Haulotte STAR 10 Maintenance Book Download Page 5

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CONTENTS

Maintenance book

Machine sheet

MS0001 -

Structural part inspection . . . . . . . . . . . . . . .

MS0002 -

Pins and bearing inspection . . . . . . . . . . . . .

MS0003 -

Cylinder inspection . . . . . . . . . . . . . . . . . . . .

MS0004 -

Breaking test procedure . . . . . . . . . . . . . . . .

MS0005 -

Torque Values . . . . . . . . . . . . . . . . . . . . . . . .

MS0010 -

Slew ring inspection . . . . . . . . . . . . . . . . . . .

MS0012 -

Condition of the cables inspection - Criteria of

replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MS0020 -

Hoses inspection - Replacement . . . . . . . . .

MS0059 -

Electrical wiring . . . . . . . . . . . . . . . . . . . . . . .

MS0042 -

Inspection of the condition of the chains -

Criteria of replacement . . . . . . . . . . . . . . . . . . . . . . . .

MS0044 -

Tires (Tyres) and pressures - Wheel

replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MS0045 -

Lubrication - Jib cylinder - Steering cylinder -

Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MS0046 -

Dismantling / Reassembling wheels reducer

MS0047 -

Replacing the wheel pivot. . . . . . . . . . . . . . .

MS0048 -

Steering cylinder replacement . . . . . . . . . .

109

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

Summary of Contents for STAR 10

Page 1: ...Maintenance book STAR 8 STAR 22J STAR 10 STAR 26J 4000414930 E 10 15 USA GB Maintenance book STAR 8 STAR 22J STAR 10 STAR 26J USA ...

Page 2: ...2 4000414930 E 10 15 USA GB STAR 8 STAR 22J STAR 10 STAR 26J ...

Page 3: ...cutionHazards 12 1 4 Explosion FireHazards 13 2 Maintenance and repair training 14 2 1 Owner sresponsability 14 2 2 Technician sresponsability 14 2 3 HAULOTTEServices 14 2 4 Training 14 2 5 Productmodification 15 2 6 AfterSalesService 15 2 7 Productinformation 15 3 Manufacturer s warranty 16 3 1 Warrantyacceptance 16 3 2 Warrantyperiod 16 3 3 Conditionsofwarranty 16 3 4 Warrantyconditions 17 ...

Page 4: ... Device layout 26 2 1 Sensorsandactuators 26 3 Consumables 27 4 Ingredient 28 4 1 Hydraulicoil 28 5 Lubrication diagram 29 5 1 Greasingpointslocalization 30 6 Machine specifications 31 6 1 Movementspeed 31 D 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 ...

Page 5: ...eria 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 MS0049 Hydraulic oil Level Replacement 113 MS0050 Hydraulic filter cartridge Replacement 115 MS0051 Battery ies 117 MS0052 Battery...

Page 6: ...nce 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 F Records 1 Intervention register 161 ...

Page 7: ...nment 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 prod...

Page 8: ...verity 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 Servic...

Page 9: ...TAINING THE MACHINE 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 maintenan...

Page 10: ...10 4000414930 E 10 15 USA GB STAR 8 STAR 22J STAR 10 STAR 26J A Preface Foreword Notes ...

Page 11: ...trictly 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 ...

Page 12: ...te 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 elect...

Page 13: ...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 cigarette...

Page 14: ...als 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 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...

Page 15: ...ide 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...

Page 16: ...ent 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 recomme...

Page 17: ...r 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 su...

Page 18: ...18 4000414930 E 10 15 USA GB STAR 8 STAR 22J STAR 10 STAR 26J B Safety Notes ...

Page 19: ...19 4000414930 E 10 15 USA GB STAR 8 STAR 22J STAR 10 STAR 26J C Familiarization Notes Familiarization ...

Page 20: ...20 4000414930 E 10 15 USA GB STAR 8 STAR 22J STAR 10 STAR 26J 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 ...

Page 21: ...sor C11 Turntable assembly C76 Guardrail C20 Tie down and or forklift loading C90 Battery bay block C27 Ground control box C136 Steer wheels C33 Counterweight C157 Position sensor mast lowered SQ530 C34 Drive wheels C158 Position sensor mast raised SQ534 C35 Document holder C159 Jib sensor SQ620 C44 Slack chain limit switch SQ801 SQ802 C160 Angle sensor SR601 C47 Battery isolation switch C161 Pres...

Page 22: ...energized Center De energizes control system Move downwards Ground control box energized 105 Beacon light 1 1 For machines fitted with Move to the right Flashing light is turned on Move to the left Flashing light is turned off 127 Mast telescoping selector Move upwards Mast extension Move downwards Mast retraction 128 Turret rotation switch Move to the left Clockwise CW rotation Move to the right ...

Page 23: ...Switch selector Press and hold Enable switch button 245 Overriding system control Emergency lowering system 252 Machine fault indicator light Intermittently lit in the event of an operation malfunction 254 Navigation button 255 Confirmation button 256 Cancellation button Symbol Description Battery charger status Active fault indicator Maintenance to perform Hourmeter ACTIV Screen 4000274010 B 254 ...

Page 24: ...24 4000414930 E 10 15 USA GB STAR 8 STAR 22J STAR 10 STAR 26J C Familiarization 1 3 PLATFORM CONTROL BOX 1 3 1 Layout G e n e r a l v i e w ...

Page 25: ...e Move backwards Reverse drive Press right side of button Right hand steering Press left side of button Left hand steering Press button 251 to select Mast extend retract movement Joystick as mast movement function Move forward Mast extension Move backwards Mast retraction Press button 252 to select Jib raising or lowering movement Jib movement joystick Move forward Jib raising Move backwards Jib l...

Page 26: ...26 4000414930 E 10 15 USA GB STAR 8 STAR 22J STAR 10 STAR 26J 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 ...

Page 27: ...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 rai...

Page 28: ...llowing 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 Ingredient HAULOTTE code Hydraulic oil 2420801310 Hydraulic oil Winter option 2505002640 Biological hydraulic oil 2820304310 Environmental conditions ISO Viscosity grade Ambient temperature between 15 C 9 F and...

Page 29: ...TTE code 3 Hydraulic oil Standard Barrel 209 l 55 2 gal US 2420801310 Hydraulic oil Winter option 2505002640 4 Biological hydraulic oil Barrel 209 l 55 2 gal US 2820304310 5 Extreme pressure lithium grease 2820304320 6 Lead free grease Aerosol 0 4 l 0 1 gal US 2820304330 Lead free grease Can 5 l 1 32 gal US 2820304340 9 High pressure lubricant DANGER 6 6 9 3 4 3 4 5 ...

Page 30: ...00414930 E 10 15 USA GB STAR 8 STAR 22J STAR 10 STAR 26J C Familiarization 5 1 GREASING POINTS LOCALIZATION Mast lubrication Slew ring Wheel axles 2 on the chassis Lubricate the pivots with lead free grease ...

Page 31: ...se 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...

Page 32: ...32 4000414930 E 10 15 USA GB STAR 8 STAR 22J STAR 10 STAR 26J C Familiarization Notes ...

Page 33: ...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 Visual inspections Systematic replacement Operation requiring HAULOTTE Services authorisation...

Page 34: ...ermediate 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...

Page 35: ...ystem 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 Area Intervals Daily After 125 h hours or 1 year After 250 h hour...

Page 36: ... 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 Particular attention to be paid when checking the crown gear Visual appearence of the interior and ext...

Page 37: ...rolled 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 According to applicable regulatory requirements If there are no local requirements then inspection must be performed at least once a year When Responsible Stakeholder What Before sale O...

Page 38: ...que 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 dai...

Page 39: ...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 movemen...

Page 40: ...educer is undamaged and operates smoothly All compartments covers open and lock properly Rotation system turret basket and jib No cracks broken weld paint chipped No deterioration and visible damage No screws missing loose parts No foreign material impurities in joints or slides Exterior gear wheel greasing Pin pin stop bearing Presence of the turret pin and its locking device No bent cracked or b...

Page 41: ...yte 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 detecto...

Page 42: ...tion 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 1 Increase in periodic inspections 2 For countries where machines are not subject to controlled periodic maintenance Symbol Description ...

Page 43: ...Brakes Hydraulic filter Emergency lowering Hydraulic oil Indicators switches and joysticks Hydraulic unit motor commutator Tilt sensor Driving motor commutator Limit switch PV radius limit weighing Variable speed calculator Power system Common areas Engine See manufacturer s guide Pulleys and wear pads Batteries terminals cleanliness attachment Bearings General points Cylinders welds leakproofness...

Page 44: ...spections For details refer to daily and periodic inspections listed earlier 1 Increase in periodic inspections 2 For countries where machines are not subject to controlled periodic maintenance Symbol Description Symbol Description Visual inspections Systematic replacement Operation requiring HAULOTTE Services authorisation Check Test See user manual or machine maintenance book 1 Visual inspection...

Page 45: ...ng Hydraulic tank cap and breather Indicators switches and joysticks Hydraulic filter Tilt sensor Hydraulic oil Limit switch PV radius limit weighing Hydraulic unit motor commutator Power system Driving motor commutator Engine See manufacturer s guide Variable speed calculator Batteries terminals cleanliness attachment Common areas General points Pins rings and pin stop Mandatory inspection Accord...

Page 46: ...rmation 1 Increase in periodic inspections 2 For countries where machines are not subject to controlled periodic maintenance Symbol Description Symbol Description Visual inspections Systematic replacement Operation requiring HAULOTTE Services authorisation Check Test See user manual or machine maintenance book 1 Visual inspection with dismantling to exchange replace if necessary Operation requirin...

Page 47: ...semblies Indicators switches joysticks and selectors Hydraulic filter Tilt sensor Hydraulic oil Limit switch PV radius limit weighing Hydraulic unit motor commutator Power system Driving motor commutator Engine See manufacturer s guide Variable speed calculator Batteries terminals cleanliness attachment Common areas General points Welds Mandatory inspection According to current legislation in the ...

Page 48: ... 10 15 USA GB STAR 8 STAR 22J STAR 10 STAR 26J D Inspection and maintenance schedule Machine sheet N B THE LIST OF MAINTENANCE INSPECTION SHEETS IS NOT EXHAUSTIVE CONTACT HAULOTTE SERVICES FOR ADDITIONAL OTHER SHEETS ...

Page 49: ...es 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 Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area Exclusively use tools and auxiliary average adapted Al...

Page 50: ...ction 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 a...

Page 51: ...ctive 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 Sectio...

Page 52: ...ents 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 ...

Page 53: ...al 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 Standard tool kit Protective goggles Gloves...

Page 54: ...shes 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 t...

Page 55: ...sing 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 After inserting the bearing lubricate and fit the pin For OPTIMUM 8 OPTIMUM 1931 E only Never grease the pins and rings of scissor arms Marking Description A At least 0 5 times the nominal diameter B Make a chamfer C Nominal diamet...

Page 56: ...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 ...

Page 57: ...ed back completely and operational 3 Control and maintenance 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 ...

Page 58: ...rm 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...

Page 59: ...e values indicated in the table below replace the cylinder Type of cylinders Maximum drift authorised due to an internal leak of the cylinder Lift cylinder arm or boom Machine with working heights 26 m 85 ft4 in After 10 mn creep 0 2 mm 7874 µ in After 60 mn creep 1 mm 0 039 in Outriggers cylinder Oscillating axle locking Lift cylinder arm or boom Machine with range limiting system After 10 mn cre...

Page 60: ...isassembling 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 ...

Page 61: ...urs 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 r...

Page 62: ...62 4000414930 E 10 15 USA GB General data Breaking test procedure MS0004 Notes ...

Page 63: ... Yellow dry Dull dry Lubed Dry Dull dry Lubed Dry Dull dry Lubed Dry 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 ...

Page 64: ... 7 61 62 7 20 41 55 5 55 74 5 60 81 3 80 108 4 68 92 1 1 2 13 57 77 3 75 101 6 80 108 4 110 149 93 126 20 64 86 7 85 115 90 122 120 162 105 142 9 16 12 80 108 4 110 149 120 162 150 203 130 176 18 90 122 120 162 130 176 170 230 140 189 5 8 11 110 149 150 203 160 217 210 284 180 244 18 130 176 170 230 180 244 240 325 200 271 3 4 10 200 271 270 366 280 379 380 515 320 433 16 220 298 300 406 310 420 4...

Page 65: ...er Loctite 243 Normal threadlocker Wheel axles 115 Nm Steering cylinder Chassis 115 Nm Slew ring Slew ring Chassis 135 Nm 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 Mast Upper and lower front pads 30 Nm Medium threadlocker Platform control box 10 Nm ...

Page 66: ...66 4000414930 E 10 15 USA GB General data Torque Values MS0005 Notes ...

Page 67: ...n 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 Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area Exclusive...

Page 68: ...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 ...

Page 69: ...HT21RT PRO SW HT61RT PRO 215 Nm 158 6 lb ft HT23RTJ O HT23RTJ O SW HT67RTJ O HT23RTJ PRO HT23RTJ PRO SW HT67RTJ PRO 215 Nm 158 6 lb ft 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 2...

Page 70: ...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 du...

Page 71: ...ion 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 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 betwee...

Page 72: ...72 4000414930 E 10 15 USA GB Chassis and turntable Slew ring inspection MS0010 Notes ...

Page 73: ...y devices must be positioned back completely and operational 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 ca...

Page 74: ...d 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 t...

Page 75: ... 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 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 H...

Page 76: ...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 collisi...

Page 77: ...t 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 ...

Page 78: ...mbly 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 Once all the hoses are correctly tight Put the machine in operational configuration Carry out some movements implementing the ...

Page 79: ...s 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 Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area Exclusiv...

Page 80: ...80 4000414930 E 10 15 USA GB Electric Electrical wiring MS0059 Notes ...

Page 81: ... 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 Standar...

Page 82: ... 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 Cha...

Page 83: ...inks 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 Check the connection points of links the lines must be parallel Distortion Crack Break Wedging ...

Page 84: ... 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 recycl...

Page 85: ...le 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 3 Technical ...

Page 86: ... 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 cha...

Page 87: ... 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...

Page 88: ...88 4000414930 E 10 15 USA GB Chassis and turntable Tires Tyres and pressures Wheel replacement MS0044 Notes ...

Page 89: ...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 Standard tool kit Brush Mu...

Page 90: ...escend 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 h...

Page 91: ...uring prolonged storage inside or outside proceed as follows Wheels aligned 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 ...

Page 92: ... cylinder Steering cylinder Lift cylinder MS0045 Lift 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 Store the machine with retracted mast ...

Page 93: ...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 ...

Page 94: ...all energy sources connected to the machine e g battery charger Identify the motor to be replaced 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 Arrière droit Rear right Arrière gauche Rear left ...

Page 95: ... GB Chassis and turntable Dismantling Reassembling wheels reducer 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 ...

Page 96: ...g wheels reducer 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 ...

Page 97: ...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 Tighten to the recommended torque on the above procedure 4 8 Nm Refit the wheel Attach the wheel using the 5 screws and washers Tighten to the recommended torque 115 Nm Mark with a pen as shown ...

Page 98: ...98 4000414930 E 10 15 USA GB Chassis and turntable Dismantling Reassembling wheels reducer MS0046 Notes ...

Page 99: ...uld 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 re...

Page 100: ... 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 Cut off the main power supply at the battery master switch Disconnect all energy sources connected to the machine e g battery charger Remove the covers Remove the wheel ...

Page 101: ...pivot 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 ...

Page 102: ...USA GB Chassis and turntable Replacing the wheel pivot 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 ...

Page 103: ...el pivot MS0047 5 Reinstall 5 1 HUB 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 Lubricate the interior of the 2 bores Separate the ball bearings from the ring Fit the ring into the hub Proceed in the same way on the large bore side ...

Page 104: ...d turntable Replacing the wheel pivot 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 ...

Page 105: ...30 E 10 15 USA GB Chassis and turntable Replacing the wheel pivot 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 ...

Page 106: ... 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 ...

Page 107: ... 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 ...

Page 108: ...47 6 Checks Switch the machine on Engage drive and steering Check there are no leaks or abnormal noises Re attach the stops right and left Refit the wheel Tighten to the recommended torque 115 Nm Lower the machine to the ground Tighten the wheel nuts to the recommended torque 115 Nm ...

Page 109: ...r 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 ...

Page 110: ...at the battery master switch Disconnect all energy sources connected to the machine e g battery charger Remove the covers 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 ...

Page 111: ...e 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 ...

Page 112: ...tch the machine on Engage drive and steering Check there are no leaks or abnormal noises 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 Tighten to the recommended torque 115 Nm Lower the machine to the ground ...

Page 113: ...l 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 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 M...

Page 114: ...l 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...

Page 115: ... 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 cartri...

Page 116: ...116 4000414930 E 10 15 USA GB Hydraulics Hydraulic filter cartridge Replacement MS0050 Notes ...

Page 117: ...n the caps located on the top of the battery The battery level must be in the maximum high position Standard tool kit Protective goggles Gloves Place barriers around the perimeter of the work area Exclusively use tools and auxiliary average adapted Always wear necessary safety clothing Remove the battery cover ...

Page 118: ...avels 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 Visually check the float on the cap indicator The battery level must be in the maximum high position In cold weather conditions centralized battery filling does not function Do not use the...

Page 119: ...tes charge status Platform control box The indicator 135 indicates charge status 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 Green indicator Battery charged 100 Yellow LED Battery charged 80 Red LED Battery in initial charging phase Battery charged Flashing Batterie...

Page 120: ...elements are below this minimum level Work in a clean and well ventilated area away from naked flames 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 Do not recharge the batteries if the ...

Page 121: ... 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 State of flashing indicator Type of alarm Description Action Red Battery presence Battery not connected or not compliant Check connection or rated voltage Yellow Temperature probe Temperature probe disconnected while charging or ...

Page 122: ... 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 ...

Page 123: ... 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 005 perdu par semaine lors d un stockage à une T de 24 C 005 per week loss in prolonged storage at 75 F 0075 per week loss in prolonged storage at 86 F 0075 perdu par semaine lors d un stockage à une T de 30 C 0015 perdu par semaine lors d un stockage à une T de 6 C 0015 per week loss in prolonged stora...

Page 124: ...124 4000414930 E 10 15 USA GB Electric Battery ies MS0051 Notes ...

Page 125: ...an 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 NO...

Page 126: ...c Battery ies MS0052 4 Removal O v e r v i e w B a t t e r i e s Lift the mast slightly Cut off the main power supply at the battery master switch Disconnect all energy sources connected to the machine e g battery charger Remove the covers ...

Page 127: ...attery 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 ...

Page 128: ... Check no alarms are present 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 Switch the machine on 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 ...

Page 129: ... 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 t...

Page 130: ... MS0053 4 Control on STAR 8 STAR 22J and STAR 10 STAR 22J only Replace in case of Broken wire C Broken strand B Kinked cable Wear on lugs Abnormal stretching of the cabel making it impossible to adjust play at the threaded end A B C 1 mm max Jeu Gap ...

Page 131: ...elves 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 wor...

Page 132: ... box Lift the mast so that tube 1 extends 300 mm beyond the foot of the mast 2 mm 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 4 2 1 3 Pied de mât Mast foot 300 mm 2 mm 300 mm 2 mm 300 mm 2 mm 306 mm 2 mm ...

Page 133: ...just 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 Adjust the chains on tube 2 to adjust the height of tube 3 Screw or unscrew the nuts B located on tube 1 with a ratchet wrench and a long 22 ...

Page 134: ...t tube 1 extends 100 mm beyond the foot of the mast 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 Adjust the chains on tube 3 to adjust the height of tube 4 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 C 100 mm 20 mm ...

Page 135: ... 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 t...

Page 136: ...136 4000414930 E 10 15 USA GB Mast Specific adjustment procedure STAR 8 STAR 20J STAR 10 STAR 26J MS0054 Notes ...

Page 137: ...rotective 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...

Page 138: ...rear axis If the mast jams when being extended increase the clearance 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 Avant Front Arrière Rear Gauche Left Dro...

Page 139: ...rvention 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...

Page 140: ...ent 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 Check the appearance of the Chain break mes...

Page 141: ... 4000414930 E 10 15 USA GB Mast Inspection of the slack chain sensors 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 ...

Page 142: ...shers 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 de...

Page 143: ...duced 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 ...

Page 144: ...144 4000414930 E 10 15 USA GB Mast Inspection of the slack chain sensors MS0062 Notes ...

Page 145: ... 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...

Page 146: ...ction reset 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 ...

Page 147: ...GB Overriding system Overriding function reset MS0085 The Overriding function is reset 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 ...

Page 148: ...148 4000414930 E 10 15 USA GB Overriding system Overriding function reset MS0085 Notes ...

Page 149: ...e FAILURES function describes the requirements relative to failures monitoring information recording information reading 1 3 REQUIREMENTS N B VAR ACTIVEFAILURE 1 IF ONE OR MORE OF THE FOLLOWING FAILURES ARE IN ACTIVE STATE 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...

Page 150: ...n Combiacx 8 Zapi failure code 45 on Combiacx 16 Zapi failure code 66 on Combiacx 32 Zapi failure code 38 on Combiacx and no Zapi failure code 38 on Acex Electrical park brake 2 F01 10 A 1 Zapi failure code 16 on Acex 2 Zapi failure code 26 on Acex 4 Zapi failure code 29 on Acex 8 Zapi failure code 45 on Acex 16 Zapi failure code 66 on Acex 32 Zapi failure code 38 on Acex and no Zapi failure code ...

Page 151: ...rt circuit and mast setpoint active YV520D FAIL STP Mast 2 Mast descent valve YV520D open circuit failure or Mast descent valve YV520D short circuit failure and mast setpoint active YV520U OPEN CIRCUIT YV520U SHORT CIRCUIT STP Mast Failure Code C Description F05 Joystick Drive Joystick SM901 F05 01 D 1 Analog signal SM901Y of main joystick SM901 out of range SM901Y 0 2V SM901Y 4 8V 2 Incoherence b...

Page 152: ...x ECU temperature F07 36 D 1 Zapi failure code 37 on Combiacx 2 Zapi failure code 37 on Acex Failure Code C Description F08 Electric circuit Supply F08 04 A 1 Zapi failure code 18 on Combiacx 2 Zapi failure code 27 on Combiacx 4 Zapi failure code 36 on Combiacx 8 Zapi failure code 60 on Combiacx 16 Zapi failure code 18 on Acex 32 Zapi failure code 27 on Acex 64 Zapi failure code 36 on Acex 128 Zap...

Page 153: ...bration data E2P Param Not Set F12 05 A 1 Model not set 2 Country not set 4 Serial number 0 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 ECU software version incoherence F12 07 A 1 Zapi software version different on Combiacx and on Acex 2 Wrong version of HAULOTTE software on the Acex 4 Wrong Acex code software on the 2 ECU...

Page 154: ... Neutral position of deadman of turret box not detected after power on SA905 1 16 Neutral position of unbraking of turret box not detected after power on SB100 1 32 Neutral position of horn option switch of turret box not detected after power on SA907T 1 Switches neutral 2 Check platform switches F13 11 A 1 Neutral position of front steering switch of platform box not detected after power on SM901...

Page 155: ...failure code 35 on Acex Speed problem F16 02 A 1 Zapi failure code 52 on Combiacx 2 Zapi failure code 52 on Acex Motor supply F16 03 A 1 Zapi failure code 19 on Combiacx 2 Zapi failure code 22 on Combiacx 4 Zapi failure code 28 on Combiacx 8 Zapi failure code 71 on Combiacx 16 Zapi failure code 72 on Combiacx 32 Zapi failure code 19 on Acex 64 Zapi failure code 22 on Acex 128 Zapi failure code 28 ...

Page 156: ... J K L M N B B 220V 110V Chargeur U2 B U1 P COMBIAX ACEX Key position Selector Basket sel ES sig all supply VAccess VYV Basket Emergency Stop Turret sel Bridge Gnd access Klaxon horn ES platform in ES platform out L1 L3 2 3 ecu Main Contactor LS Output Watering pump Diag connector ACTIV SCREEN CN03 A K hold rel ECU ecu LS output Vhold Supply of ecu BF B BF L1 L3 opening 6 5 feu à éclat flashing li...

Page 157: ...YV2a YV2b Angle roues Wheels angle Brake release déreinage OPTION Horn LCB Klaxon poste bas OPTION Mou de chaine 1 Chain strand 1 Mou de chaine 2 Chain strand 2 Capteur temp Ukraine Ukraine temp sensor Orientation left Orientation gauche Right orientation Orientation droite Mast up Montée mat Mast down Descente mat ACEX Commande maintient Holding relay ES info Commande relais AU chassis ES frame r...

Page 158: ...ndud Jib up and down Phare travail Working light WIRE 6 WIRE 5 G B C E F Ecrasement Crushing Ecrasement Crushing OPTION RAZ écrasement Reset crushing RAZ écrasement Reset crushing AB D Left steering Direction gauche Right steering Direction droite Dead man Homme mort 4 13 16 5 1 4 1 9 0 1 1 1 Sel translation Driving sel Klaxon Horn Sel translation Driving selection selection mat mast selection sel...

Page 159: ...159 4000414930 E 10 15 USA GB STAR 8 STAR 22J STAR 10 STAR 26J E Trouble shooting and diagram 3 Hydraulic diagram P U ...

Page 160: ...160 4000414930 E 10 15 USA GB STAR 8 STAR 22J STAR 10 STAR 26J E Trouble shooting and diagram Notes ...

Page 161: ...ter 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 Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 162: ...162 4000414930 E 10 15 USA GB STAR 8 STAR 22J STAR 10 STAR 26J F Records Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 163: ...163 4000414930 E 10 15 USA GB STAR 8 STAR 22J STAR 10 STAR 26J F Records Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 164: ...164 4000414930 E 10 15 USA GB STAR 8 STAR 22J STAR 10 STAR 26J F Records Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 165: ...165 4000414930 E 10 15 USA GB STAR 8 STAR 22J STAR 10 STAR 26J F Records Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 166: ...166 4000414930 E 10 15 USA GB STAR 8 STAR 22J STAR 10 STAR 26J F Records Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

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Haulotte STAR 10, Maintenance Book

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