provide protection from contact or proximity to
electrically charged conductors.
Always position the lift at a safe distance from electrically charged conductors to ensure that no part of
the machine is within an unsafe area.
Respect the local rules and the minimum safety distance from power lines.
Minimum safe approach distances
Electric voltage Minimum safety distance

Mètre Feet
0 - 300 V Avoid contact
300 V - 50 kV 3 10
50 - 200 kV 5 15
200 - 350 kV 6 20
350 - 500 kV 8 25
500 - 750 kV 11 35
750 - 1000 kV 14 45
N.B.-:-THIS TABLE IS APPLICABLE, EXCEPT WHEN THE LOCAL REGULATIONS ARE MORE STRICT.
Do not operate the machine :

• Do not operate the machine when close to live power lines, consider the
movement of the machine and the sway of the electric power lines particularly in
windy conditions.
• Do not operate the machine during lightning, thunderstorms, snow/ice or any
weather condition that could compromise operator safety.
• Do not operate the machine during lightning or storms.
• Do not use the machine as a welding earth.
• Do not wash electrical components with a high pressure washer.
• Do not weld on the machine without first disconnecting the battery terminals.
• The machine must not be used while charging the batteries.
• When using the platform AC power line, ensure it is protected with a circuit
breaker.
Keep away from the machine if it contacts energized power lines. Personnel on the
ground or in the platform must not touch or operate the machine until energized
power lines are shut off.
In the event of accidental contact with a high voltage line, wait for the power to the
line be de-energized before attempting to operate the machine.
4001055090 E 05.21 USA / GB 15

B - Safety
1.4 - EXPLOSION / FIRE HAZARDS
Always wear protective clothing and eye wear when working with
batteries and power sources/systems.
N.B.-:-ACID IS NEUTRALIZED WITH SODIUM BICARBONATE AND WATER.
• Do not start the engine if you smell or detect liquid propane gas
(LPG), gasoline, diesel fuel or other explosive substances.
• Do not work in an explosive or flammable atmosphere / environment.
• Do not touch hot components.
• Do not bridge the battery terminals with metallic objects.
• Do not service the battery in proximity of spark, open flame, lit
cigarettes.
• Do not fill up the fuel tank, when the engine is running and/or near a
flame.
16 4001055090 E 05.21 USA / GB

B - Safety
2- Maintenance and repair training
2.1 - OWNER'S RESPONSABILITY
The owner (or hirer) has the obligation to inform technician of the instructions contained in the Operator
Manual and Maintenance Book.
The owner (or hirer) has the obligation to renew all manuals or decals that are either missing or in bad
condition.
Additional copies can be ordered from HAULOTTE Services®.
The owner (or hirer) is responsible for applying the local regulations regarding maintenance of the
machine.
2.2 - TECHNICIAN'S RESPONSABILITY
The technician must read and understand the contents of this manual, operators manuals and the
decals affixed on the machine.
The technician must inform the owner (or hirer) if the manual or any decals are missing or in poor
condition, and of any malfunction of the machine.
Only authorized and qualified operators may operate HAULOTTE® machines.
2.3 - HAULOTTE SERVICES®
The HAULOTTE® is at your service in all 5 continents of the world via an extensive network of its own
factory trained technicians, who are ready to respond to your every need.
2.4 - TRAINING
Whether you want to just service your equipment or carry out a complete overhaul, HAULOTTE® can
provide you with a structured training program or we can tailor a program to suit your specific
requirements or circumstances. Training can cover the general operation of the equipment,
breakdowns, engine maintenance and repairs and electrical/hydraulic/mechanical repairs and trouble
shooting.
4001055090 E 05.21 USA / GB 17

B - Safety
2.5 - PRODUCT MODIFICATION
In a constant effort to improve the quality of machines, HAULOTTE continually monitors technical
improvements that enable to develop products with improved safety and greater reliability. The target
being that HAULOTTE® always work to build confidence in the relationships with our customers.
These improvements will be shared via the following documents :

• OI : Obligatory Intervention, Safety information requiring immediate action (take into account
by HAULOTTE®).
• NI : Technical improvement requiring immediate action (take into account by HAULOTTE®).
• RI : Improvement proposed to customers to take into account during maintenance operation.
• PI : Product information for knowledge.
2.6 - AFTER SALES SERVICE
Our HAULOTTE Services® After Sales Service is at your disposal throughout your machine's service
life to ensure the optimum use of your HAULOTTE product :
• When contacting our After Sales Service, ensure that you provide the machine model and serial
number.
• When ordering any consumables or spare parts, please use this manual and the HAULOTTE®
Essential catalogue to receive your genuine HAULOTTE® spare parts, your only guarantee of parts
interchangeability and correct machine operation.
• If there is an equipment malfunction involving a HAULOTTE® product, then contact HAULOTTE
Services® immediately even if the malfunction does not involve material and/or bodily damage.
2.7 - PRODUCT INFORMATION
Without the written permission from Haulotte, modifying a HAULOTTE® product is a Safety concern.
Any modification may violate Haulotte design parameters, local regulations and industry standards.
If you desire a modification to the product, submit a request in writing to HAULOTTE.
With the utmost care to ensure enhanced reliability and greater safety of the HAULOTTE® products, it
is pertinent that when a "Service or Safety Bulletin" is issued, action is taken immediately. Once the
bulletin has been addressed, make sure that the completed form is submitted to HAULOTTE Services®.
Do not hesitate to contact HAULOTTE Services® , should you have any questions relating to the issued
bulletin(s) or with questions on the policy itself.
3- Conditions of warranty
Our warranty conditions and extension contracts are now available on the websites of our sales network :
www.haulotte.com
18 4001055090 E 05.21 USA / GB

C - Familiarization
Familiarization
Notes
4001055090 E 05.21 USA / GB 19

C - Familiarization
1- Primary machine components
1.1 - LAYOUT
HA20RTJ - HA20RTJO - HA20RTJPRO - HA61RTJO - HA61RTJPRO
C163 C7 C4 C150 C8 C9
C35
C6 C42 C29
C22 C13
C72
C36
C23
C38
C17
C12 C33
C11 C113
C27
C1
C3 C2
C14 C20 C10 C28 C164

C165
20 4001055090 E 05.21 USA / GB

C - Familiarization
Marking Description Marking Description

C1 Chassis C23 Arm lifting cylinder
C2 Steering wheel C27 Ground control box + Universal plug
Rear drive wheel (and steer wheel if
C3 C28 Tilt sensor
4WS)
C4 Jib C29 Platform rotation cylinder
C6 Platform C33 Counterweight
C7 Platform control box C35 Document holder
C8 Input jib leveling cylinder C36 Top arm
C9 Upper boom C38 Bottom arm
C10 Slew ring C42 Foot Switch
C11 Turntable assembly C72 Output jib compensation cylinder
Left side compartment (engine, pump
C12 C113 Beacon light
and starter battery)
C13 Arm/Boom link piece C150 Jib lifting cylinder
C14 Hydraulic drive motor and reducer C163 Hand (grab) rail
Front steering axle (For HA20RTJ
C17 Right side compartment C164
only)
Front steering and oscillating axle
C20 Tie-down (and/or lifting) points C165 (For HA20RTJ O / HA20RTJ PRO /
HA61RTJ O / HA61RTJ PRO only)
C22 Boom lift cylinder
Universal plug
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C - Familiarization
1.2 - GROUND CONTROL BOX

1.2.1 - Layout
General view
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C - Familiarization
Controls and indicators
Marking Name Description Function
By pressing on : Tilt the platform towards the

front of the machine
1 Platform tilt control
By pressing on : Tilt the platform towards the

back of the machine
SA620U
By pressing on : Jib raising
2 1
Jib raising / lowering switch
SA620D
By pressing on : Jib lowering
SA530O
By pressing on : Boom extending
3 Boom telescoping switch
SA530I
By pressing on : Boom retracting
SA520U
By pressing on : Boom raising
4 Boom raising / lowering switch
SA520D
By pressing on : Boom lowering
SA420U
By pressing on : Arm raising
5 Arm raising / lowering switch
SA420D
By pressing on : Arm lowering
By pressing on :
Enable Switch / Back-up unit
6 SB800 • Validation of controls when engine started
selector
• automatic switching of emergency electropump if
the engine is stopped
SA250L By pressing on : Counter clockwise (CCW)

7 Turntable rotation switch rotation
SA250R
By pressing on : Clockwise (CW) rotation
SA750L
By pressing on : Clockwise (CW) rotation
8 Platform rotation switch
SA750R By pressing on : Counter clockwise (CCW)
rotation
Pulled out : Ground control box energized
9 SB801 E-stop button
Pushed in (activated) : De-energizes control system
Indicator, ground control box
10 HL905 LED lights up - ground control box icon
selected
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C - Familiarization
11 SA801 "Overriding system" control By pressing on : Authorize movements from

the ground control box in case of overload (Use
ONLY in case of emergency)
12 SB807 Horn button

By pressing on : Horn activation
Indicator of the platform control

13 HL906 LED lights up - platform control box icon
box selection
14 SA903 Beacon light on/off

By pressing on : Beacon light ON / OFF
Alarm icon :
• Flashes when the machine starts at the same time
as the ( 19 ) icon
• Is blinking if overriding is active :
• If there is a fault, an error code will be displayed on
15 HL909 Overload indicator the Activ' Screen
• Or Hydraulic oil temperature icon is active on the
Activ' Screen
• Or Engine pressure icon is active on the Activ'
Screen
• Or Engine stop icon is active on the Activ' Screen
• Or Overload machine status is active on the Activ'
Screen
16 SA303 Engine start-up selector By pressing on : Engine start / stop
17 SA300 Propane Gas supply2 By pressing on : Propane Gas supply

selection
18 SA305 Petrol/Gasoline or diesel supply3 By pressing on : Fuel supply selection
Alarm icon :
• Flashes when the machine starts at the same time
as the ( 15 ) icon
Engine warning indicator / Engine • Is blinking if overriding is active Warning icon is ON
19 HL908 if :
pre-heating
• Engine warning icon will be displayed on the Activ'
Screen
• Or Tilt machine status will be displayed on the
Activ' Screen
• Or Engine is pre-heating
20 SA600F DPF regeneration inhibited4 By pressing on : Refusal of the request for

regeneration
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C - Familiarization
21 SA600D DPF regeneration required5 By pressing on : Regeneration start-up
: De-energizes control system
22 SA900 Control box activation key switch

: Platform control box energized
: Ground control box energized
23 Activ'Screen 2
1. For machines fitted with
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C - Familiarization
1.2.2 - HAULOTTE Activ'Screen 2
Upon starting and during operation of the machine, the LCD screen "Activ'Screen" located on the
ground control box displays in real time the machine operating status.
HAULOTTE Activ'Screen 2
Icon Description Function Icon Description Function

HAULOTTE Activ'Screen 2
Navigation buttons - Above Activ'Screen display
Allows return to the

Permits scrolling up through
Home Button home screen at any Up Navigation
the screen (if present)
time
Permits allows scrolling down

Permits navigation to
through the screen and onto
Left navigation screens to the left (if Down Navigation
the following screen (if
present)
present)
Permits navigation to
screens to the right of Used to refuse or cancel a
Right Navigation Cancel Button
the current screen (if selection within the menu
present )
Returns the user to the Used to confirm selection

Back button Validation Button
previous screen within the menus
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C - Familiarization
On initial start-up of the machine or after 3 day of inactivity, the following screens are displayed in order.

Machine power up (Start-up screen)
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C - Familiarization
Access code not yet entered
Access code entered is correct (Level 1, 2 or 3

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

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

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

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

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

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.
Emergency mode • Ground control box is NOT selected/energized.
The Emergency mode is out of service/non-
functional
Emergency mode has been used and activation

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

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

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

• Icon is ON if there is no charge

output detected from the alternator
Battery State • Icon is flashing if a failure code for
the alternator is detected (code
F09.10)
Icon is ON when the temperature
in the hydraulic reservoir has
Hydraulic oil exceeded the maximum required
temperature temperature. Stop using the
machine and allow the oil to cool
down.
Icon is ON if engine oil pressure is
lower than required limit while
Engine oil pressure engine is running. The Engine
Warning icons zone
must be switched OFF immediately
to avoid damaging the motor.
• The engine oil level is under the

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

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

detected. Or one of the engine
Warning icons zone Engine warning
maintenance schedules has been
exceeded.
• Engine decontamination system

Engine
fault. In this case, you must
Warning icons zone decontamination
contact HAULOTTE Services® as
fault (If fitted)
soon as possible.
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C - Familiarization

• Permanently lighted if the

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

Warning icons zone
(If fitted) regeneration is inhibited
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C - Familiarization
DPF regeneration in
progress, high temperature in • Light stays on during
Warning icons zone
the exhaust system ( HEST ) regeneration
(If fitted)
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C - Familiarization

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

Bargraph
Digital Gauge - The indicator changes from

Fuel reserve GREEN to RED when the
indicator (ON/ fuel level is low and
OFF) indicator is activated
The fuel level indicator

Analog Gauge - switches from GREEN to
Fuel level gauge RED when the fuel level is
low
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Displays the machine battery
Charge Battery voltage. The indicator switches
to RED if the voltage is low.
Engine Speed
Engine speed display
(rpm)
Displays Engine coolant

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

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

Working light
light is switched on
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C - Familiarization

• Displays the pictogram

Pictogram and title
and machine status
Machine ready, displayed

Machine status zone when no failures and no
Ready
other machine state icons
is active
Alarm icon is flashing

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

Layout
Platform control Selector switch is in platform

selected control box position
Ground control Selector switch is in ground control

selected box position
The machine is elevated , and is

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

Layout
Engine’s automatic preheat

system is active. The time to pre-
heat will vary according to engine
Pre-heating
and ambient temperature. The
machine can be started as soon as
the indicator goes out.
Icon is ON if the range limit is

Radius limitation
active or faulty
The machine is charging by the

Machine is charging
engine
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C - Familiarization

Fuel level is low. Refill the fuel tank to

the marked level. Attention: Lack of
Low fuel level fuel may damage the motor/engine
and will not be covered under
warranty.
• Permanently lighted if the particle

DPF regeneration
filter requires regeneration with a high
required (If fitted)
clogging level
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C - Familiarization

Layout
Diagnostic in The HaulotteDiag console is

progress connected to the machine
Screen software Screen software update essential

obsolete Contact HAULOTTE Services®
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CAN network fault between the

F12.01 bus CAN fault
screen and the rest of the machine
Activ' Shield Bar The secondary safety system is

disable switched off
The secondary safety system is

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

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

• Displays the reference

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

Machine date and • Displays the date and time
time of the machine ECU
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C - Familiarization

Machine fault
Machine fault icons
Failure code F01.xx Fault - Variator Failure code F09.xx Fault - IC Engine
Failure code F02.xx Fault - power contactor Failure code F10.xx Fault - Functions
Failure code F03.xx Fault - command relay Failure code F11.xx Fault - machine safety
Fault - electronic control

Failure code F04.xx Fault - electro-valve Failure code F12.xx
unit ECU
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C - Familiarization

Machine fault
Machine fault icons
Failure code F05.xx Fault - joystick Failure code F13.xx Fault - Switches
Fault - weight
Failure code F06.xx Failure code F14.xx Fault - Driving pump
management system
Fault - limit switch or Fault - data communication

Failure code F07.xx Failure code F15.xx
sensor system CAN
Failure code F08.xx Fault - electrical circuit Failure code F16.xx Fault - Electric motor
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Notes
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C - Familiarization
1.3 - PLATFORM CONTROL BOX

1.3.1 - Layout
General view
Affichage pupitre de commandes haut (Led 101 - 117)

Platform control box display (Led’s 101 - 117)
40 79 44 33B
33A
259
45 46
35 41
201
230
43
54 49 129 38 50 33
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C - Familiarization

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

33A
Steering button (Steering According to selected mode ( 201 )
thumb / rocker switch) Press left side of button : Steer left -
33B
According to selected mode ( 201 )
Toggle left and hold(Activated) : Maximum
35 SA100 Differential lock selector drive torque (on difficult or sloping ground)
Release (deactivated) : Standard torque
Move to the right : Counter clockwise
38 SA751 Platform rotation switch (CCW) rotation
Move to the left : Clockwise (CW) rotation
Move upwards : Raise platform
40 SA721 Platform leveling switch
Move downwards : Platform lowers
Toggle and hold : Back-up unit activated
41 SA800 Auxiliary power switch
Release : Back-up unit deactivated
Push the horn selector down to sound the
horn
43 SA907 Horn button
The horn stops when the selector switch is
released
Push switch to the right for LPG (liquid
propane gas supply)
44 SA304 Fuel selector1
Push switch to the left for gasoline (petrol)
or diesel fuel supply
High-speed drive
45 SA110 Drive speed selector Medium speed drive
Low-speed drive
Pulled out : Platform control box energized

46 SB802 E-stop button Pressed in : De-energizes control system
(Engine stopped)
Move to the right : Counter clockwise
Turntable rotation joystick (CCW) rotation
49 SM900 Move to the left : Clockwise (CW) rotation

Move forward : Raise boom
Boom lift joystick
Move backwards : Lower boom
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C - Familiarization

Move forward : Arm raises
50 SM901 Arm lift joystick
Move backwards : Arm lowers
Hold upwards : Boom retracts
54 SA531 Boom telescoping switch
Move downwards and hold : Boom extends
Move to the left : Generator deactivated
79 SA906 Generator selector2
Move to the right : Generator activated
Hold upwards : Lifting
129 SA621 Jib raising / lowering switch3
Move downwards and hold : Lowering
All 4 wheels steer
201 SA101 Steering mode selector4 Front 2 wheels steer
Crab mode
Move backwards : Starts or Stops the
Engine start-up / stop
230 SA303 engine (depending on the engine's
selector
operating (ON/OFF) mode
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C - Familiarization
1.3.2 - Display Panel (LED'S 101 - 117)
Upper control box display
Marking Name Symbol Function
LED 101 HL900 Power ON
LED 102 HL300 Combustion engine pre-heating
LED 103 HL307 Low fuel level
LED 104 HL304 Engine warning
LED 105 HL305 Engine shutdown
LED 106 HL301 DPF regeneration required (If equipped)
DPF regeneration in progress, high temperature in the exhaust

LED 107 HL302
system ( HEST ) (If equipped)
LED 108 HL303 DPF regeneration inhibited (If equipped)
LED 1091 HL805 Not used
LED 110 HL807 Foot Switch
LED 111 HL801 Fault
LED 112 HL800 Tilt
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C - Familiarization
Marking Name Symbol Function
LED 114 HL802 Overload
LED 116 HL720 Platform leveling
1. If machine equipped with dual load

2. If machine equipped with dual load
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Symbol Description
Machine switched on :
• Rapid flashing : Machine is ON, but platform control box is not active but the ground control box is ON.
Also flashes with either E-stop pressed in
• Illuminated : Machine is turned on and platform control panel is active.
Foot Switch :
• Illuminated when Foot Switch activated
Faults :
• Rapid flashing : If a fault is active (current fault)
Overload :
• Rapid flashing : Faulty weighing / overload system
• Illuminated when overloaded
Tilt sensor :
• Illuminated when in tilt, machine stowed or unfolded
Basket levelling +/- 10° :

• Illuminated if the angle of the platform reaches +/- 10° in relation to the horizontal and movement control
Low fuel level
Combustion engine pre-heating :

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

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

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C - Familiarization
2- List of actuators and sensors
2.1 - SENSORS AND ACTUATORS
Sensors and actuators
SR721 - SR720
SP800 - SP801
SQ531- SQ530
SQ520
SQ421
YV620 U/D
YV750 R/L
YV720 U/D
SQ900
SQ300
ST900
SQ800 YV800 - YV150

YV420 - YV420 U/D
YV520 - YV520 U/D
YV530 - YV530 O/I
YV900
YV101 YV105 SP300 YV100 - YV102 - YV110

YV107 - YV108 ST300 YV111 - YV112 - YV113
YV150 L/R YV114 - YV115
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C - Familiarization
Name Description
SP109 Control's pressure for oscillating axle sensor
SP300 Engine oil pressure sensor ( TIER III engine only)
SP800 Weight sensor
SP801 Weight sensor
SQ300 Fuel low level sensor (ON = Low fuel level)
SQ421 Arm's position sensor ( SQ421 = 1 if arm folded)
SQ520 Boom's position sensor ( SQ520 = 1 if boom folded)
SQ530 Telescope's position sensor ( SQ530 = 1 if telescope retracted)
SQ531 Telescope's position sensor HA20RTJ PRO( SQ531 = 1 if telescope retracted)
SQ800 Tilt sensor ( OFF = excessive tilt position)
SQ900 Boom and arm sensor ( SQ900 = 1 if arm and boom folded)
SR720 Platform tilt sensor - 10° ( ON when tilt is above - 10°)
SR721 Platform tilt sensor + 10° ( ON when tilt is above + 10°)
ST300 Engine coolant temperature ( TIER III engine only)
ST900 Hydraulic oil overheating sensor
YV100 Differential lock electrovalve
YV101 Oscillating axle unlock electrovalve
YV102 Brake release electrovalve
YV105 Axle brake release electrovalve with 4 WS
YV107 Steering mode electrovalve
YV108 Steering mode electrovalve
YV110 Drive speed electrovalve
YV160 PWM - Electrovalve : Drive
YV150 L / R Front axle steering electrovalve
YV420 Arm PWM electrovalve
YV420 U / D Arm electrovalve : Direction
YV520 Boom PWM electrovalve
YV520 U / D Boom electrovalve : Direction
YV530 Telescope PWM electrovalve
YV530 O / I Telescope electrovalve : Direction
YV620 U / D Jib movement electrovalve
YV720 U / D Platform rotation movement electrovalve
YV750 R / L Platform level movement electrovalve
YV800 Load Sensing electrovalve
YV900 PWM Jib and platform movement and steering motion electrovalve
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C - Familiarization
3- Power source - Engine specifications
3.1 - GENERAL SAFETY AND SPECIFIC INTERVENTIONS ON MOTOR
The technician should take all steps to protect themselves or others against all risks of injury inherent
in his intervention.
The technician should ensure that suitable PPE (personal protective equipment) for the job is used, and
check the particular conditions of environment in which the material can be found (see safety
information specific to the operation site).
• Turn off the ignition, remove the key, open the battery switch before working on the engine.
• Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid
accidental engine starting, disconnect the battery cable from the negative (-) battery terminal.
Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact
with other metal surfaces which could activate the engine electrical system. Place a do not operate
tag at the start/stop switch location to inform personnel that the equipment is being worked on.
• The hot engine parts can cause injury and burns. Before performing maintenance on the engine, cool
the engine and parts.
• By touching a functioning engine, there is a risk of burns from contact with hot parts, and injuries by
the rotating parts.
• To avoid any risk of accident, using compressed air (example : blowing air filter), always wear a
headband and goggles.
• The hot coolant, steam and alkalis can cause injury. At the operating temperature, the engine coolant
is hot and under pressure. Do not open the cap of the expansion chamber before letting the circuit
cool.
• The radiator and all the pipes going to the heaters or engine contain hot coolant or steam. Contact
can cause severe burns.
The engine exhaust gases contain harmful combustion products. Always start and run the engine in a well
ventilated area. In an enclosed area, evacuate the exhaust outside.
3.2 - GENERAL SPECIFICATIONS
N.B.-:-USING UNSUITABLE FUEL MAY CAUSE DIMINISHED PERFORMANCE, DIFFICULTIES STARTING, EXCESSIVE
POLLUTION AND PREMATURATE WEAR. TO ESTABLISHED THE TYPE OF THE FUEL SUITABLE FOR THE ENGINE
FITTED ON YOUR HAULOTTE®, PLEASE REFER TO THE ENGINE MANUFACTURER'S MANUAL. THE ENGINE
MAY NOT BE COVERED BY THE WARRANTY IN CASE OF DAMAGE CAUSED BY USING UNSUITABLE FUEL.
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3.3 - CONSUMABLES
Consumable HAULOTTE® code Packaging

Air cleaner 2324007620
• Primary cartridge 4000044230
• Secondary cartridge 4000044240
Pressure filter 2427003110
Oil filter 4000076270
Engine fuel filter 4000079430
Engine belt 4000353520
Engine oil - 5W40 4000010660 60 l(15,8 gal US)
4000530600 5 l(1,32 gal US)
2820305720 209 l(55,2 gal US)
Hydraulic oil - HV32 4000096350 20 l(5,3 gal US)
4000530620 5 l(1,32 gal US)
Hydraulic oil - HV46 2420801320 20 l(5,3 gal US)
2420801310 209 l(55,2 gal US)
Biological hydraulic oil - HV46 2505003830 209 l(55,2 gal US)
4000530610 1 l(0.22 gal US)
Transmission oil - 80W90
2420801370 20 l(5.3 gal US)
Extreme-pressure lithium grease 2820304320 0,4 l(0.1 gal US)
Grease cartridge 2326005400 0,4 l(0.1 gal US)
Grease cartridge 4000561720 0,4 l(0.1 gal US)
Telescope grease 4000813570 1 kg(2.20 lb)
Telescope grease 4000813560 5 kg(11.02 lb)
Aggressive environment grease 4001088590 5 l(1,32 gal US)
4000813540 5 l(1,32 gal US)
Coolant
4000564860 25 l(6,6 gal US)
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C - Familiarization
4- Consumables (Oils - Fuels - Engine oil - Coolant level...)
4.1 - FUEL
N.B.-:-THESE FUELS CAN BE USED ON ANY TYPE OF MECHANICAL INJECTION ENGINE. PLEASE SEE MACHINE
CONFIGURATION.
Table of technically permitted fuels
Engines Fuels
European fuel oil American gas oil
Hydraulic filter European gas oil Japanese gas oil
according to BS2869 according to
cartridge according to EN590 according to NATO F54
class 2 ASTMD975-07b
HATZ 41C
DEUTZ 2011/2012
PERKINS 403/804/1104
LOMBARDINI LDW
1404
KUBOTA D1105-W1
KUBOTA V2403
KUBOTA V2403 CR
KUBOTA V2703
KOHLER KD1903
Compliant
Not compliant
4.1.1 - Other fuels
• Biofuels : According to EN14214 (EU) and ASTM D6751-07a (USA) biofuels are allowed on some
engines and under certain conditions. For more information, please contact HAULOTTE Services®.
• Jet engine fuels (kerosene) : F34 and F35 types under OTAN designation are possible on some
engines and under certain conditions. For more information, please contact HAULOTTE Services®.
• The use of vegetable oils is forbidden.
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C - Familiarization
4.2 - ENGINE OIL
The correct SAE viscosity grade of oil is determined by the minimum ambient temperature during cold
engine start-up, and the maximum ambient temperature during engine operation.
Refer to Table "Engine Oil Viscosity" (minimum temperature) in order to determine the required oil
viscosity for starting a cold engine.
Refer to Table "Engine oil Viscosity" (maximum temperature) in order to select the oil viscosity for
engine operation at the highest ambient temperature that is anticipated.
Generally, use the highest viscosity oil that is available to meet the requirement for the temperature at
start-up.
Engine oil viscosity
Ambient temperature
EMA LGR-1 / API CF, CF-4, CG-4, CH-4 / CI-4 Viscosity grade
Minimum Maximum
SAE 0W20 -40°C (-40°F) 10°C (50°F)
SAE 0W30 -40°C (-40°F) 30°C (86°F)
SAE 0W40 -40°C (-40°F) 40°C (104°F)
SAE 5W30 -30°C (-22°F) 30°C (86°F)
SAE 5W40 -30°C (-22°F) 40°C (104°F)
SAE 10W30 -20°C (-4°F) 40°C (104°F)
SAE 15W40 -10°C (14°F) 50°C (122°F)
Classification API
Fuel type Engine oil classification

API CJ4
High sulfur fuel ≤ [0.05% (500 ppm)]
(If the engine oil is used with a high sulfur level, change the engine oil at
Sulfur content < 0.50% (5000 ppm)
shorter intervals, approximately half)
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C - Familiarization
4.3 - 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 CONSOMMABLES
Viscosity HV46
HV46 HV32 HV68
grade Biodegradable
Between - 15° C (- 9° Between - 15° C (- 9° Between - 35° C (- Between 0° C (+ 32°
Ambient temperature F) and + 40° C (+ F) and + 40° C (+ 31° F) and + 35° C (+ F) and + 45° C (+
104° F) 104° F) 95° F) 113° F)
Between - 15° C (- 9° Between - 15° C (- 9° Between - 35° C (- Between 0° C (+ 32°
Hydraulic oil temperature F) and + 80° C (+ F) and + 80° C (+ 31° F) and + 80° C (+ F) and + 85° C (+
176° F) 176° F) 176° F) 185° F)
Standards
Viscosity at + 40° C (+ 104° F) ISO 3104 46 +/- 3 cst 46 +/- 3 cst 32 +/- 3 cst 68 +/- 3 cst
Viscosity at + 100° C (+ 260° F) ISO 3104 > 8 cst > 8 cst > 8 cst > 10,5 cst
Viscosity Index ISO 2909 > 150 > 160 > 250 > 150
Flashpoint ISO 2592 > 210° C (> 410° F) > 220° C (> 428° F) > 125° C (> 257° F) > 220° C (> 428° F)
Pour point ISO 3016 < - 40 ° C (< - 40° F) < - 40 ° C (< - 40° F) < - 50 ° C (< - 58° F) < - 35 ° C (< - 31° F)
60 4001055090 E 05.21 USA / GB

C - Familiarization
4.4 - GEAR MOTOR OIL
The recommended oil is EP type, the characteristics of which comply with standards MIL-L-2105 and
API GL5.
Mineral Synthetic
Normal operating condition SAE 80W/90 SAE 75W/90
Harsh operating condition SAE 85W/140 SAE 80W/140 - SAE 75W/140
4.5 - COOLANT
Always use a 50/50 blend of coolant and clean soft water.
The coolant is available in different types. For this engine, use the ethylene glycol type (EG).
The procedure for the blend of water and antifreeze differs according to the manufacture of the
antifreeze. Refer to standard SAEJ1034 and more precisely SAE J814c.
Freezing point Boiling point

Antifreeze volume (%)
°C °F °C °F
50 - 37 - 34 108 226
Never add a different brand of coolant. The different brands may have different additive components, and
the engine may fail to perform as specified. When the liquid is mixed, do not use any radiator cleaning
agent. If the liquid is mixed with a cleaning agent, an emulsion may form and the engine components may
be damaged.
4001055090 E 05.21 USA / GB 61

C - Familiarization
4.6 - 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.
4.7 - GREASE
Grease for Shell gadus S2 Polyplex Bardahl

Units Standards
telescope V220AC 2 grease grease
Nature of the lubricating oil Semi-synthetic 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
Operating temperature °C - 40 at 140 - 20 at 120 - 20 at 160
Viscosity of the basic oil at
mm² / s ISO 3104 25 220 140
40° C / 104° F
Viscosity of the basic oil at
mm² / s ISO 3104 - 18 14,5
100°C / 212° F
Penetration at 25° C / 77°
0,1 mm ISO 2137 310 - 340 277 265 - 295
F
Drop point °C / °F ISO 2176 > 180 175 > 250
Welding 4 ball test kg > 315 - > 315
Density at 20° C / 68° F 0,91 0,9 0,9
62 4001055090 E 05.21 USA / GB

C - Familiarization
4.8 - MARINE PROTECTION
In harsh environments (high levels of salinity in the atmosphere: close to the sea, industrial environment
with chloride emissions and/or humidity > 70%), we recommend applying the following protection
process :
• Wash the machine completely to remove any trace of harsh environmental pollution.
• Dry all the machine.
• Apply directly a solvent-based oil leaving an oily film after evaporation of the solvent.
• Re-apply the product every month.
After washing the machine, make sure it is fully air-dry and does not contain moisture on corrosive parts
(cylinders rods for example).
Do not wash any electrical components, particularly with high pressure washer. Wipe away dirt from
around electrical components with a dry cloth.
Viscosity at + 40° C (+ 104° F) 4 mm²/s

Flashpoint 28 °C
4001055090 E 05.21 USA / GB 63

C - Familiarization
5- Machine specifications
5.1 - MOVEMENT SPEED
To allow checking operation, refer to the following table about originally time per movement. If the
values measured by test are not equal to the following :
• Do not use the machine.
• Setting updating is needed.
Always check speed movement from the ground control box.
HA20RTJ O - HA61RTJ O -
HA20RTJ
HA20RTJ PRO - HA61RTJ PRO
Micro drive speed 0,8 km/h / 0.5 mph 0,5 km/h / 0.3 mph
Low drive speed 1,2 km/h / 0.7 mph
Medium-speed driving 2,5 km/h / 1.6 mph
High drive speed 5 km/h / 3.1 mph
Maximum towing speed 5 km/h / 3.1 mph
Time for telescopic boom extension 30 s +/- 3 s
Time for telescopic boom retraction 30 s +/- 3 s
Time for raising boom 25 s +/- 2 s
Time for descent boom 25 s +/- 2 s
Time for continue turntable rotation 50 s +/- 4 s (per 1/2 rotation)
Time for complete left / right cage rotation 25 s +/- 2 s
Time for arm lifting 30 s +/- 3 s
Time for descent arm 30 s +/- 3 s
Time for jib lifting 30 s +/- 3 s
Time for jib descent 30 s +/- 3 s
Time for raising compensation 15 s +/- 2 s
Time for lowering compensation 15 s +/- 2 s
Forward high-speed drive 37 s +/- 1 s / 50 m (164 ft) 36 s +/- 1 s / 50 m (164 ft)
Reverse high-speed drive 37 s +/- 1 s / 50 m (164 ft) 36 s +/- 1 s / 50 m (164 ft)
Forward micro-speed drive 75 s +/- 3 s / 10 m (32 ft)
Reverse micro-speed drive 75 s +/- 3 s / 10 m (32 ft)
Stop point to stop point steering 5 s +/- 1 s
64 4001055090 E 05.21 USA / GB

D - Inspection and maintenance schedule
Inspection and maintenance schedule

1- Inspection program
The machine must be inspected at regular intervals in accordance with the requirements set out in the country of
use and at least once a year. The purpose of the inspection is to detect any defect which could lead to an accident
during routine use of the machine.
Inspections and maintenance must be carried out by a qualified company or person chosen by the owner of the
machine.
The results of these visits must be recorded in a safety register created by the owner. This register as well as the
list of competent repair persons must made available to the work inspector, government inspector and company
safety committee at any time.
Person-in-
Frequency Stakeholder Type Documentation
charge
Before each hire Owner On-site technician Daily inspection Operator's manual
Before each use or
Operator Operator Daily inspection Operator's manual
each change of user
At intervals On-site technician,
Preventive
recommended Owner qualified HAULOTTE Services® Maintenance Book
maintenance
by HAULOTTE® technician
On-site technician,
Before sale Owner qualified HAULOTTE Services® Periodic inspection Maintenance Book
technician
On-site technician,
Annually ( 1 year) (*) Owner qualified HAULOTTE Services® Periodic inspection Maintenance Book
technician
After 10 years then Qualified technician HAULOTTE
Owner Major inspection Maintenance Book
every 5 years Services®
(*) Or according to local regulations.
2- Daily inspection
The daily inspection must be performed every day, before the start of a new work shift and at every change of
user.
This inspection is performed by and under the responsibility of the user and includes the visual and functional
inspection of the machine as well as the testing of its safety systems.
A description of the daily inspection can be found in the machine's user manual.
We recommend these forms to be completed daily and stored to assist with your maintenance schedule.
4001055090 E 05.21 USA / GB 65

3- Preventive maintenance
Maintenance operations must be carried out by a qualified technician chosen by the owner and ensure that the
machine operates correctly.
Severity of operating conditions may require a reduction in time between maintenance periods.
Maintenance operations performed must be recorded in a register / log book of the machine.
The information contained in our manual is to be complemented by the information found in the engine
manufacturer's maintenance manual, which can be found on the link in the associated maintenance sheet
MS0238.
Symbol meanings
Oil change To check by test Tightening
Functional adjustments / Checks /

Levelling Visual inspection
Cleaning
Lubrication-Lubrication Systematic replacement
Preventive Maintenance Level 1 - First 50H Corrected

First 50H
Page or
NOK
OK
First 50H associated Comments

procedure
Chassis assembly : Wheel, reducer, steering, wheel pivot
Tighten the wheel nuts MP0001
KUBOTA WG2503 engine
Drain the engine oil MP0036
Replace the oil filter MP0004
KUBOTA V2403M / V2403CR T4B / V2403CR T5B engine
Hydraulic : oils, filters and hoses
Replace the hydraulic filter MP0006
66 4001055090 E 05.21 USA / GB

Preventive Maintenance Level 1 - Every 250H
Every 250H
Corrected
Page or
NOK
OK
Every 250H associated Comments
procedure
Grease the steering system MP0027
Grease the bushings and pins
Drain the wheel reducer** MP0043
Slew ring
Grease the turntable slew ring MP0044
Clean the air filter MP0030
MP0007/
Check the belt tension and condition
MP0025
Clean the fuel filter MP0026
Clean the air filter MP0030
MP0007/
Check the belt tension and condition
MP0025
Arm, boom
Grease the pads MP0028
**Only in the first 250H
4001055090 E 05.21 USA / GB 67

Preventive Maintenance Level 1 - Every 6 months or 500H
Every 6 months
Corrected
or 500H
Page or
NOK
OK
Every 6 months or 500H associated Comments
procedure
Tighten the wheel nuts MP0001
Check the wheel reducer level MP0002
Tighten the steering system MS0005
Slew ring
Tighten the slew ring MP0019
Replace the belt* MP0032
Drain the engine oil* MP0036
Replace the oil filter* MP0004
Replace the fuel filter* MP0005
Replace the belt* MP0032
Check the hydraulic oil level MP0013
Jib
Tighten the rotary cylinder MP0016
Tighten the load cell MP0015
Platform
Tighten the mounting on the platform support,
MP0017
the platform floor and the platform access
* Do not take into account the deadline of 6 months, only 500H.
68 4001055090 E 05.21 USA / GB

Preventive Maintenance Level 2 - Every 1 year or 1000H
Every 1 year
Corrected
or 1000H
Page or
NOK
OK
Every 1 year or 1000H associated Comments
procedure
Drain the wheel reducer MP0043
Replace the fuel filter MP0005
Replace the air filter MP0010
Replace the air filter MP0010
Replace the hydraulic filter MP0006
Arm, boom
Check the pads-Replacement if necessary MP0011
4001055090 E 05.21 USA / GB 69

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

Check the bushings and pins-Replacement if MS0002/
necessary MP0024
Slew ring
Check the slew ring clearance MP0018
Drain the oil tank MP0020
Drain the cooling circuit MP0021
Drain the oil tank MP0020
Drain the cooling circuit MP0021
Drain the hydraulic oil MP0014
70 4001055090 E 05.21 USA / GB

Corrected
Page or
3000H
Every
NOK
OK
procedure
KUBOTA V2403CR T4B / V2403CR T5B engine
Clean the diesel particulate filter
Corrected
Page or
6000H
Every
NOK
OK
procedure
KUBOTA V2403CR T4B / V2403CR T5B engine
Replace the particulate filter
4001055090 E 05.21 USA / GB 71

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

• Extensive dismantling and reassembly
• Repairs involving the machine's essential components
• Any accident causing stress to the machine
This inspection is the responsibility of the owner, and must be conducted by a qualified technician.
Under no circumstances may this inspection replace the control required by local regulations.
Use the detailed program below.
Corrected
Periodic
Page or
NOK
OK
Periodic associated Comments

procedure
Check state of tires/tyres and inflations
Motor
Check that there are no leaks from the engine's
components (engine, hose, radiator)
Check the condition of the battery
Check for visible damage and broken welds on

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

Check the hoses, blocks and pumps, fittings,
cylinders and the tank for the absence of leaks,
deformations and damage
Platform
Test the automatic closure and locking of access
basket
Check that the harness anchor points are not
cracked or damaged
72 4001055090 E 05.21 USA / GB

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

system
Test the operation of the axle locking system MP0008
Test the operation of the loading control system

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

Calibrate if necessary
4001055090 E 05.21 USA / GB 73

5- Major inspection
The inspection is a thorough inspection of the machine to ensure that it is fully functional. It must be carried out
after 10 years then every 5 years.
This inspection is the responsibility of the owner and must be carried out by a technician HAULOTTE Services®
or an authorized and qualified person.
In order to carry it out, contact the subsidiary HAULOTTE® or the authorized distributor.
Machine sheet
N.B.-:-THE LIST OF MAINTENANCE SHEETS IS NOT EXHAUSTIVE. OTHER SHEETS MAY BE SENT UPON
REQUEST. CONTACT HAULOTTE SERVICES®.
74 4001055090 E 05.21 USA / GB

General data
Structural part inspection
MS0001
General data
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
Means of protection to be used when implementing the range
Appropriate workwear Gloves
Safety shoes
3- You will need
• Standard tool kit • Place barriers around the perimeter of the work area
4001055090 E 05.21 USA / GB 75

General data
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.
76 4001055090 E 05.21 USA / GB

General data
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.
Example
In the event of suspicion of crack, a cleaning and a sweating are to be carried out to guarantee the integrity
of the part before reassembly.
Check presence and torque of each bolts and screw used to assembly part listed in Section Familiarization.
Refer to spare part catalog for additional information if needed.
Some screws are not reusable and must be systematically changed (ex: screws from the gear ring).
4001055090 E 05.21 USA / GB 77

General data
MS0001
4.3 - FUNCTIONAL TESTS
The following tests must be performed periodically Section D - Inspection and maintenance schedule :
• An important technical intervention.
• An accident resulting from a failure of a major component.
The following tests must be realized by a qualified staff under secure conditions.
The results of the tests must be entirely documented.
To avoid the swing of the machine during the test, it is imperative that a device of reserve (chain, not of
anchoring) is used during the test.
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.
78 4001055090 E 05.21 USA / GB

General data
Pins and bearing inspection
MS0002
General data
1- Warning
2- Risk prevention
Safety shoes
3- You will need
4001055090 E 05.21 USA / GB 79

General data
MS0002
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 Section D -
Inspection and maintenance schedule : In addition to the above cited criteria, verify the following :
• Check the presence and the position of the bushes and bearings.
• Check the absence of shaving in periphery of the pins.
• Check the absence of heavy abrasion, wear or oxidation of the bushes and bearing.
• Check the absence of deformations, cracks or breakage of the bushes and bearing.
• Check the absence of radial gap > 0,5 mm (19690 µ in) on the pins.
• 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.
80 4001055090 E 05.21 USA / GB

General data
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 :
Recommended Values
A D
Marking Description
A At least 0,5 times the nominal diameter
B Make a chamfer
C Nominal diameter of the bearing - 0,2 / - 0,3 mm (-7874 µ in / -11810 µ in)
D Bearing drift
E Diameter of the bearing guide - 0,20 / - 0,25 mm (-7874 µ in / -9843 µ in)
F Bearing
G Housing
• After inserting the bearing, lubricate and fit the pin.
4001055090 E 05.21 USA / GB 81

General data
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.
82 4001055090 E 05.21 USA / GB

General data
Cylinder inspection
MS0003
General data
Cylinder inspection
1- Warning
• 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
Safety shoes
3- You will need
4001055090 E 05.21 USA / GB 83

General data
Cylinder inspection
MS0003
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.
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.
84 4001055090 E 05.21 USA / GB

General data
Cylinder inspection
MS0003
• 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
After 10 mn, creep < 0,2 mm (7874 µ in) After 60 mn, creep < 1 mm (0.039 in)
working heights > 26 m(85 ft4 in))
Outriggers cylinder, Oscillating axle locking,

Lift cylinder arm or boom (Machine with range- After 10 mn, creep < 0,5 mm (0.01196 in) After 60 mn, creep < 2,5 mm (0.098 in)
limiting system)
Lift cylinder arm or boom, Telescoping,

After 10 mn, creep < 1 mm (0.039 in) After 60 mn, creep < 6 mm (0.236 in)
Compensation, ...
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.
4001055090 E 05.21 USA / GB 85

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. Pipe weld connection.
2. Rod weld connection.
3. Ring.
4. Rod.
5. Piston.
86 4001055090 E 05.21 USA / GB

General data
Braking test procedure
MS0004
General data
1- Warning
2- Risk prevention
Safety shoes
3- You will need
4001055090 E 05.21 USA / GB 87

General data
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.
88 4001055090 E 05.21 USA / GB

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

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

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

Dull dry (A) Lubed (B) Dull dry (A) Lubed (B) Dull dry (A) Lubed (B) Dull dry Lubed Yellow dry
(C) (C) (C)
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
in-lbs
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
5 17.7 2 16 1.8 21 2.4 44 5 41 4.63 54 6.18 68 7.7 58 6.63 78 8.84 79 9 68 7.75 91 10.3
6 30 3.4 19 3.05 36 4.07 80 9.1 69 7.87 93 10.5 118 13.4 100 11.3 132 15 139 15.7 116 13.2 155 17.6
Size (mm)
Dull dry Lubed Yellow dry Dull dry Lubed Dry Dull dry Lubed Dry Dull dry Lubed Dry
ft-lbs
ft-lbs
ft-lbs
ft-lbs
ft-lbs
ft-lbs
ft-lbs
ft-lbs
ft-lbs
ft-lbs
ft-lbs
ft-lbs
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
8 5.9 8 5.4 7.41 7.2 9.88 16.2 22 14 19.1 18.8 25.5 23.6 32 20.1 27.3 26.9 36.5 28 38 23.6 32 31.4 42.6
10 12.17 16.5 10.8 14.7 14.4 19.6 32.45 44 27.9 37.8 37.2 50.5 47.2 64 39.9 54.1 53.2 72.2 55 75 46.7 63.3 62.3 84.4
12 20.65 28 19.8 25.6 25.1 34.1 56 76 48.6 66 64.9 88 81.8 111 69.7 94.5 92.2 125 95.9 130 81 110 108 147
14 33.19 45 30.1 40.8 40 54.3 89.24 121 77.4 105 103 140 131.28 178 110 150 147 200 154.15 209 129 175 172 234
16 52.37 71 46.9 63.6 62.5 84.8 139.4 189 125 170 166 226 205.04 278 173 235 230 313 239.7 325 202 274 269 365
18 72.28 98 64.5 87.5 86.2 117 192.5 261 171 233 229 311 283.2 384 238 323 317 430 331 449 278 377 371 503
20 102.5 139 91 124 121 165 272.9 370 243 330 325 441 401.2 544 337 458 450 610 469.8 637 394 535 525 713
22 140.87 191 124 169 166 225 345.4 509 331 450 442 600 551.7 748 458 622 612 830 645.3 875 536 727 715 970
24 176.27 239 157 214 210 285 469.8 637 420 570 562 762 690.3 936 583 791 778 1055 807.6 1095 682 925 909 1233
4001055090 E 05.21 USA / GB 89

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

This charts is to be used as a guide only unless noted elsewhere in this manual
A574 High strength
Grade 5 Grade 8
black oxide bolts
Size Thread
Lubed Dry Lubed Dry Lubed
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm

20 80 9 100 11.3 110 12.4 140 15.8 130 14.7
1/4
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
Lubed Dry Lubed Dry Lubed
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm

18 13 17.6 17 23 18 24 25 33.9 21 28.4
5/16
24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
3/8
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
14 37 50.1 49 66.4 50 67.8 70 94.7 61 62.7
7/16
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
13 57 77.3 75 101.6 80 108.4 110 149 93 126
1/2
20 64 86.7 85 115 90 122 120 162 105 142
12 80 108.4 110 149 120 162 150 203 130 176
9/16
18 90 122 120 162 130 176 170 230 140 189
11 110 149 150 203 160 217 210 284 180 244
5/8
18 130 176 170 230 180 244 240 325 200 271
10 200 271 270 366 280 379 380 515 320 433
3/4
16 220 298 300 406 310 420 420 569 350 474
9 320 433 490 583 450 610 610 827 510 691
7/8
14 350 474 470 637 500 678 670 908 560 759
8 480 650 640 867 680 922 910 1233 770 1044
1
12 530 718 710 962 750 1016 990 1342 840 1139
7 590 800 790 1071 970 1315 1290 1749 1090 1477
1 1/8
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 1/4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 1/2
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
90 4001055090 E 05.21 USA / GB

General data
Torque Values
MS0005
3- Hydraulic couplings and hoses tightening torque charts
Hydraulic fitting torque (Tolerance = 0 / +10%)
BSPP threads according to ISO1179

Torque
Thread
ft-lbs Nm
G1/4 26 35
G3/8 52 70
G1/2 66 90
G3/4 133 180
G1" 229 310
G1"1/4 332 450
G1"1/2 398 540
UNF threads according to ISO11926-2/3
Torque
Thread
ft-lbs Nm
7/16-20 15 20
1/2-20 30 40
9/16-18 33 45
3/4-16 59 80
7/8-14 100 135
1"1/16-12 136 185
1"5/16-12 199 270
1"5/8-12 251 340
1"7/8-12 306 415
4001055090 E 05.21 USA / GB 91

General data
Torque Values
MS0005
Metric threads according to ISO 6149-2/3 or ISO9974 / DIN 3852-1

Torque Torque
Thread ISO 6149-2/3 DIN 3852-1
ft-lbs Nm ft-lbs Nm
M10x1,0 18 25 18 25
M12x1,5 26 35 26 35
M14x1,5 30 40 33 45
M16x1,5 51 70 41 55
M18x1,5 66 90 52 70
M20x1,5 92 125 59 80
M22x1,5 100 135 74 100
M26x1,5 133 180 125 170
M33x2,0 229 310 229 310
M42x2,0 332 450 243 330
N.B.-:- ISO6149: SEALING WITH O-RING WITHOUT ANY RETAINING RING (OR FORM). ISO9974 / DIN3852:
SEALING WITH O-RING AND RETAINING RING (OR FORM).
Hydraulic hose torque (Minimum / Maximum)
JIC torque ORFS torque

Hose size JIC thread ORFS thread
ft-lbs Nm ft-lbs Nm
DN06 - 1/4" 7/16-20 11-15 15-21 9/16-18 18-21 25-28
DN10 - 3/8" 9/16-18 22-31 30-42 11/16-16 30-33 40-45
DN12 - 1/2" 3/4-16 37-52 50-70 13/16-16 41-44 55-60
DN16 - 5/8" 7/8-14 51-69 69-94 1"-14 59-66 80-90
DN19 - 3/4" 1"1/16-12 72-99 98-133 1"3/16-12 85-96 115-130
DN25 - 1" 1"5/16-12 103-140 140-190 1"7/16-12 111-125 150-170
DN32 - 1"1/4 1"5/8-12 155-210 210-285 1"11/16-12 148-166 200-225
DN38 - 1"1/2 1"7/8-12 214-280 290-380 2"-12 221-243 300-330
DN50 - 2" 2"1/2-12 332-443 450-600 2"1/2-12 367-406 500-550
92 4001055090 E 05.21 USA / GB

General data
Torque Values
MS0005
4- HA20RTJ - HA20RTJO - HA20RTJ PRO - HA61RTJO - HA61RTJ PRO
Sub-assemblies Concerned elements Torque

Wheels 250 Nm
Wheel studs / Driving reducer Loctite 243 - Normal threadlocker
Hydraulic motor / Driving reducer 57 Nm
Axles
Wheel reducer / Chassis 260 Nm
Wheel reducer / Wheel steering pivots 260 Nm
Steering cylinder / Chassis 270 Nm
Slew ring / Chassis 215 Nm
Slew ring Turntable / Slew ring 215 Nm
Hydraulic motor / Slew ring 105 Nm
ECU ECU / Carrier 6 Nm
Hydraulic pump / Engine housing 135 Nm
Engine Exhaust 85 Nm
Screw fastening elastic coupling / Flywheel 22 Nm
Counterweight Counterweight / Turntable 500 Nm
30 Nm
Telescope Pads rear telescope
Medium threadlocker
30 Nm
Boom tube Upper and lower front pads
Medium threadlocker
8 Nm
Input jib leveling cylinder Valve / Cylinder
Medium threadlocker
44 Nm
Cylinder / Link piece
Platform rotation cylinder Medium threadlocker
Screw connecting cylinder / link piece 800 Nm
Mounting on platform support and link piece
Apply torque in 3 times :
1.70 Nm
2.140 Nm
3.215 Nm
Strain gauge MOBA 215 Nm

1 3
4 2
Platform control box 16 Nm

Silentbloc fastening platform
Floor 16 Nm
control boxPlatform
4001055090 E 05.21 USA / GB 93

General data
Torque Values
MS0005
Notes
94 4001055090 E 05.21 USA / GB

Chassis and turret
Fuel tank - Filling-up
MS0009
Chassis and turret
1- Warning
2- Risk prevention
Safety shoes
3- You will need
4- Consumable
Use only oils whose features correspond to HAULOTTE® recommendations (Section C - Familiarization -
Consumable) or contact HAULOTTE Services®.
Not mix two different characteristics fuel: if necessary, purge and clean the circuit.
4001055090 E 05.21 USA / GB 95

Chassis and turret
MS0009
5- Filling
Touch the exterior of the filling hole with the pump spout before starting pouring to avoid any risk of static electricity
causing sparks.
Make sure you are standing up-wind to avoid being splashed by the fuel.
1. Loosen and remove the tank cap .

2. Fill up the tank.
3. Refit and tighten the tank cap .
4. Clean up any fuel that may have escaped from the tank.
96 4001055090 E 05.21 USA / GB

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

• Standard tool kit
• Protective goggles • Place barriers around the perimeter of the work area
• Gloves
Exclusively use tools and auxiliary average adapted. Always wear necessary safety clothing.
2- Control and inspections
The state of hoses devices plays a significant role in the safety of the machines.
Section D - Inspection and maintenance schedule :

• Check the absence of leakage to the junctions of the hoses.
• Check that all the hoses are correctly tightened.
• Check the absence of tear and crack of the external hoses.
• Check that the shielding of the hose is not apparent.
• Check the absence of chemical aggression of the membrane of the hose.
If anomalies are noted, it is necessary to replace the elements by respecting the following recommendations.
3- Hoses Disassembling
For safety reasons, respect imperatively the following conditions of disassembling :

• Fold the machine on a flat and released ground :
• The machine is not in slope.
• The boom is horizontal.
• Put the turret (if equipped) in the axis.
• Carry out a beaconing of the sector (maximum risk zone = machine height).
• Locate the hoses and their connections points to guarantee the good performance of the machine after intervention.
• Locate the hoses course to facilitate the reassembly.
To recover oil, use an oils container in order not to pollute the environment.
Unscrew the flexible device slowly in order to make fall residual water pressure.
It is imperative to secure and maintain cylinders when removing hoses cylinders. An analysis of the
hydraulic system is imperative.
After disassembling :
• Close the hose openings and the hydraulic components to avoid the pollution of the hydraulic system.
• Check the cleanliness of the hoses and the hydraulic components :
• Absence of plastic, rubber or metal shaving.
• If necessary, purge and clean the circuit (tank included).
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Hydraulics
MS0020
4- Hoses Reassembly
For safety reasons, respect imperatively the following conditions of reassembly :

• Using the reference marks carried out previously; carry out the courses of hoses.
• During the fixing of the hoses, respect the tightening torques below.
Tightening torque table
Description Torque (JIC) Torque (ORFS)

Hose 1/4" (diameter 6mm) 1,5 daN.m(11,08 lbf.ft) 2,6 daN.m(19,22 lbf.ft)
Hose 3/8" (diameter 10mm) 3,5 daN.m(25,86 lbf.ft) 4,2 daN.m(31,04 lbf.ft)
Hose 1/2" (diameter 12mm) 5 daN.m(36,95 lbf.ft) 5,7 daN.m(42,12 lbf.ft)
Hose 5/8" (diameter 16mm) 8 daN.m(59,12 lbf.ft) 8,5 daN.m(62,82 lbf.ft)
Hose 3/4" (diameter 19) 10 daN.m(73,91 lbf.ft) 12,2 daN.m(90,17 lbf.ft)
Once all the hoses are correctly tight :

• Put the machine in operational configuration
• Carry out some movements implementing the hoses concerned in order to purge the hydraulic system.
• Check the absence of leakage.
• Control the level of hydraulic oil tank.
• Check the pressures.
98 4001055090 E 05.21 USA / GB

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

• PPE (Personal Protective Equipment: glove, safety
shoes, glasses, etc ...)
• Grease-remover
• Rags
• Torque wrench (0-100in/lb)
• Torque wrench (0-50ft/lb)
• Place barriers around the perimeter of the work area
• Grease for assembly
• Assorted hydraulic fittings
• System for recovery oils
• Drive reducer Oil
• Hydraulic hand pump 0 - 250 psi
• Pressure gauge 0 - 300 psi
• Special tools (refer plans at end of document)
• The technician should take all steps to protect themselves or others against all risks of injury related to this intervention.
• The technician should ensure that suitable PPE (personal protective equipment) for the job is used, and check the particular conditions of
environment in which the material can be found (see safety information specific to the operation site).
• Position the machine on a flat ground, stabilized and in a released environment.
• Cut the contact, to remove the key, to open cut it battery.
• Place a "DO NOT USE" decal near the start/stop contactor (key switch) to inform the personnel that interventions are being carried out on
the equipment.
• The pressure in the hydraulic system is very important. It can cause accidents. Relieve the pressure before any intervention and never
search for oil leaks by hand.
• Attention to the risks of burns, the hydraulic system works at high temperatures.
2- Preliminary operation
The operations of disassembling if they exist should be carried out only on the installations completely disconnected
and must be entrusted only to people having the necessary technical training.
Respect, in addition to the instructions appearing in the present instructions, the legal tendencies generally applicable
for safety accident prevention.
All the precautions must be done in work before intervening on and near the machine.
After completion of work, all the covers and safety devices must be positioned back completely and operational.
4001055090 E 05.21 USA / GB 99

Chassis and turret
MS0026
3- Tightening and torquing bolts
If an air impact wrench is used to tighten bolts, extreme care

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

socket head cap screws in a bolt circle.
• Tighten (but do not torque) bolt- A until snug.
• Go to the opposite side of the bolt circle and tighten bolt B until equally
snug.
• Crisscross around the bolt circle and tighten remaining bolts.
• Now use a torque wrench to apply the specified torque to bolt A.
• Using the same sequence, crisscross around the bolt circle and appaly
an equal torque to the remaining bolts
4- Main disassembly
100 4001055090 E 05.21 USA / GB

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

7. Remove the Second Stage Sun Gear ( 11 ).
8. Take the External retaining Ring ( 20 ) off the Sun Gear ( 11 ) if necessary.
9. Loosen and remove the 3 Flat Heat Bolts ( 19 ) that retain the Ring Gear ( 1E ) to the Housing ( 1G ).
10. Lift the Ring Gear ( 1E ) off the Housing ( 1D ).
11. Remove the O-ring ( 18 ) from between the Housing ( 1D ) and the Ring Gear ( 1E ).
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Chassis and turret
MS0026
12. Using a 1/8" diameter punch, drive the Roll Pin ( 4G ) into the Planet Shaft ( 4E ) until it bottoms
against the Spindle ( 1A ).
13. Grasp the Roll Pin ( 4G ) using needle nosed pliers or some sort of hooked tool, and pull the Planet
Shaft ( 4E ) out of the Spindle ( 1A ).
14. Using a 1/8" diameter punch, drive the Roll Pin ( 4G ) out of the Planet Shaft ( 3E ).
N.B.-:-THE ROLL PINS ( 4G ) SHOULD NOT BE REUSED WHEN REASSEMBLING THE UNIT
15. Slide the Planet Gear ( 4 ) out of the Spindle ( 1A ) being careful to not drop the Needle
Bearings ( 4C ) in the process.
16. Remove 4 Thrust Washers ( 4B ) , 28 Needle Rollers ( 4C ) and the Thrust Spacer ( 4D ) from the
Second Stage Planet Gear ( 4F ).
17. Repeat Steps for the remaining 2 Planet Gears.
18. Remove the Thrust Washer ( 4H ) from the counterbore in the Spindle ( 1A ).
19. Remove the Input Shaft ( 9 ).
102 4001055090 E 05.21 USA / GB

Chassis and turret
MS0026
5- Input carrier disassembly
1. Using a 1/8" diameter punch, drive the Roll Pin ( 4G ) into the Planet Shaft ( 3E ) until it bottoms
against the Carrier ( 3A ).
2. Using a soft face hammer, tap the Planet Shaft ( 3E ) out of the Carrier ( 3A ).
3. Using a 1/8" diameter punch, drive the Roll Pin ( 4G ) out of the Planet Shaft ( 3E ).
N.B.-:-THE ROLL PINS ( 4G ) SHOULD NOT BE REUSED WH EN REASSEMBLING THE UNIT.
4. Siide the Planet Gear ( 3F )and the 2 Thrust Washers ( 3B ) out of the Carrier ( 3A ).
5. Remove the 14 needle Bearings ( 3C ) from the bore of the Planet Gear ( 3F ).
6. Repeat steps for each of the 2 remaining planet gears.
4001055090 E 05.21 USA / GB 103

Chassis and turret
MS0026
6- Hub Spindle disassembly
1. Place unit on special fixture with Spindle ( 1A ) flange end down. Don't sit on Coupling ( 7 ).
2. Remove 2 Set Screws ( 1G ) and Bearing Nut ( 1F ) using T-206569. It may be necessary to heat
the Locknut ( 1F ) to break down the loctite.
N.B.-:-THE HOLES IN THE BEARING NUT ( 1F ) FOR THE SET SCREWS ( 1G ) WERE STAKED FOR RETENTION OF
THE SET SCREWS ( 1G ). THE HOLES WILL NEED TO BE CLEANED UP PRIOR TO REMOVING THE SET SCREWS.
3. While supporting the unit on Hub ( 1D ) flange, press Spindle ( 1A ) out of Hub ( 1D ).
4. Remove outbound position Bearing Cone ( 1C ) from Bearing Cup ( 1C ) in Hub ( 1D ).
5. Lift Hub ( 1D ) off of Spindle ( 1A ).
6. If necessary, press 9 Studs ( 1H ) out of Hub ( 1D ). Locate Hub ( 1D ) on Seal ( 1B ) end.
7. Remove Seal ( 1B ) from Hub ( 1D ).
N.B.-:-THE SEAL ( 1B ) SHOULD NOT BE REUSED WHEN REASSEMBLING THE UNIT.
8. Remove inbound position Bearing Cone ( 1C ) from Hub ( 1D ).

9. Using a soft steel rod, carefully knock both Bearing Cups ( 1C ) out of Hub ( 1D ).
N.B.-:-INBOUND CUP & CO NE SHOULD BE KEPT SEPARATE FROM OUTBOUND CUP & CO NE IF BEING REUSED.
104 4001055090 E 05.21 USA / GB

Chassis and turret
MS0026
7- Spindle brake disassembly
N.B.-:-THIS PROCEDURE APPLIES ONLY TO UNITS WITH INTEGRAL INPUT BRAKE ( 8 ).
Eye protection must be worn while performing the steps in this procedure.
1. Place Spindle ( 1A ) such that the flange side is up. Remove 8 Bolts ( 21 ) in X pattern by backing
each boit half way out, and then finish backing them out. Remove Motor Adaptor ( 1N ). If necessary,
remove Retaining Ring ( 8C ), knock Ball Bearing ( 8B ) out of Adaptor ( 1N ) counterbore, and check
Quad Seal ( 1K ) & O'Ring ( 8F ).
2. Remove Compression Springs ( 8L ) from Piston ( 8A ).
3. Using an air hose, slowly and carefully pressurize the brake port in the Spindle ( 1A ) until the
Piston ( 8A ) comes out of piston bore of Spindle ( 1A ), then pull the Piston ( 8A ) out of the
Spindle ( 1A ) by hand.
4. Remove Backup Ring ( 8H ) and O-ring ( 8F ) from grooves in Spindle ( 1A ) & Piston ( 8A ).
5. Remove Coupling ( 7 ) from brake cavity in Spindle ( 1A ).
6. Remove Backup Ring ( 8E ) and O-ring ( 8D ) from grooves in Spindle ( 1A ).
7. Remove Rotors ( 8J ) and Stators ( 8K ) from brake cavity in Spindle ( 1A ).
8. Remove Retaining Ring ( 5 ) out of the internai groove of Coupling ( 7 ) using Truarc #0100 or equiv-
alent pliers.
9. Remove the Spacer ( 1A ) & Spring ( 1L ) out of the bore of Coupling ( 7 ).
10. Knock Ball Bearing ( 8B ) out of Spindle ( 1A ) Counterbore if needed.
11. Remove Plastic Plug & Pipe Plug ( 12 ) from Spindle ( 1A ) if applicable.
4001055090 E 05.21 USA / GB 105

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

2. Remove Thrust Washer ( 2 ) from Cover ( 6A ) pockets, if necessary.
3. Unscrew 2 Hex Head Bolts ( 6C ) and remove Disengage Cap ( 6B ) from Cover ( 6A ).
4. Pull Disengage Rod ( 6D ) out from Cover ( 6A ).
5. Use appropriate tool to remove O-ring ( 6E ) from internal groove in Cover ( 6A ).
6. Remove 2 O-Ring Pipe Plugs ( 6F ) from Cover ( 6A ).
N.B.-:-PAINT BOOTH O-RING ( 6K ) CAN BE DISCARDED IF DESIRED.
N.B.-:-FOR REASSEMBLING UNIT, PLEASE REFER TO THE EXPLODED VIEWS IN THE DISASSEMBLY SECTIONS.
106 4001055090 E 05.21 USA / GB

Chassis and turret
MS0026
9- Assembly- Input carrier subassembly

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

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

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

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

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

1. Screw 1 bolt down into the hub and rotate the hub so that the bolt is at twelve o'clock.
2. Position the torque wrench so that it is perpendicular to the vertical centerline as shown.
3. The correct reading can only be made if the torque wrench is pulled slowly (approximately 3.5 rpm )
and smoothly towards you.
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18 - Assembly drawing
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Item Description
1A Spindle
1B Lip seal
1C Tapered bearing assembly
1D Housing
1E Ring gear
1F Bearing nut
1G Socket head set screw
1H Stud
1K Quad seal
1L Spring
1M Thrust washer
1N Motor adaptor
2 Thrust spacer
3A Carrier
3B Thrust washer
3C Needle bearing
3E Planet shaft
3F Planet gear
4B Thrust washer
4C Needle bearing
4D Thrust spacer
4E Planet shaft
4F Planet gear
4G Roll pin
4H Thrust washer
5 Retaining ring- internal
6A Cover
6B Disengage cap
6C Bolt
6D Dowel pin
6E O-ring
6F Pipe plug
6G Retaining ring- internal
7 Coupling
8A Brake piston
8B Ball bearing
8C Retaining ring
8D O-ring
8E Back-up ring
8F O-ring
8H Back-up ring
8J Brake rotor
8K Brake stator
8L Spring
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Item Description
9 Input shaft
10 Sun gear
11 Sun gear
12 O-ring plug or plastic plug
15 Identification plate
16 Drive screw
17 O-ring
18 O-ring
19 Bolt
20 Retaining ring
21 Bolt
22 Pressure plug
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Procedure of dismantling / reassembling hydraulic rotary actuators
MS0028
Upper boom
1- You will need

• PIPE VISE
• HEX WRENCH
• ASSORTED SCREWS
• SAFETY GLASSES
• END CAP REMOVAL TOOLS
• DRILL
• FLASHLIGHT
• Rubber mallet
• PLASTIC MANDREL
• PRY BAR
• FELT MARKER
• T-HANDLE SCREW EXTRACTOR
• HEX WRENCH SET
• SEAL TOOLS
• PUNCH
• DOWEL PINS
• The technician should take all steps to protect themselves or others against all risks of injury related to this intervention.
• The technician should ensure that suitable PPE (personal protective equipment) for the job is used, and check the particular conditions of
environment in which the material can be found (see safety information specific to the operation site).
• Cut the contact, to remove the key, to open cut it battery.
• Place a "DO NOT USE" decal near the start/stop contactor (key switch) to inform the personnel that interventions are being carried out
on the equipment.
• The pressure in the hydraulic system is very important. It can cause accidents. Relieve the pressure before any intervention and never
search for oil leaks by hand.
• The exhaust fumes of the engines contain harmful products of combustion. Only start and run the engine in a well ventilated area. In a
closed room, you must use a suitable system to evacuate the exhaust to the outside.
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Exploded View
Item Description Quantity

1 Housing 1
2 Shaft 1
3 Piston sleeve 1
4 End cap 1
103.1 Screw 1
103.2 Washer 1
106.1 Port plug 1
106.2 Port plug 1
109 Lock pin 2
113 Set screw 6
200 T-Seal 1
202 T-Seal 1
204 O-Ring 1
205 Cup seal 2
207 Back-up ring 1
304.1 Exclusion seal 2
302 Wear guide 2
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Item Description Quantity

304 Thrust washer 2
400 Stop tube 1
401 Counterbalance valve 1
403 Motion control valve 1
2- Before disassembly
All numbers that appear in parenthesis ( ) refer to items in parts list.
Inspect the actuator for corrosion prior to disassembly. Severe

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

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

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

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

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

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

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

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

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

with one. The stop tube is an available option that limits
the rotation of the actuator.
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9. Every actuator has two sets of small punched timing

marks that indicate timing between the gear sets. The lo-
cation and appearance of the marks can vary slightly be-
tween models. One set indicates the timing between the
piston sleeve ( 3 ) and the housing ( 1 ) (photo at left), the
second set between the piston and the shaft (lower photo).
To ensure correct rotation and accurate end positions, it is
essential that the actuator be correctly timed when it is re-
assembled. The punched timing marks can be used, but
it is easier to highlight punched marks with a marker be-
fore disassembly as outlined in the steps below.
10. Prior to removing the shaft ( 2 ), use a felt marker to clearly

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

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

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

tic mandrel so the piston and housing bore are not dam-
aged.
14. At the point when the piston gear teeth come out of en-
gagement with the housing gear teeth, mark the piston
and housing with a marker as shown.
15. Remove the O-ring ( 204 ) and backup ring ( 207 ) from
end cap ( 4 ).
N.B.-:-TO AVOID DAMAGE TO MACHINED PARTS : CAREFULLY

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

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

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

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

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

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

grooves on the shaft ( 2 ) and end cap ( 4 ) around the
outside edge of the thrust washer ( 304 ).
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4. Using a seal tool install the main pressure seal ( 205 )

onto shaft ( 2 ) and end cap ( 4 ). Use the seal tool in a cir-
cular motion.
5. Install the wear guide ( 302 ) on the end cap ( 4 ) and

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

in the piston ( 3 ). Use a circular motion to insure the seal
is correctly seated in the groove. Install the outer T-
seal ( 202 ) by stretching it around the groove in a circular
motion. Each T-seal has 2 back-up rings.
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8. Beginning with the inner seal ( 200 ) insert one end of

backup ring in the lower groove and feed the rest in using
a circular motion. Make sure the wedged ends overlap
correctly.
9. Insert the other back up ring in upper groove.
10. Repeat both of these steps for the outer seal ( 2 ).
11. Insert the piston ( 3 ) into the housing ( 1 ) as shown, until

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

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

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

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

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

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

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

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

consult the supplier manuals whose reference for this engine is 4000053020.
If access is denied, contact your HAULOTTE® branch..
1- Localization identification plate
• If you need to contact HAULOTTE Services® for spare parts or other,

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

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

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

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

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

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

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

• Be sure to conduct daily checks, periodic maintenanc,
refueling or cleaning on a level surface with the engine shut off and remove the
key.
• Before allowing other people to use your engine, explain how to operate, and
have them read this manual before operation.
• When cleaning any parts, do not use gasoline but use regular cleanser.
• Always use proper tools, that are in good condition. Make

sure you understand how to use them, before performing
any service work.
• When installing, be sure to tighten all bolts lest they should be loose. Tighten
the bolts by the specified torque.
• Do not put any tools on the battery, or battery terminals may short out. Severe
burns or fire could result. Detach the battery from the engine before the
maintenance.
• Do not touch muffler or exhaust pipes while they are hot; Severe burns could
result.
Lubricating oil :
• With strict emission control regulations now in effect, the CG-4, CH-4 and CI-4 engine oils have been
developed for use with low sulfur fuels, for On-Highway vehicle engines. When a Non-Road engine runs
on high sulfur fuel, it is advisable to use a "CF or better" classification engine oil with a high Total Base
Number (a minimum TBN of 10 is recommended).
• Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed.
Fuel
Lubricating oil classification Comments
Low-sulfur High-sulfur
Total Base Number (TBN)
CF Recommendable Recommendable
superior or equal 10
CF Recommendable Not recommendable
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• Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all applicable emission
regulations for the area in which the engine is operated.
• Use of diesel fuel with sulfur content less than 0.10 % (1000 ppm) is strongly recommended.
• If high-sulfur fuel (sulfur content 0.50% (5000 ppm) to 1% (10000 ppm)) is used as a diesel fuel, change the engine
oil and oil filter at shorter intervals (approximately half).
• DO NOT USE Fuels that have sulfur content greater than 1.0 % (10000 ppm).
• Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4 standards, the use
of ultra low sulfur fuel is mandatory for these engines, when operated in US EPA regulated areas. Therefore,
please use No.2-D S15 diesel fuel as an alternative to No.2-D, and use No.1-D S15 diesel fuel as an alternative
to No.1-D for ambient temperatures below -10°C (14°F). No.1-Dor No.2-D, S15 : Ultra Low Sulfur Diesel 15 ppm
or 0.0015 wt.%.
• CJ-4 classification oil is intended for use in engines equipped with Diesel Particulate Filter and is Not Recommended
for use in Kubota E3 specification engines.
• Oil used in the engine should have API classification and Proper SAE Engine Oil according to the ambient
temperatures as shown below.
Above 25°C (77°F) SAE30, SAE10W-30 or 15W-40

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

Flash point °C (°F) Water and sediment volume % Ash weight %
Residuum %
Minimum Maximum Maximum Maximum
52 (125) 0.05 0.35 0.01
Distillation temperatures °C (°F) 90% Viscosity Kinematic cSt or mm²/s at

Viscosity Saybolt SUS at 37.8°C (100°F)
Point 40°C
Minimum Maximum Minimum Maximum Minimum Maximum
282 (540) 338 (640) 1.9 4.1 32.6 40.1
Sulfur, weight Copper Strip Corrosion Cetane Number

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

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

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

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

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

• If the clamp band is loose, apply oil to the screw of the band,
and tighten the band securely.
• If the fuel pipes, made of rubber, became worn out, replace
them and clamp bands every 2 years.
• If the fuel pipes and clamp bands are found worn or damaged
before 2 years' time, replace or repair them at once.
• After replacement of the pipes and bands, air-bleed the fuel
system.
When the fuel pipes are not installed, plug them at

both ends with clean cloth or paper to prevent dirt
from entering. Dirt in the pipes can cause fuel
injection pump malfunction.
1 Clamp band
2 Fuel pipe
5.2 - RADIATOR
5.2.1 - Checking radiator hoses and clamp

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

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

Vol % anti-freeze
°C °F °C °F
50 - 37 - 34 108 226
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6- Carriage and storage
6.1 - CARRIAGE

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

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

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

• Check the fuel tank and refill the fuel, if necessary
Lack of fuel
• Also check the fuel system for air or leaks.
Bad nozzle • If necessary, replace with a new nozzle.
When engine
suddenly stops • Check amount of engine oil with oil level gauge.
Moving parts are overheated due
• Check lubricating oil system.
to shortage of lubrication oil or
• At every 2 times of oil change, oil filter cartridge should be replaced.
improper lubrication
• Check to see if the engine bearing clearances is within factory specs.
Fuel governing device bad • Contact HAULOTTE Services® for repairs
Fuel is of extremely poor quality • Select good quality fuel.
When color of
exhaust is Nozzle is bad • If necessary, replace with new nozzle.
especially bad • Cause is poor atomization, improper injection timing, etc. Because of trouble in
Combustion is incomplete injection system or in poor valve adjustment, or compression leakage, poor
compression, etc. Check for the cause.
Engine revolution suddenly
• Check the adjustments, injection timing and the fuel system.
decreases or increases
Unusual sound is heard suddenly • Check all moving parts carefully.
Color of exhaust suddenly turns
• Check the fuel injection system, especially the fuel injection nozzle.
When engine must dark
be stopped Bearing parts are overheated • Check the lubricating system.
immediately
• Check the lubricating system.
• Check, if the engine bearing clearances are within factory specs.
Oil lamp lights up during operation • Check the function of the relieve valve in the lubricating system.
• Check pressure switch.
• Check filter base gasket.
Engine oil insufficient • Check oil level. Replenish oil as required.
Fan belt broken or elongated • Change belt or adjust belt tension.
Coolant insufficient • Replenish coolant.
Excessive concentration of
• Add water only or change to coolant with the specified mixing ratio.
antifreeze
Radiator net or radiator fin clogged
• Clean net or fin carefully.
with dust
Inside of radiator or coolant flow
• Clean or replace radiator and parts.
route corroded
When engine
Fan or radiator or radiator cap
overheats • Replace defective parts.
defective
Thermostat defective • Check thermostat and replace if necessary.
Temperature gauge or sensor
• Check temperature with thermometer and replace if necessary.
defective
Overload running • Reduce load.
Head gasket defective or water
• Replace parts.
leakage
Incorrect injection timing • Adjust to proper timing.
Unsuitable fuel used • Use the specified fuel.
N.B.-:-IF THE CAUSE OF TROUBLE CAN NOT BE FOUND, CONTACT HAULOTTE SERVICES®.
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Notes
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Wheel replacement
MS0055
Chassis and turret
Wheel replacement
1- You will need

• Protective goggles
• Gloves
• Jack
• Hoist
• Torque wrench
For safety reasons, imperatively respect the following stages during the tests :
• To set up a beaconing of safety around the test area.
• Put the machine in stowed position.
3- Technical specifications
Standard wheel
Characteristics Standard wheel HA20RTJ Standard wheel HA20RTJ O
HA20RTJ PRO
Tires (Tyres) - Curred - on Foam-filled
290 kg +/- 5,6 kg (639 lb +/- 13
Wheel mass 187,1 kg +/- 3,6 kg (413 lb +/- 8 lb)
lb)
Ply rating 12
Size Solideal 850 x 340 Solideal 1025 x 365
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4- Wheel and tires/tyres inspections
Replace the wheels and the tires if any of the following conditions exist :
• Presence of cracks, damage, deformation or other faults on the hub
• Damage to the tire :
• Cut or hole > 3 cm (2 in) in the rubber side wall.
• Blister or pronounced lump on the external and lateral wall.
• Damaged wheel stud.
• Damage or wear on the side wall to the extent that the reinforcing wire is
visible.
• Linear wear of the thread profile ( > 25 % )
Tires and rims are critical components for the stability of the machine. For safety reasons. :
• Use only HAULOTTE® spare parts according to the technical characteristics of the machine. Refer to
the spare parts catalog.
• Never replace foam filled tire with a pneumatic (air filled) tire. .
152 4001055090 E 05.21 USA / GB

Chassis and turret
Wheel replacement
MS0055
5- Wheel replacement
Procedure of replacement :
• Loosen the wheel nuts on the wheel to be removed.
• Raise the machine using a jack or a hoist.
• Remove the wheel nuts.
• Remove the wheel.
• Install the new wheel.
• Lower the machine to the ground.
• Tighten the wheel nuts to the recommended torque Refer to maintenance and repair manuals.
Standard wheel
Component Standard wheel HA20RTJ Standard wheel HA20RTJ O
HA20RTJ PRO
4000278720 4000075640
Reference number
4000278730 4000075650
Tires (Tyres) - Curred - on Standard foam
290 kg +/- 5,6 kg (639 lb +/- 13
Wheel mass 187,1 kg +/- 3,6 kg (413 lb +/- 8 lb)
lb)
Size Solideal 850 x 340 Solideal 1025 x 365
Torque 320 Nm (236 ft lbs)
Metric torque value / Imperial torque

Machine type Wheel type
value
HA20RTJ_O_PRO - HA61RTJ O_PRO Drive wheel 320 Nm (236 ft lbs)
4001055090 E 05.21 USA / GB 153

Chassis and turret
Wheel replacement
MS0055
Notes
154 4001055090 E 05.21 USA / GB

Chassis and turret
Overload system
MS0057
Chassis and turret
Overload system
1- You will need

• Gloves
• Weight of 250 kg / 551 lb (for procedure reset 250 kg /
551 lb)
• Weight between 75 kg / 165 lb and 300 kg / 662 lb (for
procedure reset using variable weight)
• Lifting equipment adapted and suitable for placing and
removing the load from the platform
• Computer with HaulotteDiag and diagnostic
kit ( 4000009300 ) or DiagPad diagnostic
console ( 400031760 )
2- Level of knowledge required
The use of this card implies that its user is trained on this kind of machine and that this training was delivered
by HAULOTTE® or an authorised representative, following the program for DIAG LEVEL II.
It is important that the person performing the work on the machine knows all the relative safety information contained
in the instruction manual.
Only an authorized and qualified technician can work on HAULOTTE® machines.
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Chassis and turret
Overload system
MS0057
3- Safety instructions
• The technician should take all steps to protect themselves or others against all risks of injury related to
this intervention.
• The technician should ensure that suitable PPE (personal protective equipment) for the job is used, and
• Mark out the work area.
• Cut the contact, to remove the key, open the battery cut if fitted.
• Place a "DO NOT USE" decal near the start/stop contactor (key switch) to inform personnel that
interventions are currently underway on the equipment.
before any intervention and never search for oil leaks using your hands.
• The exhaust fumes of the engines contain harmful products of combustion. Only start and run the engine
in a well ventilated area. In a closed room, you must use a suitable system to evacuate the exhaust to
the outside.
4- Periodic inspection
To test the function :

• Put the machine in lower position on flat ground.
• Select turret control box using the key selector.
• Level the platform if needed.
• Put a load of 300 kg (662 lb) in the center of the platform (as drawn below), using adequat tools.
• Verify that audible and visual warning device are actuated.
If not, overload system setting is needed. Do not use the machine. Refer to maintenance book for
operation setting.
156 4001055090 E 05.21 USA / GB

Chassis and turret
Overload system
MS0057
5- Calibration procedure
The machine is equipped with a 2 channel load cell type weight management system, mounted between the platform
and the boom assembly.
The location of the load cell means calibration is required when the system values become out of correct range, or
when any of the platform sub assembly components (cage, support, flooring etc) are replaced.
The system can be recalibrated in 3 ways depending on the software version :

• Reset of the Zero (empty cage) value.
• Calibration using a fixed known weight of 250 kg (551 lb).
• Calibration with a known weight of any value between 75 kg(165 lb) and 300 kg(662 lb).
5.1 - CONFIGURING THE MACHINE BEFORE START CALIBRATION
• The machine must be completely stowed.

• Tilt inactive
• Weight sensors not out of range.
• Platform tilt in - 10°, + 10°.
• Ground control box selected.
5.2 - CONNECTION AND USE CONSOLE
N.B.-:-CONTACT HAULOTTE SERVICES®
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Chassis and turret
Overload system
MS0057
5.3 - PROCEDURE
• Depending on the calibration you will do, select the code level
2 or 3 in ACCESS CODE : Main menu > Access code(Level
2 or 3)
• In the main menu select : Main menu > Machine settings >
Calibration
• Then select the calibration you will do RESET 0KG
(calibration of the offset) or RESET 250KG (calibration of the
gain with fixed weight of 250 kg / 551 lbs) or 75 kg / 165 lbs
(calibration of the gain with adjustable weight between 300 kg
/ 662 lbs and 75 kg / 165 lbs)
158 4001055090 E 05.21 USA / GB

Chassis and turret
Overload system
MS0057
5.4 - RESET OF THE ZERO (EMPTY CAGE) VALUE
Before any calibration procedure, make sure to remove from the basket / platform all options weighing
more than 15 kg / 33 lbs (Welding machine support, Basket mesh, ...).
For calibration with a fixed or adjustable weight, the load must integrate the weight of all basket options.
N.B.-:-ACCESS CODE LEVEL (2)
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Chassis and turret
Overload system
MS0057
5.5 - CALIBRATION USING A FIXED KNOWN WEIGHT OF 250 KG (551 LBS)
N.B.-:-ACCESS CODE LEVEL (2)
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Chassis and turret
Overload system
MS0057
5.6 - CALIBRATION WITH A KNOWN WEIGHT OF ANY VALUE BETWEEN 75 KG (165 LBS) AND 300 KG (662 LBS)
N.B.-:-AVEC CODE D'ACCÈS NIVEAU 3 (CODE JOURNALIER)
N.B.-:-INSERT A KNOWN WEIGHT (TOLERANCE +/- 5 KG – 11LBS).
4001055090 E 05.21 USA / GB 161

Chassis and turret
Overload system
MS0057
6- Checks
Set a known weight in the cage and check the value displayed in Activ'Screen :
• Main menu > Diagnosis > Machine status > Overload(Strain gauge) > Estimated weight
162 4001055090 E 05.21 USA / GB

Chassis and turret
Ramps and speeds adjustment
MS0058
Chassis and turret
1- You will need

• Gloves
• Timer
Exclusively use tools and auxiliary average adapted. Always wear
1
necessary safety clothing.
For safety reasons, imperatively respect the following stages during the tests :
• To set up a beaconing of safety around the test area.
• Put the machine in stowed position.
• Use safety straps.
3- Specific adjustment procedure
3.1 - PRINCIPLE
The minimum speed setting is the minimum signal sent to the main distributor proportional coil (PVM). This
minimum value is set from one machine to the other because the sensitivity of the coils varies. The minimum
speed is set lower than the coil :
• Significant blank on joystick coarse (important range of angle between the off neutral and the beginning of
the movement).
• Extension of the acceleration and deceleration ramps because the ramp starts at a lower point.
The minimum speed is set higher than the coil :

• The movement starts and stops suddenly.
• Drive motor brakes will operate very early and the machine will store pressure.
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Chassis and turret
MS0058
The maximum speed setting is the maximum signal sent to the platform control box coil (PWM).
From the turntable control box, all movements are slowed down. Do not set the maximum speeds from the
ground control box.
From the platform control box, adjust the machine as follows :

1. Minimum speeds setting
2. Maximum speeds setting
3. Acceleration and deceleration ramps setting(if needed)
4. Maximum speeds check and setting if needed(In case of ramps' modification)
3.2 - MINIMUM SPEEDS SETTING
The speeds setting is done from the platform control box.
To set minimum speeds, activate option Min Speed Setting in menu SETTING > MAINTENANCE.
This option allows to :

• Control all movements at minimum speeds regardless of the joystick.
• Cancel the acceleration and deceleration ramps.
Set each minimum speed to make the movement as slow as possible. It is possible to adjust the setting
during the movement
3.3 - MAXIMUM SPEEDS SETTING
The speeds setting is done from the platform control box.
Set the maximum speed to make a specific travel time.
Use a timer to estimate the time used for the movement.
3.4 - RAMPS ADJUSTMENT
N.B.-:-DO NOT TOUCH IN FACTORY EXCEPT IN CASE OF FORCE MAJEURE.
Ramps allow to soften the acceleration and deceleration phases.
A lower setting may result in :

• A sudden start of the movement
• A sudden slowdown followed by a deceleration ramp(impression that the machine stops and then starts
again)
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Chassis and turret
MS0058
A higher setting may result in :

• An important response time at the beginning of the movement
• A considerable stopping distance
For most of movements , there is no limit on movements' stop. However, all movements must stop for
maximum 1 s or 2 s (full speed movement) after stopping the command.
Always ensure that there is a sudden and quick stop rather than a long and soft stop.
For drive, stop the machine in high speed at maximum 1,7 m (5 ft 7 in) +/- 0,3 (1 ft).
N.B.-:-DO NOT INCREASE THIS DISTANCE.
3.5 - ADJUSTMENT CARD-INDEX OF MACHINE TIMES HA20RTJ - HA20RTJ O
Movement Settings Direction Theoretical adjustment

Forwards drive(Maximum) Forwards drive-High speed 37s +/- 1s / 50 m
Reverse drive(Maximum) Reverse drive-High speed 37s +/- 1s / 50 m
Forwards drive(Minimum) Forwards drive Beginning of the movement
Reverse drive(Minimum) Reverse drive Beginning of the movement
Driving and steering Forwards drive-Micro-
Forwards drive-Micro-speed 75 s +/- 3 s / 10 m
speed(Maximum)
Reverse drive-Micro-
Reverse drive-Micro-speed 75 s +/- 3 s / 10 m
speed(Maximum)
Steering(Maximum) Lock to lock 5 s +/- 1 s
Boom up(Maximum) Lifting 25 s +/- 2 s
Boom Boom lowering(Maximum) Lowering 25 s +/- 2 s
Boom(Minimum) Lowering Beginning of the movement
Arm lifting(Maximum) Lifting 30 s +/- 3 s
Arm Arm lowering(Maximum) Lowering 30 s +/- 3 s
Arm (Minimum) Lowering Beginning of the movement
Turntable rotation(Maximum) Left and Right 50 s +/- 4 sa half turn
Turntable rotation
Turntable rotation(Minimum) Left and Right Beginning of the movement
Boom extends(Maximum) Extension 30 s +/- 3 s
Boom telescoping Boom retracts(Maximum) Retraction 30 s +/- 2 s
Boom telescoping(Minimum) Extension Beginning of the movement
Jib lifting(Maximum) Lifting 30 s +/- 3 s
Jib Jib lowering(Maximum) Lowering 30 s +/- 3 s
Jib lifting(Minimum) Lowering Beginning of the movement
Lifting compensation(Maximum) Lifting 15 s +/- 2 s
Lowering
Compensation Lowering 15 s +/- 2 s
compensation(Maximum)
Compensation(Minimum) Lowering Beginning of the movement
Platform rotation(Maximum) Left and Right 25 s +/- 2 s
Platform rotation
Platform rotation(Minimum) Left or Right(Basket 0°) Beginning of the movement
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Chassis and turret
MS0058
3.6 - ADJUSTMENT CARD-INDEX OF MACHINE TIMES HA20RTJ PRO
Movement Settings Direction Theoretical adjustment

Forwards drive(Maximum) Forwards drive-High speed 36 s +/- 1s / 50 m
Reverse drive(Maximum) Reverse drive-High speed 36 s +/- 1s / 50 m
Forwards drive(Minimum) Forwards drive Beginning of the movement
Reverse drive(Minimum) Reverse drive Beginning of the movement
Driving and steering Forwards drive-Micro-
Forwards drive-Micro-speed 75 s +/- 3 s / 10 m
speed(Maximum)
Reverse drive-Micro-
Reverse drive-Micro-speed 75 s +/- 3 s / 10 m
speed(Maximum)
Steering(Maximum) Lock to lock 5 s +/- 1 s
Boom up(Maximum) Lifting 25 s +/- 2 s
Boom Boom lowering(Maximum) Lowering 25 s +/- 2 s
Boom(Minimum) Lowering Beginning of the movement
Arm lifting(Maximum) Lifting 30 s +/- 3 s
Arm Arm lowering(Maximum) Lowering 30 s +/- 3 s
Arm (Minimum) Lowering Beginning of the movement
Turntable rotation(Maximum) Left and Right 50 s +/- 4 sa half turn
Turntable rotation
Turntable rotation(Minimum) Left and Right Beginning of the movement
Boom extends(Maximum) Extension 30 s +/- 3 s
Boom telescoping Boom retracts(Maximum) Retraction 30 s +/- 2 s
Boom telescoping(Minimum) Extension Beginning of the movement
Jib lifting(Maximum) Lifting 30 s +/- 3 s
Jib Jib lowering(Maximum) Lowering 30 s +/- 3 s
Jib lifting(Minimum) Lowering Beginning of the movement
Lifting compensation(Maximum) Lifting 15 s +/- 2 s
Lowering
Compensation Lowering 15 s +/- 2 s
compensation(Maximum)
Compensation(Minimum) Lowering Beginning of the movement
Platform rotation(Maximum) Left and Right 25 s +/- 2 s
Platform rotation
Platform rotation(Minimum) Left or Right(Basket 0°) Beginning of the movement
166 4001055090 E 05.21 USA / GB

Upper boom
Sensor ILS adjustment
MS0063
Upper boom
1- You will need

• PPE (Personal Protective Equipment: glove, safety
shoes, glasses, etc ...)
• Computer with HaulotteDiag and diagnostic
kit ( 4000009300 ) or DiagPad diagnostic
console ( 400031760 )
Additional information :
1
• Telescoping cylinder weight : Approx. 33 kg / 73 lb
2- Level of knowledge required
The use of this card implies that its user is trained on this kind of machine and that this training was delivered
by HAULOTTE® or an authorised representative, following the program for DIAG LEVEL II.
It is important that the person performing the work on the machine knows all the relative safety information contained
in the instruction manual.
Only an authorized and qualified technician can work on HAULOTTE® machines.
3- Safety instructions
• The technician should take all steps to protect themselves or others against all risks of injury related to
this intervention.
• The technician should ensure that suitable PPE (personal protective equipment) for the job is used, and
• Cut the contact, to remove the key, open the battery cut if fitted.
• Place a "DO NOT USE" decal near the start/stop contactor (key switch) to inform personnel that
interventions are currently underway on the equipment.
before any intervention and never search for oil leaks using your hands.
• The exhaust fumes of the engines contain harmful products of combustion. Only start and run the engine
in a well ventilated area. In a closed room, you must use a suitable system to evacuate the exhaust to
the outside.
4001055090 E 05.21 USA / GB 167

Upper boom
MS0063
4- Sensor ILS (SQ520) adjustment - Upper boom

SQ520 - ILS boom angle ( SQ520 = 1 if boom folded)
SQ520
Adjustment :
• Lower the boom to the lowest point (Cylinder at end stop).
• Raise the boom to obtain the dimension of 160 mm +/- 10 mm (7 in +/-
1 in) between the 2 pads.
• Connect the console to view the state of the sensor.

• Loosen the nuts to immobilize the sensor.
• Move the sensor closer to the magnet until you obtain the ON status on
the console.
• Move the sensor away from the magnet until you obtain the OFF status
on the console.
• Tighten the nuts, ensuring that the OFF status remains on the console.
168 4001055090 E 05.21 USA / GB

Upper boom
MS0063
5- Sensor ILS (SQ421) adjustment - Lower arm

SQ421 - ILS Arm angle ( SQ421 = 1 if arm folded)
• The maximum lateral play in arm assembly is 6,5 mm (0.25 in). For safety purposes, the sensor must be placed
7,5 mm / 0.3 in (6,5 mm + 1 / 0.25 in + 0.04) from the magnet.
• If the play is set at the minimum amount, the magnet will be 1 mm / 0.04 in (7,5 mm - 6,5 mm / 0.3 in - 0.25 in) from
the sensor. At this distance, the arm deceleration functions.
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Upper boom
MS0063
• If the play is set at the maximum amount, the magnet will be 14 mm / 0.55 in (7,5 mm + 6,5 mm / 0.3 in + 0.25 in)
from the sensor. At this distance, the arm deceleration is more faintly detected, but it functions.
Adjustment :
• Lower the boom and the arm to the mechanical stop.
• Raise the arm to obtain the dimension of 140 mm +/- 10 mm (5.6 in +/-
1 in) between the 2 pads.
• Connect the console to view the state of the sensor.

• Loosen the nuts to immobilize the sensor.
• Move the sensor closer to the magnet until you obtain the ON status on
the console.
• Move the sensor away from the magnet until you obtain the OFF status
on the console.
• Tighten the nuts, ensuring that the OFF status remains on the console.
• If the distance between the sensor and the magnet is less than 7,5 mm
/ 0.3 in, lower the position of the metal support, then make the
adjustment again.
170 4001055090 E 05.21 USA / GB

Upper boom
MS0063
6- Sensor ILS (SQ900) adjustment - Lower arm - Upper boom - For

HA20RTJ O - HA20RTJ PRO - HA61RTJ O - HA61RTJ PRO only
SQ900 - ILS Boom angle ( SQ520 = 1 if boom folded)
SQ900
Adjustment :
• Lower the boom to the lowest point (Cylinder at end stop).
• Lower the arm to the lowest point (Cylinder at end stop).
• Adjust the sensor to make a gap of 4 mm +/- 0,5 mm (0.16 in +/- 0.04 in) between the sensor head and the pad.
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Upper boom
MS0063
7- Sensor ILS (SS530 - SQ531) adjustment - Lower arm - Telescope
1. SQ531 : For HA20RTJ O - HA20RTJ PRO - HA61RTJ O - HA61RTJ PRO only. ILS Telescope (
SQ531 = 1 if telescope retracted)
2. SQ530 : ILS Telescope ( SQ530 = 1 if telescope retracted)
Adjustment :
• Retract the telescope to the maximum point.
• Adjust the sensor(s) to have 6 mm +/- 1 mm (0.24 in +/- 0.04 in) between the sensor head and the magnet.
172 4001055090 E 05.21 USA / GB

Hydraulics
Pressure adjustment
MS0064
Hydraulics
Pressure adjustment
1- You will need

• Protective goggles • Place barriers around the perimeter of the work area
• Gloves
Exclusively use tools and auxiliary average adapted. Always wear necessary safety clothing.
2- Pressure adjustment
To allow checking operation, refer to the following table about originally pressure adjustment
If the values measured by test are not equal to the following :

• Do not use the machine.
• Setting updating is needed.
3- Port plug for pressures control
Marking Function
1 Pump 34.2 cc(0/-0.5 cc)
2 LS adjustment 21 b (+/-2 b)
3 P maxi adjustment 240 b (+/-5 b)
4 Port plug on PVG element
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Hydraulics
Pressure adjustment
MS0064
Pressures
Designation Pressure Ajustement point

Maxi pressure setting 240 bar +/- 5b On pump
Load sensing setting 21 bar +/- 2b On pump
Pressure turret orientation 128 bar +/- 5b On proportional block
Boom lowering 132 bar +/- 5b On boom cylinder valve
Arm down 130 bar +/- 5b On the arm cylinder valve
Rising arm 162 bar +/- 5b On proportional block
Telescope exit 142 bar +/- 5b On proportional block
Emergency pump 240 bar +/- 5b On emergency pump
174 4001055090 E 05.21 USA / GB

Upper boom
Check and replacing the pads
MS0066
Upper boom
1- You will need

• Gloves
• EPI (Personal protective equipment)
• Normal threadlocker
• Grease for the pads
• ORFS plug kit
• 1 hoisting strap(s) for 3000 kg / 6,615 lbs at a length of
2 m / 6 ft 7 in
• 2 hoisting strap(s) for 1000 kg / 2,205 lbs at a length of
1 m / 3 ft 3 in
• Lifting and handling equipment(bridge crane, crane, etc)
• Palettes for placement under the platform (about 700
mm / 28 in)
• Work platform for reaching the telescope's front and back
pads
1
• The worker must make sure to have the EPI (Personal Protective Equipment) suited to the work and to the
environment's specific conditions in which the equipment is located (see safety information specific to the work site.
• Position the machine on a flat and firm surface, clear of obstructions (beware of power lines).
• Switch off the ignition and remove the ignition key.
• Put a "DO NOT USE" decal near the start/stop button to inform personnel that work is currently in progress on the
equipment.
• 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.
• Engine exhaust gases contain harmful products of combustion. Always start and run the engine in a well-ventilated
area. In a closed room, ensure the exhaust gases are evacuated to the outside.
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Upper boom
MS0066
3- Check the worn of friction pads
Check the telescoping friction pad wear indicators.
Change the pad if the indicator is not visible.
4- Dis-assembly
1. Position the machine on a flat and firm surface, clear of

obstructions (beware of power lines). Mark out the work
area.
2. Raise the arm above the counterweight to remove the ac-
cess plate from the output compression cylinder.
176 4001055090 E 05.21 USA / GB

Upper boom
MS0066
1. Extend the telescope about 100 mm / 4 in to disassemble

the front pads located on the boom shaft.
1. Raise the boom slightly to access the shaft-side pin of the

output compensation cylinder.
1. Make a stable pallet stack about 700 mm / 28 in tall.

2. Put the platform on the pallets by using the jib function.
1. Switch off the ignition and remove the ignition key.
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Upper boom
MS0066
Relieve the pressure between the output compensation cylinder and the
compensation receiver cylinder. That prevents the shaft of the output
compensation cylinder from coming out while removing the shaft-side pin :
1. Carefully loosen the hoses that go to the compensation re-
ceiver cylinder.
2. As soon as a trickle of oil appears, let it flow out.
3. When there is no longer any residual pressure, re-tighten
the fittings.
1. Mark the adjustment pallets and disassemble the pads on

the boom shaft.
2. Remove the 2 upper pads, then the 2 lower pads.
1. Sling the telescope by using a hoisting strap that supports

3000 kg / 6,65 lbs at a length of 2 m / 6 ft 7 in.
178 4001055090 E 05.21 USA / GB

Upper boom
MS0066
1. To remove the pads, lift up the tube by using the hoisting

device.
2. Mark the adjustment pallets then disassemble the 2 lower
front pads.
1. Place the platform on the pallets by releasing the tension

in the hoisting device.
2. Remove the 6 plate's fastening screws that give access
to the output compensation cylinder.
1. Remove the shaft-side pin's stopper clevis from the output

compensation cylinder.
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Upper boom
MS0066
1. Pull out the pin in the output compensation cylinder.
1. Tilt the output compensation cylinder backwards to access

the pads.
2. Spread apart the hoses and the wire harness to pull out
the cylinder.
1. Mark the adjustment pallets then disassemble the 2 lower

lateral pads and the 2 lower pads.
180 4001055090 E 05.21 USA / GB

Upper boom
MS0066
1. To make it easier to access the upper lateral pads and the

upper pads, remove the pin on the back side of the tele-
scoping cylinder.
2. Mark and disconnect the 2 supply hoses.
3. After disassembly, install the plug openings.
1. Run a hoisting strap that supports 1000 kg / 2,205 lbs at

a length of 1 m / 3 ft 3 in over the telescope cylinder.
2. Pull out the strap above the cylinder then sling it with the
hoisting device.
1. Remove the stopper clevis from the pin found on the back
side of the telescope cylinder.
1. Apply a small amount of tension to the hoisting device.

2. Pull out the pin.
3. Lower the cylinder to rest against the tube.
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Upper boom
MS0066
1. Mark the adjustment pallets and remove the 2 lateral

pads.
2. For the upper pads, mark the adjustment pallets and take
out the screws.
3. Sling the telescope by using a hoisting strap that supports
3000 kg / 6,65 lbs at a length of 2 m / 6 ft 7 in.
4. Put a small amount of tension on the telescope to remove
the pads.
5- Reassembly
To install the new pads, go through the disassembly instructions in reverse order :
• Grease the surface of the new pads while making sure to put the adjustment palettes in the same places.
• Install the screws with threadlock.
• Install the back upper pads.
• Install the back upper lateral pads.
• Install the telescope cylinder : Grease the pin. Install the pin's stopper clevis. Check that the seals are on the
connections before reconnecting the hoses.
• Install the back lower pads.
• Install the back lower lateral pads.
• Install the output compensation cylinder : Grease the pin. Install the pin's stopper clevis.
• Install the front lower pads.
• Install the front lateral pads.
• Install the front upper pads.
6- Additional operations
• Clean off any residual oil or grease.
• Move the telescope back and forth to ensure that it is not stuck. No jerky movements because of sticking.
• Check that there is no leak of oil at the removing connections.
• Re-install the plate on the output compensation cylinder side.
• Top up the hydraulic oil if necessary.
182 4001055090 E 05.21 USA / GB

Turntable
Remove - Replace counterweight
MS0067
Turntable
1- You will need

• Gloves
• 2 hoisting strap(s) for 2000 kg / 4,41 lbs at a length of 2
m / 6 ft 7 in
• Ratchet wrench and 46 mm / 2 in socket
• 2 hoisting rings M30 ( 2000 kg / 4,41 lbs minimum)
• 2 bow shackles ( 2000 kg / 4,41 lbs minimum)
• Torque wrench 500 Nm + 46 mm / 2 in socket
• Grease
1
equipment.
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Turntable
MS0067
3- Removing the counterweight
1. Position the machine on a flat and firm surface, clear of ob-

structions (beware of power lines). Mark out the work ar-
ea.
2. Stow the machine completely.
1. Take off the plastic caps that protect the threads on the
counterweight.
2. If the threads are oxidized, pass a M30 thread tap over
them.
3. Grease the threads on the hoisting ring.
4. Screw the rings all the way into the counterweight.
5. Sling the counterweight by using the 2 hoisting straps and
the 2 bow shackles.
Counterweight mass :
• HA20 RTJ - HA20 RTJ O - HA61 RTJ O : 2380 kg / 5,248 lbs
• HA20 RTJ PRO - HA61 RTJ PRO : 2400 kg / 5,292 lbs
6. Apply a small amount of tension to the hoisting device.
184 4001055090 E 05.21 USA / GB

Turntable
MS0067
1. Unscrew the engine casing fastening screws.

2. Open the engine casing then lock it.
1. Remove the 4 screws that hold the plate ( 1 ) on the coun-

terweight.
2. Take off the plate.
4001055090 E 05.21 USA / GB 185

Turntable
MS0067
1. Remove the 2 counterweight fastening screws.
1. Remove the fastening screw from the hydraulic oil tank

side.
186 4001055090 E 05.21 USA / GB

Turntable
MS0067
1. Lift the counterweight slightly then pull it out while ensur-

ing that it doesn't hit the fuel tank.
Do not place the counterweight in a vertical position. Tip-

over Hazards. Place it up against the wood wedges.
4- Re-install the counterweight
Make sure not to hit the fuel tank while installing the counterweight.
• Carry out the operations in the reverse order.

• Tighten the 3 counterweight supports to the torque ratio of 500 Nm.
• Grease the inside of the counterweight threading.
• Re-install the plastic caps.
• Clean the counterweight.
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Turntable
MS0067
Notes
188 4001055090 E 05.21 USA / GB

Lower arm
Remove - Replace arm assembly
MS0068
Lower arm
1- You will need

• Gloves
• Pin 25 mm / 1 in length 130 mm / 6 in for extracting the tie rod pins
• Pin 40 mm / 2 in length 800 mm / 32 in minimum for extracting the
arm hinge pin
• ORFS plug kit
• Place barriers around the perimeter of the
• 3 hoisting strap(s) for 3000 kg / 6,615 lbs at a length of 3000 mm / 9
work area
ft 10 in
• 2 ratcheting straps that support 2000 kg / 4,41 lbs at a length of 4000
mm / 13 ft 1 in
• 1 ratcheting straps that support 1000 kg / 2,205 lbs at a length of
4000 mm / 13 ft 1 in
• Fuel collection tray - Fuel tank capacity : 80 l / 21 gal US
• Collars COLSON
• Weight of 290 kg / 639 lbs for performing the static test
• Circlips pliers
Exclusively use tools and auxiliary average adapted. Always wear necessary
1
safety clothing.
equipment.
4001055090 E 05.21 USA / GB 189

Lower arm
MS0068
3- Removal
1. Remove the counterweight MS0067 - Remove - Replace

counterweight.
2. Remove the boom/jib/box assembly MS0069 - Remove -
Replace the boom/jib/box assembly.
3. Pull out the arm with the arm cylinder shaft about 70 mm
/ 3 in to access the tie rod pins on the counterweight side.
4. Disconnect the plug for the minimum fuel level indicator
gauge.
1. On the engine side, disconnect the fuel hoses.

2. Plug the hoses with plugs.
3. Fold the hoses at the level of the fuel tank.
N.B.-:-IF THE HOSES ARE LONG ENOUGH AROUND THE FUEL TANK,
DISCONNECT THEM AFTER PULLING THE TANK. IF THE HOSES ARE
LONG ENOUGH, DISCONNECT THEM ON THE ENGINE SIDE.
190 4001055090 E 05.21 USA / GB

Lower arm
MS0068
Removing the tank :

1. If the tank is full, empty it.
2. Unscrew the 2 the fastening strap screws on the fuel tank.
1. Remove the tank.
4001055090 E 05.21 USA / GB 191

Lower arm
MS0068
• To access the the lower arm hinge pin, unscrew the 2 fastening screws
on the strap support plate.
• Mark, disconnect and plug all the hoses from the motion block that supply the arm, boom, telescope and block ON/
OFF.
• Mark, disconnect, and plug the hose on the hydraulic tank.
192 4001055090 E 05.21 USA / GB

Lower arm
MS0068
4001055090 E 05.21 USA / GB 193

Lower arm
MS0068
A1 Motion block -> V2 Arm lifting cylinder

A2 Motion block -> V2 Boom lift cylinder
A3 Motion block -> V1 Boom telescopic cylinder
T1 Tank -> Bulkhead
B1 Motion block -> V1 Arm lifting cylinder
B2 Motion block -> V1 Boom lift cylinder
B3 Motion block -> V2 Boom telescopic cylinder
A5 Motion block -> Bulkhead
1. Mark the passage of the hoses through the collars.

2. In order to reposition the hoses easily during reassembly,
mark each hose at the entrance and exit of the collars.
3. Remove the fastening screws from the collars.
4. Bring the hoses to the back of the arm.
194 4001055090 E 05.21 USA / GB

Lower arm
MS0068
Markings on the hoses (Respect the lengths noted below between the exit
from the motion block and the entrance into the collars on the swing joint
side of the turntable. Mark at the level of the collars. ) :
• 3a : 1250 mm / 4 ft 1 in
• 4a : 1150 mm / 3 ft 9 in
• 5a : 1090 mm / 3 ft 7 in
• 5b : 1090 mm / 3 ft 7 in
• 7a : 1250 mm / 4 ft 1 in
• 8a : 1070 mm / 3 ft 6 in
• A : Lower arm
• B : Telescope
• C : Upper boom
• T : Block pressure ON/OFF
• R : Block return ON/OFF
4001055090 E 05.21 USA / GB 195

Lower arm
MS0068
1. Disconnect the sensors harness ILS (connector CN02).

2. Bring the harness to the back of the arm.
196 4001055090 E 05.21 USA / GB

Lower arm
MS0068
1. Disconnect the arm sensor plug SQ421.

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Lower arm
MS0068
1. Strap the tie rods to the link piece using a ratcheting strap
supporting 1000 kg / 2,205 lbs at a length of 4000 mm /
13 ft 1 in.
2. Put a small amount of tension on the strap
198 4001055090 E 05.21 USA / GB

Lower arm
MS0068
1. Strap the lower arm and the upper arm using the racketing
strap that supports 2000 kg / 4,41 lbs at a length of 4000
mm / 13 ft 1 in.
1. Strap the lower arm and the upper arm using the racketing
strap that supports 2000 kg / 4,41 lbs at a length of 4000
mm / 13 ft 1 in.
2. Pass the strap between the arms and the tie rods.
4001055090 E 05.21 USA / GB 199

Lower arm
MS0068
1. For safety reasons, set up a stack of pallets about 1140

mm / 3 ft 9 in.
1. Anchor the arm assembly using hoisting straps that

support 3000 kg / 6,615 lbs at a length of 3000 mm / 9 ft
10 in.
2. At the front, tie down the link piece holes by using the 2
bow shackles supporting 4500 kg / 9,923 lbs and the 2
hoisting straps supporting 3000 kg / 6,615 lbs at a length
of 3000 mm / 9 ft 10 in.
3. At the back, install the boom pin with the back pin clevis.
4. On the pin, double wrap the 3000 kg / 6,615 lbs hoisting
strap, 3000 mm / 9 ft / 10 in long.
1. Align the bridge and add tension to it.
200 4001055090 E 05.21 USA / GB

Lower arm
MS0068
1. Remove the 2 pins that connect the lower tie rods to the
turntable.
2. Remove the circlips.
3. Loosen the screws that hold the locking pins.
1. Remove the pins on the lower tie rods.
4001055090 E 05.21 USA / GB 201

Lower arm
MS0068
1. Take out the screw that holds the locking pin.

2. Extract the pin by knocking it out to the fuel tank side, con-
necting the lower arm casing to the turntable. . .
1. Place the assembly on a flat surface while ensuring the

assembly's stability.
2. Mark out the work area.
202 4001055090 E 05.21 USA / GB

Lower arm
MS0068
4- Re-installation
• Grease the pins, the seals, and the bored holes.
• Make sure to install the locking pin screws and circlips (change them if they became damaged during
disassembly).
• Make sure the seals are present during the reassembly.
• Hold the hoses to ensure that they don't turn while tightening the connections (risk of seal damage).
• Make sure the hoses follow their correct paths and the harnesses are under the arm casing.
• Check the fuel tank and refill the fuel, if necessary.
• Move the arm and the boom using the ground control box :
• Check the articulation of the hoses.
• Check the articulation of the wire harnesses.
• Using the console, check the status change of the senses ILS.
• Check for any oil leaks.
• Top up the oil level, if necessary.
• Make sure that the assembly functions properly by testing all the movements using the ground and platform control
boxes.
• Perform a static test by putting 290 kg / 639 lbs on the platform :
• With the machine unfolded, check the performance of all the parts after it's been running for 15 mn (arm cylinder,
boom cylinder, telescope cylinder, compensation receiver cylinder, jib cylinder)
N.B.-:-I N COMPLIANCE WITH THE COUNTRY ' S LAWS , HAVE THE MACHINE APPROVED BY AN ACCREDITED
ORGANIZATION.
4001055090 E 05.21 USA / GB 203

Lower arm
MS0068
Notes
204 4001055090 E 05.21 USA / GB

Upper boom
Remove - Replace telescope cylinder
MS0069
Upper boom
1- You will need

• Gloves
• 2 hoisting strap(s) for 1000 kg / 2,20 lbs at a length of 2 m / 6 ft 7 in
• Collars COLSON
• ORFS plug kit
• Wood pallet length 1100 mm / 3 ft 7 in, width 50 mm / 5 in, height 20
work area
mm / 1 in estimated
• Pin diameter 25 mm / 1 in, length 300 mm / 12 in
• Pallets under the platform about 700 mm / 28 in
• Circlips pliers
• Pry bar
• Grease
• Hydraulic oil
1
safety clothing.
Telescoping cylinder weight : 115 kg / 254 lbs
equipment.
4001055090 E 05.21 USA / GB 205

Upper boom
MS0069
3- Removing the cylinder

ea.
2. Raise the arm to remove the access plate for the output
compensation cylinder (above the counterweight).
1. With the boom in a horizontal position, take out the tele-

scope to access the shaft-side pin.
1. Put the platform on a pallet stack by using the jib function.
206 4001055090 E 05.21 USA / GB

Upper boom
MS0069
1. Relieve the pressure between the output compensation

cylinder and the compensation receiver cylinder. That pre-
vents the shaft of the output compensation cylinder from
coming out while removing the shaft-side pin.
ceiver cylinder.
the fittings.

to the output compensation cylinder(Ratchet wrench and
16 mm socket).
4001055090 E 05.21 USA / GB 207

Upper boom
MS0069

compensation cylinder(Ratchet wrench and 16 mm sock-
et).
1. Pull out the pin in the output compensation cylinder(Mallet

and pin diameter 25 mm / 1 in length 300 mm / 12 in min-
imum).

the telescope cylinder.
2. Spread apart the hoses and the wire harness to pull out the
cylinder.
208 4001055090 E 05.21 USA / GB

Upper boom
MS0069
1. Locate and disconnect the 2 telescope cylinder supply

hoses.
2. Plug the openings after disassembly.
1. Remove the sensor ILS - SQ520.
4001055090 E 05.21 USA / GB 209

Upper boom
MS0069
1. Disconnect the plugs for the sensors ILS SQ530 and

SQ531 ( SQ531 are only found on the O and PRO ma-
chines).
1. Take off the circlips and extract the shaft-side pin.
1. Run a hoisting strap supporting 1000 kg / 2,20 lbs and 1

m / 3 ft 4 in long under the telescope cylinder.
2. Make sure not to damage the sensors ILS.
3. Have the strap come out through the access hole above
the cylinder and tie to the bridge.
210 4001055090 E 05.21 USA / GB

Upper boom
MS0069
1. Remove the stopper clevis from the pin found on the back
side of the telescope cylinder.
1. Apply a small amount of tension on thebridge crane and

extract the pin.
2. Lower the cylinder to rest against the tube.
1. Attach a sling to the cylinder.

2. Make sure not to damage the sensors ILS.
1. Pull the cylinder lightly.

2. Maker sure not to snag anything (hoses, wire harness-
es...).
4001055090 E 05.21 USA / GB 211

Upper boom
MS0069
1. Make sure not to damage the magnets while guidance part

of the cylinder comes out of the telescope.
1. When the cylinder has come out far enough and the guid-
ance portion of the cylinder is still in the foot of the boom,
position fork lift (or another means of handling the move-
ment) under the cylinder.
1. When the guidance part is outside the linking piece, turn

the cylinder 1/4 of a turn to make it easier for the shaft-
side boss to pass.
212 4001055090 E 05.21 USA / GB

Upper boom
MS0069
1. Place the cylinder on the ground.
4- Re-installing the cylinder
1. If you are installing a new cylinder, note the serial number.

2. Install and grease the front guiding pads.
4001055090 E 05.21 USA / GB 213

Upper boom
MS0069
1. Carry out the operations in the reverse order.

2. In order to make it easier for the guidance part to enter the
telescope, position a wooden wedge in the boom foot.
• Grease all the pins and bored holes of the boom and the telescope.
• Make sure to install the locking pin screws and circlips (change them if they became damaged during disassembly)
• 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 sensors ILS and re-install the sensor ILS - SQ520.
• From the ground control box, run the platform compensation and telescoping functions in order to flush out the
hydraulic system.
• Top up the hydraulic oil if necessary (machine in road driving position).
• Using the console, check the status change of the senses ILS. Refer to MS0063 - Sensor ILS adjustment.
• Machine unfolded, 15 mn after checking the performance of its parts : Arm cylinder, telescope cylinder,
compensation cylinder, jib cylinder.
In compliance with the country's laws, have the machine approved by an accredited organization.
214 4001055090 E 05.21 USA / GB

Upper boom
Remove - Replace arm cylinder
MS0070
Upper boom
1- You will need

• Gloves
• Grease
• ORFS plug kit
• 1 ratcheting straps that support 1000 kg / 2,205 lbs at a length of 4 m • Place barriers around the perimeter of the
/ 13 ft 1 in work area
• Fork lift with Europe pallet
• Pin diameter 30 mm / 1.18 in, length 500 mm / 19 ft 65 in
• Pin diameter 25 mm / 0.984 in, length 500 mm / 19 ft 65 in
• Hydraulic oil
• Oil collection pan
1
safety clothing.
Arm cylinder weight : 116 kg / 256 lbs
equipment.
4001055090 E 05.21 USA / GB 215

Upper boom
MS0070
3- Removing the cylinder
1. Position the machine on a flat and firm surface, clear of

obstructions (beware of power lines). Mark out the work
area.
2. Put the arm against the pad, with the telescope retracted,
the jib folded, and the boom raised.
4. Remove the fastening screw from the engine casing.
5. Open the engine casing and hold it open with the ratchet-
ing strap.
216 4001055090 E 05.21 USA / GB

Upper boom
MS0070
6. Remove the locking device from the engine casing.
7. Hold out the ratcheting strap to access the pin on the back
side of the arm cylinder.
8. Make sure to not pull it too much.
9. Check that the articulation of the hose in the engine casing
linkage.
10. Pull off the fastening screws from the PVG.

11. Move the bloc to the side in order to extract the back-side
pin on the arm cylinder.
4001055090 E 05.21 USA / GB 217

Upper boom
MS0070
12. Remove the blocking pin axis.
13. Locate, disconnect and plug the hoses that supply the arm
cylinder.
14. Using a hoisting strap, sling the shaft-side arm cylinder.

15. Apply a small amount of tension on the bridge crane.
16. Remove the locking pin on the shaft side then extract the
pin.
218 4001055090 E 05.21 USA / GB

Upper boom
MS0070
17. Turn the cylinder clevis 90° to make it easier to pass it

through at the level of the tie rods.
18. Place the cylinder on a wooden pallet positioned between
the lower arm.
19. Place a wooden pallet lengthwise on the forks of the fork-

lift.
4001055090 E 05.21 USA / GB 219

Upper boom
MS0070
20. Put the strap through the upper arm and tie down the cyl-
inder.
220 4001055090 E 05.21 USA / GB

Upper boom
MS0070
22. Extract the pin on the back side.
23. Place the cylinder on a wooden pallet.
24. Pass the hoisting strap in front of the cross beam connect-
ing the arms.
25. Sling the cylinder at its center of gravity.
4001055090 E 05.21 USA / GB 221

Upper boom
MS0070
26. Lift the cylinder slightly. .

27. Pull the cylinder on the counterweight side to avoid the
cross beam which connect the lower arms.
28. Guide the cylinder and slowly lower it onto the pallet.
29. Slide the cylinder towards the front and place it on the pal-
let.
30. Place the cylinder on the ground.
222 4001055090 E 05.21 USA / GB

Upper boom
MS0070
4- Re-installing the cylinder

1. If you are installing a new cylinder, note the serial number.
3. Grease the pins, the cylinder seals, and the boom bore holes
4. Make sure to install the locking pin screws and circlips (change them if they became damaged during
disassembly)
5. Check that the seals are on the connections before reconnecting the hoses.
6. 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.
• Using the ground control box, raise then lower the arm the maximum amounts in order to flush out the cylinder.
• Using the console, check the status change of the senses ILS. Refer to MS0063 - Sensor ILS adjustment
• Perform a static test by putting 290 kg / 639 lbs on the platform : Machine unfolded, 15 mn after checking the
performance of its parts.
4001055090 E 05.21 USA / GB 223

Upper boom
MS0070
Notes
224 4001055090 E 05.21 USA / GB

Upper boom
Remove - Replace boom assembly
MS0071
Upper boom
1- You will need

• Gloves
• Pin diameter 30 mm / .181 in, length 300 mm / 11.81 in
• Pin diameter 40 mm / .1574 in, length 800 mm / 31.49 in
• ORFS plug kit
• 1 hoisting strap(s) for 3000 kg / 6,615 lbs at a length of 5 m / 16 ft 5 in • Place barriers around the perimeter of the
• 1 ratcheting straps that support 1000 kg / 2,205 lbs at a length of 4 m work area
/ 13 ft 1 in
• 2 trestles with a minimum capacity of 1000 kg / 2,205 lbs
• Wooden pallets
• Thread puller needle or cord
• Collars COLSON
• Lift truck
1
safety clothing.
Weight of boom/jib/platform assembly : 1000 kg / 2,205 lbs
equipment.
4001055090 E 05.21 USA / GB 225

Upper boom
MS0071
3- Removal

ea.
2. Put the machine in the folded-up position with the tele-
scope retracted, the jib horizontal, and the platform empty.
3. Raise the arm until you can access the shaft-side pin of the
output compensation cylinder.
4. For safety reasons, place the fork lift under the platform.
6. Relieve the pressure between the output compensation

cylinder and the compensation receiver cylinder. That pre-
vents the shaft of the output compensation cylinder from
coming out while removing the shaft-side pin.
ceiver cylinder.
the fittings.
226 4001055090 E 05.21 USA / GB

Upper boom
MS0071
10. Remove the counterweight. Refer to MS0067 - Re-

move - Replace counterweight.
to the output compensation cylinder(Ratchet wrench and
16 mm socket).
compensation cylinder(Ratchet wrench and 16 mm sock-
et).
13. Pull out the pin in the output compensation cylinder(Mallet

and pin diameter 30 mm / 1.181 in length 300 mm / 11.81
in minimum).
4001055090 E 05.21 USA / GB 227

Upper boom
MS0071

the telescope cylinder.
the cylinder.
16. Locate and disconnect the 2 telescope cylinder supply

hoses.
18. Mark and disconnect, at the bulkheads, the 2 block supply

hoses ON/OFF.
228 4001055090 E 05.21 USA / GB

Upper boom
MS0071
20. On the turntable, behind the main block, disconnect the

CN06.1 and CN06.2 plugs.
21. In order to avoid getting the connectors dirty, protect the
plugs with a plastic bag.
22. Remove the plug for the 220 V line cable.

23. Bring the harnesses to the back of the arm.
24. Unscrew the STAUFF collar which holds the harnesses.
25. Mark the cables at the entrance and exit of the collar. This
is so you can reposition them correctly during reassembly.
26. Extract the 4 screws in order to remove the cap at the

front of the arm.
4001055090 E 05.21 USA / GB 229

Upper boom
MS0071
27. On the left side, mark where the hoses and harnesses
pass through the STAUFF clamp.
28. Mark where the hoses and harnesses enter and exit the
collar. This is so you can reposition them correctly during
reassembly.
29. Remove the collar.
30. Attach the thread puller to the BUS CAN harness at the
back of the arm.
31. Pull the harnesses at the front of the lower arm.
32. Pull the harnesses on the side of the output compensation

cylindar.
33. Cut the collars in the linking pieces.
34. Bring the ON / OFF block hoses and the harnesses to the
exterior right side of the boom.
35. Attach the assembly to the COLSON collars.
230 4001055090 E 05.21 USA / GB

Upper boom
MS0071
36. Disconnect the ILS SQ520 SQ530 SQ900 and SQ531

sensors
37. For HA20RTJ O - HA20RTJ PRO - HA61RTJ O -
HA61RTJ PRO only : Disconnect the ILS SQ900 and
SQ531 sensors.
38. All the sensors should be disconnected at the linking
piece, except the SQ900 which should be disconnected
at the boom rest pad.
39. Sling the boom using a 3000 kg / 6,615 lbs hoisting strap
at a length of 4 m / 13 ft 1 in on the platform side, and a
3000 kg / 6,615 lbs hoisting strap at a length of 5 m / 16 ft
5 in on the boom foot boss side.
40. To sling the boom, refer to the opposing photos.
42. Strap the boom cylinder using a 1000 kg / 2,205 lbs ratch-
eting strap at a length of 4 m / 13 ft 1 in.
43. Remove the locking pin on the shaft side then pull out the
pin.
44. Put the cylinder on the wooden pallet.
45. Remove the locking pin at the boom joint then extract the
pin.
46. Remove the boom.
4001055090 E 05.21 USA / GB 231

Upper boom
MS0071
Before positioning the boom on the trestles, place the

platform-side trestle at the end of the boom foot. If the trestle
is not positioned correctly, there's a risk of it tipping over.
47. Place wooden pallets to avoid crushing the wireways.

48. Place the boom.
232 4001055090 E 05.21 USA / GB

Upper boom
MS0071
4- Re-installation
• Remount in reverse order to removal.
• Grease all the pins, seals, and bore holes.
• . . Make sure to install the locking pin screws and circlips (change them if they became damaged during disassembly)
• Make sure the hoses and harnesses are set in their correct routes.
Using the ground control box and after reassembling the boom assembly, perform all the arm and boom motions :
• Check the articulation of the hoses.
• Check the articulation of the wire harnesses.
• Using the console, check the status change of the senses ILS. Refer to MS0063 - Sensor ILS adjustment
• From the ground and platform control boxes, apply weight through all of the machine's movements.
Perform a static test by putting 290 kg / 639 lbs on the platform :

• Machine unfolded, 15 mn after checking the performance of its parts : Arm cylinder, boom cylinder, telescope
cylinder, compensation receiver cylinder, jib cylinder.
4001055090 E 05.21 USA / GB 233

Upper boom
MS0071
Notes
234 4001055090 E 05.21 USA / GB

Upper boom
Remove - Replace Boom cylinder
MS0074
Upper boom
1- You will need

• Gloves
• Grease
• Height wedge 400 mm / 1 ft 5 in
• Height wedge 1500 mm / 4 ft 11 in
• ORFS plug kit • Place barriers around the perimeter of the
• 1 hoisting strap(s) for 1000 kg / 2,205 lbs at a length of 2 m / 6 ft 7 in work area
• Pin diameter 35 mm / 4 in, length 800 mm / 2 ft 7 in
• 2 trestles with a minimum capacity of 1000 kg / 2,205 lbs
• Lift truck
1
safety clothing.
Height boom cylinder : 130 kg / 287 lbs
equipment.
4001055090 E 05.21 USA / GB 235

Upper boom
MS0074
3- Removal
1. Arm cylinder rod, out of about 80 mm / 4 in.

2. Make an appropriate wedging of about 440 mm / 1 ft 5 in
between the arm and the boom positioned at pads.
3. Lower the boom on the wedging.
4. Make a wedging, solid and stable under the basket about

1500 mm / 4 ft 11 in.
5. Move the jib in order to lay the basket on the wedging.
6. When using forklift (minimum capacity 2000 kg / 4,41 lbs),
place the forks directly under the boom and rest the boom
on the forks.
236 4001055090 E 05.21 USA / GB

Upper boom
MS0074
8. Remove the stop pin axis, side rod.
9. Sling the cylinder with the 2000 kg / 4,41 lbs hoisting

strap, 2 m / 6 ft 7 in in length.
10. Apply a small amount of tension on thebridge crane and
extract the pin. (Use a shaft diameter 35 mm / 2 in and
length 300 mm / 12 in).
11. Switch on the machine and command the boom cylinder

rod retraction. Place the cylinder on a wooden pallet.
13. Mark, disconnect and stub hoses that feed the boom cyl-
inder.
14. Move the hoisting strap to tie the cylinder at the center of
gravity. Apply a small amount of tension on the bridge
crane.
4001055090 E 05.21 USA / GB 237

Upper boom
MS0074
15. Remove the stop pin axis, bottom side axis of the cylinder.
16. Use a shaft diameter 35 mm / 2 in and length 800 mm /

32 in.
Do not remove completely the axis as it maintains the upper arm and link part. Take out the axis of
maximum length 400 mm / 16 in in order to be able to release the cylinder.
Extend the cylinder.
Lay down the cylinder on wooden blocks.
238 4001055090 E 05.21 USA / GB

Upper boom
MS0074
4- Re-installation
• If you are installing a new cylinder, note the traceability number.
• Grease all the pins, seals, and bore holes.
• Make sure to install the locking pin screws and circlips (change them if they became damaged during disassembly)
• Make sure the hoses and harnesses are set in their correct routes.
• From the lower control box, raise up and down boom up to purge the cylinder.
4001055090 E 05.21 USA / GB 239

Upper boom
MS0074
Notes
240 4001055090 E 05.21 USA / GB

Upper boom / Lower arm
Boom and arm pads adjustment
MS0075
1- You will need

• Gloves
1
equipment.
4001055090 E 05.21 USA / GB 241

MS0075
3- Concerned assembly
4- Arm pad support wedging
• Fasten the pads ( 6 ) under the lower arm ( 6 ) and the pads under the boom link part ( 2 ) without wedges.
• Rise up a bit the boom and the arm.
• Lower slowly the arm to put the boom link part ( 2 ) pad on the turntable ( 3 ) (do not force).
• Measure the distance between the arm support pads ( 4 ) on the turrent and the 2 opposite pads ( 1 ) on the arm.
• Lift the arm to access the pads ( 1 ) on the arm.
242 4001055090 E 05.21 USA / GB

MS0075
• Remove the pads ( 1 ) on the arm and put in as many wedges ( 5 ) as the value measured previously.
• Re-install the pad ( 1 ) with the wedges ( 5 )
• Check that the pads on the arm and those on the boom link pieces come into contact on their respective receptacles
at the same time.
5- Boom support pad wedging adjustment
This operation must only be carried out if the arm support pads have previously been wedged.
• The pad ( 1 ) must be mounted with no wedge under the boom ( 2 ).

• The pad ( 3 ) must be mounted with no wedge on the top arm ( 4 ).
• Fully lower the boom ( 2 ) (to cylinder stop ( 5 )).
• Measure the distance between the boom pad ( 1 ) and the pad ( 3 ) on the top arm.
• Lift the boom ( 2 ) slightly to access the screws and put in as many wedges ( 6 ) as the value measured previously.
• Check that when the boom lowering movement reaches the end, there is no unnecessary movement of the arm and
boom.
4001055090 E 05.21 USA / GB 243

MS0075
Notes
244 4001055090 E 05.21 USA / GB

Turntable
Remove - Replace turret/platform CAN BUS wiring harness
MS0076
Turntable
1- You will need

• Gloves
• Thread puller needle or cord
• Collars COLSON
1
equipment.
4001055090 E 05.21 USA / GB 245

Turntable
MS0076
3- Removal

ea.
2. Put the machine in the folded-up position with the tele-
scope retracted, the jib horizontal, and the platform empty.
1. Remove the counterweight. MS0067 - Remove - Replace counterweight

2. On the turntable, behind the main block, disconnect the CN06.1 and CN06.2 plugs. Protect the plugs
with a plastic bag to avoid polluting the connectors.

4. Unscrew the STAUFF clamp through which the wiring harnesses run.
5. Make a mark on the cables where they enter and leave the clamp. This will enable them to be correctly
repositioned when re-installing.
246 4001055090 E 05.21 USA / GB

Turntable
MS0076
6. Remove the cover at the front of the arm.
7. On the left side, mark where the hoses and harnesses pass through the STAUFF clamp.
8. Make a mark on the wiring harness and hoses where they enter and leave the clamp. This will enable
them to be correctly repositioned when re-installing.
9. Remove the clamp.
4001055090 E 05.21 USA / GB 247

Turntable
MS0076
1. At the back of the arm (counterweight side) attach the

BUS CAN wire puller.
2. Pull the harnesses at the front of the lower arm.
1. Then pull the wiring harness on the output compensation

cylinder side.
2. Cut the collars in the link piece.
3. Bring the wiring harness on the outside right-hand side of
the boom.
1. Disconnect the plug on the left side of the platform control

box and cut the COLSON collars.
248 4001055090 E 05.21 USA / GB

Turntable
MS0076
1. Remove the cable gland on the plug and loosen the 4

screws on the plug insert.
2. Disconnect the wires from the insert.
3. To do so, position a small screwdriver between the tabs,
turn through a 1/4 turn to separate them and pull on the
wire.
1. Remove the wires from the plug and protect them with a
bag or adhesive tape.
4001055090 E 05.21 USA / GB 249

Turntable
MS0076
1. Open the plastic collar on the link piece and remove the
guide bar.
2. Remove the first layer of the corrugated sheath.
3. Remove the CAN BUS wiring harness.
1. Cut the COLSON collars holding the CAN BUS wiring

harness on the upper duct of the jib arm as far as where it
enters the chain.
250 4001055090 E 05.21 USA / GB

Turntable
MS0076
1. Pull the wiring harness as far as the chain entrance.

2. Cut the COLSON collars where it leaves the chain.
1. Attach the wire puller or a rope to the wiring harness and

pull the CAN BUS wiring harness to remove it from the
plastic chain.
4001055090 E 05.21 USA / GB 251

Turntable
MS0076
1. Pull gently on the wiring harness at the end of the lower

duct.
1. Cut the COLSON collars on the duct located under the

boom and pull the CAN BUS wiring harness.
4- Re-installation
• Re-install the counterweight.
252 4001055090 E 05.21 USA / GB

Upper boom
Remove - Replace load cell
MS0077
Upper boom
1- You will need

• Gloves
• Torque wrenches for torque of 70 Nm / 140 Nm / 215
Nm
• 24 mm / 1 in socket
• Short 24 mm / 1 in socket
• M16 x 1,5 bushing
• Circlips pliers
• Palettes for placement under the platform (about 700
mm / 28 in)
1
equipment.
4001055090 E 05.21 USA / GB 253

Upper boom
MS0077
3- Removal

ea.
2. With the arm and boom folded and the telescope extended
to access the pin on the side at the bottom of the output
compensation cylinder, support the platform on pallets.
4. Loosen the 4 screws connecting the platform support to

the gauge.
254 4001055090 E 05.21 USA / GB

Upper boom
MS0077
5. Remove the circlip and withdraw the pin linking the link
piece to the platform support.
6. Disconnect the stress gauge plug.

7. Pull slightly on the platform assembly to free access to the
stress gauge.
4- Re-installation
1. If the cell has been replaced, note the traceability number.
4001055090 E 05.21 USA / GB 255

Upper boom
MS0077
2. If the screws are replaced, fit the M16 x 1,5 bushing (extra
thickness linked to the screw treatment). If this is not done,
the tapping in the load cell will be damaged.
3. Precautions on the surfaces in contact with the stress

gauge :
• A : The surfaces in contact with load cell must not be painted. The load
cell must not be in contact with the machined side or with the paint.
• B : Ensure that the load cell has no marks (impacts or scratches) on the
surface in contact or the grooves on the 2 sides.
256 4001055090 E 05.21 USA / GB

Upper boom
MS0077
4. Reassemble in the reverse order of dismantling.
Apply the following torques :

• 70 Nm
• 140 Nm
• 215 Nm
N.B.-:-E N S U R E T H E S P A C ER W A SH E R S A R E C O R R EC T L Y
POSITIONED ON THE PLATFORM SIDE. THEY MUST BE CENTRED IN
THE COUNTERBORES.
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. Check there are no foreign bodies (even small) between
the cell and the brackets.
4001055090 E 05.21 USA / GB 257

Upper boom
MS0077
5. Tighten the fastening screws successively 3 times with a

torque wrench.
Tightening recommendations :
• No lubrication on these screws.
• Tighten the screws crosswise.
• Tighten to the indicated final torque in 3 phases :
• Tighten to a third of the torque (impact wrench authorised without
exceeding one third of the torque).
• Tighten to 2 of the torque with a torque wrench.
• Tighten to nominal torque using a torque wrench.
• If tightened too much and not in a crosswise fashion, the weight indicator
will be damaged and will give incorrect results.
• Tighten the screws in the order 1, 2, 3, 4(See photo opposite).
• Proceed in the same way on the 2 sides.
6. Remember to re-install the pin connecting the link piece to

the platform bracket.
7. Fit the washer and circlip (circlip to be changed if stretched
when removing).
258 4001055090 E 05.21 USA / GB

Upper boom
MS0077
• Calibrate the load cell. MS0057 - Overload system.

4001055090 E 05.21 USA / GB 259

Upper boom
MS0077
Notes
260 4001055090 E 05.21 USA / GB

Jib
Remove/Re-install rotary actuator
MS0078
Jib
1- You will need

• Gloves
• Mallet and pin diameter 20 mm / 1 in length 300 mm / 12 in minimum
• ORFS plug kit
work area
• Torque wrench to tighten to a torque of 800 Nm, 36 mm / 2 in socket
• Torque wrench to tighten to a torque of 44 Nm, 17 mm / 1 in socket
• Hydraulic oil
• Palettes for placement under the platform (about 700 mm / 28 in)
• Grease
1
safety clothing.
equipment.
4001055090 E 05.21 USA / GB 261

Jib
MS0078
3- Removal

ea.
4. Loosen the 4 screws connecting the platform support to

the gauge.
262 4001055090 E 05.21 USA / GB

Jib
MS0078
5. Remove the circlip and withdraw the pin linking the link
piece to the platform support.
6. Disconnect the stress gauge plug.

7. Pull slightly on the platform assembly to free access to the
stress gauge.
4- Re-installation
1. If the cell has been replaced, note the traceability number.
4001055090 E 05.21 USA / GB 263

Jib
MS0078
2. If the screws are replaced, fit the M16 x 1,5 bushing (extra
thickness linked to the screw treatment). If this is not done,
the tapping in the load cell will be damaged.
3. Precautions on the surfaces in contact with the stress

gauge :
• A : The surfaces in contact with load cell must not be painted. The load
cell must not be in contact with the machined side or with the paint.
• B : Ensure that the load cell has no marks (impacts or scratches) on the
surface in contact or the grooves on the 2 sides.
264 4001055090 E 05.21 USA / GB

Jib
MS0078
4. Reassemble in the reverse order of dismantling.
Apply the following torques :

• 70 Nm
• 140 Nm
• 215 Nm
N.B.-:-E N SU R E T H E SP A C E R W A S H E R S A R E C O R R E C T L Y
POSITIONED ON THE PLATFORM SIDE. THEY MUST BE CENTRED IN
THE COUNTERBORES.
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. Check there are no foreign bodies (even small) between
the cell and the brackets.
4001055090 E 05.21 USA / GB 265

Jib
MS0078
5. Tighten the fastening screws successively 3 times with a

torque wrench.
Tightening recommendations :
• No lubrication on these screws.
• Tighten the screws crosswise.
• Tighten to the indicated final torque in 3 phases :
• Tighten to a third of the torque (impact wrench authorised without
exceeding one third of the torque).
• Tighten to 2 of the torque with a torque wrench.
• Tighten to nominal torque using a torque wrench.
• If tightened too much and not in a crosswise fashion, the weight indicator
will be damaged and will give incorrect results.
• Tighten the screws in the order 1, 2, 3, 4(See photo opposite).
• Proceed in the same way on the 2 sides.
6. Remember to re-install the pin connecting the link piece to

the platform bracket.
7. Fit the washer and circlip (circlip to be changed if stretched
when removing).
266 4001055090 E 05.21 USA / GB

Jib
MS0078
• Calibrate the load cell. MS0057 - Overload system.

4001055090 E 05.21 USA / GB 267

Jib
MS0078
Notes
268 4001055090 E 05.21 USA / GB

Upper boom
Remove/Re-install output compensation cylinder
MS0079
Upper boom
1- You will need

• Gloves
• Collars COLSON
• Grease for pins
• ORFS plug kit
work area
• Hydraulic oil
• 290 kg / 640 lbs load for static test
1
safety clothing.
equipment.
4001055090 E 05.21 USA / GB 269

Upper boom
MS0079
3- Dis-assembly

ea.
2. Raise the arm above the counterweight to remove the ac-
cess plate from the output compression cylinder.
1. Make a stable pallet stack about 700 mm / 28 in tall.

2. Put the platform on the pallets by using the jib function.
270 4001055090 E 05.21 USA / GB

Upper boom
MS0079
Relieve the pressure between the output compensation cylinder and the
compensation receiver cylinder. That prevents the shaft of the output
compensation cylinder from coming out while removing the shaft-side pin :
ceiver cylinder.
the fittings.
1. Place the platform on the pallets by releasing the tension

in the hoisting device.
2. Remove the 6 plate's fastening screws that give access to
the output compensation cylinder.

compensation cylinder.
4001055090 E 05.21 USA / GB 271

Upper boom
MS0079
1. Pull out the pin in the output compensation cylinder.

the pads.
the cylinder.
1. Locate, disconnect and plug the hoses supplying the out-

put compensation cylinder
272 4001055090 E 05.21 USA / GB

Upper boom
MS0079
1. Attach the cylinder to the bridge crane with the hoisting

strap.
1. Remove the stop clevis from the pin found on the back side
of the output compensation cylinder.
2. Pull out the pin.
4001055090 E 05.21 USA / GB 273

Upper boom
MS0079
1. Remove the cylinder.
4- Reassembly
1. If you are installing a new cylinder, note the traceability number.
2. Purge air from actuator :
• Re-install the cylinder and fit only the pin on the back side.
• Reconnect the hoses.
• From the lower control box, move the output compensation cylinder in and out without going right to the end stops.
• Pin the cylinder on the rod side.
4. Grease the pins and bores before refitting.
5. Remember to refit the axle locking pins and the immobilisation screws.
6. Check for the presence of seal on connections.
• From the lower control box, operate the platform compensation functions to flush out the hydraulic circuit.

• Machine unfolded, 15 mn after checking the performance of its parts : Arm cylinder, telescope cylinder, input
274 4001055090 E 05.21 USA / GB

Upper boom
Remove/Re-install input compensation cylinder
MS0080
Upper boom
1- You will need

• Gloves
• Collars COLSON
• Grease for pins
• ORFS plug kit
work area
• 1 ratcheting straps that support 1000 kg / 2,205 lbs at a length of 4 m
/ 13 ft / 1 in
• Hydraulic oil
• Wooden pallets
1
safety clothing.
equipment.
4001055090 E 05.21 USA / GB 275

Upper boom
MS0080
3- Dis-assembly

ea.
1. Place a wedge under the cylinder and attach the rod with
the ratchet strap.
276 4001055090 E 05.21 USA / GB

Upper boom
MS0080
1. Remove the locking pin on the shaft side then pull out the
pin.
2. Remove the strap and rest the cylinder on the wooden
wedge.
1. Start the ignition and retract the cylinder rod.

2. Locate and gently release the hoses that go to the receiv-
ing cylinder. As soon as a trickle of oil appears, let it flow
out. When there is no longer any residual pressure, dis-
connect the hoses and plug the connectors.
4001055090 E 05.21 USA / GB 277

Upper boom
MS0080
1. Bring the hoses up to the cylinder.
1. Remove the circlips. Ensure the cylinder does not slip for-
wards during extraction. Do not remove the pin used for
extraction without first holding the cylinder in place manu-
ally.
1. Remove the cylinder ( 2 people are required).
4- Reassembly
2. Carry out the operations in the reverse order. To pin the cylinder on the back side more easily, extend
the cylinder rod to give a longer lever arm.
3. Grease the pins and bores before refitting.
4. Remember to refit the locking pins in the pins, the immobilisation screws and the circlips.
278 4001055090 E 05.21 USA / GB

Upper boom
MS0080
• From the lower control box, operate the platform compensation functions to flush out the hydraulic circuit.

4001055090 E 05.21 USA / GB 279

Upper boom
MS0080
Notes
280 4001055090 E 05.21 USA / GB

Upper boom
Remove/Re-install jib cylinder
MS0081
Upper boom
1- You will need

• Gloves
• ORFS plug kit
• Pin diameter 30 mm / 1.18 in, length 500 mm / 20 in
• Pin diameter 25 mm / 1 in, length 300 mm / 12 in • Place barriers around the perimeter of the
• 1 ratcheting straps that support 1000 kg / 2,205 lbs at a length of 4 m work area
/ 13 ft / 1 in
• Hydraulic oil
• Grease for pins and rings
1
safety clothing.
Weight of the jib cylinder : 23 kg / 51 lbs
equipment.
4001055090 E 05.21 USA / GB 281

Upper boom
MS0081
3- Dis-assembly

ea.
2. With the arm and boom folded and the telescope retracted,
support the platform on pallets.
1. Locate, disconnect and plug the hoses supplying the jib

cylinder.
282 4001055090 E 05.21 USA / GB

Upper boom
MS0081
1. Strap the arm and jib tie-rods using a ratchet strap.
1. Remove the 2 end-play take up screws.
1. Withdraw the pin from the cylinder but leave the pin used
for withdrawal in place. Only remove it after removing the
pin on the rod side
1. Remove the rod-side clevis pin and remove the pin.
4001055090 E 05.21 USA / GB 283

Upper boom
MS0081
1. Hold the cylinder and remove the extraction pin on the

back side.
2. Slide the cylinder to free it of the ratchet strap.
3. Remove the cylinder.
4- Reassembly
2. Carry out the operations in the reverse order. To pin the cylinder on the back side more easily, extend
the cylinder rod to give a longer lever arm.
3. Grease the pins, the seals, and the bored holes.
4. Remember to refit the pin stop screws.
Ensure of the good hose path.
• From the ground control box, operate the cylinder to flush out the hydraulic circuit.

284 4001055090 E 05.21 USA / GB

Chassis
Remove/Re-install wheel reduction gear
MS0082
Chassis
1- You will need

• Gloves
• 1 hoisting strap(s) for 1000 kg / 2,205 lb at a length of 2 m / 6 ft 7 in
• Jack 10 tonnes / 22,05 lbs
• Wood wedges of approximately 400 mm / 16 in under the chassis • Place barriers around the perimeter of the
• Oil collection pan work area
• 1 syringe for oil filling
• Torque wrench : 260Nm
• 1" 1/16 socket
• 15/16" socket
• 5/16" - BTR socket
1
safety clothing.
• Wheel weight : 285 kg / 628 lbs
• Weight of the reduction gear : 53 kg / 117 lbs
• Weight of the wheel steering pivots : 33 kg / 73 lbs
equipment.
4001055090 E 05.21 USA / GB 285

Chassis
MS0082
3- Dis-assembly

ea.
2. The machine is completely folded, all of the movements
are at the mechanical stop
3. Switch off the ignition and remove the ignition key
1. Lift the machine with the jack to raise the wheel off the
ground.
2. Place a 400 mm / 16 in wedge under the chassis for safe-
ty.
1. Sling the wheel with the strap.
1. Remove the wheel and lay it down flat on a pallet with the
outer side downwards.
286 4001055090 E 05.21 USA / GB

Chassis
MS0082
1. Relive the pin connecting the steering tie-rod to the wheel

steering pivot.
2. Set the tie-rod aside.
1. Mark, disconnect and plug the drain and brake hoses on

the reduction gear.
4001055090 E 05.21 USA / GB 287

Chassis
MS0082
1. Unscrew the screws holding the motor on the reduction

gear.
2. Pull the motor, taking care not to damage the seals, and
attach it to the chassis.
1. Remove the greasers on the pins connecting the wheel

steering pivot to the chassis.
288 4001055090 E 05.21 USA / GB

Chassis
MS0082
2. Sling the steering pivot.

3. Remove the locking pin screws and withdraw the pins con-
necting the steering pivot to the chassis.
4001055090 E 05.21 USA / GB 289

Chassis
MS0082
4. Remove the steering pivot + reduction gear assembly.
Set aside the bronze washers.
5. Place the assembly on the ground.

6. Sling the assembly by the holes in the wheel steering piv-
ot.
7. Position the assembly on the wheel with the reduction
gear studs inserted into the rim.
290 4001055090 E 05.21 USA / GB

Chassis
MS0082
8. Loosen the 8 screws connecting the reduction gear to the

wheel steering pivot.
9. Remove the wheel steering pivot.
4- Reassembly
1. If the reduction gear has been replaced, note its traceabil-

ity number.
2. Remount in reverse order to removal.

3. Grease the pins when re-installing and comply with the tightening torque.
4001055090 E 05.21 USA / GB 291

Chassis
MS0082
4. Check state and presence of the seals on hydraulic motor.
292 4001055090 E 05.21 USA / GB

Chassis
MS0082
1. If the reduction gear has been replaced, check the oil lev-
el.
2. Fill the reduction gear if it is empty.
3. If the machine is still on wedges, disengage the reducer in
order to turn it manually.
4. Position the plugs correctly to fill up or top up with oil
• Manually release the reduction gear.
• Loosen the 2 screws from the central plate and turn it over to disengage
the reduction gear.
5. When the plate is in the correct position, the reduction

gear is disengaged from the brake.
4001055090 E 05.21 USA / GB 293

Chassis
MS0082
6. Turn the reduction gear to position the oil top-up, filling and
drain plugs.
7. The level can only be established when the plug is posi-
tioned in the horizontal axis of the reduction gear.
8. Remove the plug.
9. The oil should be just level with the hole.
10. Top up using the syringe if necessary
11. Remember to put the plate back into the correct position
once the operation is finished.
12. Grease the wheel steering pivot pins.
13. Clean off any residual oil or grease.
14. Move the steering and check that the hose movement
range is correct
15. Perform a travel test and check the stopping distance.
Perform a travel test and check the stopping distance. At
high speed, the machine must stop between 1,2 m (3,9 ft)
and 1,6 m (5,2 ft).
16. Check for any oil leaks.
294 4001055090 E 05.21 USA / GB

Turntable
Remove/Re-install slip ring (electric rotary coupling)
MS0083
Turntable
1- You will need

• Gloves
• Heat gun (To heat the heat-shrinkable sheath) • Place barriers around the perimeter of the work area
• Collars COLSON
• 1 hoisting strap(s) for 3000 kg / 6,615 lb at a length of 4
m / 13 ft 1 in
1
Weight of the jib cylinder : 23 kg / 51 lbs
equipment.
4001055090 E 05.21 USA / GB 295

Turntable
MS0083
4- Dis-assembly

ea.
2. With the arm and boom folded and the telescope retract-
ed, support the platform on pallets.
1. To remove the manifold, disconnect the CE01 and CE02

connectors.
296 4001055090 E 05.21 USA / GB

Turntable
MS0083
1. Bring the cable to the side of the turrent.
1. Using needle-nose pliers, remove the wedges in the wiring

harness connectors on the slip ring (electric rotary cou-
pling) side.
4001055090 E 05.21 USA / GB 297

Turntable
MS0083
1. Use a small flat screwdriver to push the tabs, then pull on

the wires to withdraw them from the connectors. Remove
the wires from the 2 connectors.
1. Correspondance between the location and the wire numbers on the connectors on the slip ring (elec-
tric rotary coupling) side :
298 4001055090 E 05.21 USA / GB

Turntable
MS0083
1. Correspondance between the location and the wire numbers on the connectors on the turret wiring
harness side :
1. Cut the heat-shrinkable sleeve as it will not fit through the

nut on the cable gland.
4001055090 E 05.21 USA / GB 299

Turntable
MS0083
1. Protect the wires with adhesive tape.
1. Unscrew the small hose and the protective sleeve in order

to be able to unscrew the cable gland nut at the hydraulic
rotary joint.
300 4001055090 E 05.21 USA / GB

Turntable
MS0083
1. Unscrew the plastic nut on the cable gland.

2. Remove the nut and the rubber seal from the cable.
1. Cut the collar and disconnect the 2 CE01 and CE02

plugs on the slip ring (electric rotary coupling) side.
1. Correspondance between the location and the wire numbers on the connectors on the slip ring (elec-
tric rotary coupling) side :
4001055090 E 05.21 USA / GB 301

Turntable
MS0083
1. Correspondance between the location and the wire numbers on the connectors on the chassis wiring
harness side :
1. Remove the rotation stop lug on the slip ring (electric rotary
coupling).
302 4001055090 E 05.21 USA / GB

Turntable
MS0083
1. Loosen the lockwasher.

2. Loosen the nut.
3. Fully release the slip ring (electric rotary coupling).

4. Pull the cable to withdraw it from the hydraulic rotary joint.
5- Reassembly
2. Remember to refit the rotation stop lug.
3. After running the cable through the plastic nut on the cable gland, fit the heat-shrinkable sleeve (de-
livered with the slip ring (electric rotary coupling)) on the upper cable.
4. Heat the sleeve using the heat gun.
5. Connect the plugs.
6. Attach the cables.
7. Refit the protective sleeve.
8. Connect the hose to the hydraulic rotary joint.
4001055090 E 05.21 USA / GB 303

Turntable
MS0083
• Test all the functions on the chassis part.
304 4001055090 E 05.21 USA / GB

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

• The tracker with its cable.
• A clamp to strip the wires.
• A clamp to crimp the wires. • Place barriers around the perimeter of the work area
1 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.
Step 3 :
• Take the wedgelock off the plug.
• Thread the wires in the positions regarding the information.
4001055090 E 05.21 USA / GB 305

Turntable
Universal plug
MS0133
C1 Universal connector
Pin 1 + permanent battery
Pin 2 GND (0 V)
Pin 3 + battery voltage
• Machine with engine : Engine ON information.
Pin 4
• Electrical machine : Movement and driving information.
Pin 5 Power ON information
Pin 6
Pin 7 Movement information (Flashing light option activation)
Pin 8 Driving information
Pin 9 CAN 1 H
Pin 10 CAN 1 L
Pin 11 CAN 2 H
Pin 12 CAN 2 L
N.B.-:-R EFER TO THE INSTRUCTIONS PROVIDED WITH THE TRACKER FOR THE WIRES CORRESPONDENCE .
DEPENDING OF THE TYPE OF UNIT, A RESISTANCE (200 OHMS, 1 W) MUST BE INTEGRATED BETWEEN SIGNAL AND
GROUND.
Step 4 :
• Put the wedgelock back on the plug to fix the pins.
Step 5 :
• Reconnect the plugs.
• Mount the tracker.
• The tracking device is operational.
306 4001055090 E 05.21 USA / GB

Chassis
Links to engine manufacturer manuals - Fuel-powered machines
MS0238
Chassis
1- Links to engine manufacturer manuals - Fuel-powered machines
For online reference and to download engine maintenance manuals for HAULOTTE® machines, go to :
https://www.e-technical-information.com :
• Username : Haulotte-Manuals
• Password : manuals
2- KUBOTA
V1505 – D1105 E3 Engine :

• In french : Manuel d'atelier 9Y111-00543
• In english : Workshop manual 9Y111-00126
V1505 – D1105 E4 Engine :

V2403 CR Engine :
V2403M Engine :
V2607 CR E4 Engine :
V2607 MT E3 Engine :
WG1605 Engine :
• In french : Manuel atelier moteur réf 4000208650
• In english : Workshop manual engine ref 4000208650
WG2503 Engine :
WG3800 Engine :
4001055090 E 05.21 USA / GB 307

Chassis
MS0238
WG972 Engine :
3- PERKINS
1104D Engine :
• In french : Manuel de l'opérateur Moteur PERKINS 1104D-44T
• In english : Operator's manual PERKINS engine type 1104D-44T
4- DEUTZ
TCD 2,9 L4 Engine :

• In french : Manuel de l'opérateur 03124630_10_2013
• In english : Operator's manual 03124628 en
5- KOHLER
KDI 3404 TCR Engine :

• In french : ED0053030060 UM_KDI_3404TCR_REV_00_FR_HD
• In english : ED0053030050 UM_KDI_3404TCR_REV_00_EN_HD
KDI 1903 TC - STAGE V Engine :

• In english : ED0053029490_UM_KDI_1903_2504TCR_REV_19_1_EN
• In french : ED0053029710_UM_KDI_1903_2504TCR_REV_19_1_FR
6- YANMAR
Range Extender P6000 :

• In english : Yanmar Operation Manual EN0016
308 4001055090 E 05.21 USA / GB

Chassis
Wheel tightening procedure
MP0001
Chassis
1- Concerned machines
• HA16 RTJ - HA16 RTJ O - HA16 RTJ PRO - HA46 RTJ O - HA46 RTJ PRO
• HA20 RTJ - HA20 RTJ O - HA61 RTJ O
2- Concerned area
3- Warning
4- Risk prevention
Safety shoes
4001055090 E 05.21 USA / GB 309

Chassis
MP0001
5- You will need

• "DO NOT OPERATE" tag
• Personal protective equipment
• Torque wrench
1 person
6- Procedure
• Put the machine in stowed position, boom and arm fully retracted and lowered.
• Mark out the work area (barriers, cones, marking tape).
• Restrict access to the area (restricted access sign).

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

• Check the tightening torque of the 8 studs : 215 N.m (159 lbf.ft).
310 4001055090 E 05.21 USA / GB

Chassis
MP0001
Chassis or wheel steering pivot / Reduction gear :

• Clean the work area.
4001055090 E 05.21 USA / GB 311

Chassis
MP0001
Notes
312 4001055090 E 05.21 USA / GB

Chassis
MP0001
Chassis
• HA20 RTJ PRO - HA61 RTJ PRO
• HT21 RT O - HT21 RT O SW - HT61 RT O - HT21 RT PRO - HT21 RT PRO SW - HT61 RT PRO - HT23 RTJ O -
HT23 RTJ O SW - HT67 RTJ O HT23 RTJ PRO - HT23 RTJ PRO SW - HT67 RTJ PRO
2- Concerned area
3- Warning
4- Risk prevention
Safety shoes Safety goggles
4001055090 E 05.21 USA / GB 313

Chassis
MP0001
5- You will need

• Torque wrench
1 person
6- Procedure

Wheel / Reduction gear :

314 4001055090 E 05.21 USA / GB

Chassis
MP0001
Chassis or wheel steering pivot / Reduction gear :

4001055090 E 05.21 USA / GB 315

Chassis
MP0001
Notes
316 4001055090 E 05.21 USA / GB

Chassis
Wheel reducer level procedure
MP0002
Chassis
• HA20 RTJ - HA20 RTJ O - HA61RTJ O
2- Warning
3- Risk prevention
Safety shoes
4- You will need

• Jack 20T
• Chocks 4000mm
1 person
4001055090 E 05.21 USA / GB 317

Chassis
MP0002
5- Consumables
Gear box oil SAE 80W90
Packaging Part number HAULOTTE®

Can 1L 4000530610
Can 20L 2420801370
Barrel 209L 2420801380
6- Procedure
6.1 - YOU HAVE A MEANS OF LIFTING THE MACHINE
• Lift the machine with the jack to raise the wheel off the ground.
• Place wedges under the chassis and lower the jack slowly.
• Disconnect the gear system :

• Loosen the 2 screws from the central plate and turn it over to
disengage the reduction gear.
318 4001055090 E 05.21 USA / GB

Chassis
MP0002
• Manually turn the wheel to position the filler cap to the top of
the vertical axis (1).
• Open the caps (1,2) :
• If the level is correct, oil should drain from the orifice (2).
• If not, add oil via the cap ( 1 ) using the syringe until oil flows
through the hole ( 2 ).
• Close the caps and wipe up any oil that has spilled on the floor.
6.2 - YOU DO NOT HAVE THE MEANS TO LIFT THE MACHINE
• Rotate the wheel, moving it slowly to place a filler cap at the top
of the vertical axis (1).
• Open the caps (1, 2) :
• Clean any oil traces.
4001055090 E 05.21 USA / GB 319

Chassis
MP0002
Notes
320 4001055090 E 05.21 USA / GB

Chassis
MP0002
Chassis
• HA20 LE - HA20 LE PRO - HA61 LE - HA61 LE PRO
• HA26 RTJ O - HA26 RTJ O SW - HA26 RTJ PRO - HA26 RTJ PRO SW - HA80 RTJ O - HA80 RTJ PRO
• HT26 RT O - HT26 RT O SW - HT28 RTJ O - HT28 RTJ O SW - HT28 RTJ PRO - HT28 RTJ PRO SW - HT80 RT
O - HT85 RTJ O - HT85 RTJ PRO
2- Warning
3- Risk prevention
Safety shoes
4- You will need

• Jack 20T
Place barriers around the perimeter of the work area
• Chocks 4000mm
1 person
4001055090 E 05.21 USA / GB 321

Chassis
MP0002
5- Consumables
Gear box oil SAE 80W90

Can 1L 4000530610
Can 20L 2420801370
Barrel 209L 2420801380
6- Procedure
6.1 - YOU HAVE A MEANS OF LIFTING THE MACHINE

• Loosen the 2 screws from the central plate and turn it over to
disengage the reduction gear.
• Manually turn the wheel to position the filler cap to the top of
the vertical axis (3).
• Re-tighten the central screw, close the caps and wipe any oil
that has spilled on the floor.
322 4001055090 E 05.21 USA / GB

Chassis
MP0002
6.2 - YOU DO NOT HAVE THE MEANS TO LIFT THE MACHINE
• Rotate the wheel, moving it slowly to place a filler cap at the top
of the vertical axis (1).
• It is level when the oil overflows from the hole ( 2 ).
• Clean any oil traces.
4001055090 E 05.21 USA / GB 323

Chassis
MP0002
Notes
324 4001055090 E 05.21 USA / GB

Turntable
Procedure for checking the level of engine oil
MP0003
Turntable
• HA20 RTJ - HA 20RTJ O - HA20 RTJ PRO - HA61 RTJ O - HA61 RTJ PRO
• HT16 RTJ O - HT16 RTJ PRO - HT46 RTJ O - HT46 RTJ PRO
2- Warning
• The engine exhaust gases contain harmful combustion products. Always start and run the engine in a
well ventilated area. In a closed room, ensure the exhaust gases are evacuated to the outside.
• Be sure to stop the engine before checking and changing the engine oil and the oil filter cartridge.
• Do not touch muffler or exhaust pipes while they are hot; Severe burns could result.
• Always stop the engine and allow it to cool before conducting inspections, maintenance, or for a cleaning
procedure.
• Contact with engine oil can damage your skin.
• If you come in contact with engine oil, wash it off immediately.
4001055090 E 05.21 USA / GB 325

Turntable
MP0003
3- Risk prevention
4- You will need

• Rags
1 person
5- Procedure

326 4001055090 E 05.21 USA / GB

Turntable
MP0003
• Check the engine oil level before starting or more than 5 minutes after
stopping the engine.
• Remove the oil level gauge, wipe it clean and reinstall it (4).
• Remove the gauge again :
• If the oil level is between the marks ( 1 ) and ( 2 ), the oil level is correct.
• If the oil level is lower than the minimum mark (1) :

• Remove the oil filling cap ( 3 ) and top up with new oil until it reaches the
correct level.
• After adding oil, wait more than 5 minutes and check the oil level again.
• If the level is still below the limit, repeat the operation.
4001055090 E 05.21 USA / GB 327

Turntable
MP0003
Notes
328 4001055090 E 05.21 USA / GB

Turntable
Replacing the engine oil filter
MP0004
Turntable
• HA20RTJ - HA20RTJ O - HA20RTJ PRO - HA61RTJ O - HA61RTJ PRO
2- Concerned area
3- Warning
• Be sure to stop the engine before checking and changing the engine oil and the oil filter cartridge.
• Do not touch muffler or exhaust pipes while they are hot; Severe burns could result.
• Always stop the engine and allow it to cool before conducting inspections, maintenance, or for a cleaning
procedure.
• Contact with engine oil can damage your skin.
• If you come in contact with engine oil, wash it off immediately.
4001055090 E 05.21 USA / GB 329

Turntable
MP0004
4- Risk prevention
5- You will need

• Oil filter wrench • Place barriers around the perimeter of the work area
• Rags
• Engine oil filter - 4000076270
• Container
1 person
6- Procedure

330 4001055090 E 05.21 USA / GB

Turntable
MP0004
• The oil cartridge is at the rear of the engine. To access it, swivel the
engine by removing the screw (1).
• Remove the oil filter ( 2 ) using a filter wrench.

• Apply a layer of clean oil to the seal of the new cartridge.
• Tighen the new cartridge by hand until it comes into contact, then tighten
through 3/4 of a turn using the wrench.
N.B.-:-AFTER REPLACING THE CARTRIDGE, THE OIL LEVEL FALLS

SLIGHTLY. REMEMBER TO CHECK THE LEVEL.
4001055090 E 05.21 USA / GB 331

Turntable
MP0004
Notes
332 4001055090 E 05.21 USA / GB

Turntable
Diesel filter replacement
MP0005
Turntable
2- Warning
3- Risk prevention
Safety shoes
4001055090 E 05.21 USA / GB 333

Turntable
MP0005
4- You will need

• Diesel filter cartridge - 4000079430
• Seals - 4000210630 - 4000079450
• Standard tool kit Place barriers around the perimeter of the work area
• Filter wrench
• Container
1 person
5- Procedure
• Place a do not operate tag at the start/stop switch location to inform personnel that the equipment is being worked on.
Dis-assembly :
• Set the handle of the separator to "OFF" (1).
• Loosen and remove the container ( 2 ) using a filter wrench.
• Remove the cartridge from the diesel filter (3).
Assembly :
• Clean the inside of the diesel filter jar (2).
• Replace the seal of the container ( 4 ) and reassemble in the reverse
order to disassembly.
• Apply a thin layer of fuel to the surface of the seal of the container (4).
• Tighten the container by hand then lock with the filter wrench.
• Open the fuel valve ( 1 ), setting it to "ON", and reboot the system using
the button behind the engine (5).
• Release the air by loosening the screw, then re-tightening it (6).
334 4001055090 E 05.21 USA / GB

Turntable
MP0005
Disconnecting the engine start sensor to reboot the pump is

recommended.
• Switch on the engine for a few moments and check that there are no fuel
leaks in the filter.
4001055090 E 05.21 USA / GB 335

Turntable
MP0005
Notes
336 4001055090 E 05.21 USA / GB

Turntable
Hydraulic oil filter replacement
MP0006
Turntable
2- Concerned area
3- Warning
4- Risk prevention
4001055090 E 05.21 USA / GB 337

Turntable
MP0006
5- You will need

• Filter replacement every year or every 1000 h
• Hydraulic filter cartridge - 2427003110
• Vacuum pump
• Rags
• Container
• Collection tray 1L
1 person
6- Procedure

338 4001055090 E 05.21 USA / GB

Turntable
MP0006
• Lift the boom to access the hydraulic filter.

• Place a container under the filter.
• Unlock the filter container using a wrench then unscrew by hand (1).
• Change the cartridge inside the container.
• Re-tighten the container by hand then tighten using a wrench to finish.
• Wipe away any run-off and check that the system has no leaks.
Perform the operation when it is at room temperature.
4001055090 E 05.21 USA / GB 339

Turntable
MP0006
Notes
340 4001055090 E 05.21 USA / GB

Turntable
Procedure for checking engine belt tension
MP0007
Turntable
2- Concerned area
3- Warning
4001055090 E 05.21 USA / GB 341

Turntable
MP0007
4- Risk prevention
Safety shoes
5- You will need

• Tools for checking belt tension
• Lever
1 person
6- Procedure
Do not start the engine and disconnect the battery.
• Remove the protective cover if there is not sufficient access ( 3 ).
342 4001055090 E 05.21 USA / GB

Turntable
MP0007
• Press halfway between the fan drive pulley and the alternator pulley with
a force of 98 N (10 kg) to measure the deflection( 1 ).
• The value measured must be between 7 mm and 9 mm.
• If the value is within this range, the tension is correct.
• If the value is not within this range :

• Loosen the fastening screw of the alternator (2).
• Adjust its position.
4001055090 E 05.21 USA / GB 343

Turntable
MP0007
Notes
344 4001055090 E 05.21 USA / GB

Chassis
Front axle locking function check
MP0008
Chassis
2- Concerned area
3- Warning
4- Risk prevention
Safety shoes
4001055090 E 05.21 USA / GB 345

Chassis
MP0008
5- You will need

150 mm / 5.9 in support that can support the weight of
the machine
1 person
6- Procedure
The front axles will oscillate when the boom is in transport position (i.e. when the boom is less than 15° above
horizontal and not extended beyond 30cm (12in) on the machine and drive is selected.
• Ensure the axles are extended and the boom is fully retracted, lowered,
and centered betweeen the rear wheels prior to beginning lockout
cylinder test.
• Place a ramp 15 cm (6 in) high in front of the front right wheel.
• From platform control box, start engine.
• Place the drive control lever to the forward position and carefully drive
machine up ascension ramp until left front wheels is on top of block.
• Carefully extend the boom just enough to get it out of the transport
position.
346 4001055090 E 05.21 USA / GB

Chassis
MP0008
• With boom in this position, place drive control lever to reverse and
carefully drive machine off of block and ramp.
• Have an assistant check to see that left front or right rear wheel remains
elevated in position off of the ground.
• Carefully return the boom to the transport position. When boom reaches
the transport position, carefully activate drive to release cylinders. To
lockout cylinders should release and allow the wheel to rest on ground.
This operation must be realized with extremes precautions by standing
strongly on the platform by the contact with the ground.
• Repeat the procedure for the right oscillation cylinder checking to see that the right front or left rear wheel remains
elevated in position off of the ground.
• If lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to any further
operation.
4001055090 E 05.21 USA / GB 347

Chassis
MP0008
Notes
348 4001055090 E 05.21 USA / GB

Turntable
Air filter replacement
MP0010
Turntable
2- Concerned area
3- Warning
4- Risk prevention
Safety shoes
4001055090 E 05.21 USA / GB 349

Turntable
MP0010
5- You will need

• Primary cartridge – 4000044230
• Secondary cartridge – 4000044240
1 person
6- Procedure

• Pull the pin and swivel the cover to remove it ( 1 ).
350 4001055090 E 05.21 USA / GB

Turntable
MP0010
• Remove the main element ( 2 ) and secondary element ( 3 ).

• Replace with new cartridges.
• Close the cover again using the pin ( 1 ).
Do not use oil.
4001055090 E 05.21 USA / GB 351

Turntable
MP0010
Notes
352 4001055090 E 05.21 USA / GB

Upper boom
Wear pad check
MP0011
Upper boom
Wear pad check
2- Concerned area
3- Warning
4- Risk prevention
Safety shoes
4001055090 E 05.21 USA / GB 353

Upper boom
Wear pad check
MP0011
5- You will need

• Grease
• Greasing the pads - 2326005410
• Wear pads kit - KITPATINHA20RTJ
1 person
6- Procedure
Front pads :
• Telescope of the boom slightly.
• Check the wear on the 4 upper and lower pads.
• If the chamfers ( 1 ) are visible on the pads, the pad is compliant.
• If the chamfers are not visible on the pads, replace the pads.
Rear pads :
• Retract the telescoping boom.
• Remove the plate on the back of the telescope.
354 4001055090 E 05.21 USA / GB

Upper boom
Wear pad check
MP0011
• Check the wear on the 4 upper and lower pads :

• If the chamfers ( 1 ) are visible on the pads, the pad is compliant.
• If the chamfers are not visible on the pads, replace the pads.
• Replace the plate.
4001055090 E 05.21 USA / GB 355

Upper boom
Wear pad check
MP0011
Notes
356 4001055090 E 05.21 USA / GB

Turntable
Hydraulic tank level
MP0013
Turntable
• HA32 RTJ PRO - HA100 RTJ PRO - HA41 RTJ PRO - HA130 RTJ PRO
• HT43 RTJ PRO - HT132 RTJ PRO
2- Warning
3- Risk prevention
Safety shoes
4001055090 E 05.21 USA / GB 357

Turntable
MP0013
4- You will need

• - 2505003830 Hydraulic oil
• Rags
1 person
5- Consumable
Reference Part number HAULOTTE®
Can - 5L, Standard oil HV46 4000530620
20L bucket, Standard oil HV46 2420801320
Barrel 209L, Standard oil HV46 2420801310
Barrel 209L, Oil - Winter option 2505002640
Barrel 209L, Organic oil 2820304310
6- Procedure
• Put the machine in stowed position, boom and arm fully retracted and lowered. Jib is in transportation position and
telescope is retracted.
• Check the filling level of the hydraulic tank.
• The oil level should be between the minimum and maximum levels.
• Open the hydraulic tank cap to refill the oil level.
N.B.-:-DO NOT FILL TO THE MAXIMUM LEVEL , AS THE OIL COULD

LEAK OUT.
358 4001055090 E 05.21 USA / GB

Turntable
Emptying the hydraulic tank
MP0014
Turntable
2- Concerned area
3- Warning
4- Risk prevention
4001055090 E 05.21 USA / GB 359

Turntable
MP0014
5- You will need

• Vacuum pump
• Funnel with a pipe of around 1 m / 3 ft 28 in
• 120 L / 32 gals canister for hydraulic oil collection
• Rags
• Hand pump
• 120 L / 32 gals tank
1 person
6- Consumable
Hydraulic oil
Reference Part number HAULOTTE®

Can - 5L, Standard oil HV46 4000530620
20L bucket, Standard oil HV46 2420801320
Barrel 209L, Standard oil HV46 2420801310
Barrel 209L, Oil - Winter option 2505002640
Barrel 209L, Organic oil 2820304310
7- Procedure
• Put the machine in stowed position, boom and arm fully retracted and lowered. Jib is in transportation position and
telescope is retracted.

360 4001055090 E 05.21 USA / GB

Turntable
MP0014
• Place a recipient under the hydraulic oil tank ( 1 ).
• Remove the drain plug ( 2 ) under the tank and allow the oil to fully drain
out.
N.B.-:-REMOVE THE FILLING CAP TO FACILITATE DRAINING (3).
• Refit and tighten the drain out ( 2 ).
4001055090 E 05.21 USA / GB 361

Turntable
MP0014
• Fill the tank with new oil.
N.B.-:-DO NOT FILL TO THE MAXIMUM LEVEL , AS THE OIL COULD

LEAK OUT.
• Run several cycles with the machine and ensure that the oil is between
the minimum and maximum level.
362 4001055090 E 05.21 USA / GB

Platform
Load cell tightness check
MP0015
Platform
2- Concerned area
3- Warning
4001055090 E 05.21 USA / GB 363

Platform
MP0015
4- Risk prevention
Safety shoes
5- You will need

• Torque wrench
• Torque multiplier
1 person
6- Procedure
Check the tightness of the jib-side load cell :

• Single load machine : Torque wrench for 215 Nm. Short 24 mm socket.
• Dual load machine : Torque wrench for 370 Nm. Short 30 mm socket.
N.B.-:-C HECK THE SCREWS IN LINE A TIGHTENING CROSSWISE

ORDER.
Check the tightness of the platform-side load cell :

• Single load machine : Torque wrench for 215 Nm. 24 mm pin with
extension.
• Dual load machine : Torque wrench for 370 Nm. 30 mm pin with
extension.
N.B.-:-C HECK THE SCREWS IN LINE A TIGHTENING CROSSWISE

ORDER.
364 4001055090 E 05.21 USA / GB

Platform
Rotary cylinder tightness check
MP0016
Platform
2- Concerned area
3- Warning
4001055090 E 05.21 USA / GB 365

Platform
MP0016
4- Risk prevention
Safety shoes
5- You will need

• Torque wrench
• Torque multiplier
1 person
6- Procedure

366 4001055090 E 05.21 USA / GB

Platform
MP0016
• Check the torque of the rotatory cylinder central nut is at 800 Nm

(590lbf.ft)
N.B.-:-USE A SPANNER AND A TORQUE SPANNER FOR TIGHTENING.
• Visually inspect the 8 screws on the rotary cylinder
N.B.-:-DO NOT TIGHTEN USING A TORQUE WRENCH AS THE SCREWS

ARE TIGHTENED WITH THREADLOCKER.
4001055090 E 05.21 USA / GB 367

Platform
MP0016
Notes
368 4001055090 E 05.21 USA / GB

Platform
Checking the platform
MP0017
Platform
2- Concerned area
3- Warning
4001055090 E 05.21 USA / GB 369

Platform
MP0017
4- Risk prevention
Safety shoes
5- You will need

• Personal protective equipment • Place barriers around the perimeter of the work area
1 person
6- Procedure
• Check the platform floor is mounted.
• Check the tightening torque of the 8 screws between the platform and
the platform mount 44 Nm.
370 4001055090 E 05.21 USA / GB

Platform
MP0017
• Check the platform access rail or gate.
4001055090 E 05.21 USA / GB 371

Platform
MP0017
Notes
372 4001055090 E 05.21 USA / GB

Turntable
Slew ring clearance check
MP0018
Turntable
2- Warning
3- Risk prevention
Safety shoes
4- You will need

• Magnetic piston comparator
1 person
4001055090 E 05.21 USA / GB 373

Turntable
MP0018
5- Procedure
Put the machine into the following configuration :

• No load in the platform.
• Boom raised as far as possible.
• Telescope retracted.
• Jib lifted as far as possible.
• Boom aligned.
• Fix the magnetic comparator between the chassis and turntable ( 100mm from the bearing aligned with the boom).
374 4001055090 E 05.21 USA / GB

Turntable
MP0018
• Using the magnetic comparator, read the clearance (J1) between the chassis and the turntable.

• Lower the arm to the lowest point.
• Jib platform assembly :
• Extend the telescope as far as possible.
• Boom aligned.
4001055090 E 05.21 USA / GB 375

Turntable
MP0018
The clearance between (J1) and (J2) must be less than 2 mm :

• If the clearance is greater than this, check that the tightness of the slew ring. Refer to MP0019 -
Serrage au couple de la couronne d'orientation.
• After checking the tightness, if the value remains greater than 2 mm, replace the slew ring
376 4001055090 E 05.21 USA / GB

Turntable
MP0018

• No load in the platform.
• Boom raised as far as possible.
• Telescope retracted.
• Jib lifted as far as possible.
• Turret at 90°.
4001055090 E 05.21 USA / GB 377

Turntable
MP0018
378 4001055090 E 05.21 USA / GB

Turntable
MP0018

• Lower the arm to the lowest point.
• Jib platform assembly :
• Extend the telescope as far as possible.
• Turret at 90°.
The clearance between (J3) and (J4) must be less than 2 mm :

• If the clearance is greater than this, check that the tightness of the slew ring. Refer to MP0019 -
Serrage au couple de la couronne d'orientation.
• After checking the tightness, if the value remains greater than 2 mm, replace the slew ring
4001055090 E 05.21 USA / GB 379

Turntable
MP0018
Notes
380 4001055090 E 05.21 USA / GB

Turntable
Torque tightening of the slew ring
MP0019
Turntable
2- Concerned area
3- Warning
4- Risk prevention
Safety shoes
4001055090 E 05.21 USA / GB 381

Turntable
MP0019
5- You will need

• Voltage absence tester
• Handling equipment
• Hose clamps
• Torque wrench
1 person
6- Procedure
• Position the machine on a flat and firm surface, clear of obstructions (beware of power lines)
• Lift the arm to access the ring's screw.

382 4001055090 E 05.21 USA / GB

Turntable
MP0019
Tightening the chassis / Slew ring :

• Check the tightening torque on the 18 screws: 215 N.m (159 ft.lbf).
These screws can be accessed by opening the side of the

chassis.
Tightening the turntable / Slew ring :

• Check the tightening torque on the 18 screws: 215 N.m (159 ft.lbf).
Check the tightness of the inaccessible screws using a spanner.
4001055090 E 05.21 USA / GB 383

Turntable
MP0019
Notes
384 4001055090 E 05.21 USA / GB

Turntable
Emptying the diesel tank
MP0020
Turntable
• HT21 RT O - HT21 RT O SW - HT61 RT O HT21 RT PRO - HT21 RT PRO SW - HT61 RT PRO - HT23 RTJ O -
HT23 RTJ O SW - HT67 RTJ O - HT23 RTJ PRO - HT23 RTJ PRO SW - HT67 RTJ PRO
2- Warning
3- Risk prevention
4- You will need

• Provide a container sufficient for the contents of the tank
• Rags
1 person
4001055090 E 05.21 USA / GB 385

Turntable
MP0020
5- Procedure
• Open the cover on the control box-side.
• Place a container under the diesel fuel tank.
386 4001055090 E 05.21 USA / GB

Turntable
MP0020
• Unscrew the drain plug from the diesel fuel tank.

• Allow the fuel to completely drain.
• Then rinse with clean diesel.
• Once drained, screw the drain plug back on (At 15 N.m).

• Fill the tank back up with fuel.
4001055090 E 05.21 USA / GB 387

Turntable
MP0020
Notes
388 4001055090 E 05.21 USA / GB

Turntable
Draining the cooling circuit
MP0021
Turntable
2- Warning
• 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.
• Do not stop the engine suddenly, stop it after about 5 minutes of unloaded idling.
• Work only after letting the engine and radiator cool off completely (more than 30 minutes after it has
been stopped).
• Do not remove the radiator cap while coolant is hot. Slightly loosen the cap when stationary, before
completely removing it
• If overheating occurs, steam may spout from the radiator or emergency tank. This could result in severe
burns.
4001055090 E 05.21 USA / GB 389

Turntable
MP0021
3- Risk prevention
Safety shoes
4- You will need

• 1 tube of around 1 m / 3 ft 28 in
• Collection tray 10L
• Coolant - Can 25L - 4000564860
1 person
N.B.-:-T HE WAY COOLING WATER AND ANTIFREEZE ARE MIXED VARIES DEPENDING ON THE PRODUCT
MANUFACTURER. IT MUST FUNDAMENTALLY BE IN LINE WITH STANDARD SAE J1034. FOR MORE DETAILS, SEE
SAE J814C.
Anti-freeze :
• Antifreeze volume in % : 50
• Solidification point : -37
• Boiling point : 108° C
390 4001055090 E 05.21 USA / GB

Turntable
MP0021
5- Procedure
• Stop the engine and leave the coolant to reach room temperature.
• Pivot the engine compartment.
• Remove the plug from the radiator ( 1 ) in order to fully drain the coolant
liquid.
N.B.-:-GENTLY UNSCREW THE RADIATOR PLUG TO RELEASE THE

PRESSURE.
4001055090 E 05.21 USA / GB 391

Turntable
MP0021
• Position the collection tray. Open the drain valve (2).
N.B.-:-IT IS ADVISABLE TO PLACE A PIPE BETWEEN THE DRAIN VALVE

AND THE COLLECTION TRAY.
• Remove the expansion bottle and empty it.

• Once all of the coolant liquid is drained, close the drain valve again.
• Fill with liquid through the radiator cap ( 1 ) and into the expansion tank
up to the maximum mark ( 3 ).
• Start the engine and leave it to turn over for a few minutes.
• Stop the engine and leave the coolant to reach room temperature.
• Check the coolant liquid level in the radiator and expansion tank ( 3 ).
N.B.-:-WHEN MIXING ANTI-FREEZE AND WATER, ENSURE THAT THE

PROPORTION OF ANTI-FREEZE IS 50%.
392 4001055090 E 05.21 USA / GB

Turntable
Starter battery inspection
MP0023
Turntable
• HT21RT O - HT21RT O SW - HT61RT O HT21RT PRO - HT21RT PRO SW - HT61RT PRO HT23RTJ O - HT23RTJ
O SW - HT67RTJ O HT23RTJ PRO - HT23RTJ PRO SW - HT67RTJ PRO
2- Warning
• 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.
3- Risk prevention
Safety shoes
4001055090 E 05.21 USA / GB 393

Turntable
MP0023
4- You will need

1 person
5- Procedure
• Open the engine cover.

• Remove screw ( 1 ) that is blocking the engine compartment.
• Pull then swivel the engine compartment.

• Lock the engine compartment using the locking lever ( 1 ).
394 4001055090 E 05.21 USA / GB

Turntable
MP0023
• Check battery terminals for oxidation.

• Check terminals for oxidation.
• Check battery terminals for cleanliness and tightness.
• Check that the battery is secure.
4001055090 E 05.21 USA / GB 395

Turntable
MP0023
Notes
396 4001055090 E 05.21 USA / GB

Turntable
Checking the bushings and pins
MP0024
Turntable
2- Warning
3- Risk prevention
Safety shoes
4- You will need

1 person
4001055090 E 05.21 USA / GB 397

Turntable
MP0024
5- Procedure
• Check the presence and the position of the rings.

• Check the absence of heavy abrasion, wear or oxidation of the rings.
• Check the absence of deformations, cracks or breakage of the rings.
Criteria of replacement : Replace as soon as the anomaly

indicated above appears.
398 4001055090 E 05.21 USA / GB

Turntable
MP0024
• Check the condition of the pins.
N.B.-:-IN CASE OF DOUBT : CHECK THE ABSENCE OF RADIAL GAP

> 0,5 MM (19690 IN) ON THE PINS.
• Check the absence of shaving in periphery of the pins.
Criteria of replacement : Replace as soon as the anomaly

indicated above appears.
4001055090 E 05.21 USA / GB 399

Turntable
MP0024
Notes
400 4001055090 E 05.21 USA / GB

Turntable
Checking the condition of belts
MP0025
Turntable
2- Warning
3- Risk prevention
Safety shoes
4- You will need

1 person
4001055090 E 05.21 USA / GB 401

Turntable
MP0025
5- Procedure
• Check the degree of wear on the fan belt.

• Check the subsidence of the belt in the pulley groove :
(A) Proper.
(B) Wear.
• Replace it/them if necessary.
402 4001055090 E 05.21 USA / GB

Turntable
Checking and cleaning the fuel filter
MP0026
Turntable
2- Warning
3- Risk prevention
Safety shoes
4001055090 E 05.21 USA / GB 403

Turntable
MP0026
4- You will need

• Filter wrench
1 person
5- Procedure
• Check whether the water and dirt contained in the fuel has been
decanted into the water separator.
• If there are no impurities in the water: no action to be taken.
• If there are impurities or water in the bottom of the container :
• Set the handle of the separator to "OFF" (1).
• Loosen and remove the container ( 2 ) using a filter wrench ; Clean with
diesel.
• Clean the filtering part with diesel.
• Replace the filtering element with diesel protected from dust.
• Re-tighten the container ( 2 ) then reboot the system using the button at
the back of the engine ( 3 ).
• Release the air by loosening the screw, then re-tightening it (4).
404 4001055090 E 05.21 USA / GB

Chassis
Steering system greasing
MP0027
Chassis
2- Warning
3- Risk prevention
Safety shoes
4- You will need

• Grease pump
1 person
4001055090 E 05.21 USA / GB 405

Chassis
MP0027
5- Consumable
Lead-free grease

Aerosol 0.4L 2820304330
Can 5L 2820304340
6- Procedure
On each of the steering wheels :

• Place the grease pump on each of the two greasers located between the
steering pivot and the chassis.
• There is enough grease when you can see grease running from the axle.
• Place the grease pump on the two greasers located on the tie rod.
406 4001055090 E 05.21 USA / GB

Upper boom
Greasing the pads
MP0028
Upper boom
Greasing the pads
2- Warning
3- Risk prevention
Safety shoes
4- You will need

• Grease brush
1 person
5- Consumable
Teflon grease aerosol

Aerosol 400ml 2326005410
4001055090 E 05.21 USA / GB 407

Upper boom
Greasing the pads
MP0028
6- Procedure
• Fully extend the boom (1).

• Clean the greased surfaces.
• Apply the Teflon grease to the boom using a spray or brush.
408 4001055090 E 05.21 USA / GB

Turntable
Jib cylinder lubrication
MP0029
Turntable
2- Warning
3- Risk prevention
Safety shoes
4- You will need

• Grease pump
1 person
5- Consumable
Lead-free grease

Aerosol 0.4L 2820304330
Can 5L 2820304340
4001055090 E 05.21 USA / GB 409

Turntable
MP0029
6- Procedure
• Place the grease pump on each of the two greasers at the ends of the jib
cylinder.
The top greaser is at the rear of the cylinder pin.
410 4001055090 E 05.21 USA / GB

Turntable
Cleaning of air cleaner element
MP0030
Turntable
2- Warning
3- Risk prevention
Safety shoes
4- You will need

• Air compressor
1 person
4001055090 E 05.21 USA / GB 411

Turntable
MP0030
5- Procedure
• Turn on the engine.

• Check the clogging indicator ( 1 ).
• If the LED is green, the filter does not need to be changed.
• If the LED turns red :
• Remove the drain valve, let the particles escape then refit it ( 4 ).
• Pull the pin ( 2 ) and swivel the cap to remove it.
• Remove the main element ( 3 ).

• Blow the inside of the main element ( 3 ) with clean and dry compressed
air. Pressure of compressed air must be under 205 kPa (2,1 kgf/cm
2,30 psi).
• Remove the main element ( 3 ). Close the cover again using the
pin ( 2 ).
Do not use oil.
Do not touch the secondary element unless it has to be

replaced.
412 4001055090 E 05.21 USA / GB

Turntable
Coolant level
MP0031
Turntable
Coolant level
2- Warning
3- Risk prevention
Safety shoes
4- You will need

• Coolant -37°, Can 25L - 4000564860
1 person
4001055090 E 05.21 USA / GB 413

Turntable
Coolant level
MP0031
5- Procedure
Before unscrewing the cooling system filler cap, shut off the
engine and wait for the parts of the cooling system to cool down.
Then slowly unscrew the cooling system filler cap to release the
pressure :
• Check that the cooling liquid sits between the maximum ( 1 ) and
minimum ( 2 ) levels of the expansion vessel.
• If the cooling liquid level is too low, find out why this is the case.
Case 1 :
Evaporation has lowered the cooling liquid level: top up with

clean fresh water only.
Case 2 :
A leak has lowered the cooling liquid level: top up with a cooling
liquid with the same brand and reference number using the
recommended mixing ratio (clean fresh water and L.L.C.).
If it is not possible to identify the brand of coolant, drain it and add

a new coolant mixture.
414 4001055090 E 05.21 USA / GB

Turntable
Replace the belt
MP0032
Turntable
Replace the belt
• HA16RTJ - HA16RTJO - HA16RTJ PRO - HA46RTJO - HA46RTJ PRO
2- Warning
3- Risk prevention
Safety shoes
4- You will need

• Belt 4000210820
1 person
4001055090 E 05.21 USA / GB 415

Turntable
Replace the belt
MP0032
5- Procedure
• Remove the protective cover if there is not sufficient access ( 3 ).
• Loosen the alternator using the screw ( 2 ).
• Remove the fan belt ( 1 ).

• Replace the belt with a new one.
• Refit the alternator.
• Check the belt deflection to tighten it correctly :
• Press halfway between the fan drive pulley and the alternator pulley with
a force of 98N (10 kg) to measure the deflection (1).
• The value measured must be between 7 mm and 9 mm.
• If the value is within this range, the tension is correct.
• If the value is not within this range :
• Loosen the fastening screw of the alternator (2).
• Adjust its position.
416 4001055090 E 05.21 USA / GB

Turntable
Drain the engine oil
MP0036
Turntable
2- Warning
3- Risk prevention
Safety shoes
4- You will need

1 person
4001055090 E 05.21 USA / GB 417

Turntable
MP0036
5- Consumables
Engine oil 15W40

Can 5L 4000530600
20L bucket 2420801360
Barrel 209L 2820305720
6- Procedure
• Start the engine and leave it to turn over for a few minutes.
Shut off the engine before draining the engine oil.
• Place a container under the engine.

• Remove the drain plug ( 1 ) under the engine and leave the oil to drain
out completely.
• Refit and tighten the drain out ( 1 ).
418 4001055090 E 05.21 USA / GB

Turntable
MP0036
• Open the cap ( 2 ) and fill the engine with new oil until it reaches the
upper mark of the gauge ( 3 ).
Do not touch the hot parts of the engine.
4001055090 E 05.21 USA / GB 419

Turntable
MP0036
Notes
420 4001055090 E 05.21 USA / GB

Turntable
Greasing the cage rotation cylinder
MP0037
Turntable
2- Warning
3- Risk prevention
Safety shoes
4- You will need

• Grease pump
1 person
4001055090 E 05.21 USA / GB 421

Turntable
MP0037
5- Consumables
Lead-free grease

Aerosol 0.4L 2820304330
Can 5L 2820304340
6- Procedure
• Place the grease pump on the greasers located under the basket
rotation cylinder pin.
422 4001055090 E 05.21 USA / GB

Turntable
Draining the wheel reducer
MP0043
Turntable
• HA20 RTJ - HA20 RTJ O - HA61 RTJ O
2- Warning
3- Risk prevention
Safety shoes
4- You will need

• Jack 20T
• Chocks 4000mm • Place barriers around the perimeter of the work area
• Filling syringe
• Collection tray 1.5L
1 person
4001055090 E 05.21 USA / GB 423

Turntable
MP0043
5- Consumable
Gear box oil SAE 80W90 - Quantity 1.1L

Can 1L 4000530610
Can 20L 2420801370
Barrel 209L 2420801380
6- Procedure
You have a means of lifting the machine :


the reduction gear.
• Manually turn the wheel to place the drain plug to the bottom of the
vertical axis ( 2 ) and the other horizontal ( 1 ).
• Position the oil collection tray under the plug ( 2 ).
• Open the caps (1, 2).
• Allow the liquid to drain completely ; To make the flow easier, the oil
should still be hot.
424 4001055090 E 05.21 USA / GB

Turntable
MP0043
• Manually turn the wheel to position the filler cap to the top of the vertical
axis (1).
• Add the oil via the hole ( 1 ) using a syringe until the oil flows from the
hole ( 2 ).
• Quantity 1.1L.
You do not have the means to lift the machine :

• Turn the wheel slowly to place a drain plug to the bottom of the vertical
axis ( 2 ) and the other horizontal ( 1 ).
• Rotate the wheel, moving it slowly to place a filler cap at the top of the
vertical axis (1).
hole ( 2 ).
• Quantity 1.1L.
4001055090 E 05.21 USA / GB 425

Turntable
MP0043
Notes
426 4001055090 E 05.21 USA / GB

Turntable
MP0043
Turntable
2- Warning
3- Risk prevention
Safety shoes
4- You will need

• Jack 20T • Place barriers around the perimeter of the work area
• Chocks 4000mm
• Filling syringe
• Collection tray 1.5L
1 person
4001055090 E 05.21 USA / GB 427

Turntable
MP0043
5- Consumable
Gear box oil SAE 80W90 - Quantity 1.1L

Can 1L 4000530610
Can 20L 2420801370
Barrel 209L 2420801380
6- Procedure
You have a means of lifting the machine :


the reduction gear (1).
• Manually turn the wheel to place the drain plug to the bottom of the
vertical axis ( 2 ) and the other horizontal ( 3 ).
428 4001055090 E 05.21 USA / GB

Turntable
MP0043
• Manually turn the wheel to position the filler cap to the top of the vertical
axis (3).
hole ( 2 ).
• Quantity 1.1L.
• Retighten the 2 central plate screws ; Close the caps and wipe up any
oil that has spilled on the floor.
You do not have the means to lift the machine :

• Turn the wheel slowly to place a drain plug to the bottom of the vertical
axis ( 2 ) and the other horizontal ( 1 ).
• Rotate the wheel, moving it slowly to place a filler cap at the top of the
vertical axis (1).
hole ( 2 ).
• Quantity 1.1L.
4001055090 E 05.21 USA / GB 429

Turntable
MP0043
Notes
430 4001055090 E 05.21 USA / GB

Turntable
Greasing the turntable rotation gearbox
MP0044
Turntable
2- Warning
3- Risk prevention
4- You will need

• "DO NOT OPERATE" tag • Place barriers around the perimeter of the work area
• Grease pump
• Brush
1 person
4001055090 E 05.21 USA / GB 431

Turntable
MP0044
5- Consumable
Lead-free grease

Aerosol 0.4L 2820304330
Can 5L 2820304340
Extreme-pressure lithium grease

Extreme-pressure lithium grease 2820304320
6- Procedure
• Place the grease pump on each of the 3 greasers located on the worm
screw system :
• Lead-free grease.
• Place the grease pump on each of the 2 greasers located inside the
slew ring :
• Lead-free grease.
Lift the arm in order to access the 2 greasers.
• Grease the slew ring using a brush :

• Extreme-pressure lithium grease.
In order to grease the slew ring well, pivot the turntable several
times to access all of the teeth.
432 4001055090 E 05.21 USA / GB

E - Trouble shooting and diagram
Trouble shooting and diagram

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

• There is sufficient fuel.
• Sufficient engine oil.
• Sufficient hydraulic oil in the tank.
• Batteries are charging.
• Control box E-stop push-buttons are pulled out.
• The control box selector key is set to platform or ground control box.
• Control box relays are engaged.
• Fuse status.
• Ground control box solenoid valve status.
If the malfunction persists, consult the troubleshooting table to identify the problem.
IF you cannot identify the problem, contact HAULOTTE Services®.
1.2 - DESCRIPTION
The FAILURES function describes the requirements relative to failures : monitoring, information
recording, information reading.
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
FAIL_xx_002
inactive
A code CODE is linked to failures which have several causes of activation to identify the one of activation (if
FAIL_xx_003
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
FAIL_xx_004
power off
FAIL_xx_005 The failure log and failure counter are changed for a failure which internal code is changed
N.B.-:- VAR[ACTIVEFAILURE] = 1 IF ONE OR MORE OF THE FOLLOWING FAILURES ARE IN ACTIVE STATE
4001055090 E 05.21 USA / GB 433

1.4 - FAILURES LIST

1.4.1 - List of failures per category
Failures N C Description
Contactors
• Digital output's failure : Emergency pump relay.
F02.02 --> KM120=FAIL
Emergency Pump D • Check relay.
KM120 • Check connection to ground.
• Check connection to U106 ECU.
• Incoherence between the emergency stop status and the presence of voltage on power
line.
--> EMSTOP=0 & (12VD1>8.00V | 12VD2>8.00V | 12VD3>8.00V | 12VD4>8.00V |
F02.04
12VD5>8.00V | 12VF1>8.00V | 12VF2>8.00V | 12VF3>8.00V | 12VF4>8.00V)
Power Contactor D
• Check emergency stop.
KMP
• Check relay KMP.
• Check fuses.
• Check wiring.
• Digital output's failure : Preheating relay.
F02.05 --> KM160=FAIL & CFG[Engine]=TierIII V2403-M
Heating Relay D • Check relay.
KM160 • Check connection to ground.
Relays
• Digital output's failure : Horn relay.
F03.06 --> KA9=FAIL
Horn Relay D • Check relay.
KA9 • Check connection to ground.
• Digital output's failure : Starter relay.
F03.08 --> KA4=FAIL
Start Relay D • Check relay.
KA4 • Check connection to ground.
• Digital output's failure : Engine supply relay.
F03.09
--> KA3=FAIL
Supply/Key Switch
D • Check relay.
Rel • Check connection to ground.
KA3 • Check connection to U106 ECU.
• Digital output's failure : Generator relay failure while generator on (And failure is not low
current).
F03.11
--> KA2=FAIL& SETP[Generator]=ON
Generator Relay D
• Check relay.
KA2
• Check connection to ground.
• Digital output's failure : Gasoline/LPG selector relay.
F03.13
--> KA140=FAIL & CFG[Engine]= TierIII WG2503 GL
Gasoline/LPG
D • Check relay.
selector Relay • Check connection to ground.
KA140 • Check connection to U106 ECU.
434 4001055090 E 05.21 USA / GB

Electrovalves
• For each failure, check the internal code.
For failures about digital electro valves controlled by the U104 ECU (platform slave ECU) :
• The detected failures are "open circuit" or "short circuit", check the harness between the ECU and the hydraulic block controlling
the movement, check the valves.
For failures about proportional or digital electro valves controlled by U106 ECU (turret master ECU) :
• The detected failures are open circuit ( OC), short-circuit to VBAT (SC+) , short-circuit to GROUND ( SC-), low current ( LC) and
power supply error ( PSE)
• First check the type of failure by reading the status of the output in the menu "INPUTS-OUTPUTS => DIGITAL OUTPUTS /
ANALOGUE OUTPUTS".
If OC/SC+/SC-/LC :
• check harness, check there is no misconnection between signal and ground supply or power supply.
If PSE :
• Check the supplies are well connected : 12VD1 (1B.18), 12VD2 (2A.08), 12VD3 (2B.02), 12VD4 (3A.01), 12VF1 (1B.32), 12VF2
(2A.07), 12VF4 (3A.07).
For steering (movement and mode), drive (speed), differential lock, brake releasing and oscillating axle electro valves :
• Check the connections through the electrical collector.
Proportional output's failure : Steering movement (with or without movement).
1
--> YV900=FAIL
F04.01
Digital output's failure : Left steering movement (with or without movement).
Steering D 2
--> YV150L=FAIL
YV900/150L/150R
Digital output's failure : Right steering movement (with or without movement).
4
--> YV150R=FAIL
Proportional output's failure : Basket level movement (with or without movement).
1
--> YV900=FAIL
F04.02
Digital output's failure : Platform level raise movement (with or without movement).
Compensation D 2
--> YV720U=FAIL
YV900/720U/720D
Digital output's failure : Platform level descent movement (with or without movement).
4
--> YV720D=FAIL
Proportional output's failure : Turntable rotate movement (with or without movement).
1
--> YV250=FAIL
F04.03
Digital output's failure : Turntable rotate left movement (with or without movement).
Turret rotation D 2
--> YV250L=FAIL
YV250/250L/250R
Digital output's failure : Turntable rotate right movement (with or without movement).
4
--> YV250R=FAIL
Proportional output's failure : Arm movement (with or without movement).
1
--> YV420=FAIL
F04.04
Digital output's failure : Arm lifting movement (with or without movement).
Arm D 2
--> YV420U=FAIL
YV420/420U/420D
Digital output's failure : Arm lowering movement (with or without movement).
4
--> YV420D=FAIL
Proportional output's failure : Boom movement (with or without movement).
1
--> YV520: Boom lifting proportional electrovalve failure.
F04.05
Digital output's failure : Boom lifting movement (with or without movement).
Boom D 2
--> YV520U=FAIL
YV520/520U/520D
Digital output's failure : Boom lowering movement (with or without movement).
4
--> YV520D=FAIL
Proportional output's failure : Telescope movement (with or without movement).
1
--> YV530=FAIL
F04.06
Digital output's failure : Telescope extension movement (with or without movement).
Telescope D 2
--> YV530O=FAIL
YV530/530O/530I
Digital output's failure : Telescope retraction movement (with or without movement).
4
--> YV530I=FAIL
4001055090 E 05.21 USA / GB 435

Electrovalves
Proportional output's failure : Jib movement (with or without movement).
1
--> YV900: Jib lifting proportional electrovalve.
F04.07
Digital output's failure : Jib lifting movement (with or without movement).
Jib D 2
--> YV620U: Jib raise digital electrovalve failure.
YV900/620U/620D
Digital output's failure : Jib lowering movement (with or without movement).
4
--> YV620D: Jib raise digital electrovalve failure.
Proportional output's failure : Platform rotation movement (with or without movement).
1
--> YV900=FAIL
F04.08
Digital output's failure : Platform rotation left movement (with or without movement).
Cage Rotation D 2
--> YV750L: Cage rotation left digital electrovalve failure.
YV900/750L/750R
Digital output's failure : Platform rotation right movement (with or without movement).
4
--> YV750R: Cage rotation right digital electrovalve failure.
• Proportional output's failure : Drive movement while driving.
--> YV160=FAIL
• YV160 is supplied powered via the YV160S output from U106 ECU during 2 s (once) at
1 startup and when drive is running. Otherwise YV160 is not supplied and then seen as
failing.
• Check YV160 : Connection to ground (pin3), and to U106 ECU (pin1), to YV160S (pin4).
• Check YV160S : Connection to YV160 electrovalve (pin4).
• Digital output supplying the PVG while driving is failing.
--> YV160S=FAIL
F04.10
Drive D
2 startup and when drive is running. Otherwise YV160 is not supplied and then seen as
YV160/160S/160FA
failing.
• Check YV160 : Connection to ground (pin3), and to U106 ECU (pin1), to YV160S (pin2).
• Check YV160S : Connection to YV160 electrovalve (pin2).
• Failure indicator for PVG is active.
--> YV160FA :
• Failure indicator provided by PVG component, mechanical problem detected.
4
startup and when drive is running. Otherwise YV160 is not supplied and then seen as
failing.
• Digital output's failure : LS valve (HSD).
--> YV800=FAIL
1 • See §LS Valve : YV800 and YV800G are activated when drive, steering or movement(s)
F04.11 are running.
Principal • Otherwise YV800 and YV800G are not connected and then seen as failing.
D
movements • Digital output's failure : LS valve ground supply (LSD).
Check YV800 --> YV800G=FAIL
2 • See §LS Valve : YV800 and YV800G are activated when drive, steering or movement(s)
are running.
• Otherwise YV800 and YV800G are not connected and then seen as failing.
436 4001055090 E 05.21 USA / GB

Electrovalves
• Digital output's failure : Drive middle and high speed.
--> YV112=FAIL
1 • Check YV112/YV114 : Check valves, check connection between the two U106 ECU
outputs ( 690 wire), check connection to electrical collector, check connection between
electrical collector and electro valves, check connections to ground.
--> YV113=FAIL
2 • Check YV113/YV115 : Check valves, check connection between the two U106 ECU
--> YV114=FAIL
4 • Check YV112/YV114 : Check valves, check connection between the four U106 ECU
F04.20 electrical collector and electro valves, check connections to ground.
Drive Speed D
YV111..YV115
--> YV115=FAIL
• Digital output's failure : Drive high speed.
--> YV110=FAIL
• Digital output's failure : Drive high speed.
--> YV111=FAIL
• Digital output's failure : Differential locking.
F04.21 --> YV100=FAIL
Differential locking D • Check YV100 : Check valves, check connection to U106 ECU outputs ( 689 wire), check
YV100 connection to electrical collector, check connection between electrical collector and electro
valves, check connections to ground.
• Digital output's failure : Steering mode with 4 wheels steering option activated.
--> YV107=FAIL & VAR[4WSEnable]
1 • Check YV107/YV108 : Check valves, check connection to U106 ECU outputs ( 621/622
wire), check connection to electrical collector, check connection between electrical collector
F04.33 and electro valves, check connections to ground.
Steering mode D
• Digital output's failure : Steering mode with 4 wheels steering option activated.
YV107/YV108
--> YV108=FAIL & VAR[4WSEnable]
2 • Check YV107/YV108 : Check valves, check connection to U106 ECU outputs ( 621/622
wire), check connection to electrical collector, check connection between electrical collector
and electro valves, check connections to ground.
4001055090 E 05.21 USA / GB 437

Electrovalves
• Digital output's failure : Oscillating axle unlocking with oscillating axle option.
--> YV101=FAIL& VAR[OscillatingAxleEnable]
1 • Check YV101 : Check connection to ground, check connection to U106 ECU digital
output, check connection to electrical collector, check connection between electrical
collector and electroalve.
• Detection of incoherence between the state of control for oscillating axle and pressure in
the oscillating axle control valve when drive control is above the third of maximum control.
--> YV101=ON & D2000ms((WUI-SP109)<1500mV) & VAR[OscillatingAxleEnable]
• Check YV101 : Check connection to ground, check connection to U100 ECU digital
output, check connection to electrical collector, check connection between electrical
collector and electrovalve.
2 • Check SP109 : Check connection to ground, check connection to U100 ECU digital input,
F04.34
check connection to electrical collector, check connection between electrical collector and
Front Axle
D electrovalve.
Unlocking • Check also minimum speed for both directions (when reaching the third of the joystick’s
YV101 stroke on front direction, drive must be effective “wheels are turning to front direction” / when
reaching the third of the joystick’s stroke on reverse direction, drive must be effective “wheels
are turning to reverse direction”).
• Detection of incoherence between the state of control for oscillating axle and pressure in
the oscillating axle control valve : Control is OFF and detection of pressure.
--> YV101=OFF & D2000ms((WUI-SP109)>1100mV) & VAR[OscillatingAxleEnable]
• Check YV101 : Check connection to ground, check connection to U100 ECU digital
4 output, check connection to electrical collector, check connection between electrical
collector and electroalve.
• Check SP109 : Check connection to ground, check connection to U100 ECU digital input,
electro valve.
• Digital output's failure : Brake releasing.
--> YV102=FAIL
1 • Check YV102 : Check connection to U106 ECU outputs ( 782 wire), check connection to
electrical collector, check connection between electrical collector and electrovalve, check
F04.35 connections to ground.
Brake Releasing D
• Digital output's failure : Brake releasing with 4 wheels steering option activated.
YV102/YV105
--> YV105=FAIL& VAR[4WSEnable]
2 • Check YV105 : With 4WS activated, check connection to U106 ECU outputs ( 783 wire),
electrovalve, check connections to ground.
438 4001055090 E 05.21 USA / GB

Joysticks
The following joysticks’ failures are relevant if failure F08.05 is not active (failure of 5 V supplying signal). First check the 5 V
supplying the joysticks, then the harness between ECU and joysticks.
Drive joystick failure : Out of range [0.2.4.8] V.
1
--> SM902Y < 0.20V | SM902Y > 4.80V
F05.01
Drive joystick failure : Analogue signal and out of neutral incoherence.
Drive Joystick D
--> (SM902F = 1 | SM902B = 1) & (2.45V < SM902Y < 2.55V)
SM902Y 2
--> Or SM902F = 0 & SM902Y < 2.00V
--> Or SM902B = 0 & SM902Y > 3.00V
Arm joystick failure : Out of range [0.2..4.8] V.
1
F05.02 --> SM901Y < 0.20V | SM901Y > 4.80V
Arm Joystick D Arm joystick failure : Analogue signal and out of neutral incoherence.
SM901Y 2 --> SM901N = 1 & (2.45V < SM901Y < 2.55V
--> Or SM901N = 0 & (SM901Y < 2.00V | SM901Y>3.00V
Boom joystick failure : Out of range [0.2..4.8] V.
1
--> SM900Y < 0.20V | SM900Y > 4.80V
F05.04
Boom joystick failure : Analogue signal and out of neutral incoherence.
Boom Joystick D
--> SM900N = 1 & (2.45V < SM900Y < 2.55V) & (2.45V < SM900X < 2.55V)
SM900Y 2
--> Or SM900N = 0 & (SM900Y < 2.00V & SM900Y > 3.00V) & (SM900X < 2.00V | SM900X
> 3.00V)
Turret rotation joystick failure : Out of range[0.2..4.8] V.
1
--> SM900X < 0.20V | SM900X > 4.80V
F05.05 Turret rotation joystick failure : Analogue signal and out of neutral incoherence.
Turret Joystick D Boom joystick failure : Analogue signal and out of neutral incoherence.
SM900X 2 --> SM900N = 1 & (2.45V < SM900Y < 2.55V) & (2.45V < SM900X < 2.55V)
--> Or SM900N = 0 & (SM900Y < 2.00V | SM900Y > 3.00V) & (SM900X < 2.00V | SM900X >
3.00V)
F05.11 No detection of joystick's neutral position at machine's power-on. --> SM902Y < 2.3V |
Joystick neutral A SM902Y > 2.65V
SM902Y Release joystick / Check joystick.
F05.12 No detection of joystick's neutral position at machine's power-on. --> SM901Y < 2.3V |
Joystick neutral 2 A SM901Y > 2.65V
SM901Y Release joystick / Check joystick.
F05.13 No detection of joystick's neutral position at machine's power-on. --> SM900X < 2.35V |
Joystick neutral 3 A SM900X > 2.65V | SM900Y < 2.35V | SM900Y > 2.65V
SM900X/Y Release joystick / Check joystick.
4001055090 E 05.21 USA / GB 439

Weighing system
F06.01 No overload calibration, do/redo overload calibration.
No Loading Cal A VAR[GaugesNotCalibrated]=1
Calibrate Complete calibration.
Gauges out of range (load management system activated).
--> SP800 Not in [1500; 20500]µA.
F06.03 1
VAR[GaugesOutOfRange]=1
Gauges out of Check SP800 connections to ground, to U104 ECU analogue inputs.
D
Range
Gauges out of range (load management system activated).
SP800/SP801
2 --> SP801 Not in [1500; 20500]µA.
Check SP801 connections to ground, to U104 ECU analogue inputs.
SP800 measured weight and SP801 measured weight are more than 50kg far (and gauges
F06.04 are not out of range and gauges are calibrated).
Incoh Gauges D VAR[GaugesIncoherent]=1
SP800/SP801 Check SP800 and SP801 connections to ground, to U104 ECU analog inputs.
Redo calibration.
F06.05
Low power for strain gauges is detected low : VbattB2 basket is under 8500 V.
Low Power D
Check gauge's power supply.
Gauges supply
Negative load (<-40kg) :
1.Gauge 1 measures negative load below -40kg VAR[WeightSP800] < -40kg.
F06.09
A 2.Gauge 2 measures negative load below -40kg VAR[WeightSP800] < -40kg.
Negative load
Gauges supply • Check the platform does not lie on an obstacle.
• Check weighing system.
• Check the integrity of the structure.
440 4001055090 E 05.21 USA / GB

Sensors
Failure : Incoherence states between SQ900 and SQ421 sensor's value :
--> SQ900=ON & SQ421=OFF
Machine folded, check the state of the sensors :
--> SQ900=ON & SQ421=ON
1
Then unfold slowly the machine and check the next sensor's state is :
--> SQ900=OFF & SQ421=ON
F07.01 --> SQ900=OFF & SQ421=OFF
Low Position D
Failure : Incoherence states between SQ900 and SQ520 sensor's value :
SQ900/SQ421/SQ520
--> SQ900=ON & SQ520=OFF
Machine folded, check the state of the sensors :
--> SQ900=ON & SQ520=ON
2
--> SQ900=OFF & SQ520=ON
--> SQ900=OFF & SQ520=OFF
Failure of voltage of SQ520 sensor, above [6.0V] : possibly short circuit to UBAT, or
F07.03 5V_REF output supply voltage is failing. --> VAR[BoomSensorFailure]=1
Boom Angle D Check SQ520 voltage value.
SQ520 Check short circuit between signal and 12 V or 5VREF and 12 V.
Check sensor's power supply is 5VREF.
5V_REF output supply voltage is failing.
F07.06
--> VAR[ArmSensorFailure]=1
Arm Angle D
Check SQ421 voltage value.
SQ421
Check short circuit between SQ421 and 12 V or 5VREF and 12 V.
5V_REF output supply voltage is failing.
F07.10
--> VAR[ArmSensorFailure]=1
Teles. Length D
Check SQ530 voltage value.
SQ530
Check short circuit between SQ530 and 12 V or 5VREF and 12 V.
Incoherence between basket tilt sensors : SR721/SR720.
Check position sensors with basket tilt = 0°.
F07.15 SR721=OFF & SR720=0FF
Compensation pos. D Check position sensors with basket tilt > 10°.
SR721/SR720 SR721=ON & SR720=OFF
Check position sensors with basket tilt <-10°.
SR721=OFF & SR720=ON
F07.30
Incoherence between engine pressure signal and engine state : engine is not running and
Engine oil pressure N
SP300 in ON position (engine running).
SP300
F07.31
N D+ is present but engine is not running
D+ failure
4001055090 E 05.21 USA / GB 441

Sensors
Difference between supply voltage and SP109 sensor voltage is below 200 V : Open circuit
detected.
1 3.Check connectors (sensor and ECU side).
4.Check harness.
F07.34
Front Axle 5.Check / replace sensor.
D
Unlocking Difference between supply voltage and SP109 sensor voltage is above 6000 V : Short
SP109 circuit is detected.
2 6.Check / Plug connectors (sensor and ECU side).
7.Check / Plug harness.
8.Check / replace sensor.
Open circuit on fuel level sensor (only for analog fuel level sensor type) : Check fuel level
1 sensor SL300
F07.39 --> SL300 > 400 ohms & CONFIG[FuelLevelSensorType] = Analog
Fuel level sensor D
Short circuit to ground on fuel level sensor (only for analog fuel level sensor type) : Check
SL300
2 fuel level sensor SL300
--> SL300 = 0 ohms & CONFIG[FuelLevelSensorType] = Analog
442 4001055090 E 05.21 USA / GB

Electric circuit-Power supply
Detected ECU voltage difference.
--> Difference between U106 (SPU) and U104 (basket B2).
F08.04
Check U100, U104 and U106 supply voltage.
Calc. Input Supply D
Check fuses.
U104/U106
Check supply voltage coherence between all ECU (more than 2000 V far during the first 4
seconds after start).
Failure on regulated 5 V output of U104 ECU (basket slave node ) supplying the joysticks.
--> 5 V output is measured out the range [4.5;5.5]V and 5 V output not failing.
1
Check fuses.
F08.05 Check the harness (check short circuit to power supply, to ground supply, open circuit…).
Calc. Input Supply D
Failure on regulated 5 V output of U104 ECU (basket slave node ) supplying the joysticks.
U106 5V regul
--> Detected failure on 5 V output.
2
Switch OFF/ON the machine, check the failure has gone (probable cause: internal failure of
the ECU).
Supplies’ input detected as unplugged on connectors : Check the CN1.B connectors for
1 U106 ECU :
--> 12VD1 < 5.00V & 12VF1 < 5.00V
Supplies’ input detected as unplugged on connectors : Check the CN2.A connectors for
2 U106 ECU :
--> 12VD2 < 5.00V & 12VF2 < 5.00V
F08.08
Unplugged
D 4 U106 ECU :
connector --> 12VD3 < 5.00V & 12VF3 < 5.00V
Connectors / Fuses
Supplies’ input detected as unplugged on connectors : Check the CN3.A connectors for
8 U106 ECU :
--> 12VD4 < 5.00V & 12VF4 < 5.00V
16 U106 ECU :
--> 12VD5 < 5.00V
4001055090 E 05.21 USA / GB 443

Engine
F09.01
Engine overheat :
Water temperature D
--> T2s (ST300 & T15s (VAR[Engine]=RUNNING))
Engine overheat
F09.02
Engine oil pressure :
Oil pressure D
--> T6s (SP300 & T15s(VAR[Engine]=RUNNING))
Engine pressure
F09.07
Available with Tier III variable RPM electronic engine and Tier III dual fuel engine, warning
Amber warning
D lamp received from engine ECU :
lamp Check DIAGNOSTIC => FUNCTIONS => Engine T3 Var => Failure SPN
Check Engine
F09.08 Available with Tier III variable RPM electronic engine and Tier III dual fuel engine, stop lamp
Red stop lamp D code received from engine ECU :
Check Engine Check DIAGNOSTIC => FUNCTIONS => Engine T3 Var => Failure SPN
Alternator failure (alternator not charging battery).
F09.10 • Alternator not charging.
D+ D --> T2s (CTRL[Engine]=RUNNING & DPLUS=OFFOr
Engine alternator • DPLUS active while engine is not running (but supplied) : IG wire cut or alternator issue.
--> T1s (CTRL[Engine]≠RUNNING & DPLUS>6.00V & KA3=ON)
F09.11
Detecting removal or disconnection of all sensors on DPF muffler
Removal of DPF D
--> Frame DM1: SPN = 3936, FMI = 7
system
F09.12
Abnormal delta pressure during the engine operation
Loss of function of D
--> Frame DM1: SPN = 3936, FMI = 2
DPF system
F09.13
Failure of Particle Removal of delta pressure sensor
D
Control Diagnostic --> Frame DM1: SPN = 3251, FMI = 3
(PCD) system
F09.14
Removal of Mass Disconnection of EGR-CAN line
D
Air Flow (MAF) --> Frame DM1: SPN = 523578, FMI = 2
Sensor
F09.15
Disconnection of Disconnection of Mass Air Flow (MAF) sensor
D
Mass Air Flow --> Frame DM1: SPN = 132, FMI = 4
(MAF) Sensor
F09.18
Ash load has reached 100%, cleaning is required
DPF Ash cleaning D
--> (VAR[AshLoad] ≥ 100% & VAR[AshLoad] ≠ 255 )
required
444 4001055090 E 05.21 USA / GB

Functions
Digital output's failure : Lower control box buzzer.
F11.06
--> HA901=FAIL
Buzzer N 1
Upper panel's buzzer is not tested (impedance off buzzer component is too low, seen as
HA901
failing even if not failing).
Container mode is active.
F11.07
A 1 --> OPT[ContainerMode]=Active
Container Mode Check the wheels fitting orientation. Deactivate the "Container mode" option.
Internal faults
CAN network failure detected with turret B2 ECU (U100).
Machine switched OFF, with multimeter, check the resistance between 1001 (CAN high)
and 1002 (CAN low) is nearly 60 ohms (if 0 ohm or 120 ohm : failure, check RES TERM
F12.01 1
connection for all ECUs).
CAN Fault D Check ECU supplies line.
Check wires Check address connections for each B2 ECU (CN106.18/CN106.19/CN106.20).
2 CAN network failure detected with keyboard switches ECU (U107)
4 CAN network failure detected with onboard screen ECU (U101)
F12.02
E2P Read/Write Internal failure of SPU: access to EEPROM (read or write).
D
Error Restart machine.
Change - U106 ECU
Detected change in software machine identification: all the settings forced to default values
1
(ramps, speeds, options, machine configuration and erase of calibration).
2 Detected changes in machine speeds and ramps
F12.04 4 Detected changes in machine options

E2P Param Reset D 8 Detected changes in machine configuration
Check settings 16 Detected changes in machine maintenances
32 Detected changes in machine daily logs
64 Detected changes in machine events counters
128 Detected changes in machine events logs
4001055090 E 05.21 USA / GB 445

Internal faults
Machine’s model is not set.
1
Set machine model (HA20RTJ/HA20RTJO/HA20RTJPRO).
Country not set.
2
Set country (USA/AUS/EUR/EAC/CHN/JPN/INT).
Serial number not set.
4
Set machine serial number.
Some speed or ramp parameters are not set.
8
Set all speed and ramp parameter.
Some options are not set.
16
Set machine options (Buzzer, Flashing light, Fleet management, Activ' Shield Bar).
Some configurations are not set.
32
Set all machine's options(Engine).
Activ’Shield Bar option is active while Activ’Shield Bar system version is set to "Not
mounted".
Set the Activ’Shield Bar system configuration to the version conforming with the type of
hardware on the machine.
V1 - Version
F12.05
Machine not set D
Check settings
64
V2 - Version
446 4001055090 E 05.21 USA / GB

Switches
Detected failure on upper console switches : Two directions active at the same time for
1 telescope switch.
--> SA531O=ON & SA531I=ON
Detected failure on upper console switches : Two directions active at the same time for jib
2 switch.
--> SA621U=ON & SA621D=ON
4 platform rotation switch.
--> SA751U=ON & SA751D=ON
F13.02 Detected failure on upper console switches : Two directions active at the same time for
Platform switches D 8 platform level switch.
SW 2 steering active --> SA721U=ON & SA721D=ON
16 steering rocker switch.
--> SM902L=ON & SM902R=ON
32 steering mode switch.
--> SA101C=ON & SA101S=ON
64 speed selector switch.
--> SA110H=ON & SA110L=ON
Neutral detection failure at machine's power-on for lower console switches : Arm switch is
1
active.
Neutral detection failure at machine's power-on for lower console switches : Boom switch is
2
active.
Neutral detection failure at machine's power-on for lower console switches : Telescope
4
switch is active.
Neutral detection failure at machine's power-on for lower console switches : Turret rotation
8
switch is active.
Neutral detection failure at machine's power-on for lower console switches : Jib switch is
16
active.
Neutral detection failure at machine's power-on for lower console switches : Platform level
32
switch is active.
F13.10
Neutral detection failure at machine's power-on for lower console switches : Engine start/
Switches neutral A 64
stop switch is active.
Sw: Lower box
Neutral detection failure at machine's power-on for lower console switches : Enable switch is
128
active.
Neutral detection failure at machine's power-on for lower console switches : Overriding
256
switch is active (not checked if platform emergency switch is pushed)
Neutral detection failure at machine's power-on for lower console switches : Platform rotation
512
switch is active (Not checked if platform emergency switch is pushed)
Neutral detection failure at machine's power-on for lower console switches : Horn switch is
1024
active (Not checked if platform emergency switch is pushed)
Neutral detection failure at machine's power-on for lower console switches : Beacon rotation
2048
switch is active (Not checked if platform emergency switch is pushed)
Neutral detection failure at machine's power-on for lower console switches : Dual fuel
4096
selection switch is active (Not checked if platform emergency switch is pushed)
4001055090 E 05.21 USA / GB 447

Switches
Neutral detection failure at machine's power-on for upper console switches : Telescope
1
switch is active.
Neutral detection failure at machine's power-on for upper console switches : Jib switch is
2
active.
Neutral detection failure at machine's power-on for upper console switches : Platform
4
rotation switch is active.
Neutral detection failure at machine's power-on for upper console switches : Platform level
8
switch is active.
Neutral detection failure at machine's power-on for upper console switches : Steering rocker
F13.11 16
switch is active.
Switches neutral 2 A
Neutral detection failure at machine's power-on for upper console switches : Engine start/
Sw: Lower box 32
stop switch is active.
Neutral detection failure at machine's power-on for upper console switches : Emergency
64
pump switch is active.
Neutral detection failure at machine's power-on for upper console switches : Horn switch is
128
active.
Neutral detection failure at machine's power-on for upper console switches : Differential lock
256
switch is active.
Neutral detection failure at machine's power-on for upper console switches : Foot Switch is
512
active.
CAN J1939
Problem detected in J1939 CAN.
Machine not supplied, with multimeter, check the resistance between 2001 (CAN high) and
F15.06 2002 (CAN low) is nearly 60 ohms (if 0 ohm or 120ohm : failure, check RES TERM
D
Check CAN 2 connection for all ECUs).
Check ECU supplies line.
Check CAN connection for Display and/or engine.
448 4001055090 E 05.21 USA / GB

Notes
4001055090 E 05.21 USA / GB 449

2- Legend
2.1 - PCB TURRET
Location on the machine
450 4001055090 E 05.21 USA / GB

Location
4001055090 E 05.21 USA / GB 451

452 4001055090 E 05.21 USA / GB

Marking Description
FU1 Not used
FU2 Fuse - 20A - Generator
FU3 Engine shutdown / Acceleration - 15A -
FU4 Fuse - 25A - Starter
FU5 Fuse - 30A - General
FU6 Fuse - 20A - Options
FU7 Fuse - 15A - ECU
FU8 Fuse - 20A - Option
FU9 Fuse - 20A - Attachments
FU10 Not used
FU11 Fuse - 7.5A - + Permanent
FU12 Not used
FU13 Fuse - 20A - Power
FU14 Not used
FU15 Not used
FU16 Not used
FU17 Fuse - 5A -Selection ground / upper controls
FU18 Not used
FU19 Not used
FU23 Option overspeed relay - 40A -
FU34 Supply strain gauges -1A-
FU122 Emergency pump -250A-
FU161 Preheating -100A-
FU180 Cooler option -30A-
KA1 Not used
KA2 Relay - 1RT - 12V - Generator (192)
KA3 Engine shutdown / Acceleration (170)
KA5 Not used
KA4 Starter (169)
KA5 Not used
KA7 For engine start
KA9 Relay - 1RT - 12V - Horn (187)
KMG Relay - 1T - 12V/70A - Main relay (142)
KMP Relay - 1T - 12V/70A - Power (142)
SD85 Option overspeed relay
KM120 Emergency pump (145)
KM160 Pre-heating (162)
KM300 Starter motor (165)
4001055090 E 05.21 USA / GB 453

3- Electric diagram
Engine part - Tier III - 4000419850H folio 02
454 4001055090 E 05.21 USA / GB

Turntable part - PCB - 4000419850H folio 03
4001055090 E 05.21 USA / GB 455

Turntable part - SPU 1/3 + CLUSTER - 4000419850H folio 04
456 4001055090 E 05.21 USA / GB

Turntable part - SPU 2/3 - 4000419850H folio 05
4001055090 E 05.21 USA / GB 457

Turntable part - SPU 3/3 - 4000419850H folio 06
458 4001055090 E 05.21 USA / GB

Cage part-Node B 1/2 - 4000419850H folio 07
4001055090 E 05.21 USA / GB 459

Cage part-Node B 2/2 - 4000419850H folio 08
460 4001055090 E 05.21 USA / GB

Engine part - Tier IV / Stage5 Kubota - 4000419850H folio 09
4001055090 E 05.21 USA / GB 461

Engine part-Petrol/gas - 4000419850H folio 10
462 4001055090 E 05.21 USA / GB

Engine part-ON/OFF KUBOTA - 4000419850H folio 11
4001055090 E 05.21 USA / GB 463

Option - 4000419850H folio 12
464 4001055090 E 05.21 USA / GB

System architecture - 4000419850H folio 13
4001055090 E 05.21 USA / GB 465

4- Hydraulic diagram
HA20RTJ - 4000134920I - 1/2
466 4001055090 E 05.21 USA / GB

HA20RTJ - 4000134920I - 2/2
4001055090 E 05.21 USA / GB 467

HA20RTJ O - 4000134920I - 1/2
468 4001055090 E 05.21 USA / GB

HA20RTJ O - 4000134920I - 2/2
4001055090 E 05.21 USA / GB 469

HA20RTJ PRO - 4000138050J - 1/2
470 4001055090 E 05.21 USA / GB

HA20RTJ PRO - 4000138050J - 2/2
4001055090 E 05.21 USA / GB 471

HA20RTJ PRO - 4000138050J - Generator with cooler option - 1/2
472 4001055090 E 05.21 USA / GB

HA20RTJ PRO - 4000138050J - Generator with cooler option - 2/2
4001055090 E 05.21 USA / GB 473

Notes
474 4001055090 E 05.21 USA / GB

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

Date Type of intervention Intervenor
hours intervention number
4001055090 E 05.21 USA / GB 475

F - Records
Number of HAULOTTE Services®

Date Type of intervention Intervenor
hours intervention number
476 4001055090 E 05.21 USA / GB

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Maintenance Book

HA20RTJ - HA20RTJ O - HA20RTJ PRO -

4001055090 E 05.21 USA / GB

2 4001055090 E 05.21 USA / GB

2.7 - Product information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

MS0076 - Remove - Replace turret/platform CAN BUS

MP0001 - Wheel tightening procedure . . . . . . . . . . . . 309

We would particularly like to draw your attention to 2 essential points :

If regular maintenance is not carried out, this may :

4001055090 E 05.21 USA / GB 9

1- Symbols and colors

Danger : Risk of injury or death

Caution : Risk of material damage

Prohibition relating to work safety and quality

Reminder to use good practice or follow pre-operation checks

Cross-reference to another part of the manual

Cross-reference to another manual

Cross-reference to repair (contact HAULOTTE Services®)

N.B. : Additional technical information

10 4001055090 E 05.21 USA / GB

Color Title Description

Danger : Indicates a hazardous situation which if not avoided,

Warning : Indicates a hazardous situation which if not avoided,

Caution : Failure to comply could result in minor or moderate

Notice : Indicates practices not related to personal injury.

Procedure : Indicates a maintenance operation.

4001055090 E 05.21 USA / GB 11

12 4001055090 E 05.21 USA / GB

1.1 - MAINTENANCE IMPLEMENTATION

Before performing any maintenance interventions, place the machine in maintenance

1. Place the machine on firm, level ground.

4001055090 E 05.21 USA / GB 13

1.2 - UNCONTROLLED MOVEMENT HAZARD

Be aware of uncontrolled movement and always respect the following :

14 4001055090 E 05.21 USA / GB

1.3 - ELECTRIC SHOCK HAZARDS

Minimum safe approach distances

Electric voltage Minimum safety distance

Do not operate the machine :

4001055090 E 05.21 USA / GB 15

1.4 - EXPLOSION / FIRE HAZARDS

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

16 4001055090 E 05.21 USA / GB

2- Maintenance and repair training

2.1 - OWNER'S RESPONSABILITY

Additional copies can be ordered from HAULOTTE Services®.

2.2 - TECHNICIAN'S RESPONSABILITY

Only authorized and qualified operators may operate HAULOTTE® machines.

2.3 - HAULOTTE SERVICES®

4001055090 E 05.21 USA / GB 17

2.5 - PRODUCT MODIFICATION

These improvements will be shared via the following documents :

2.6 - AFTER SALES SERVICE

2.7 - PRODUCT INFORMATION

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

18 4001055090 E 05.21 USA / GB

4001055090 E 05.21 USA / GB 19

1- Primary machine components

HA20RTJ - HA20RTJO - HA20RTJPRO - HA61RTJO - HA61RTJPRO