Star 8

Maintenance book
STAR 8 - STAR 22J - STAR 10 - STAR 26J
Maintenance book
USA
4000414930 E 10.15 USA / GB

2 4000414930 E 10.15 USA / GB

Maintenance book
CONTENTS
Preface -
Foreword
1 - Symbols and colors . . . . . . . . . . . . . . . . . . . . . . 8
B
Safety
1 - General safety rules . . . . . . . . . . . . . . . . . . . . . 11
1.1 - Maintenance implementation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CONTENTS
1.2 - Uncontrolled movement Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 - Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4 - Explosion / Fire Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 - Maintenance and repair training . . . . . . . . . . . 14
2.1 - Owner's responsability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 - Technician's responsability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 - HAULOTTE Services®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 - Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5 - Product modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6 - After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.7 - Product information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 - Manufacturer's warranty . . . . . . . . . . . . . . . . . 16
3.1 - Warranty acceptance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 - Warranty period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 - Conditions of warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 - Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3
Maintenance book
C
Familiarization
1 - Primary machine components . . . . . . . . . . . . 20
1.1 - Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2 - Ground control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.2 - ACTIV'Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3 - Platform control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 - Device layout . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.1 - Sensors and actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3 - Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4 - Ingredient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 - Hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5 - Lubrication diagram . . . . . . . . . . . . . . . . . . . . . 29
5.1 - Greasing points localization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6 - Machine specifications . . . . . . . . . . . . . . . . . . 31
6.1 - Movement speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Inspection and
maintenance
schedule
1 - Maintenance Schedule . . . . . . . . . . . . . . . . . . . 33
2 - Inspection program . . . . . . . . . . . . . . . . . . . . . 37
3 - Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . 38
4 - Periodic inspection . . . . . . . . . . . . . . . . . . . . . 42
5 - Reinforced inspection . . . . . . . . . . . . . . . . . . . 44
6 - Major inspection . . . . . . . . . . . . . . . . . . . . . . . . 46
4
Maintenance book
Machine sheet
MS0001 - Structural part inspection . . . . . . . . . . . . . . . 49
MS0002 - Pins and bearing inspection . . . . . . . . . . . . . 53
MS0003 - Cylinder inspection . . . . . . . . . . . . . . . . . . . . 57
MS0004 - Breaking test procedure . . . . . . . . . . . . . . . . 61
MS0005 - Torque Values . . . . . . . . . . . . . . . . . . . . . . . . 63
MS0010 - Slew ring inspection . . . . . . . . . . . . . . . . . . . 67
MS0012 - Condition of the cables inspection - Criteria of
replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
MS0020 - Hoses inspection - Replacement . . . . . . . . . 77
MS0059 - Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . 79
MS0042 - Inspection of the condition of the chains -
Criteria of replacement . . . . . . . . . . . . . . . . . . . . . . . . 81
MS0044 - Tires (Tyres) and pressures - Wheel
replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
MS0045 - Lubrication - Jib cylinder - Steering cylinder -
Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
MS0046 - Dismantling / Reassembling wheels reducer93
MS0047 - Replacing the wheel pivot. . . . . . . . . . . . . . . 99
MS0048 - Steering cylinder replacement . . . . . . . . . . 109
CONTENTS
MS0049 - Hydraulic oil - Level Replacement . . . . . . . 113
MS0050 - Hydraulic filter cartridge Replacement . . . 115
MS0051 - Battery (ies) . . . . . . . . . . . . . . . . . . . . . . . . . 117
MS0052 - Battery (ies) . . . . . . . . . . . . . . . . . . . . . . . . . 125
MS0053 - Return cables . . . . . . . . . . . . . . . . . . . . . . . . 129
MS0054 - Specific adjustment procedure STAR 8 -
STAR 20J - STAR 10 - STAR 26J . . . . . . . . . . . . . . . 131
MS0061 - Tube wedging procedure . . . . . . . . . . . . . . 137
MS0062 - Inspection of the slack chain sensors . . . . 139
MS0085 - Overriding function reset . . . . . . . . . . . . . . 145
5
Maintenance book
E
Trouble
shooting and
diagram
1 - Trouble shooting . . . . . . . . . . . . . . . . . . . . . . 149
1.1 - Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.2 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.3 - Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2 - Electric diagram . . . . . . . . . . . . . . . . . . . . . . . 156
3 - Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . 159
Records
1 - Intervention register . . . . . . . . . . . . . . . . . . . . 161
6
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 adjustments 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.
4000414930 E 10.15 USA / GB 7

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.
S y m b o l
Symbol Description
Danger : Risk of injury or death
Caution : Risk of material damage
Prohibition relating to work safety and quality
Reminder to use good practice or follow pre-operation checks
Cross-reference to another part of the manual
Cross-reference to another manual
Cross-reference to repair (contact HAULOTTE Services®)
Maintenance sheet
Time required for intervention
Recommended tools
Recommended part
Safety
N.B. : Additional technical information
8 4000414930 E 10.15 USA / GB

D e c a l s
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 MACHINE.
4000414930 E 10.15 USA / GB 9

Notes
10 4000414930 E 10.15 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 push-button to cut off the electricity supply.
Never leave the hydraulic cylinders fully extended or retracted before switching off the machine, or when
stationary for an extended period of time. Keep the elements of the machine in configuration of
maintenance thanks to mechanics devices.
Report that the machine is under maintenance by tagging the platform and ground control boxes.
Note :
• Using the machine during maintenance is strictly forbidden.
• Do not climb onto the covers.
• The handling of parts must be carried out using appropriate equipment (Chains, Lifting slings, Lifting
anchors).
• Plug the end of any hoses removed, and cap any open ports to prevent contamination during
maintenance.
1. 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 or retracted before switching off the machine, or
when stationary for an extended period of time.
• Fold the machine with the mast fully retracted and lowered and the jib aligned.
• 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.
4000414930 E 10.15 USA / GB 11

B- Safety
1.3 - ELECTROCUTION HAZARDS
The machine is not electrically insulated and does not provide protection from contact or proximity to
electrically charged conductors.
Always position the lift at a safe distance from electrically charged conductors to ensure that no part of
the machine is within an unsafe area.
Respect the local rules and the minimum safety distance from power lines.
M i n i m u m s a f e a p p r o a c h d i s t a n c e s
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.
12 4000414930 E 10.15 USA / GB

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.
4000414930 E 10.15 USA / GB 13

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 Group 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.
14 4000414930 E 10.15 USA / GB

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

• OI : Obligatory Intervention, Safety information requiring immediate action (take into account
by HAULOTTE®).
• NI : Technical improvement requiring immediate action (take into account by HAULOTTE®).
• RI : Improvement proposed to customers to take into account during maintenance operation.
• PI : Product information for knowledge.
2.6 - AFTER SALES SERVICE
Our HAULOTTE Services® After Sales Service is at your disposal throughout your machine's service
life to ensure the optimum use of your HAULOTTE product :
• When contacting our After Sales Service, ensure that you provide the machine model and serial
number.
• When ordering any consumables or spare parts, please use this manual and the HAULOTTE®
Essential catalogue to receive your genuine HAULOTTE® spare parts, your only guarantee of parts
interchangeability and correct machine operation.
• If there is an equipment malfunction involving a HAULOTTE® product, then contact HAULOTTE
Services® immediately even if the malfunction does not involve material and/or bodily damage.
2.7 - PRODUCT INFORMATION
Without the written permission from Haulotte, modifying a HAULOTTE® product is a Safety concern.
Any modification may violate Haulotte design parameters, government regulations and industry
standards.
If you desire a modification to the product, submit a request in writing to HAULOTTE Group.
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.
4000414930 E 10.15 USA / GB 15

B- Safety
3 - Manufacturer's warranty
3.1 - WARRANTY ACCEPTANCE
On reception of his machine, the owner or rental company must check the machine's condition and fill
out the machine reception slip provided.
3.2 - WARRANTY PERIOD
The present warranty is valid for a period of 12 months or up to a maximum of 1000 operating hours for
lifting and handling equipment and 2000 operating hours for public works machinery, starting from
delivery and terminating when the first limit is reached.
Spare parts are covered by a 6 month warranty.
3.3 - CONDITIONS OF WARRANTY
HAULOTTE® guarantees its products against defects, faults or manufacturing defects when the owner
or rental company has informed HAULOTTE® of the defect.
The warranty does not cover the consequences of normal wear, nor any defects, failure or damage
resulting from poor maintenance or abnormal usage, in particular overloading, impact by an external
source, faulty installation or any modification made to products marketed by HAULOTTE® and
performed by the owner or rental company.
In the event of operation or use which does not comply with the instructions or recommendations in the
maintenance book, warranty claims will not be accepted.
The machine utilisation period must be recorded by reading the engine hour meter whenever an
intervention is made. The engine hour meter must be maintained in good working order to guarantee
maximum working life and to justify maintenance at the recommended time.
Warranty obligations for the time period stated above will cease immediately in situations where the
defect is due to the following reasons :
• Use of spare parts that are not HAULOTTE® originals.
• If elements or products other than those recommended by the manufacturer are used.
• If the HAULOTTE® name, serial numbers or identification marks are removed or altered.
• After an unreasonably long delay before reporting a manufacturing problem.
• If the owner or rental company continues to use the machine despite problems.
• If damage is caused by modifications that do not comply with HAULOTTE® specifications.
• If lubricants, hydraulic oils or fuels that do not comply with HAULOTTE® recommendations are used.
• If the machine is incorrectly repaired or used by the customer.
If no particular agreement has been made, any claims made after the previously established warranty
period has expired will be refused.
16 4000414930 E 10.15 USA / GB

B- Safety
The present warranty does not cover damage that may result directly or indirectly from any flaws or
defects covered by the latter :
• Consumables : No claims will be accepted for objects or parts replaced in the context of normal
machine usage.
• Settings : Adjustments of all sorts may become necessary at any time. Therefore adjustments are
considered a part of normal machine usage conditions and are not covered by the warranty.
• Hydraulic and fuel circuit contamination : Every possible precaution is taken to ensure that fuel and
hydraulic liquid delivered is clean. On the other hand, in certain cases it is possible to contaminate fuel
and hydraulic circuits, especially when fuel and lubricants are stored on the work site. Moreover,
irregular or poor cleaning of the decanting device may also cause fuel/hydraulic circuit contamination
and therefore damage the parts in direct contact with these liquids. HAULOTTE® will not accept any
claims concerning cleaning of the fuel circuit, filter, injection pump or any other equipment in direct
contact with fuel or lubricants.
• Wearing parts (pads, bearings, tires/tyres, connections, etc.) : These parts are, by definition, subject
to deterioration during the period of operation. Wearing parts will therefore not be covered by the
warranty agreement.
3.4 - WARRANTY CONDITIONS
To benefit from the warranty, the owner or rental company must inform the nearest HAULOTTE®
subsidiary or the subsidiary that delivered the machine (the only dealer authorised to carry out an
intervention under the manufacturer's warranty agreement) of the defect in writing as quickly as
possible.
The subsidiary will decide whether to repair or replace the part that proves to be faulty.
The owner or rental company must present the duly completed maintenance book supplied with the
machine as proof that the maintenance operations recommended by the manufacturer have been
carried out.
The owner or rental company must ensure that the defect covered by the HAULOTTE® warranty is
reported to and acknowledged by the HAULOTTE® subsidiary the only dealer authorised to carry out
work covered by the warranty) as rapidly as possible or must report the defect in writing.
Work carried out under the HAULOTTE® warranty will be performed by the subsidiary which delivered
the machine, wherever possible.
4000414930 E 10.15 USA / GB 17

B- Safety
Notes
18 4000414930 E 10.15 USA / GB

C- Familiarization
Familiarization
Notes
4000414930 E 10.15 USA / GB 19

C- Familiarization
1 - Primary machine components
1.1 - LAYOUT
S T A R 8 - S T A R 2 2 J - S T A R 1 0 - S T A R 2 6 J
20 4000414930 E 10.15 USA / GB

C- Familiarization
Marking Description Marking Description
C1 Chassis C54 Telescopic mast
C4 Jib C57 Cable reel
C6 Platform C58 Pothole protection
C7 Platform control box C59 Hinged midrail
C10 Slew ring C64 Tilt sensor
C11 Turntable assembly C76 Guardrail
C20 Tie-down (and/or forklift loading) C90 Battery bay (block)
C27 Ground control box C136 Steer wheels
Position sensor mast lowered -
C33 Counterweight C157
SQ530
C34 Drive wheels C158 Position sensor mast raised - SQ534
C35 Document holder C159 Jib sensor - SQ620
Slack chain limit switch - SQ801 -
C44 C160 Angle sensor - SR601
SQ802
C47 Battery isolation switch C161 Pressure sensor - SP600
C50 Battery charger socket C162 Steering potentiometer - SR150
4000414930 E 10.15 USA / GB 21

C- Familiarization
1.2 - GROUND CONTROL BOX
1.2.1 - Layout
G e n e r a l v i e w
C o n t r o l s a n d i n d i c a t o r s
Marking Description Function

Pulled out : E-stop activated
15 E-stop button
Pushed in : E-stop deactivated
90 Battery charging indicator Battery charger status
Move upwards : Platform control box energized
92 Control box activation key selector Center : De-energizes control system
Move downwards : Ground control box energized
Move to the right : Flashing light is turned on
105 Beacon light 1
Move to the left : Flashing light is turned off
Move upwards : Mast extension
127 Mast telescoping selector
Move downwards : Mast retraction
Move to the left : Clockwise (CW) rotation
128 Turret rotation switch
Move to the right : Counter clockwise (CCW) rotation
Move upwards : Jib raising
129 Jib raising / lowering switch
Move downwards : Jib lowering
253 Diagnostic tool socket
258 Brake release telecommand connection2
1. For machines fitted with
2. For machines fitted with
22 4000414930 E 10.15 USA / GB

C- Familiarization
1.2.2 - ACTIV'Screen
I n d i c a t o r s
254
ACTIV’Screen
255
245
!
256
228
4000274010 B
252 6
Marking Description
6 Platform overload indicator : Intermittently lit in case of overload
228 'Enable Switch' selector : Press and hold 'Enable switch' button
245 "Overriding system" control : Emergency lowering system
Machine fault indicator light : Intermittently lit in the event of an operation
252
malfunction
254 Navigation button
255 Confirmation button
256 Cancellation button
Symbol Description
Battery charger status
Active fault indicator
Maintenance to perform
Hourmeter
4000414930 E 10.15 USA / GB 23

C- Familiarization
1.3 - PLATFORM CONTROL BOX
1.3.1 - Layout
G e n e r a l v i e w
24 4000414930 E 10.15 USA / GB

C- Familiarization
C o n t r o l s a n d i n d i c a t o r s
Marking Description Function

27 Tilt indicator Machine on excessive slope
30 Platform overload indicator Platform overload
Press and hold the horn button to sound the horn
43 Horn button
Sound stops when the horn button is released
Pulled out : Platform control box energized
46 E-stop button
Pushed in : De-energizes control system
'Enable Switch' selector / Turret rotation Press in and hold : Validation of turret rotation selection
132
control Release : Cancellation of turret rotation selection
100%
Battery charged
135 Battery charging indicator

40%
Flashing : Batteries have 40 % charge left
20%
Constantly on : Batteries have only 20 % charge left
146 Machine fault indicator light Machine operating fault
Press in button ( 250 ) to select either the drive or steer movement
Move forward : Forward drive
Move backwards : Reverse drive
Drive and steering joystick
Press right side of button : Right-hand steering
Press left side of button : Left-hand steering
244 Press button ( 251 ) to select Mast extend / retract movement
Move forward : Mast extension
Joystick as mast movement function
Move backwards : Mast retraction
Press button ( 252 ) to select Jib raising or lowering movement
Move forward : Jib raising
Jib movement joystick
Move backwards : Jib lowering
Move to the right : Counter-clockwise turret rotation
249 Turret rotation selector
Move to the left : Clockwise turret rotation
Pressed down (activated) : Movement selection (Without
Drive and steer control activating the joystick ( 244 ), under 8 s, the movement is
250
cancelled.)
Drive and steering indicator mode On : Activated mode
Mast extension / retraction control activating the joystick ( 244 ), under 8 s, the movement is
251
cancelled.)
Mast movement indicator mode On : Activated mode
Jib raising / lowering control activating the joystick ( 244 ), under 8 s, the movement is
252
cancelled.)
Jib movement indicator mode On : Activated mode
4000414930 E 10.15 USA / GB 25

C- Familiarization
2 - Device layout
2.1 - SENSORS AND ACTUATORS
S e n s o r s a n d a c t u a t o r s
26 4000414930 E 10.15 USA / GB

C- Familiarization
Description Name
Starting up centralized battery refilling SA911
Pressure transducers SP600
Position sensor mast lowered SQ530
Position sensor mast raised SQ534
Sensor - Tilt 3° SQ800
Sensor - chain tension detection 1 SQ801
Sensor - chain tension detection 2 SQ802
Steering potentiometer SR150
Angle sensor (weighing) SR601
Right rear brake-release solenoid valve YB100
Left rear brake-release solenoid valve YB101
Left steering electro-distributor YV150L
Right steering electro-distributor YV150R
Mast left electro-distributor rotation YV250L
Mast right electro-distributor rotation YV250R
Mast lowering solenoid valve YV520D
Mast raising solenoid valve YV520U
Jib raising solenoid valve YV620U
3 - Consumables
Consumable HAULOTTE® code
Hydraulic filter cartridge 2505000970
4000414930 E 10.15 USA / GB 27

C- Familiarization
4 - Ingredient
Ingredient HAULOTTE® code
Hydraulic oil 2420801310
Hydraulic oil (Winter option) 2505002640
Biological hydraulic oil 2820304310
4.1 - HYDRAULIC OIL
Hydraulic oils must comply with the following requirements :

• Oil filterability must be compatible with absolute filters
• Have properties such as :
• Antifoam and deaeration
• Anti-wear, anti-shear and antioxydant
• Rust and corrosion inhibitors (copper)
The recommended viscosity grades depending on the environmental conditions are as follows :
Environmental conditions ISO Viscosity grade
Ambient temperature between - 15° C (- 9° F) and + 40° C (+ 104° F) HV 46
Ambient temperature between - 35° C (- 31° F) and + 35° C (+ 95° F) HV 32
Ambient temperature between 0° C (32° F) and + 45° C (+ 113° F) HV 68
Biodegradable oils may be used if they comply with the following requirements :
• Ambient operating temperature between - 15° C (- 9° F) and + 40° C (+ 104° F)
• HEES type biodegradable oil only according to standards ISO 15380 and VDMA 24568
• Necessary characteristics :
Viscosity grade ISO Viscosity grade
Viscosity at + 40° C (+ 104° F) 46 +/- 3 mm² / s
Viscosity at + 100° C (+ 260° F) > 8 mm² / s
Viscosity index > 160
Flashpoint > 220° C (> 572° F)
Pour point < - 40° C (> - 104° F)
28 4000414930 E 10.15 USA / GB

C- Familiarization
5 - Lubrication diagram
3
DANGER
5 6 6 4
L i s t o f i n g r e d i e n t s
Marking Ingredient Symbol HAULOTTE® code

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

6
Lead-free grease - Can 5 l(1,32 gal US) 2820304340
9 High-pressure lubricant
4000414930 E 10.15 USA / GB 29

C- Familiarization
5.1 - GREASING POINTS LOCALIZATION
• Slew ring.
• Wheel axles : 2 on the chassis.
Lubricate the pivots with lead-free grease.
• Mast lubrication :
30 4000414930 E 10.15 USA / GB

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

STAR 8 - STAR 22J STAR 10 - STAR 26J
Micro drive speed 0,6 km/h / 0.4 mph
High drive speed 5 km/h / 3.1 mph
Maximum towing speed 5 km/h / 3.1 mph
Time for mast lifting 28 s 30 s
Time for mast lowering 38 s 30 s
Time for jib lifting 27 s
Time for jib descent 25 s 27 s
Time for lifting at maximum height 59 s 57 s
Time for lowering to minimum height 64 s 57 s
Time for continue turntable rotation 60 s
4000414930 E 10.15 USA / GB 31

C- Familiarization
Notes
32 4000414930 E 10.15 USA / GB

D- Inspection and maintenance schedule

Inspection and maintenance schedule
1 - Maintenance Schedule
There are a number of factors which can affect the design life including but not limited to, severity of operating
conditions/routine maintenance.
Dependent on the frequency of use and severity of the operating environment, planned inspections shall be
carried out at a frequency to enable the aerial work platform to be kept in a safe and satisfactory condition. The
harsher the operating environment, the more frequent the inspection will be.
Maintenance operations must be carried out by a qualified technician whose selection is the responsibility of the
company manager (Company employee or other qualified person).
Maintenance operations performed must be recorded in a register / log book of the machine.
Symbol Description Symbol Description

Systematic replacement
Visual inspections Operation requiring HAULOTTE
Services® authorisation
Visual inspection with dismantling
Check-Test to exchange/replace if necessary
See user manual or machine Operation requiring HAULOTTE
maintenance book (1) Services® authorisation
Increase in periodic inspections
Check level Tightening (bolt, etc.)
Lubrication Tolerance (clearance)
Static and dynamic tests

For countries where machines are
Oil change
(2) not subject to controlled periodic
maintenance
4000414930 E 10.15 USA / GB 33


Intervals
Area After 125 h After 250 h After 1500 h After 5000 h
Daily
(hours) or 1 year (hours) or 1 year (hours) or 3 years (hours) or 10 years
Platform assembly
Structural parts
Platform
Guardrail
Sliding (or swinging) intermediate

guardrail
Swing doors
Floor
Lanyard attachment points
Mast assembly
Structural parts
Chains
(1)
Cables
Turntable assembly
Structural parts
Slew ring (3)
Turntable rotation gearbox
Chassis assembly
Structural parts
Tie down/lifting points
Tires (Tyres) and rims
Wheel nuts and bolts
Wheel reducer
Wheel axles
Functions and controls
Platform control box (indicators, etc.)
Ground control box (indicators, etc.)
'Enable switch' / foot pedal
E-stop buttons (on all control boxes)
Circuit breaker and contactors
Overload system
Horn
34 4000414930 E 10.15 USA / GB


Intervals
Daily
Brakes
Emergency lowering
Indicators, switches and joysticks
Tilt sensor
Limit switch ( PV, radius limit, weighing)
Return to neutral position - all joysticks,

switches, etc.
Power system
Engine See manufacturer's guide
Batteries (terminals, cleanliness,
attachment)
Hydraulic and electric assemblies
Hydraulic pump
Hydraulic tank, cap and breather
Hydraulic filter
Hydraulic oil
Electrical connections
Hydraulic unit motor commutator

(1)
Driving motor commutator

(1)
Variable speed calculator

(1)
Common areas
Structural parts
4000414930 E 10.15 USA / GB 35


Intervals
Daily
Welds
(1)
Hoses and couplings

(1)
Pins, rings and pin stop

(1)
Pulleys and wear pads

(1)
Bearings
Cylinders (welds, leakproofness,

(2)
external leak, excessive distortion)
Caps and covers
General points
User manual and intervention register
Safety decals and manufacturer's plate
Mandatory inspection According to current legislation in the country of use and at least once a year
Performance check for all functions and
safety devices
Greasing and lubrication according to

the maintenance schedule
General condition of the machine, paint,
no leaks, cracks or excessive distortion,
etc.
Machine integrity, no modifications
without HAULOTTE Services®
authorisation
1 - Increase in periodic inspections.
2 - For countries where machines are not subject to controlled periodic maintenance.
3 - Particular attention to be paid when checking the crown gear.

Particular attention to be paid when checking the crown gear :
• Visual appearence of the interior and exterior (floating or broken bolts, etc.).
• Check bolt tightness by testing a sample, making sure that the bolts are slightly loosened before
retightening with a torque wrench. Section C E005 Maintenance sheet
• Check the crown gear's functional clearance (every 1500 h). Consult the After-Sales Service.
36 4000414930 E 10.15 USA / GB


2 - Inspection program
The machine must be inspected on a regular basis at intervals in accordance with the requirements set forth in
the Country of use but no less than 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.
HAULOTTE Services® requires Reinforced and Major Inspections to be carried out on the product to extend its
service life.
Inspections must be carried out by a qualified company or person whose selection is the responsibility of the
company manager.
The inspection results must be recorded in the safety register or machine log book controlled and overseen by
the company manager. This register or machine log book and the list of competent repair persons must be made
available to the Government Work Inspector and company safety committee at any time.
When Responsible Stakeholder What

Competent technician or
Before sale Owner (or renter) qualified technician Periodic inspection
HAULOTTE Services®
Before rent Owner (or renter) qualified technician
HAULOTTE Services® Daily inspection
Before use or every
User User
change of user
6 months or 1 year (*) Owner (or renter) qualified technician Periodic inspection
HAULOTTE Services®
Qualified technician
5 years Owner (or renter) Reinforced inspection
HAULOTTE Services®
Qualified technician
10 years Owner (or renter) Major inspection
HAULOTTE Services®
(*) According to applicable regulatory requirements. If there are no local requirements, then inspection must be
performed at least once a year.
4000414930 E 10.15 USA / GB 37


3 - Daily inspection
The content and method of inspection must be conducted by operators before using the machine, it includes a
visual inspection and functional and security systems testing of the machine.
This inspection is the responsibility of the user.
Each day and before the beginning of a new work period and with each change of operator, the machine must
be subjected to a visual inspection and a complete functional test. This inspection is called Daily Inspection.
Any repairs required must be performed before the machine is used, its correct operation depends on it.
To tighten loosened hardware, refer to recommended torque value table in maintenance book.
In case of leaks, tighten or replace the damaged part before placing the machine in service.
In case of structural part deformation, cracks, broken weld, paint chipped, replace the part before placing the
machine in service.
S a m p l e o f b r o k e n w e l d s
Inspection Forms are provided to assist your inspection process.
We recommend these forms to be completed daily and stored to assist with your maintenance schedule.
Each action is depicted in the daily inspection sheet using the following symbols.
Visual inspection without

Lubrication-Greasing Functional adjustments
disassembly
To drain off To check by test Tightening
Levelling Systematic replacement
Visual inspection with small

disassembly or movement Proof tests. Need HAULOTTE Services® authorization. For countries
needed to reach the part. where machines are not subject to controlled periodic maintenance.
Replacement is necessary.
38 4000414930 E 10.15 USA / GB

Daily inspection
Visual inspection without disassembly Check level
To check by test
Not
Yes No Corrected
applicable
Manuals and displays. Clean or replace if necessary.
Presence, cleanliness and legibility of the

manufacturer's plate
Presence, cleanliness and legibility of operator's and

maintenance manuals
Presence, cleanliness and legibility of capacity/load

chart decal of the machine
Control box (Ground and Platform)
Presence and cleanliness of the control box
No visible damage
All decals at the control boxes are clean and legible
Operation of start / stop device
Operation of E-stop button device
Operation of enable switch/foot pedal
Operation of horn from platform control box
Operation of movement from platform control box
Test warning alarm lights and buzzer
Overriding indicators turn off after 1 sec
No abnormal noise and jerky movements from

platform control box
Joysticks and movement switches return to neutral
Work Platform. Floor, guardrails, access and extensions
No cracks, broken weld, paint chipped
No deterioration and visible damage
Lanyard anchor points are not cracked or damaged,

and decal is attached and legible
No screws missing / loose parts
Entry bar/gate closes automatically and is not

prevented from closing.
Folding guard-rail (if fitted) is fixed securely in position
4000414930 E 10.15 USA / GB 39


Extending structure (jib, mast)
No foreign material / impurities in joints or slides
Presence of securely fitted maintenance devices

(safety stand)
All compartments covers open and lock properly
Frame, axle, steering system, stabilizers arms ...
Condition of tires/tyres (wear, cutting, damage ...)
Wheel reducer is undamaged and operates smoothly
All compartments covers open and lock properly
Rotation system : turret, basket and jib
Exterior gear wheel greasing
Pin, pin stop, bearing ...
Presence of the turret pin and its locking device
No bent, cracked or broken pins, pin stops, bushes or

bearings
Pulleys, chains and wire rope
No cracked or broken chains, links and fittings
Pulleys and clamps are not worn, rusted or damaged
Cylinder and hydraulic component : pumps, filters, manifold
No leaks on the pump, tank or fittings
No deformation, visible damage, broken weld or leaks

on hydraulic cylinder
Hydraulic oil level
Energy storage and motorisation: tanks, batteries and engine
40 4000414930 E 10.15 USA / GB


Battery electrolyte level
Level of centralized battery refilling
Presence and good condition of hydraulic hose
Presence and good condition of engine components
Presence and good condition of the batteries:

terminations and clamps, electrolyte level ...
Electric cables
No torn or split wire sheaths
No evidence of chemical damage or corrosion on all

cables
No oxidation or corrosion on terminals
Sensors and safety device
Slope limiting device operates properly
Test of load sensing system (visual warning at control

box)
Check that the safety devices operates correctly
E-stop buttons (on all control boxes)
'Enable switch' / foot pedal
Fault detector displays
Tilt sensor
Travel speed limitation
Serial number : Model :
Hours of operation :
HAULOTTE Services® contract reference : Signature :
Intervention record number :
Date :
Name :
4000414930 E 10.15 USA / GB 41


4 - Periodic inspection
The Periodic inspection is a thorough inspection of the operation and safety features of the machine. This
inspection must be done before the sale/resale of the machine and at a frequency of 125 hours or once a year,
according to the regulations. Local regulations may have specific requirements on frequency, and content of
inspections.
Otherwise or in addition, use the detailed program below.
This inspection is the responsibility of the owner, and must be conducted by a qualified technician.
To ensure safe use and improve the life of machine, HAULOTTE® recommends performing this inspection at
every 125 hours intervals.
Perform this inspection in addition to the daily inspection checks.
Intervention to be made after :

• Extensive dismantling and reassembly.
• Repairs involving the machine's essential components.
• Any accident causing stress to the machine.

to exchange/replace if necessary
Check-Test See user manual or
Operation requiring HAULOTTE
machine maintenance book (1) Services® authorisation

Oil change
maintenance
1 - Increase in periodic inspections
2 - For countries where machines are not subject to controlled periodic maintenance
42 4000414930 E 10.15 USA / GB


Periodic inspection
In addition to the daily inspection program
Area Type of intervention Area Type of intervention
Mast assembly Functions and controls
Platform control box (indicators,
Chains
etc.)
Ground control box (indicators,

Turntable assembly etc.)
Slew ring 'Enable switch' / foot pedal
E-stop buttons (on all control

Turntable rotation gearbox
boxes)
Chassis assembly Circuit breaker and contactors
Wheel nuts and bolts Overload system
Wheel axles Horn
Hydraulic and electric assemblies Brakes
Hydraulic filter Emergency lowering
Indicators, switches and

Hydraulic oil
joysticks
Hydraulic unit motor commutator Tilt sensor
Limit switch ( PV, radius limit,

Driving motor commutator
weighing)
Variable speed calculator Power system
Common areas Engine See manufacturer's guide

attachment)
Bearings General points

Cylinders (welds, leakproofness, According to current legislation
external leak, excessive Mandatory inspection in the country of use and at least
distortion) once a year
Greasing and lubrication
according to the maintenance
schedule
Machine integrity, no
modifications
authorisation
Date :
Number of hours :
Intervenor :
Comments
HAULOTTE Services® contract number :
Intervention sheet number :
Signature :
4000414930 E 10.15 USA / GB 43


5 - Reinforced inspection
Reinforced periodic inspection is a thorough inspection of the machine structure and to ensure proper
functionality. It must be performed every 1500 h or every 3 years, whichever occurs first.
This inspection is the responsibility of the owner, and it must be conducted by a HAULOTTE Services® technician
or a qualified company or person.
This inspection is in addition to the daily and periodic inspections. For details, refer to daily and periodic
inspections listed earlier.

to exchange/replace if necessary
Check-Test See user manual or
Operation requiring HAULOTTE
machine maintenance book (1) Services® authorisation

Oil change
maintenance
44 4000414930 E 10.15 USA / GB


Reinforced inspection
In addition to daily and periodic inspections
Mast assembly Functions and controls
Chains
etc.)

Cables
etc.)
Turntable assembly 'Enable switch' / foot pedal

Slew ring
boxes)
Turntable rotation gearbox Circuit breaker and contactors
Chassis assembly Overload system
Wheel nuts and bolts Horn
Wheel axles Brakes
Hydraulic and electric assemblies Emergency lowering
Indicators, switches and

Hydraulic tank, cap and breather
joysticks
Hydraulic filter Tilt sensor

Hydraulic oil
weighing)
Hydraulic unit motor commutator Power system
Driving motor commutator Engine See manufacturer's guide

attachment)
Common areas General points

According to current legislation
Pins, rings and pin stop Mandatory inspection in the country of use and at least
once a year
Pulleys and wear pads according to the maintenance
schedule
modifications
Bearings
authorisation
external leak, excessive
distortion)
Date :
Number of hours :
Intervenor :
Comments
Signature :
4000414930 E 10.15 USA / GB 45


6 - Major inspection
Major inspection is to ensure the continued safe use of the aerial work platform past the designed life of the
machine and for predicted use until the next recommended major inspection. It must be performed every 5000
h or every 5 years, whichever occurs first, and subsequently every 5 years thereafter.
This inspection is the responsibility of the owner, and it must be conducted by a HAULOTTE Services® technician
or by a qualified and authorized company or person.
This inspection includes the daily, periodic and reinforced inspections. Refer to the Operators manual for further
information.

Check-Test to exchange/replace if necessary
See user manual or machine Operation requiring HAULOTTE
maintenance book (1) Services® authorisation

Oil change
maintenance
A Major inspection report must be written describing the inspection method used, areas inspected and
tests conducted. If parts were disassembled but were not replaced, it should be specified/noted in the
report along with any comments and recommendations.
46 4000414930 E 10.15 USA / GB


Major inspection
In addition with daily, periodic, and reinforced
inspections
Platform assembly Functions and controls
Platform
etc.)
Mast assembly etc.)
Chains 'Enable Switch' pedal

Turntable assembly boxes)
Slew ring Circuit breaker and contactors
Turntable rotation gearbox Overload
Chassis assembly Horn
Wheel nuts and bolts Brakes
Wheel axles Emergency lowering
Indicators, switches, joysticks

Hydraulic and electric assemblies and selectors
Hydraulic filter Tilt sensor

Hydraulic oil
weighing)
Hydraulic unit motor commutator Power system
Driving motor commutator Engine See manufacturer's guide

attachment)
Common areas General points

According to current legislation
Welds Mandatory inspection in the country of use and at least
once a year
Hoses and couplings according to the maintenance
schedule
modifications
Pins, rings and pin stop
authorisation
Bearings

external leak, excessive
distortion)
Date :
Number of hours :
Intervenor :
Comments
Signature :
4000414930 E 10.15 USA / GB 47


Machine sheet
N.B.-:-THE LIST OF MAINTENANCE / INSPECTION SHEETS IS NOT EXHAUSTIVE. CONTACT HAULOTTE

SERVICES® FOR ADDITIONAL / OTHER SHEETS.
48 4000414930 E 10.15 USA / GB

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

• Standard tool kit
• Protective goggles • Place barriers around the perimeter of the work area
• Gloves
Exclusively use tools and auxiliary average adapted. Always wear necessary safety clothing.
For safety reasons, imperatively respect the following stages during the tests :
• To set up e beaconing of safety around the test area.
• To put the machine in position transport (horizontal jib accepted)
• Use safety straps.
2 - Preliminary operation
The operations of disassembling if they exist should be carried out only on the installations completely disconnected
and must be entrusted only to people having the necessary technical training.
Respect, in addition to the instructions appearing in the present instructions, the legal tendencies generally applicable
for safety accident prevention.
All the precautions must be done in work before intervening on and near the machine.
After completion of work, all the covers and safety devices must be positioned back completely and operational.
4000414930 E 10.15 USA / GB 49

General data
MS0001
3 - Control and maintenance

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

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

reinforced control will have to be carried out to judge
conformity of the part :
• Absence of foreign body to the articulations and slides.
• Absence of deformation and visible damage.
• Absence of crack, broken welding, oxidation, glare of
painting.
• Absence of excessive gap to the articulations and slides.
• Check that locking device are not damaged and are
functional.
• No screws or missing part loosened or unscrew.
• Anchorage points firmly fixed and not damaged.
The list of part to check are define Section Familiarization.
50 4000414930 E 10.15 USA / GB

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

• Boss welds on chassis, turret, arms, booms and jib.
• Booms and arms welds.
E x a m p l e
In the event of suspicion of crack, a cleaning and a sweating are to be carried out to guarantee the integrity
of the part before reassembly.
Check presence and torque of each bolts and screw used to assembly part listed in Section Familiarization.
Refer to spare part catalog for additional information if needed.
Some screws are not reusable and must be systematically changed (ex: screws from the gear ring).
4000414930 E 10.15 USA / GB 51

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

• The machine carried out all the movements without jolts while supporting the load.
• All the security device function correctly.
• Authorized maximum speeds of operation are not exceeded.
Refer to the user manual for the description of the safety device and technical characteristics to be reached.
3.5 - STRUCTURAL TEST (OVERLOAD)
The following test shows that the structure of the machine is in conformity with the safety requirements.
The machine must be place on level and firm ground.
With 125 % of the maximum allowed load, operate from ground control box (or emergency control box) all
the movements :
• 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.
52 4000414930 E 10.15 USA / GB

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

• Gloves
4000414930 E 10.15 USA / GB 53

General data
MS0002

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

• Abnormal noise during movements of the structure.
• Prolonged storage of the machine ( 6 months).
• Specific storage and use Environment (strong moisture and salinity of the air).
4 - Criteria of replacement
The pins, stop pins, bushes and bearing must be replaced as soon as one of the anomalies quoted above is noted.
Bearing and bushes must be imperatively changed at the end of 10 years of use.
54 4000414930 E 10.15 USA / GB

General data
MS0002
5 - Procedure of reassembly
5.1 - PINS AND BUSHES
For OPTIMUM 8 - OPTIMUM 1931 E only : Never grease the pins and rings of scissor arms.
When reassembling bearings and pins ensure that :

• Lightly lubricate the housing into which the bearing is to be installed.
• Insert the bearing using a bearing drift, preferably out of mild steel.
• The bearing, the bearing drift and the bearing housing must be correctly aligned during the assembly
process.
• The recommended values for the bearing drift are given on the diagram below :
R e c o m m e n d e d V a l u e s
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.
4000414930 E 10.15 USA / GB 55

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

• Clean boring and/or the pins to remove all the foreign bodies.
• Slightly lubricate boring and/or pins.
• Lubricate the ring of the bearing slightly.
• To fit bearing in a boring: take support on the external ring of the bearing.
• To fit bearing on an axis: take support on the interior ring of the bearing.
56 4000414930 E 10.15 USA / GB

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

• Gloves
• To set up a beaconing of safety around the test area.
• To put the machine in stowed position.

3.1 - VISUAL INSPECTIONS
The hydraulic actuating cylinders must be subjected to visual inspections periodic all the 250 hours or 6
months such as defined below :
• Absence of leakage.
• Absence of deformations, visible damage , cracks on the body and fixing of the cylinder.
• Absence of rust and shock on the rod.
• Absence of foreign body on all surfaces.
• Absence of missing or loosened part (bolt, nut, connection, flexible device, etc).
4000414930 E 10.15 USA / GB 57

General data
Cylinder inspection
MS0003
3.2 - FUNCTIONAL TESTS
To guarantee an optimal level of performance and safety, functional tests must be realized all the 250 hours
or 6 months.
The periodicity can evolve under the following conditions :

• Anomaly noted during visual inspection.
• Abnormal noise during movements of the structure.
• Prolonged storage of the machine ( 6 months).
• Specific storage and use Environment (strong moisture and salinity of the air).
Generic Control :
• Position a load equal to the rated capacity on the cage (or platform).
• Raise the cage (or the platform) using the ground control box. To activate the cylinder to be tested, proceed
as follows :
• Lift Arm hydraulic cylinder : Lift the arm to approximately half full height. The telescopic boom should be fully
extended and in the horizontal position. (For machines fitted with).
• Boom lifting cylinder or Jib cylinder : Lift the concerned equipment (boom or jib) of approximately half way. Extend
the telescope to its maximum.
• Telescoping cylinder : Lift the boom to its maximum angle and telescope approximately 50 cm (19.69 in).
• Measure the distance between the floor of the cage (or of the platform) and the ground.
• Leave the machine in this condition for 15 mn (minutes).
• Measure the distance between the floor of the cage (or of the platform) and the ground.
• If the difference between two measurements does not exceed 4 cm (1.575 in) : the test validates correct operation.
• If the difference between two measurements exceeds 4 cm (1.575 in), contact HAULOTTE Services® or carry out
the additional tests described below.
58 4000414930 E 10.15 USA / GB

General data
Cylinder inspection
MS0003
Control cylinder by cylinder :

• Position a load equal to the rated capacity on the cage (or platform).
• Perform the movement of the concern cylinder to half of its stroke.
• Fix the cylinder with a comparator :
• Attach the body of the comparator on the cylinder rod.
• The needle of the comparator must be in contact with the end of the casing of the cylinder.
• The target is to measure the creep of the cylinder rod.
• If the creep of the cylinder rod is higher than the values indicated in the table below, replace the cylinder.
Maximum drift authorised due to an internal leak of

Type of cylinders
the cylinder
Lift cylinder arm or boom (Machine with working heights After 10 mn, creep After 60 mn, creep
> 26 m(85 ft4 in)) < 0,2 mm (7874 µ in) < 1 mm (0.039 in)
Outriggers cylinder, Oscillating axle locking, Lift cylinder After 10 mn, creep After 60 mn, creep
arm or boom (Machine with range-limiting system) < 0,5 mm (0.01196 in) < 2,5 mm (0.098 in)
After 10 mn, creep After 60 mn, creep
Lift cylinder arm or boom, Telescoping, Compensation, ...
< 1 mm (0.039 in) < 6 mm (0.236 in)
After 10 mn, creep After 60 mn, creep
Steering cylinder
< 1,5 mm (0.059 in) < 9 mm (0.354 in)
These tests must be made in conditions of equivalent temperatures.
4000414930 E 10.15 USA / GB 59

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

• Absence of deformation and visible damage.
• Absence of crack, broken welding, oxidation, glare of painting.
Check :
1. Weld connection.
2. Weld connection to piston rod.
3. Bushe.
4. Surface.
5. Assembly and surface.
60 4000414930 E 10.15 USA / GB

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

• Gloves
• Set up a beaconing of safety around the test area.
• Put the machine in position transport (Pendular horizontal accepted).
3 - Test procedure
The brake system is a significant component of the safety of the machine. It is necessary to carry out functional tests
periodically all the 250 hours or every 6 months.
High speed :
• On a flat ground or slightly inclined (always lower than the authorized slope: see plate manufacturer).
• Trace on the ground, a line being used as reference mark of stop.
• Roll moving front until reaching maximum speed :
• Between 3 km/h (1.9 mph) and 6,5 km/h (4,039 mph) according to the machines.
• Release the manipulator as soon as the wheels axles are on the level of the traced reference mark.
• Stopped machine, measure the distance between the wheel axles and traced reference mark on the ground :
• If the distance lies between 0.2 m (0ft 8in) and 2,7 m (8 ft 11 in), the test is validated.
• If not, Contact HAULOTTE Services® to repair the system.
4000414930 E 10.15 USA / GB 61

General data
MS0004
Notes
62 4000414930 E 10.15 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
Yello Yello
Size Yellow dry
Dull dry (A) Lubed (B) Dull dry (A) Lubed (B) w dry Dull dry (A) Lubed (B) w dry Dull dry Lubed Yellow dry
(mm) (C)
(C) (C)
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs 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
Dull dry Lubed Yellow dry Dull dry Lubed Dry Dull dry Lubed Dry Dull dry Lubed Dry
Size
(mm)
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs 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
4000414930 E 10.15 USA / GB 63

General data
Torque Values
MS0005
2 - SAE fastener torque chart

SAE fastener torque chart
This charts is to be used as a guide only unless noted elsewhere in this manual
A574 High
Grade 5 Grade 8 strength black
oxide bolts
Size Thread
Lubed Dry Lubed Dry Lubed
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
20 80 9 100 11.3 110 12.4 140 15.8 130 14.7
1/4
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
Lubed Dry Lubed Dry Lubed
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
18 13 17.6 17 23 18 24 25 33.9 21 28.4
5/16
24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
3/8
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
14 37 50.1 49 66.4 50 67.8 70 94.7 61 62.7
7/16
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
13 57 77.3 75 101.6 80 108.4 110 149 93 126
1/2
20 64 86.7 85 115 90 122 120 162 105 142
12 80 108.4 110 149 120 162 150 203 130 176
9/16
18 90 122 120 162 130 176 170 230 140 189
11 110 149 150 203 160 217 210 284 180 244
5/8
18 130 176 170 230 180 244 240 325 200 271
10 200 271 270 366 280 379 380 515 320 433
3/4
16 220 298 300 406 310 420 420 569 350 474
9 320 433 490 583 450 610 610 827 510 691
7/8
14 350 474 470 637 500 678 670 908 560 759
8 480 650 640 867 680 922 910 1233 770 1044
1
12 530 718 710 962 750 1016 990 1342 840 1139
7 590 800 790 1071 970 1315 1290 1749 1090 1477
1 1/8
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 1/4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 1/2
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
64 4000414930 E 10.15 USA / GB

General data
Torque Values
MS0005
3 - STAR 8 - STAR 22J - STAR 10 - STAR 26J

Sub-assemblies Concerned elements Torque
Chassis Wheels 32 Nm
Wheel studs / Driving reducer Loctite 243 - Normal threadlocker
Wheel axles 115 Nm
Steering cylinder / Chassis 115 Nm
Slew ring / Chassis 135 Nm
Slew ring Turntable / Slew ring 195 Nm
Hydraulic motor / Slew ring 76 Nm
ECU ECU / Carrier 10 Nm
Engine Screw fastening elastic coupling / Flywheel 35 Nm
Counterweight Counterweight / Turntable 320 Nm
30 Nm
Mast Upper and lower front pads
Medium threadlocker
Platform control box 10 Nm
4000414930 E 10.15 USA / GB 65

General data
Torque Values
MS0005
Notes
66 4000414930 E 10.15 USA / GB

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

• Gloves
• Do not smoke.
4000414930 E 10.15 USA / GB 67

MS0010
3 - Lubrication
The maintenance of the slew ring is essential for the safety of the machine and to guarantee its service life. Whatever
the type of system installed on the machine, interior or external teeth, follow the recommendations of greasing as
indicated in the program.
• Grease the (internal and external) crown gear teeth.
• Grease the raceways (access to greasers via the holes situated on the turntable, until the oil escapes from the crown
lip seal).
68 4000414930 E 10.15 USA / GB

MS0010
4 - Tightening
To ensure safety operation, tightening check should be performed on slew ring.
Please refer to follow value for this procedure using a torque wrench.
Machine type Metric torque value Imperial torque value

HT21RT O - HT21RT O SW - HT61RT O - HT21RT PRO -
215 Nm 158.6 lb ft
HT21RT PRO SW - HT61RT PRO
HT23RTJ O - HT23RTJ O SW - HT67RTJ O - HT23RTJ PRO -
215 Nm 158.6 lb ft
HT23RTJ PRO SW - HT67RTJ PRO
HA16RTJ 215 Nm 158.6 lb ft
HA32PX - HA100JRT 215 Nm 158.6 lb ft
HA41PX-NT - HA130JRT-NT 215 Nm 158.6 lb ft
STAR 8 - STAR 22J - Ring on plate 135 Nm 100 lb ft
STAR 8 - STAR 22J - Plate on mast foot 195 Nm 144 lb ft
STAR 8 - STAR 22J - Ring on chassis 135 Nm 100 lb ft
STAR 10 - STAR 26J - Ring on plate 135 Nm 100 lb ft
STAR 10 - STAR 26J - Plate on mast foot 195 Nm 144 lb ft
STAR 10 - STAR 26J - Ring on chassis 135 Nm 100 lb ft
4000414930 E 10.15 USA / GB 69

MS0010
5 - Slew ring inspection

Check the slewing system every 500 h or each major intervention done on the machine.
5.1 - VISUAL AND SOUND CHECK
• Check for the presence of all the locating bolts.

• Check that the accessible screws are not loosened. If necessary, tighten the screws. (Refer to the
"tightening torque" table. )
• Visually check the presence of the teeth and gear (if possible).
• Check the appearance of the teeth.
A tight spot or grinding sound during rotation or the presence of metal particles escaping from the lip seal are
signs of abnormal wear in the raceway (Contact HAULOTTE Services®).
Replace slew ring in the following cases :

• Abnormal noise during the turntable rotation.
• Movement jolts during the rotation of the turret.
• Gear teeth missing or damaged.
• Presence of metal particles in the grease.
• Wear on gear teeth.
• Abnormal clearance of the gear ring.
70 4000414930 E 10.15 USA / GB

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

• On flat ground, Set up barriers to define the test area.
• No load in the platform.
• From the ground control box, align the turret at 90 ° to the chassis.
• Retract the mast.
• Jib in horizontal position (if fitted).
From the magnetic comparator, note the clearance ( J1) between chassis (or turret) and the slew ring.
C l e a r a n c e b e t w e e n c h a s s i s ( o r t u r r e t ) a n d s l e w r i n g
J1
After having carried out the measurement :

• Jib in horizontal position(if fitted).
In its new configuration, note the clearance ( J1) between chassis (or turret) and the slew ring as previously.
• If the difference between two measurements does not exceed 2 mm (0.08 in) : the test validates correct
operation.
• Otherwise, contact HAULOTTE Services® to repair the system.
4000414930 E 10.15 USA / GB 71

MS0010
Notes
72 4000414930 E 10.15 USA / GB

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

• Gloves
3 - Control wire rope system

To guarantee a full safety use of the machine , Haulotte recommends respecting the following inspections :
3.1 - DAILY CHECK
• To position the machine on a flat and firm ground.

• To put the machine under tension and select the ground control box.
• To raise the boom with horizontal (not necessary for masts type machine).
• To carry out a cycle of extending/retracting of the boom assembly on approximately 2 m (6ft 7 in) or of
rising/lowering for masts type machines.
• To check the synchronization and the symmetry of the movements and the absence of abnormal noises.
If these phenomena occur, carry out a reinforced control (see paragraph below).
4000414930 E 10.15 USA / GB 73

Upper boom
MS0012
3.2 - PERIODIC CONTROL
This operation must be realized as of the first 50 hours, then :

• for STAR all 250 hours or 3 months.
• for the other machines all 250 h hours or 6 months.
To reach the elements :

• To position the machine on a flat and firm ground.
• Dismount the inspection door and/or covers.
• To put the machine under tension and select the ground control box.
• To raise the boom with horizontal (not necessary for masts type machines).
• To check the presence and the tightening of the fastenings of the cables on the visible points of fixing.
• To extend the structure to obtain an access to the wire rope :
• To extend the boom at least 3 m (9 ft 10 in) for the telescopic machines.
• To raise the masts unit to the doors inspection.
Using a flash light, perform a visual inspection of the following items :

• Check that cables are properly aligned with one another.
• Check that the cables under are equal tension.
• Check that the pulleys are properly aligned with the cables.
• Check that the cable is properly seated in the pulley.
• Check that nothing blocks the chain guides.

• Check the condition of the cables. If any of the following defects are observed, replace the pair of cables.
Replace defective parts with genuine HAULOTTE® replacements.
74 4000414930 E 10.15 USA / GB

Upper boom
MS0012
Machine Original diameter

STAR 6 - STAR 13 - STAR 8 - STAR 22J - STAR 10 - STAR 22J 3 mm
H21TX - H23TPX - H25TPX 9 mm
HA16JRT To be completed
HA20RTJ_O_PRO To be completed
HT21RT - HT61RT - HT23RTJ - HT67RTJ 11,2 mm
H43TPX 19 mm
• No broken strands must be observed, in particular at the ends.

• Replacement is compulsory when 3 strands or more are broken along the length of the cable.
• Replacement is compulsory when 1 strand is broken near the ends.
• No deformed folds or frayed strands must be observed.
• No signs of corrosion must be observed.
4000414930 E 10.15 USA / GB 75

Upper boom
MS0012
4 - Tension checking
This operation must be realized as of the first 50 hours, then :
• for STAR all 250 hours or 3 months.
• for the other machines all 250 h hours or 6 months.
For the particular procedures of adjustment untreated in maintenance book, it is necessary to contact HAULOTTE
Services®. MS0018 Boom adjustment procedure.
5 - Criteria of replacement
Cables with a diameter measuring less than 6 mm (STAR) must be replaced every 5 years.
All other cables must imperatively be replaced every 7 years.
Replacement may be required more frequently for the following reasons :

• Machine operates in a particularly hostile environment.
• Abnormal noises are produced during movement of structure.
• Machine has been in storage for more than 6 months.
• Machine has been submitted to an abusive load or serious collision.
• Machine has been exposed to an electrical arc.
Contact Haulotte Services for further advice.
Cables and cable elements are made from case hardened steel in a high-quality process. Deliver any scrap cables or
cable elements to a dealer specialised in metal recycling in compliance with regulations.
76 4000414930 E 10.15 USA / GB

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

• Gloves
2 - Control and inspections

The state of hoses devices plays a significant role in the safety of the machines.
For the hoses device accessible without consequent disassembling, a visual inspection must be realized all the 250
hours or 1 year :
• Check the absence of leakage to the junctions of the hoses.
• Check that all the hoses are correctly tightened.
• Check the absence of tear and crack of the external hoses.
• Check that the shielding of the hose is not apparent.
• Check the absence of chemical aggression of the membrane of the hose.
For the non visible hoses without disassembling, a reinforced visual inspection must be realized all the 5000 hours
or 5 years.
If anomalies are noted, it is necessary to replace the elements by respecting the following recommendations.
4000414930 E 10.15 USA / GB 77

Hydraulics
MS0020
3 - Hoses Disassembling
For safety reasons, respect imperatively the following conditions of disassembling :
• Fold the machine on a flat and released ground :
• The machine is not in slope.
• The boom is horizontal.
• Put the turret (if equipped) in the axis.
• Carry out a beaconing of the sector (maximum risk zone = machine height).
• Locate the hoses and their connections points to guarantee the good performance of the machine after intervention.
• Locate the hoses course to facilitate the reassembly.
To recover oil, use an oils container in order not to pollute the environment.
Unscrew the flexible device slowly in order to make fall residual water pressure.
It is imperative to secure and maintain cylinders when removing hoses cylinders. An analysis of the
hydraulic system is imperative.
After disassembling :
• Close the hose openings and the hydraulic components to avoid the pollution of the hydraulic system.
• Check the cleanliness of the hoses and the hydraulic components :
• Absence of plastic, rubber or metal shaving.
• If necessary, purge and clean the circuit (tank included).
4 - Hoses Reassembly
For safety reasons, respect imperatively the following conditions of reassembly :
• Using the reference marks carried out previously; carry out the courses of hoses.
• During the fixing of the hoses, respect the tightening torques below.
T i g h t e n i n g t o r q u e t a b l e
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.
78 4000414930 E 10.15 USA / GB

Electric
Electrical wiring
MS0059
Electric
Electrical wiring
1 - You will need

• Gloves
Maintaining electrical wiring in good condition is essential to safe operation and good machine performance. Failure
to find and replace burnt, chafed, corroded or pinched wires could result in unsafe operating conditions and may cause
component damage.
• Open the side covers.
• Inspect the following areas for burnt, chafed, corroded and loose wires :
• Cable carrier cat track.
• Engine wiring harness.
• Hydraulic manifold wiring.
• Gear ring rotation block.
• Mast lowering emergency block.
4000414930 E 10.15 USA / GB 79

Electric
Electrical wiring
MS0059
Notes
80 4000414930 E 10.15 USA / GB

Upper boom
Inspection of the condition of the chains - Criteria of replacement
MS0042
Upper boom
1 - You will need

• Gloves
4000414930 E 10.15 USA / GB 81

Upper boom
MS0042
3 - Lubrication
Lubricant must be applied with a brush to the external chains at least every 250 hours or every 6 months. The
frequency of application depends on surrounding conditions and conditions of use. The frequency of application must
ensure that a sufficient quantity of fluid oil is present in the chain links.
If the chain has been exposed to corrosive fluids, clean the chain immediately and apply lubricant.
N.B.-:-TELESCOPING OPERATIONS MAY BE NECESSARY TO ACCESS ELEMENTS.
Before applying new lubricant, remove any foreign particles from the chain. Use recommended lubricants
Section B 1Recommendations-Lubrication diagram.
When cleaning chains, follow regulations concerning the environment.
3.1 - CHECK THE CONDITION OF THE CHAINS
To carry out the following operations, perform a complete telescoping.

• Check that the lifting chains and safety chains are clean.
• Check that there are no foreign particles on the chains and guide.
• Check that there are no signs of corrosion on chain elements.
Chains with any of the defects described below must be replaced.

• Check for elongation wear :
• Elongation of up to 2 %, over 12 segments, of the original chain length is permitted.
• Measure the value of (3) using an appropriate method. Compare with the value of *1 indicated in the table
below.
Machine Link width (2) Length of 12 links (4)

STAR 6 - STAR 13 - STAR 8 - STAR 22J - STAR 10 - STAR 26J
HA32/41PX-NT 11.5 mm 152.40 mm
H28TJ+/H43TPX
STAR 8 - STAR 22J - STAR 10 - STAR 26J 14.50 mm 190.50 mm
HTL 4014/17 - HTL 3614/17 24 mm 304.80 mm
82 4000414930 E 10.15 USA / GB

Upper boom
MS0042
• Check for external wear on rollers and links :

• External wear must not measure more than 2 % from the section of the original link (2), see table above.
• Measure the value of (1) using an appropriate method.
• Check that no line or element is damaged or missing.

• Check that links are not distorted, deformed or broken.
Crack
Distortion
Break
Wedging
• Check the connection points of links (the lines must be parallel).
4000414930 E 10.15 USA / GB 83

Upper boom
MS0042
3.2 - CHECK THE TENSION OF THE CHAINS
Refer to the technical data sheet for your product following this sheet. To make any other adjustments not
detailed in this maintenance logbook : Contact Haulotte Services for further advice.
4 - Replacing the chains

The chains must imperatively be changed every 10 years.
Contact Haulotte Services for further advice.
Les chains and chain elements are made from case hardened steel in a high-quality process. Deliver any scrap chains
or chain elements to a dealer specialised in metal recycling in compliance with regulations.
84 4000414930 E 10.15 USA / GB

Tires (Tyres) and pressures - Wheel replacement
MS0044
1 - You will need

• Protective goggles
• Gloves
• Place barriers around the perimeter of the work area
• Jack
• Hoist
• Torque spanner
3 - Technical specifications
Component Standard wheel
Reference number Solideal
Type Solid tires/tyres
Drive wheel mass 18,5 kg - 41 lb
Steer wheel mass 20,6 kg - 45 lb
Size 406 mm / 100 mm (16 in/ 5 in)
Torque 115 Nm (84.81 ft lbs)
4000414930 E 10.15 USA / GB 85

MS0044
4 - Wheel and tires/tyres inspections

Replace the wheels and the tires/tyres if any of the following conditions exist :
• Presence of cracks, damage, deformation or other faults on the hub
• Damage to the tire :
• Cut or hole > 3 cm (2 in) in the rubber side wall.
• Blister or pronounced lump on the external and lateral wall.
• Damaged wheel stud.
• Damage or wear on the side wall to the extent that the reinforcing wire is
visible.
• Consistent wear of the ground contact surface greater than 25%
Tires and rims are critical components for the stability of the machine. For safety reasons. :
• Use only HAULOTTE® spare parts according to the technical characteristics of the machine. Refer to
the spare parts catalog.
• Never replace foam filled tire with a pneumatic (air filled) tire.
86 4000414930 E 10.15 USA / GB

MS0044
5 - Wheel replacement
Procedure of replacement :
• Loosen the wheel nuts on the wheel to be removed.
• Raise the machine using a jack or a hoist.
• Remove the wheel nuts.
• Remove the wheel.
• Install the new wheel.
• Lower the machine to the ground.
• Tighten the wheel nuts to the recommended torque Refer to maintenance and repair manuals.
Component Standard wheel

Reference number Solideal
Type Solid tires/tyres
Drive wheel mass 18,5 kg - 41 lb
Steer wheel mass 20,6 kg - 45 lb
Size 406 mm / 100 mm (16 in/ 5 in)
Torque 115 Nm (84.81 ft lbs)
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MS0044
Notes
88 4000414930 E 10.15 USA / GB

Lubrication - Jib cylinder - Steering cylinder - Lift cylinder
MS0045
1 - You will need

• Brush
• Multipurpose grease (of mineral type) • Place barriers around the perimeter of the work area
• Gloves
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MS0045
3 - Lubrication
Jib cylinder
In order to maintain the lifting cylinder in good condition and avoid any internal or external corrosion during prolonged
storage (inside or outside), proceed as follows :
• Machine stowed
Carry out the movements to lift and descend of jib or platforme every 2 or 3 days to lubricate cylinder tube.
• Machine unfolded
Using a brush, apply multipurpose grease (of mineral type) to all the chrome and unpainted parts of the cylinder ( 1 ).
Lubricate the cylinder rod 1 once a month ( 1 ).
Do not use synthetic grease. Synthetic grease can damage the seals of cylinder.
Before operating the machine, remove the grease from the cylinder rod.
Do not high pressure wash the cylinder as this could cause damage to the cylinder rod, as well as
penetration of water into the guide seal (corrosion, contamination, seizing).
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MS0045
Steering cylinder
• Wheels aligned
1 1
Lubricate the cylinder rod 1 once a month ( 1 ).
Do not use synthetic grease. Synthetic grease can damage the seals of cylinder.
Before operating the machine, remove the grease from the cylinder rod.
Do not high pressure wash the cylinder as this could cause damage to the cylinder rod, as well as
penetration of water into the guide seal (corrosion, contamination, seizing).
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MS0045
Lift cylinder
• Store the machine with retracted mast.
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Dismantling / Reassembling wheels reducer
MS0046
1 - You will need

• PPE (Personal Protective Equipment: glove, safety shoe,
glasses, etc…)
• Torque wrench
• Strap (Capacity : 500 kg / 1100 lb)
• Bridge crane 1000 kg(2200 lb) (minimum)
• Grease
• Hydraulic oil
Exclusively use tools and auxiliary average adapted. Always wear necessary safety clothing. This procedure is to be carried out after the
first 50 hours and then every 250 hours.
2 - Level of knowledge required

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 they have the PPE (personal protective equipment) suitable for the job and
the particular conditions of environment in witch 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.
• 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.
• 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 using your hands.
• Attention to the risks of burns, the hydraulic system works at high temperatures.
• 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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MS0046
4 - Removal
• Cut off the main power supply at the battery master switch.
• Disconnect all energy sources connected to the machine (e.g. battery
charger).
• Identify the motor to be replaced.
Arrière droit / Arrière gauche /

Rear right Rear left
• Disconnect the U/V/W cables and the 3 connectors (braking, temperature

and speed sensors).
• Place the machine on resistant and stable wedges. Dismantle the relevent
wheel.
• Unscrew the 6 CHC M8X30 fastening screws and the 6 M8 flat washers.
94 4000414930 E 10.15 USA / GB

MS0046
• Sling the gear motor assembly using a 500 kg(1100 lb) sling and a bridge
crane.
N.B.-:-IF THE GEAR MOTOR NEEDS TO BE DISMANTLED, UNSCREW THE

4 FASTENING SCREWS.
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MS0046
5 - Reinstall
• Reposition the assembly in the notch.
• Push the motor into the highest position.
• Attach the assembly using screws and washers.

• Tighten to the recommended torque : 32 Nm.
• Mark with a pen as shown.
• Reconnect all the U/V/W cables and the 3 connectors.
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MS0046
• Tighten to the recommended torque on the above procedure (4,8

Nm).
• Refit the wheel.

• Attach the wheel using the 5 screws and washers.
• Mark with a pen as shown.
6 - Additional operations
• Check the wheel gear oil level.
• If missing, perform the filling (Typ Shell SPIRAX 80W90 Quantity 0,68 l).
7 - Checks
• Switch the machine on.
• Engage drive in forward and then reverse (high and low drive speed).
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MS0046
Notes
98 4000414930 E 10.15 USA / GB

Replacing the wheel pivot
MS0047
1 - You will need

glasses, etc…)
• Bridge crane 1000 kg(2200 lb) (minimum) • Place barriers around the perimeter of the work area
• Torque wrench (10 Nm - 115 Nm)
• Wrench and sockets up to diameter 36 mm
• Mounting punches (50 - 70 mm)
• Grease

this intervention.
the outside.
4000414930 E 10.15 USA / GB 99

MS0047
4 - Removal
The procedure is identical for the front left and front right pivots.
F r o n t r i g h t p i v o t
F r o n t l e f t p i v o t
charger).
• Remove the covers.

• Remove the wheel.
100 4000414930 E 10.15 USA / GB

MS0047
• Lift the machine using a hoist (or a jack). Place chocks under the chassis to
ensure the machine is safely immmobilised.
• Remove the V4X45 pin and M18 flat washer.
• Unscrew the fastening plate from the steering pivots (right or left depending
on the pivot to be changed).
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MS0047
L e f t s t o p ( S c r e w r i n g H E 6 X 1 6 )
R i g h t s t o p ( S c r e w r i n g C H C 6 X 1 6 )
• Use a mallet to knock the assembly out of its seating.
• Sling the hub.
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MS0047
5 - Reinstall
5.1 - HUB
• Lubricate the interior of the 2 bores.

V i e w f r o m l a r g e b o r e s i d e
V i e w f r o m s m a l l b o r e s i d e
• Separate the ball bearings from the ring.

• Fit the ring into the hub.
• Proceed in the same way on the large bore side.
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MS0047
• Lubricate the inner and outer rings and slide the assembly into the
cage, as shown.
• Fit the seal into its seating.
Take care it is mounted the right way round.
• Lubricate the pivot at 3 points as shown.
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MS0047
• Slide on the wheel hub.

• Using a punch, insert the wheel hub up to the stop.
Do not force it.
• Using a punch, insert the small bearing into its cage.
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MS0047
• Position the M30 washer in the centre.

• Screw up the nut.
• Tighten with a torque wrench to a torque of 10 Nm.
N.B.-:-IF NECESSARY, FINISH TIGHTENING WITH A RATCHET WRENCH TO

LINE UP THE HOLE FOR THE PIN.
• Inser the V5X 50 pin around the M24 nut.

• Using a punch, fill the 62 mm diameter cap with grease and install
it.
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MS0047
5.2 - WHEEL AXLES
• Lubricate the shaft of the pivot.

• Apply grease to the 2 sides of the washer.
• Position the washer at the stop.
• Position the chamfer on the top as shown.
• Lubricate the ring on the chassis.

• Lubricate the shaft of the pivot connecting to the steering tie-rod.
• Insert the pivot into its seating.

• Refit the washer and pin on the axle.
4000414930 E 10.15 USA / GB 107

MS0047
• Re-attach the stops (right and left).
• Refit the wheel.

• Tighten the wheel nuts to the recommended torque : 115 Nm
6 - Checks
• Engage drive and steering. Check there are no leaks or abnormal noises.
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Steering cylinder replacement
MS0048
1 - You will need

glasses, etc…)
• Grease

this intervention.
the outside.
4000414930 E 10.15 USA / GB 109

MS0048
4 - Removal
charger).
• Lift the machine using a hoist (or a jack).

• Stabilize the machine correctly.
• Remove the front wheels.
• On each side of the cylinder, remove the V4X45 pin and the M18 flat
washer in order to free the steering tie-rods.
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MS0048
• Remove the 4 HM12x40 cl 10.8 fastening screws using a 16 mm

diameter wrench in order to remove the cylinder assembly and the 2
steering tie-rods.
• Extend the cylinder.

• Remove the V4X45 pin and the M16 flat washer from each side.
• Remove the 3/8 BSPP male unions from the cylinder and refit them on the
new cylinder.
4000414930 E 10.15 USA / GB 111

MS0048
5 - Reinstall
• Refit the tie-rods.
Take care that the yoke shoulder is the right way round.
• Re-build the actuator.

• Attach the cylinder to the wheel pivots.
• Refit the wheels.

6 - Checks
• Engage drive and steering. Check there are no leaks or abnormal noises.
112 4000414930 E 10.15 USA / GB

Hydraulics
Hydraulic oil - Level Replacement
MS0049
Hydraulics
1 - You will need

• Place barriers around the perimeter of the
work area
• Gloves
3 - Level control
Each day before use, check the hydraulic oil level to ensure safety operation.
N.B.-:-CHECK THE OIL LEVEL WHEN COLD AND WHEN THE MACHINE IS STOWED (BEFORE BEGINNING A NEW PERIOD
OF WORK)
The oil level (1) must be between the upper and lower markers .
2
Top up the oil level, if necessary :
1. Loosen and remove the tank cap (2).
2. Top up the oil level.
3. Refit and tighten the tank cap (2).
1
4000414930 E 10.15 USA / GB 113

Hydraulics
MS0049
4 - Replacement of hydraulic oil

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

• The machine must be completely folded (for the machines equipped: raised stabilizers).
• Fill the tank.
• Carry out a complete cycle (to go/return) of each cylinder.
• Fill the tank if necessary (never more than the maximum level).
• Repeat stages 1 and 2 for each cylinder of the machine.
When filling, it is forbidden to remove the strainer filter.
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Hydraulics
Hydraulic filter cartridge Replacement
MS0050
Hydraulics
1 - You will need

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

Before dismantling, ensure that the oil circuit is no longer under pressure and that the oil temperature is
not too high.
1. Loosen and remove plug ( 1 ).

1
2. Remove the cartridge.
3. Install a new cartridge.
4. Refit and tighten plug .
4000414930 E 10.15 USA / GB 115

Hydraulics
MS0050
Notes
116 4000414930 E 10.15 USA / GB

Electric
Battery (ies)
MS0051
Electric
Battery (ies)
1 - You will need

• Gloves
2 - Control
Remove the battery cover.
Loosen the caps located on the top of the battery.
The battery level must be in the maximum high position.
4000414930 E 10.15 USA / GB 117

Electric
Battery (ies)
MS0051
3 - Centralized battery refilling

The machine is delivered with the centralized filling tank empty.
When using the machine for the first time, the user must fill the tank with demineralized water up to the
maximum level.
• Press and hold the button. The water travels from the tank to the batteries.
Holding permanently the toggle switch for battery filling must

not exceed more than 5 mn.
When the batteries are full, the filling motor forces.

Stop pressing the filling button.
• Check the battery level :
• Remove the battery cover.
• Visually check the float on the cap indicator.

• The battery level must be in the maximum high position.
The lack of demineralized water has no effect on the centralized battery filling system.
In cold weather conditions, centralized battery filling does not function.
Do not use the centralized battery filling system before the first 10 battery charge/discharge cycles.
Do not run the centralized battery filling system during use or when on charge.
Centralized battery filling must only be carried out when the batteries are charged.
118 4000414930 E 10.15 USA / GB

Electric
Battery (ies)
MS0051
4 - Filling the batteries manually

In cold weather conditions, centralized battery filling does not function.
Perform battery filling manually.
Loosen the caps located on the top of the battery.
If the level of electrolyte is below the level of the plates :

1. Top up with distilled water.
2. Refit and tighten the battery caps.
5 - Battery charge
Battery charger status
Ground control box :
The indicator (90) indicates charge status.
• Green indicator : Battery charged 100 %.

• Yellow LED : Battery charged 80 %.
• Red LED : Battery in initial charging phase.
Platform control box :
The indicator (135) indicates charge status.
• Battery charged :
100%
• Flashing : Batteries have 40% charge left :
40%
• Constantly on : Batteries have only 20% charge left :
20%
4000414930 E 10.15 USA / GB 119

Electric
Battery (ies)
MS0051
When should the batteries be charged? :

• Never discharge the batteries to more than 80 % of their capacity in 5 h (hours).
• When the batteries are discharged to between 35 % and 80 % of their nominal capacity.
• If installing new batteries, recharge them after 3 or 4 hours of use 3 to 5 times
• After a long period of non-use.
• Never leave the batteries discharged.
• Do not put off recharging the batteries in cold weather as the electrolyte may freeze.
• Do not recharge the batteries if the temperature of the electrolyte exceeds 40 °C(104 °F) . Allow to cool
down.
• Keep the top of the batteries clean and dry. Incorrect connection or corrosion may cause a high loss of
power
• The charger settings are adjusted in the factory using its own cable. If the cable needs changing,
the HAULOTTE® factory must be contacted to obtain authorisation.
How to charge the batteries ? :
Before charging the batteries, switch the machine off.
• Use the machine's on-board charger. The charger has a charge rate compatible to the battery capacity.
• Ensure that the mains supply is compatible to the charger's consumption.
• Top up the batteries with distilled water to the minimum electrolyte level if any of the elements are below this
minimum level.
• Work in a clean and well-ventilated area away from naked flames.
Charger type 24 V - 35 A
Electric power supply 220 V single phase 50 Hz
Delivered voltage 24 V
Charging time Approximately 10 h for batteries discharged to 80 %
Mains connection Standard plug
Start-up is automatic as soon as the mains connection is established. The charger is fitted with a LED indicator placed
near the special holding frame :
• Green indicator : Battery charged 100 %
• Yellow LED : Battery charged 80 %
• Red LED : Charger in the intitial charge phase
120 4000414930 E 10.15 USA / GB

Electric
Battery (ies)
MS0051
When there is a fault, the LED indicator flashes in various colours depending on the type of alarm :
State of flashing indicator Type of alarm Description (Action)
Battery not connected or not compliant : Check connection or

Red Battery presence
rated voltage.
Temperature probe disconnected while charging or outside the

Yellow Temperature probe functional range : Check connection and measure battery
temperature.
Phase 1 or 2 is longer than the maximum allowed time : Check

Green Specified time
battery capacity
Red-Yellow Battery current Loss of output current control : Faulty control logic.
Loss of output voltage control : Battery disconnected or faulty

Red-Green Battery voltage
control logic.
Red-Yellow-Green Temperature Overheating of semiconductors : Check fan operation.
In case of an alarm, the charger stops supplying power
During charging :
• The machine's electric system is automatically deactivated while the external power supply is connected to the
machine
• Ensure that the battery are at a temperature not exceeding 45 °C(113 °F) (be careful in summer or in places with a
high ambient temperature)
• Do not remove or open the caps on the elements.
Charge interruption :
• To turn off the charger, disconnect it from the mains.
• Should the machine need to be operated during a charging cycle, first diconnect the charger. This may reduce the
life span of the batteries. Re-connect the charger once the operation is over.
After charging :
• Top up the electrolyte level, if necessary.
• Avoid overflowing.
• Wash the top of the batteries without removing the caps.
• Dry with compressed air or clean cloths.
• Oil the terminals.
When the charger is connected to the mains for more than 48 h (hours), a new charging cycle starts up at
the end of the previous charging cycle in order to offset self-discharge.
4000414930 E 10.15 USA / GB 121

Electric
Battery (ies)
MS0051
B a t t e r y c h a r g e s t a t u s a c c o r d i n g t o d e n s i t y a n d
t e m p e r a t u r e
Do not store machines, outside and in cold weather conditions, when batteries are discharged : Risk of
damaging batteries.
122 4000414930 E 10.15 USA / GB

Electric
Battery (ies)
MS0051
L o s s o f c a p a c i t y d u r i n g p r o l o n g e d s t o r a g e
.0015 perdu par semaine lors d'un stockage à une T° de 6°C

.0015 per week loss in prolonged storage at 42°F

%
remaining
en%
Capacityremaining
restanten
Specific gravity
Densité acide
Capacitérestant
%Capacity
Capacité
%
Temps (semaines)
Times (weeks)
E l e c t r o l y t e f r e e z i n g p o i n t a c c o r d i n g t o t h e d e n s i t y
o f t h e a c i d a n d s t a t e o f c h a r g e
Specific gravity Battery charger status Freezing point

1.280 100 % -69 °C(-92 °F)
1.265 92 % -57 °C(-71,3 °F)
1.250 85 % -52 °C(-62 °F)
1.200 62 % -27 °C(-16 °F)
1.150 40 % -15 °C(5 °F)
1.100 20 % -7 °C(19 °F)
4000414930 E 10.15 USA / GB 123

Electric
Battery (ies)
MS0051
Notes
124 4000414930 E 10.15 USA / GB

Electric
Battery (ies)
MS0052
Electric
Battery (ies)
1 - You will need

glasses, etc…)
• Standard tool kit • Place barriers around the perimeter of the work area

this intervention.
the outside.
4000414930 E 10.15 USA / GB 125

Electric
Battery (ies)
MS0052
4 - Removal
• Lift the mast slightly.
charger).
O v e r v i e w - B a t t e r i e s
126 4000414930 E 10.15 USA / GB

Electric
Battery (ies)
MS0052
• Disconnect all the cables connected to the battery elements.

• Disconnect the centralized filling pipes.
• Loosen and remove the 2 fastening screws .
• Remove the upper cover bracket.
• Remove the battery compartment using a bridge crane.
4000414930 E 10.15 USA / GB 127

Electric
Battery (ies)
MS0052
5 - Reinstall
• Refit a the new battery pack.
• Re-attach and reconnect all the cables and pipes to the centralized filling
system.
Take care with the connections.

• Check the levels and top up as required.
• Recharge the batteries.
• Once charging is finished, check the voltage and density.
The density level is approximately 1,28 kg/l to 20°.
6 - Checks
• Test the movements from the platform and ground control boxes.
• Check no alarms are present.
128 4000414930 E 10.15 USA / GB

Mast
Return cables
MS0053
Mast
Return cables
1 - You will need

• Gloves

this intervention.
the outside.
4000414930 E 10.15 USA / GB 129

Mast
Return cables
MS0053
4 - Control
on STAR 8 - STAR 22J and STAR 10 - STAR 22J only :
Replace in case of :
• Broken wire ( C )
C
• Broken strand ( B )
Jeu B
• Kinked cable Gap

1 mm max.
A
• Wear on lugs
• Abnormal stretching of the cabel making it impossible to adjust play at the
threaded end
130 4000414930 E 10.15 USA / GB

Mast
Specific adjustment procedure STAR 8 - STAR 20J - STAR 10 - STAR 26J
MS0054
Mast
1 - You will need

glasses, etc…)
• A tape-measure, a ruler
• Ratchet wrench + socket S22.HLA and S24.HLA • Place barriers around the perimeter of the work area
• Spanner 4, 10, 13, 14, 24
• Flat pliers
• Ratchet version 10 flat wrench
• 5 BTR wrench

this intervention.
the outside.
4000414930 E 10.15 USA / GB 131

Mast
MS0054
4 - Inspection of chain adjustment

From the ground control box :
• Lift the mast so that tube 1 extends 300 mm beyond the foot of the mast (+/- 2 mm).
4 306 mm +/- 2 mm
3 300 mm +/- 2 mm
2 300 mm +/- 2 mm
1 300 mm +/- 2 mm
Pied de mât / Mast foot
• Check the height of the tubes :
For STAR 10 - STAR 26J :

• Tube 1 : 300 mm (+/- 2 mm)
• Tube 2 : 300 mm (+/- 2 mm)
• Tube 3 : 300 mm (+/- 2 mm)
• Tube 4 : 306 mm (+/- 2 mm)
For STAR 8 - STAR 22J :

• Tube 1 : 300 mm (+/- 2 mm)
• Tube 2 : 300 mm (+/- 2 mm)
• Tube 3 : 312 mm (+/- 2 mm)
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Mast
MS0054
• If not compliant :
Carry out the operations from the ground control box.
Before adjusting the chains, check that the return cables are not tight.
Adjust the chains on tube 1 to adjust the height of tube 2 :

• Screw or unscrew the nuts A located under the machine with a ratchet
wrench and a long 24 socket
• Check via the inspection hatch at the foot of the mast located on tube 1
that the chains are not twisted.

• Screw or unscrew the nuts B located on tube 1 with a ratchet wrench and
a long 22 socket
• Hold the chain yolks with a 24 flat wrench.
4000414930 E 10.15 USA / GB 133

Mast
MS0054

• Screw or unscrew the nuts C located on tube 2 with a ratchet wrench and
a long 22 socket.
• Hold the chain yolks with a 14 flat wrench.
5 - Inspection of chain adjustment

From the ground control box :
• Lift the mast so that tube 1 extends 100 mm beyond the foot of the mast (+/- 20 mm).
100 mm +/- 20 mm
Inspect the 6 return cables ( 4 for the STAR 8). The clearance between the washer and the foot of the mast or tube
must be 2 mm.
134 4000414930 E 10.15 USA / GB

Mast
MS0054
2 mm
• If not compliant :
For the cables at the foot of the mast and tube 1 :

• Hold the cable lub with a 4 flat wrench
• Adjust the cable tension : Screw or unscrew the M6 locknut, preferably with a ratchet version 10 flat wrench
For the cables on tube 3 :

• Remove the left chain from tube 3 so as to free access to the return cable
• Adjust the clearance to 2 mm for both chains
• Refit the chaine once the adjustment has been made
• Check that both chains have the same tension.
For chain adjustment : Only remove one chain from tube 3 at a time.
Check the height of the tubes again after refitting the chains.
4000414930 E 10.15 USA / GB 135

Mast
MS0054
Notes
136 4000414930 E 10.15 USA / GB

Mast
Tube wedging procedure
MS0061
Mast
1 - You will need

• Gloves

this intervention.
the outside.
4000414930 E 10.15 USA / GB 137

Mast
MS0061
4 - Procedure
Wedging of the folded mast must be carried out with a functional clearance of 1 mm in the left/right axis and 0,5 mm
in the front/rear axis.
If the mast jams when being extended, increase the clearance.
Avant / Front
Gauche / Left Droite / Right
Arrière / Rear
If the distribution of the wedges cannot be equivalent on each side of a tube, wedge the right and rear sides more
according to the red dots on the diagram below.
The maximum wedging authorised per pad is 2 mm.
The pads must be attached with pre-coated CHC M6x20 screws and M6 contact washers.
138 4000414930 E 10.15 USA / GB

Mast
Inspection of the slack chain sensors
MS0062
Mast
1 - You will need

glasses, etc…)
• Standard tool kit • Place barriers around the perimeter of the work area
• 2 slings 6 T - 3 m(9 ft10 in)
• Bridge crane 4000 kg(8,82 lb) (minimum)

this intervention.
the outside.
4000414930 E 10.15 USA / GB 139

Mast
MS0062
4 - Procedure
• Lift the machine to a height of 1 m(3 ft3 in) using a hoist.
Sensor SQ801 :
• Place an insulating element between the sensor and the chain rod.
• The sensor should switch off and a fault should be displayed on the screen (ground control box).
• Check the appearance of the "Chain break" message on the screen.
N.B.-:-THE APPEARANCE OF THE "CHAIN BREAK" MESSAGE MEANS THAT THE SENSOR IS WORKING.
Sensor SQ802 :
• Place an insulating element between the sensor and the chain rod.
• The sensor should switch off and a fault should be displayed on the screen (ground control box).
N.B.-:-THE APPEARANCE OF THE "CHAIN BREAK" MESSAGE MEANS THAT THE SENSOR IS WORKING.
Perform the same operation for the 2 sensors at the same time.
N.B.-:-THE APPEARANCE OF THE "CHAIN BREAK" MESSAGE MEANS THAT THE SENSORS ARE WORKING.
If the "Chain break" message does not appear, start the slack chain sensor adjustment procedure again.
140 4000414930 E 10.15 USA / GB

Mast
MS0062
5 - Slack chain detector adjustment procedure

Installation of the SQ801 and SQ802 detectors
S Q 8 0 1 ( L e f t )
S Q 8 0 2 ( R i g h t )
4000414930 E 10.15 USA / GB 141

Mast
MS0062
F i g u r e 1
Distance between the edge of the sensor and the Belleville washers : 5 mm
F i g u r e 2
Distance between the edge of the sensor and the Belleville washers : 3 mm
Adjustment :
• Using a mallet, position the 2 threaded rods at the bottom of the 20 diameter hole (See direction of the arrows on
figure 1).
• Adjust the detectors to 5 mm
• Hit with the mallet again in the opposite direction (See direction of the arrows on figure 2)to recentre the rods and
bring them closer to the detectors (approx. 3 mm).
During mounting, the detectors must be in the top position to detect the Belleville washers and not the
nut.
142 4000414930 E 10.15 USA / GB

Mast
MS0062
The oblong holes must be reduced in height so that the bottom position is not permitted.
N.B.-:-THE DETECTOR CONNECTORS MUST BE AT 90 % AND NOT STRAIGHT AS THEY TOUCH THE SLEW RING.
Detection of the washers whatever the position of the threaded rod :
The detectors remain on even if the threaded rod is completely to the left (1 mm) or right (5 mm).
4000414930 E 10.15 USA / GB 143

Mast
MS0062
Notes
144 4000414930 E 10.15 USA / GB

Overriding system
Overriding function reset
MS0085
Overriding system
1 - You will need

glasses, etc…)

4000414930 E 10.15 USA / GB 145

Overriding system
MS0085
4 - Overriding function reset

If the Overriding function has been requested, the machine displays the following screen at startup :
4.1 - PROCEDURE
• Enter the access code level 2 or 3.
• Select the menu : 3. Machine settings.
• Select the menu : 3.3 Machine config.
146 4000414930 E 10.15 USA / GB

Overriding system
MS0085
• Enter menu "Option settings".
• Move down to the line "Emergency mode not reset".
• Press the button to deselect the option.
• Return to the welcome screen.
The Overriding function is reset.
4000414930 E 10.15 USA / GB 147

Overriding system
MS0085
Notes
148 4000414930 E 10.15 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 :

• 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
FAIL_xx_002 A DETECTED failure ( D ) signals the cause of the failure has been valid one at least power on, but is inactive
A code CODE is linked to failures which have several causes of activation to identify the one of activation (if
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
4000414930 E 10.15 USA / GB 149


Failure Code C Description
F01 : Inverter
1 Zapi failure code 17 on Combiacx
Inverter Master F01.01 (A)
Pump failure F01.05 (A) 4 Zapi failure code 55 on Combiacx
Overheating F01.06 (A)
2 Zapi failure code 32 on Acex
Low Battery F01.08 (A) 1 Zapi failure code 33 on Combiacx (Battery level below 10%)
Electrical park brake 1 F01.09 (A) 8 Zapi failure code 45 on Combiacx
Zapi failure code 38 on Combiacx and no Zapi failure code 38
32
on Acex
Electrical park brake 2 F01.10 (A) 8 Zapi failure code 45 on Acex
Zapi failure code 38 on Acex and no Zapi failure code 38 on
32
Combiacx
Inverter slave F01.11 (A) 4 Zapi failure code 31 on Acex
Wrong controller 1 Combiacx is not a power version
F01.12 (D)
Hardware 2 Acex is not a power version

F02 : Contactor
Power contactor
F02.04 (D) 4 Zapi failure code 46 on Combiacx
SB801
Supervisor status = alarm or wait reset and Main Contactor is not
8
forced open by a Zapi failure

F03 : Relay
1 Stuck relay KAH
Relay failure F03.07 (D)
2 Stuck relay KAH2
150 4000414930 E 10.15 USA / GB


F04 : Electrovalves
Steering front left valve YV150L failure (short circuit) and
1
Steering steering setpoint active - YV150L = FAIL & STP (Steering)
F04.01 (D)
YV150L/YV150R Steering front right valve YV150R failure (short circuit) and
2
steering setpoint active - YV150R = FAIL & STP (Steering)
Turret rotation left valve YV250L failure (short circuit) and
1
Turret rotation orientation setpoint active - YV250L = FAIL & STP (Orientation)
F04.03 (D)
YV250L/YV250R Turret rotation right valve YV250R failure (short circuit) and
2
orientation setpoint active - YV250R = FAIL & STP (Orientation)
Jib lift valve YV620U failure (short circuit) and jib setpoint active
1
- YV620U = FAIL & STP (Jib)
Jib
F04.07 (D) Jib valve YV620 open circuit failure or Jib valve YV620 short
YV620/YV620U
2 circuit failure and jib setpoint active - YV620 = OPEN-CIRCUIT ||
(YV620 = SHORT-CIRCUIT & STP (Jib))
Mast lift valve YV520U failure (short circuit) and mast setpoint
1
active - YV520D = FAIL & STP (Mast)
Mast Mast descent valve YV520D open circuit failure or Mast descent
F04.39 (D)
YV520D/YV520U valve YV520D short circuit failure and mast setpoint active -
2
YV520U = OPEN-CIRCUIT || (YV520U = SHORT-CIRCUIT &
STP (Mast))

F05 : Joystick
Analog signal SM901Y of main joystick SM901 out of range -
1
SM901Y < 0,2V | SM901Y > 4,8V
Drive Joystick Incoherence between analogue and out of neutral signals of
F05.01 (D)
SM901 main joystick SM901
2
• SM901N = 1 & (2,45V < SM901Y < 2,55V)
• or SM901N = 0 & (SM901Y < 2V | SM901Y > 3V)
Analog signal SM902 of orientation joystick SM902 out of range
1
- SM902 < 0,2V | SM902 > 4,8V
Turret Joystick Incoherence between analogue and out of neutral signals of
F05.05 (D)
SM902 orientation joystick SM902
2
• SM902HN = 1 & (2,45V < SM902 < 2,55V)
• or SM902HN = 0 & (SM902 < 2V | SM902 > 3V)
Joystick Neutral Neutral position of main joystick SM901 not detected after power
F05.11 (A)
SM901 on - SM901 < 2.35V | SM901 > 2.65V
Joystick Neutral Neutral position of orientation joystick SM902 not detected after
F05.12 (A)
SM902 power on - SM902 < 2.35V | SM902 > 2.65V

F06 : Overload
No Loading Cal Angle / pressure weighting system missing or not calibrated and
F06.01(A)
Calibration required EU / AU / RUK
4000414930 E 10.15 USA / GB 151


F07 : Sensors
Broken Chain 1 SQ801 = 1
F07.02 (D)
SB801/SB802 2 SQ802 = 1
Motor Temperature F07.05 (D)
Pressure sensor 1 SP601<20pts (Circuit open)
F07.21 (D)
SR601 2 SP601>4000pts (Short-circuit)
Analogue signal calibrated SR601 of arm angle sensor
Jib Angle
F07.22 (D) 1 calibrated and out of range (-58.40° to 71.50°) - (SR601
SR601
<min(pts)-500 | SR601 >max(pts+500) & calilbrated)
Analogue signal calibrated SR150 of steer angle sensor
Steer Angle
F07.33 (D) calibrated and out of range (-44.1° to 75.0°) - (SR150 < -54.1° |
SR150
SR150 > +85°) & calibrated
Motor encoder F07.35 (D)
ECU temperature F07.36 (D)

F08 : Electric circuit
Supply F08.04 (A)
1 Supply on but no control box signal (SA901B=SA901T=0)
Control box incoherence F08.07 (A)
2 Both control box signal present (SA901B=SA901T=1)
Common outputs supply F08.09 (A)
Zapi failure code 38 on Acex and Zapi failure code 38 on
1
Combiacx
Power supply F08.10 (D)

F10 : Functions
Steering angle not
F10.14 (D) 1 Steer angle not calibrated
calibrated
Jib angle not calibrated F10.15 (D) 1 Jib angle not calibrated
152 4000414930 E 10.15 USA / GB


F12 : Internal faults
1 Cantiller RX failure
2 Screen RX failure
Zapi failure code 39 on Combiacx or no information received
CAN Fault 4
F12.01 (A) from the Acex
Check wiring
No time (date/hour) update (problem with screen
16
communication)
1 EEPROM failure status error
2 EEPROM failure stack full
E2P Read / Write Error
F12.02 (D) 8 Zapi failure code 69 on Combiacx
Change calc.
64 Read EEPROM during init failed
ID of software loaded into machine is different from the ID stored
E2P Param Reset into EEPROM : All machine parameters have been reset and
F12.04 (D)
Check SETTINGS must then be set again (speeds, ramps, options, configs, access
code level 2, failure counters and calibration data).
1 Model not set
2 Country not set
4 Serial number = 0
E2P Param Not Set F12.05 (A)
8 At least one of the parameter used and not set
16 At least one option used and not set
32 At least one config not set
1 Zapi software version different on Combiacx and on Acex
ECU software version
F12.07 (A) 2 Wrong version of HAULOTTE® software on the Acex
incoherence
4 Wrong Acex code software on the *2
ECU fault (master) F12.08 (A)
ECU fault (slave) F12.09 (A)
Wrong default Incoherence of the ZAPI parameter table ;restart the machine, it
F12.10 (A) /
parameters will restore the correct table
4000414930 E 10.15 USA / GB 153


F13 : Switches
Incoherence between the 2 signals of jib lifting switch of turret
1 box (both active)
• SA620U = 1 & SA620D = 1
Incoherence between the 2 signals of mast orientation switch of
Lower Box Switches
F13.01 (D) 2 turret box (both active)
Check switches
• SA250L = 1 & SA250R = 1
Incoherence between the 2 signals of mast lifting switch of turret
4 box (both active)
• SA520U = 1 & SA520D = 1
Incoherence between the 2 signals of front steering switch of
Platform switches
F13.02 (D) 1 platform box (both active)
Check switches
• SM901L = 1 & SM901R = 1
Neutral position of jib lifting switch of turret box not detected after
1 power on
• SA620U = 1 | SA620D = 1
Neutral position of mast orientation switch of turret box not
2 detected after power on
• SA250L = 1 | SA620R = 1
Neutral position of mast lifting switch of turret box not detected
4 after power on
Neutral switch • SA520U = 1 | SA520D = 1
F13.10 (A)
Check chassis switches Neutral position of deadman of turret box not detected after
8 power on
• SA905 = 1
Neutral position of unbraking of turret box not detected after
16 power on
• SB100 = 1
Neutral position of horn option switch of turret box not detected
32 after power on
• SA907T = 1
Neutral position of front steering switch of platform box not
• SM901L = 1 | SM901R = 1
Neutral position of deadman of platform box not detected after
2 power on
• SM901DM = 1
Neutral position of orientation selection of platform box not
detected after power on and no deadmanpedal configuration
4
activated
• (SA200 = 1 && CFG[DeadmanPedal]=0)
Neutral position of horn switch of platform box not detected after
8 power on
Switches neutral 2 • SA907 = 1
F13.11 (A)
Check platform switches Neutral position of jib selection switch of platform box not
• SA102 = 1
Neutral position of mast selection switch of platform box not
• SA500= 1
Neutral position of orientation selection switch of platform box not
• SA600 = 1
Neutral position of orientation selection of platform box not
detected after power on and deadmanpedal configuration
128
activated
• (SB800 = 1 && CFG[DeadmanPedal]=1)
154 4000414930 E 10.15 USA / GB


F15 : J1939 Failure
J1939 F15.06 (D) 1 Error on J1939

F16 :Motor
Overheating F16.01 (A)
Speed problem F16.02 (A)
Motor supply F16.03 (A)
4000414930 E 10.15 USA / GB 155

156
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
98
A
KM900 Key position Selector
98
220V - 110V
A
133
02-4
0 Basket sel
B
B 101
Chargeur
113
104 98 98
CN01 7
4000414930
C
T O B
FU3 10A KM900
01-6
hold rel
98
screen
CN03
KAH 135
Diag connector
02-4
D D KAH D1 KAH2 Turret sel
01-5 FU5 CN01
L1 10A
SA901 3
2 - Electric diagram
SB801 hold rel ECU

5
E SB801
1001
01-13 01-13
1002
6
L3
02-11
138
02
Basket Emergency Stop
F 02-12
KAH2 02 CN01 CN01 CN01
01-10 ES platform in
114
03-15
D2
SA911 9 10 11
114 K A 109
ES platform out
115
136
01-7 03-14
G
02
ES sig+all supply
1001
1002
M900
02-1
101
2 1001
CN01 6 SUPPLY CAN_L CAN_H
03-17 03-17
109
1
SB801
Watering pump
H 114
AU_info
0
109
3
ecu LS output
01-10 ACTIV SCREEN
Vhold/Supply of ecu
107
E 10.15
84
03-3
FU4 5A VAccess S _ REL GND _
I 02-8
02-1 02-1
ecu Main Contactor LS Output CN01 CN01
L1/L3 opening 8 12
E l e c t r i c i t y
J 118 0
1 1 103 103 VYV 103
FU2 10A
02-1
1
1
103
103
p a r t
+BF U2 +BF
FU1A FU1C KA1 KA2
L 165A 350A 02-17 02-3
A2
+B +B
GB1
32
184
HA907
M
0
ACEX Gnd access
M COMBIAX
Pump 00
0
03-2
A1 -P EL901 CNO
Klaxon/horn
B- B- 8 Bridge
0
U1
N
0
feu à éclat/flashing light
0
0 0 0 0 0
02-1
OPTION
DESSINE PAR DATE DE CREATION 4000133730 MODIF IND DATE MODIFICATION VISA NBRE TOTAL DE FOLIOS
ELEC 03
03
VERIFIE PAR DATE DE VERIFICATION

STAR 10 AC
La Péronnière 4000133730
BP 9 42152 L'HORME TEL: 04 77 29 24 24 G 01
USA / GB
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
01-22 03-21
4000414930
OPTION OPTION
A
01-17 02
109 109 109
01-6 CNO CNO CNO CNO
6 11 9 12
114
0
B
KA4 SB100
0
103 KA4 103b ST903 SA907T SA250 SA520
1 SA620 SA103
SQ530 SQ534 02-21 CNO
0 3 02-2 1 SQ801 SQ802
C
01-22
01-22
14
15
40
41
21
22
23
24
18
01-15
08
11
SQ800
29
30
CN02 CN02 CNO CNO CNO CN02 CN02 CN02 CN02 CN02
109
2 1 2 2 3 4 7 3 4 5 6
01-15
D CN01 CN01 SR150
135
103b
1 2
08
C A
114
114
R120
48
49
B
1002
103b
0
47
1001
133
E
Dévers 3° 12
Tilt sensor 3°
Montée pendulaire
Jib up
Mat teles rentré
Mast teles detector in 1
Mat sorti
Mast teles detector out
135
1001
1002
Descente pendulaire
Jib down
déreinage
Brake release
Mou de chaine 1
Chain strand 1
Mou de chaine 2
Chain strand 2
Capteur temp Ukraine
Ukraine temp sensor
Klaxon poste bas
Horn LCB
Orientation gauche
Orientation left
Orientation droite
Right orientation
Montée mat
Mast up
Descente mat
Mast down
GND GND E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR +24 KEY +24 YV CAN_L CAN_H CAN_L CAN_H +24 YV +24 KEY PPOT_12V SIGNAL NPOT E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR GND
E 10.15
Angle roues
F
Wheels angle
ES info
V a r i a b l e
Turret selection
Platform selection
COMBI-ACEX ACEX
H
temp moteur analog. vitesse moteur Frein Frein vitesse moteur temp moteur analog.
s p e e d
OPTION engine temp analog. engine speed Brake Brake engine speed engine temp analog.
I
PPOT _ 12V MC _ LS LS _ HORN PWM _ LS LS _ 3 LS _ 4 LS _ 5 LS _ 6 _ _ _ P _ TH N _ TH P _ ENC ENC _ B ENC _ A N _ ENC P _ EB N _ EB N _ EB P _ EB P _ ENC ENC _ B ENC _ A N _ ENC P _ TH N _ TH _ _ _ LS _ HORN LS _ LED PWM _ LS LS _ 5 LS _ 4 LS _ 3 LS _ TOR
Jib up
Buzzer
Bruiteur
J
Sortie mat
64
63
68
67
12 VOLTS
Steering left
Rentrée mat
Mast teles in
Holding relay
Steering right
Mast teles out
Orientation left
Direction droite
Horn command
orientation right
26
27
60
65
61
62
16
17
66
69
71
72
Direction gauche
relais Feu à éclat

Orientation droite
U V W A B A B U V W
Montée pendulaire
Flashing light relay

Commande klaxon
Orientation gauche
2 2
d r i v e
3 3
Commande maintient
412
ES frame relay command

1 2 2 1
31
M M
Commande relais AU chassis

K 1 2 1 2
CNO 1 4 4
54
33
04
70
19
55
56
57
YB100
YB101
1
53
3 3
03-18
7 ST302 ST303
M370 SV300 SV301 KA1
YV150R YV620U
01-13 YV520D YV520U YV250L YV250R
84 (YV1a) (YV3a) HA901 M371
L (YV4) (YV3b) (YV2a) (YV2b)
p a r t
01-5 KA2
115 YV150L
(YV1b)
02-9
103
M 01-17
103 103 103
USA / GB
DESSINE PAR DATE DE CREATION 4000133730 MODIF IND DATE MODIFICATION VISA NBRE TOTAL DE FOLIOS
INVERTERS 03
03
VERIFIE PAR DATE DE VERIFICATION

STAR 10 AC
La Péronnière 4000133730
BP 9 42152 L'HORME TEL: 04 77 29 24 24 G 02
157
USA / GB E 10.15 4000414930 158
I
L
F
K
E
B
A
H
D
C
M
1
La Péronnière
Phare travail
EL904
WIRE 6 00 134
01-19
CNB02 7
Working light
BP 9 42152 L'HORME
SA904
2
WIRE 5107
01-17
CNB02 8
3
B609 Option active 0 0

Option active
3
5
TEL: 04 77 29 24 24
0
CNAC
CNAC
KAC
03-4
4
HL901
93 RAZ écrasement 90
E_TOR
STOR _ LS
Reset crushing
2
7
KAC
AB
CNAC
CNAC
HL902
Ecrasement
Crushing
109
OPTION
5
VERIFIE PAR
RAZ écrasement
R1
DESSINE PAR
91a 91
1
6
Reset crushing
EL905
Ecrasement
CNAC
92
EANA_4..20mA
SB900
STOR_ LS
Crushing
CNAC
CNAC
1k ohm
6
Hors neutre gauche 05

E_TOR
E
Null position left

05
G
0
Hors neutre droit 05

F
109
Null position right

DATE DE CREATION
DATE DE VERIFICATION
7
SM902
52
GND
D
montee/descente pendud. 82 Orientation tourelle 39

C
STOR _ LS
Jib up and down

CNB01 3
turntable orientaton
CNB01 10
8
51 51
51
YV620
EANA_0..5VALIM_5V
Défauts 43
51
4
STOR _ LS
Alarm
9
CNB01
HL903
décharge batterie 42 Angle 81

STOR _ LS
Battery discharge Angle

5
SR601
0
EANA_0..5V
9
HL904
CNB01
10
CNB01
Surcharge 44 96
11
STOR_ LS
Overload
ALIM_5V
109
BASKET
Translation/levage 73
10
HL802
STAR 10 AC
Driving/lifting
Dévers 45
4000133730
11
STOR _ LS
Tilt
9
74
EANA_0-5V GND
SM901
HL800
G
109
Hors neutre AV/montée 75

14
E_TOR
Nul position FW/up

Sel translation 46
13
75
12
STOR _ LS
Driving selection
1
Hors neutre AR/desncet 75

Nul position REV.Down
HL100
6
selection mat 94 Direction gauche 35

E_TOR
STOR _ LS
mast selection Left steering

16
13
Direction droite 36
HL500
E_TOR
Right steering
3
selection pendulaire 95
STOR _ LS
jib selection
109
WIRE 1
MODIF IND
5
4
109 Homme mort 37

HL600
E_TOR
14
Dead man
CNB02 1
01-16
109
CAN TILLER
DATE
WIRE 3
02 02
01-16
15
CNB02 3
Klaxon 34
ALIM _ 24V E_TOR
0
109
Horn
97
SB802
03-19
Sel translation 85
E_TOR
Driving sel
A.U / E.S plateform
16
Sel mat 76
E_TOR
WIRE BLUE
Mast sel
1001
CAN _ L
01-22
CNB02 5
Sel pendulaire 78
MODIFICATION
E_TOR
Jib sel
R120
1002 1002
01-22
CAN _ H
17
SA907 SA102 SA500 SA600 SA200
WIRE RED Validation orientation 77

E_TOR
Orientation Validation
77
WIRE 2
SB800
VISA
OPTION
18
412
02-1
6 CNB02 CNB02 2
03-16
0 Surveillance SB802 97
GND _
E_TOR
U4
Check SB802
03-20
19
(12V)
SP601
Pression 79 412
0
03-19
(12V)
Pressure
CNB01 2
CNB01 11
EANA_4..20mA
4000133730
20
03
03
WIRE 4
0
02-21
CNB02 4
03
NBRE TOTAL DE FOLIOS
p a r t C a g e

3 - Hydraulic diagram
P U
4000414930 E 10.15 USA / GB 159

Notes
160 4000414930 E 10.15 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.-:-IN 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
4000414930 E 10.15 USA / GB 161

F- Records
162 4000414930 E 10.15 USA / GB

F- Records
4000414930 E 10.15 USA / GB 163

F- Records
164 4000414930 E 10.15 USA / GB

F- Records
4000414930 E 10.15 USA / GB 165

F- Records
166 4000414930 E 10.15 USA / GB

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Maintenance book

STAR 8 - STAR 22J - STAR 10 - STAR 26J

STAR 8 - STAR 22J - STAR 10 - STAR 26J

4000414930 E 10.15 USA / GB

2 4000414930 E 10.15 USA / GB

4000414930 E 10.15 USA / GB 7

Danger : Risk of injury or death

Caution : Risk of material damage

Prohibition relating to work safety and quality

Reminder to use good practice or follow pre-operation checks

Cross-reference to another part of the manual

Cross-reference to another manual

Cross-reference to repair (contact HAULOTTE Services®)

Time required for intervention

N.B. : Additional technical information

8 4000414930 E 10.15 USA / GB

Color Title Description

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.

4000414930 E 10.15 USA / GB 9

10 4000414930 E 10.15 USA / GB

1. Pull the E-stop button.

1.2 - UNCONTROLLED MOVEMENT HAZARD

Be aware of uncontrolled movement and always respect the following :

4000414930 E 10.15 USA / GB 11

Electric voltage Minimum safety distance

Do not operate the machine :

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

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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®

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These improvements will be shared via the following documents :

2.6 - AFTER SALES SERVICE

2.7 - PRODUCT INFORMATION

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3.2 - WARRANTY PERIOD

Spare parts are covered by a 6 month warranty.

3.3 - CONDITIONS OF WARRANTY

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3.4 - WARRANTY CONDITIONS

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Marking Description Function

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Battery charger status

Active fault indicator

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Marking Description Function

135 Battery charging indicator

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4.1 - HYDRAULIC OIL