Haulotte STAR 6P - STAR 13P Maintenance Manual 4001033900

STAR 6P - STAR 13P

Maintenance Book

Maintenance Book

STAR 6P - STAR 13P USA

4001033900

E 01.23

USA / GB

STAR 6P - STAR 13P

2

4001033900

E 01.23

USA / GB

Maintenance Book

CONTENTS

A Preface - Foreword 1 - Symbols and colors . . . . . . . . . . . . . . . . . . . . . . 8

B Safety 1 - General safety rules . . . . . . . . . . . . . . . . . . . . . 11 1.1 1.2 1.3 1.4 -

Maintenance implementation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Uncontrolled movement Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Electric Shock Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Explosion / Fire Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2 - Maintenance and repair training . . . . . . . . . . . 15 2.1 2.2 2.3 2.4 2.5 2.6 2.7 -

Owner's responsability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Technician's responsability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 HAULOTTE Services®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Product modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Product information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

CONTENTS

3 - Conditions of warranty . . . . . . . . . . . . . . . . . . 16

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Maintenance Book

C Familiarization 1 - Primary machine components . . . . . . . . . . . . 18 1.1 - Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1.2 - Maintenance support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 1.3 - Picking tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 1.3.6 1.3.7 -

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Pre-use inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Loading instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Special decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Cold weather operational recommendation . . . . . . . . . . . . . . . . 22

1.4 - Ground control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1.4.1 1.4.2 1.4.2.1 -

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 HAULOTTE Activ'Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 LCD screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.5 - Platform control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 1.5.1 -

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.6 - Auxiliary control box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 1.6.1 -

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2 - List of actuators and sensors . . . . . . . . . . . . . 34 2.1 - Sensors and actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3 - Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . 36 4 - Ingredient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 4.1 - Hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 4.2 - Marine protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5 - Lubrication diagram . . . . . . . . . . . . . . . . . . . . . 37 6 - Greasing points localization . . . . . . . . . . . . . . 38 7 - Machine specifications . . . . . . . . . . . . . . . . . . 39 7.1 - Movement speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

D Inspection and maintenance schedule 1 - Inspection program . . . . . . . . . . . . . . . . . . . . . 41 2 - Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . 41 3 - Preventive maintenance . . . . . . . . . . . . . . . . . 42 4 - Periodic inspection . . . . . . . . . . . . . . . . . . . . . 47 5 - Major inspection . . . . . . . . . . . . . . . . . . . . . . . . 49

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Maintenance Book

Machine sheet MS0001 - Structural part inspection . . . . . . . . . . . . . . . 51 MS0002 - Pins and bearing inspection . . . . . . . . . . . . . 55 MS0003 - Cylinder inspection . . . . . . . . . . . . . . . . . . . . 59 MS0004 - Braking test procedure . . . . . . . . . . . . . . . . . 63 MS0005 - Torque Values . . . . . . . . . . . . . . . . . . . . . . . . 65 MS0020 - Hoses inspection - Replacement . . . . . . . . . 69 MS0059 - Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . 71 MS0061 - Clearance procedure . . . . . . . . . . . . . . . . . . . 73 MS0086 - Steering cylinder removal . . . . . . . . . . . . . . . 75 MS0087 - Pothole cylinder replacement. . . . . . . . . . . . 79 MS0102 - Tires (Tyres) - Wheel replacement . . . . . . . . 81 MS0103 - Hydraulic oil - Level Replacement . . . . . . . . 87 MS0104 - Lubrication - Steering cylinder -

CONTENTS

Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 89 MS0106 - HAULOTTE Activ'Screen . . . . . . . . . . . . . . . 91 MS0112 - Control-Lubrication . . . . . . . . . . . . . . . . . . . 107 MS0113 - Battery (ies) - Standard machine . . . . . . . . 113 MS0133 - Universal plug . . . . . . . . . . . . . . . . . . . . . . . 119 MS0242 - Check of tilt sensor . . . . . . . . . . . . . . . . . . . 121 MS0245 - Dismantling/Reassembling the Tilt Sensor . . 127

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Maintenance Book

E Trouble shooting and diagram 1 - Trouble shooting . . . . . . . . . . . . . . . . . . . . . . 135 1.1 1.2 1.3 1.4 -

Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Failures list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

2 - Electric diagram . . . . . . . . . . . . . . . . . . . . . . . 148 3 - Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . 154

F Records 1 - Intervention register . . . . . . . . . . . . . . . . . . . . 155

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STAR 6P - STAR 13P

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/modifications 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 confused 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.

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A- Preface - Foreword 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 Recommended tools Recommended part Safety

N.B. :

8

Additional technical information

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A- Preface - Foreword 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 TELEHANDLER. B

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A- Preface - Foreword Notes

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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.

The maintenance stand must be in place before any maintenance operation is begun.

Placing the machine in maintenance configuration : • Raise the telescoping mast upto 1,20 m(3 ft11 in).

• Insert the safety prop ( 1 ) in the hole to lock the mast.

To avoid any crushing hazard, insert the safety prop in the designated hole to lock the mast.

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

Putting in use position : • To put back the machine into its normal operation, reverse the steps used above.

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B- Safety Never leave the hydraulic cylinders fully extended before switching off the machine, or when stationary for an extended period of time. Keep the elements of the machine in configuration of maintenance thanks to mechanics devices.

Report that the machine is under maintenance by tagging the platform and ground control boxes.

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.

1.2 -

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

• Maintain clearance from generators, radar, electromagnetic fields.

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

• Never tow the machine over extended distances.

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

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

• Put the machine in stowed position.

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

• Ensure all compartments are closed and secured.

• Chock the wheels.

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B- Safety 1.3 -

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

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

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

M i n i m u m

s a f e

a p p r o a c h

Electric voltage

d i s t a n c e s

Minimum safety distance Mètre

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

Feet Avoid contact

3 5 6 8 11 14

10 15 20 25 35 45

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

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

• Do not operate the machine during lightning or storms.

• Do not use the machine as a welding earth.

• Do not 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.

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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 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.

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B- Safety 2-

Maintenance and repair training 2.1 -

OWNER'S RESPONSABILITY The owner (or hirer) has the obligation to inform technician of the instructions contained in the Operator Manual and Maintenance Book.

The owner (or hirer) has the obligation to renew all manuals or decals that are either missing or in bad condition.

Additional copies can be ordered from HAULOTTE Services®.

The owner (or hirer) is responsible for applying the local regulations regarding maintenance of the machine.

2.2 -

TECHNICIAN'S RESPONSABILITY The technician must read and understand the contents of this manual, operators manuals and the decals affixed on the machine.

The technician must inform the owner (or hirer) if the manual or any decals are missing or in poor condition, and of any malfunction of the machine.

Only authorized and qualified operators may operate HAULOTTE® machines.

2.3 -

HAULOTTE SERVICES® The HAULOTTE® is at your service in all 5 continents of the world via an extensive network of its own factory trained technicians, who are ready to respond to your every need.

2.4 -

TRAINING Whether you want to just service your equipment or carry out a complete overhaul, HAULOTTE® can provide you with a structured training program or we can tailor a program to suit your specific requirements or circumstances. Training can cover the general operation of the equipment, breakdowns, engine maintenance and repairs and electrical/hydraulic/mechanical repairs and trouble shooting.

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B- Safety 2.5 -

PRODUCT MODIFICATION In a constant effort to improve the quality of machines, HAULOTTE continually monitors technical improvements that enable to develop products with improved safety and greater reliability. The target being that HAULOTTE® always work to build confidence in the relationships with our customers.

These improvements will be shared via the following documents : • OI : Obligatory Intervention, Safety information requiring immediate action (take into account

by HAULOTTE®).

• NI : Technical improvement requiring immediate action (take into account by HAULOTTE®).

• RI : Improvement proposed to customers to take into account during maintenance operation.

• PI : Product information for knowledge.

2.6 -

AFTER SALES SERVICE Our HAULOTTE Services® After Sales Service is at your disposal throughout your machine's service life to ensure the optimum use of your HAULOTTE product : • When contacting our After Sales Service, ensure that you provide the machine model and serial number.

• When ordering any consumables or spare parts, please use this manual and the HAULOTTE® Essential catalogue to receive your genuine HAULOTTE® spare parts, your only guarantee of parts interchangeability and correct machine operation.

• If there is an equipment malfunction involving a HAULOTTE® product, then contact HAULOTTE Services® immediately even if the malfunction does not involve material and/or bodily damage.

2.7 -

PRODUCT INFORMATION Without the written permission from Haulotte, modifying a HAULOTTE® product is a Safety concern.

Any modification may violate Haulotte design parameters, local regulations and industry standards.

If you desire a modification to the product, submit a request in writing to HAULOTTE. With the utmost care to ensure enhanced reliability and greater safety of the HAULOTTE® products, it is pertinent that when a "Service or Safety Bulletin" is issued, action is taken immediately. Once the bulletin has been addressed, make sure that the completed form is submitted to HAULOTTE Services®.

Do not hesitate to contact HAULOTTE Services® , should you have any questions relating to the issued bulletin(s) or with questions on the policy itself.

3-

Conditions of warranty Our warranty conditions and extension contracts are now available on the websites of our sales network : www.haulotte.com C

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C- Familiarization Familiarization

Notes

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C- Familiarization 1-

Primary machine components 1.1 -

LAYOUT S T A R

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C- Familiarization Marking

Description

Marking

Description

C1

Chassis

C76

Guardrail

C6

Platform

C77

Platform access step (on both sides)

C7

Platform control box

C90

Battery bay (block)

C20

Tie-down (and/or forklift loading)

C136

Front steer wheels

C27

Ground control box + Universal plug

C142

Lanyard attachment points

C34

Rear drive wheels

C154

Picking tray

C35

Document holder

C156

Platform entry (on both sides) Beetle-wing doors

C42

Foot Switch (For Japan only)

C170

Brake release switch

C47

Battery isolation switch

C173

Emergency lowering valve

C50

Battery charger socket

C174

Auxiliary control box

C54

Telescopic mast

C175

Support tube

C58

Pothole protection

C176

Bumper

C64

Tilt sensor

C177

Foldable side panels

U n i v e r s a l

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C- Familiarization 1.2 -

MAINTENANCE SUPPORT The maintenance stand must be in place before any maintenance operation is begun.

Placing the machine in maintenance configuration : • Raise the telescoping mast upto 1,20 m (3 ft 11in).

• Insert the safety prop ( 1 ) in the hole to lock the mast.

To avoid any crushing hazard, insert the safety prop in the designated hole to lock the mast.

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

Putting in use position : • To put back the machine into its normal operation, reverse the steps used above.

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C- Familiarization 1.3 -

PICKING TRAY 1.3.1 - Description This picking tray is designed as an attachment to the platform to transport parcels to and from elevated heights.

1.3.2 - Safety precautions Before using machine in the picking mode : • Cordon off the surrounding area of the machine when used in the picking mode.

• Do not use the tray for any other purpose than to lift parcels to the overhead/elevated temporary work places.

• Do not use/operate the machine when alone. A survey person or immediate Supervisor must be present on the ground in case of emergency.

• Ensure that support tube is secured to the platform.

• Do not sit, stand, or climb on the tray.

• Do not place loads overhanging beyond the picking tray.

1.3.3 - Pre-use inspection • Check that the picking tray and support tube have no cracks or other damage.

• Check that the picking tray is secured to the platform.

• Check that the information/capacity decal is present on the picking tray and is legible.

1.3.4 - Loading instructions • The foldable side panels must be used to prevent objects falling from the picking tray.

• Lift up and fix the foldable side panels into the upright position.

• Only place parcels that do not exceed the surface area of the picking tray.

• The picking tray must be situated at the same height as the load to be transferred.

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C- Familiarization 1.3.5 - Special decal The load on the picking tray should not exceed 80 kg(176 lb).

1.3.6 - Operation

refer to Section B 3.6 Auxiliary control box to perform the picking tray and mast movements.

1.3.7 - Cold weather operational recommendation For temperatures between 0 °C(32 °F) and - 20 °C(- 4 °F) : • The picking tray with the allowable maximum load of 3 on it, must be raised/lowered 5 to 80 kg(176 lb) cycles to ensure the movement.

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C- Familiarization 1.4 -

GROUND CONTROL BOX 1.4.1 - Layout G e n e r a l

C o n t r o l s Marking

Name

15

SB801

a n d

v i e w

i n d i c a t o r s

Description

Function Pulled out : Ground control box energized

E-stop button Pushed in : De-energizes control system

43

HA907

Horn button1

Horn Move upwards : Platform control box energized

92

SA901

Control box activation key switch

Center : De-energizes control system Move downwards : Ground control box energized

105 253

EL901 CN03

Beacon light 2 Diagnostic tool socket

Move to the right : Activated Move to the left : Off Connection to the diagnostic tool (HaulotteDiag)

1. For machines fitted with 2. For machines fitted with

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C- Familiarization 1.4.2 - HAULOTTE Activ'Screen Upon starting and during operation of the machine, the LCD screen "Activ'Screen" located on the ground control box displays in real time the machine operating status.

H A U L O T T E

C o n t r o l s Marking 1 2 3 4 5 6 7 8 9 10

24

A c t i v ' S c r e e n

a n d

Description

i n d i c a t o r s Function

Mast control LCD screen Navigation button Confirmation button Cancellation button Platform overload indicator Machine fault indicator Navigation button Enable Switch Mast control

Mast lifting Display status of operation of the machine Navigation of menu to select function - Scroll up Confirmation of the selected function Go back Not used Constantly lit in the event of an operation malfunction Navigation of menu to select function - Scroll down Press in and hold : Enable switch Mast retraction

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C- Familiarization LCD screen At startup : At startup with the ground or platform controls selected; system initiates a self check : • Bar gets filled up.

• Home screen comes on with status icon of the machine - okay to proceed functioning the controls.

Symbol

Description

1

Information icons

2

Information text

3

Status icon of the machine

Symbol

Description Battery status Maintenance use

Fault / alarms Hour meter

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C- Familiarization • Pressing either one of the buttons

, the following screen shot will be displayed :

Symbol

Description

1

Software part number

2

Software version + Screen software version + Screen version

3

Screen identification + Screen software version

4

Machine serial number displayed

• After again pressing either one of the buttons

, the following screen shot will be

displayed • Access code screen comes on - refer to maintenance manual for entering the access code

• Validation by pressing on is active only if access code is known and entered - refer to maintenance manual for the procedure for the different level code useage

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C- Familiarization Alarm status : Alarm status displayed as applicable - samples shown below Tilt :

Overload :

Low battery :

Recharge the batteries :

Fully recharge the batteries.

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C- Familiarization Low battery water level :

Low water tank level :

Present fault :

28

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C- Familiarization Notes

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C- Familiarization 1.5 -

PLATFORM CONTROL BOX 1.5.1 - Layout G e n e r a l

v i e w

-

S T A R

6

P

-

S T A R

1 3

P

123

108

135

43 20%

40%

100%

85 30 110

27

111 112

46 4000311500c

245

30

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C- Familiarization C o n t r o l s

a n d

i n d i c a t o r s

Marking

Name

Description

27

HL800

Tilt indicator

Machine on excessive slope

30

HL802

Overload indicator

Not used

43

SA907

Horn button

Move upwards and hold to activate horn

46

SB802

E-stop button

85

HL903

Fault indicator

Pulled out : Platform control box power supply energized Pushed in : De-energizes control system Faulty or tilting machine

Movement joystick 108

Function

SM901 Front axle steering selector

Move forward : Forward drive or mast lifting Move backwards : Reverse drive or mast descent Press right side of thumb button : Right-hand steering Press left side of thumb button : Left-hand steering

110

HL4203

Mast lifting / descent selection On : Mast lifting / descent selection activated indicator Off : Mast extension / retraction movement is not selected

111

HL100

Driving selection indicator

112

SA908

2-position selector

123

SA905

Enable Switch

On : Driving function activated Off : Driving movement is not selected Move to the left : Mast lifting / descent Move to the right : Drive and steer movements Press in : Associated command is validated Release : Associated command movement is halted

100%

Battery charged

135

HL904

Battery charging indicator 40%

Flashing : Batteries have 40 % charge left

20%

Constantly on : Batteries have only 20 % charge left 245

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SB800

Foot Switch (For Japan only)

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Press in and hold : Enable switch

USA / GB

31

STAR 6P - STAR 13P

C- Familiarization 1.6 -

AUXILIARY CONTROL BOX 1.6.1 - Layout G e n e r a l

32

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

Name

247

SB806

Enable Switch

253

SA723

Picking tray control

254

SA520

Mast control

255

SB805

E-stop button

4001033900

Description

a n d

i n d i c a t o r s Function

Press in and hold : Enable switch Move upwards and hold : Raising Move downwards and hold : Lowering Move upwards and hold : Raising Move downwards and hold : Lowering

E 01.23

Pulled out : Platform control box power supply energized Pushed in : De-energizes control system

USA / GB

33

STAR 6P - STAR 13P

C- Familiarization 2-

List of actuators and sensors 2.1 -

SENSORS AND ACTUATORS S e n s o r s

34

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S T A R

6

P

-

S T A R

1 3

P

USA / GB

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C- Familiarization Name KA911 M911 SL901 SL911 SQ144 SQ145 SQ721 SQ700 SQ701 SQ724 SQ725 SQ800 SR150 ST309 YB100 YB101 YV144 YV145 YV150L YV150R YV520 YV903

4001033900

Description Water refill pump control relay Water pump - Motor (Centralized filling option - If option installed) Battery level sensor for centralized filling (If option installed) Level sensor in water tank (Centralized filling option - If option installed) Pothole limit sensor Pothole limit sensor Position sensor mast folded Door sensor - Door 1 - Right Door sensor - Door 2 - Left Limit switch tray up Limit switch tray down Sensor - Tilt 3° Steering potentiometer Temperature sensor in batterie for centralized filling (If option installed) Right rear brake-release solenoid valve Left rear brake-release solenoid valve Pothole extraction solenoid valve Pothole retraction solenoid valve Left steering electro-distributor Right steering electro-distributor Mast lifting/lowering solenoid valve Discharge valve

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C- Familiarization 3-

4-

Consumables Consumable

HAULOTTE® code

Hydraulic filter cartridge

2505000970

Ingredient Ingredient

HAULOTTE® code

Hydraulic oil Hydraulic oil (Winter option) Biological hydraulic oil Aggressive environment grease

4.1 -

2420801310 2505002640 2820304310 4001249850

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) Ambient temperature between - 35° C (- 31° F) and + 35° C (+ 95° F) Ambient temperature between 0° C (32° F) and + 45° C (+ 113° F)

HV 46 HV 32 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) Viscosity at + 100° C (+ 260° F) Viscosity index Flashpoint Pour point

36

4001033900

46 +/- 3 mm² / s > 8 mm² / s > 160 > 220° C (> 572° F) < - 40° C (> - 104° F)

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C- Familiarization 4.2 -

MARINE PROTECTION In harsh environments (high levels of salinity in the atmosphere: close to the sea, industrial environment with chloride emissions and/or humidity > 70%), we recommend applying the following protection process : • Wash the machine completely to remove any trace of harsh environmental pollution.

• Dry all the machine.

• Apply directly a solvent-based oil leaving an oily film after evaporation of the solvent.

• Re-apply the product every month.

After washing the machine, make sure it is fully air-dry and does not contain moisture on corrosive parts (cylinders rods for example).

Do not wash any electrical components, particularly with high pressure washer. Wipe away dirt from around electrical components with a dry cloth.

N.B.-:-REFER TO

- CONSUMABLES

Viscosity at + 40° C (+ 104° F)

4 mm²/s

Flashpoint

28 °C

5-

Lubrication diagram

9

3

3 4

4

L i s t Marking

9

o f

Ingredient

i n g r e d i e n t s Symbol

HAULOTTE® code

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

9

High-pressure lubricant

3

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C- Familiarization 6-

Greasing points localization • Wheel steering pivots : 2 on the chassis.

Lubricate the pivots with lead-free grease.

• Mast lubrication :

Picking tray chain : • Remove the plate 1.

Apply oil to the top sprocket after cleaning the chain.

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C- Familiarization 7-

Machine specifications 7.1 -

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 6 P- STAR 13 P

Micro drive speed High drive speed Maximum towing speed Time for mast lifting Time for mast lowering

0,8 km/h / 0.5 mph 4,5 km/h / 2.8 mph 4,5 km/h / 2.8 mph 16 s 19 s

D

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C- Familiarization Notes

40

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D- Inspection and maintenance schedule Inspection and maintenance schedule 1-

Inspection program

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

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

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

Frequency Before each hire Before each use or each change of user At intervals recommended

by HAULOTTE®

Person-in-charge

Stakeholder

Type

Owner

On-site technician

Daily inspection

Operator

Operator

Daily inspection

On-site technician, qualified HAULOTTE Services® technician On-site technician, qualified HAULOTTE Services® technician On-site technician, qualified HAULOTTE Services® technician Qualified technician HAULOTTE Services®

Owner

Before sale

Owner

Annually ( 1 year) (*)

Owner

After 10 years then every 5 years

Owner

Documentation Operator's manual Operator's manual

Preventive maintenance

Maintenance Book

Periodic inspection

Maintenance Book

Periodic inspection

Maintenance Book

Major inspection

Maintenance Book

(*) Or according to local regulations.

2-

Daily inspection The daily inspection must be performed every day, before the start of a new work shift and at every change of user.

This inspection is performed by and under the responsibility of the user and includes the visual and functional inspection of the machine as well as the testing of its safety systems.

A description of the daily inspection can be found in the machine's user manual.

We recommend these forms to be completed daily and stored to assist with your maintenance schedule.

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D- Inspection and maintenance schedule 3-

Preventive maintenance Maintenance operations must be carried out by a qualified technician chosen by the owner and ensure that the machine operates correctly.

Severity of operating conditions may require a reduction in time between maintenance periods.

Maintenance operations performed must be recorded in a register / log book of the machine.

S y m b o l

m e a n i n g s

Oil change

To check by test

Tightening

Levelling

Visual inspection

Functional adjustments / Checks / Cleaning

Lubrication-Lubrication

42

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Systematic replacement

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D- Inspection and maintenance schedule

OK

-

F i r s t Corrected

1

1

NOK

OK

L e v e l

Page or associated procedure

First 50H

L e v e l First 50H

M a i n t e n a n c e

Every 2 weeks

P r e v e n t i v e

5 0 H

Comments

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

Hydraulic : oils, filters and hoses Replace the hydraulic filter

Page or associated procedure

Every 2 weeks

–

E v e r y

Corrected

M a i n t e n a n c e

NOK

P r e v e n t i v e

2

w e e k s

Comments

Chassis assembly : Wheel, reducer, steering, wheel pivot Check the electrolyte level of the battery/batteries

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D- Inspection and maintenance schedule -

E v e r y

Corrected

Page or associated procedure

1

NOK

Every 6 months or 250H

L e v e l 2 5 0 H

OK

M a i n t e n a n c e o r

Every 6 months or 250H

P r e v e n t i v e

6

m o n t h s

Comments

Chassis assembly : Wheel, reducer, steering, wheel pivot Grease the steering system Control steering system Check that the ground strap is present and in good condition

Mast ; Boxes Grease mast

Picking tray Clean and grease chains

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

Platform Tighten the mounting on the platform support, the platform floor and the platform access

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D- Inspection and maintenance schedule -

E v e r y

Corrected

Page or associated procedure

Every 1 year or 500H

2

NOK

L e v e l 5 0 0 H

OK

M a i n t e n a n c e

Every 1 year or 500H

P r e v e n t i v e

1

y e a r

o r

Comments

Preventive Maintenance Level 1 Perform the 6 months or 250H maintenance

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

Batteries Check the condition of the battery terminals, cables(Corrosion, not damaged) Grease the terminals

Hydraulics : Oil, filters and pressure checks Replace the hydraulic filter Drain the hydraulic oil

Mast ; Boxes Check the pads-Replacement if necessary

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D- Inspection and maintenance schedule E v e r y

Corrected

Page or associated procedure

-

NOK

Every 2 years or 1000H

2

OK

M a i n t e n a n c e L e v e l o r 1 0 0 0 H Every 2 years or 1000H

P r e v e n t i v e

2

y e a r s

Comments

Preventive Maintenance Level 1 Perform the 6 months or 250H maintenance

Preventive Maintenance Level 2 Perform the 1 year or 500H maintenance

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

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D- Inspection and maintenance schedule 4-

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

This intervention must take place after : • Extensive dismantling and reassembly • Repairs involving the machine's essential components • Any accident causing stress to the machine This inspection is the responsibility of the owner, and must be conducted by a qualified technician.

Under no circumstances may this inspection replace the control required by local regulations.

Corrected

NOK

OK

Page or associated procedure

Periodic

Periodic

Use the detailed program below.

Comments

Chassis assembly : Wheel, reducer, steering, wheel pivot Check state of tires/tyres and inflations

Batteries Check the condition of the battery

Hydraulic : oils, filters and hoses Check the hoses, blocks and pumps, fittings, cylinders and the tank for the absence of leaks, deformations and damage

Platform Test the closure and locking of access platform Check that the harness anchor points are not cracked or damaged

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Corrected

NOK

OK

Page or associated procedure

Periodic

Periodic

D- Inspection and maintenance schedule Comments

General Check for the presence, cleanliness and readability of the manufacturer's plates, security labels, user manual and maintenance manual Check the cleanliness and readability of the control box Check chassis opening and locking of covers Check the condition of electrical harnesses, cables and connectors Check for the absence of abnormal noise and jerky movements Check for the absence of visible deterioration and damage Check for the absence of cracks, broken welds and chipped paintwork on the structure Check for the absence of missing or loose screws and bolts Check for the absence of deformation, cracking and breakage of axis stops, bushing and axes Check for the absence of foreign bodies in joints and sliding parts

Safety devices Test the operation of the upper and lower control boxes: manipulators, switches, buttons, horn, emergency stops, screens and lights Check the absence of visual and audible alarms Test the operation of the tilt system Test the operation of the emergency lowering system Test the operation of the Activ Shield Bar (If equipped) Test the operation of the drive speed limiter systems Test the speed and behavior of movements Check the operation of the load control system Calibrate if necessary

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D- Inspection and maintenance schedule 5-

Major inspection The inspection is a thorough inspection of the machine to ensure that it is fully functional. It must be carried out after 10 years then every 5 years.

This inspection is the responsibility of the owner and must be carried out by a technician HAULOTTE Services® or an authorized and qualified person.

In order to carry it out, contact the subsidiary HAULOTTE® or the authorized distributor.

Machine sheet

N.B.-:-THE LIST OF MAINTENANCE / INSPECTION SHEETS IS NOT EXHAUSTIVE. CONTACT HAULOTTE SERVICES® FOR ADDITIONAL / OTHER SHEETS.

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D- Inspection and maintenance schedule Notes

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General data Structural part inspection

MS0001 General data Structural part inspection

1-

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

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

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

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

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

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

2-

Risk prevention M e a n s

o f

p r o t e c t i o n

Appropriate workwear

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

w h e n

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

Gloves

Safety shoes

3-

You will need • Standard tool kit

4001033900

• Place barriers around the perimeter of the work area

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51

General data Structural part inspection

MS0001 4-

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

4.1 -

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

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

• Absence of deformation and visible damage.

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

• Absence of excessive gap to the articulations and slides.

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

• No screws or missing part loosened or unscrew.

• Anchorage points firmly fixed and not damaged.

The list of part to check are define Section Familiarization.

4.2 -

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

The criteria quoted above are applicable.

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

• Booms and arms welds.

52

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General data Structural part inspection

MS0001 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).

4.3 -

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

Section D - Inspection and maintenance schedule :

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

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

The results of the tests must be entirely documented.

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

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General data Structural part inspection

MS0001 4.4 -

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

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

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

• All the security device function correctly.

• Authorized maximum speeds of operation are not exceeded.

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

4.5 -

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

The machine must be place on level and firm ground.

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

• Leave the machine in static during 15 mnn.

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

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

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

MS0003 - § 3.2 Cylinder inspection.

54

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General data Pins and bearing inspection

MS0002 General data Pins and bearing inspection

1-

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

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

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

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

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

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

2-

Risk prevention M e a n s

o f

p r o t e c t i o n

Appropriate workwear

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

w h e n

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

Gloves

Safety shoes

3-

You will need • Standard tool kit

4001033900

• Place barriers around the perimeter of the work area

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55

General data Pins and bearing inspection

MS0002 4-

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

Section D - Inspection and maintenance schedule :

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

• Check the presence of the screws.

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

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

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

Section D -

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

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

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

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

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

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

• Check the presence of material of friction.

• For the bearings :

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

• Clean the bearing with a suitable solvent.

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

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

The periodicity can evolve under the following conditions

Section D - Inspection and maintenance schedule :

• Abnormal noise during movements of the structure.

• Prolonged storage of the machine ( 6 months).

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

5-

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

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

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General data Pins and bearing inspection

MS0002 6-

Procedure of reassembly 6.1 -

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

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

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

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

V a l u e s

C

A

D

E B F

G

Marking A B C D E F G

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

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

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General data Pins and bearing inspection

MS0002 6.2 -

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

• Slightly lubricate boring and/or pins.

• Lubricate the ring of the bearing slightly.

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

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

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General data Cylinder inspection

MS0003 General data Cylinder inspection

1-

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

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

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

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

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

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

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

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

2-

Risk prevention M e a n s

o f

p r o t e c t i o n

Appropriate workwear

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

w h e n

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

Gloves

Safety shoes

3-

You will need • Standard tool kit

4001033900

• Place barriers around the perimeter of the work area

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General data Cylinder inspection

MS0003 4-

Control and maintenance 4.1 -

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

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

• Absence of rust and shock on the rod.

• Absence of foreign objects on all surfaces.

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

4.2 -

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

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

• Abnormal noise during movements of the structure.

• Prolonged storage of the machine ( 6 months).

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

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

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

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

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

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

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

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

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

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

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General data Cylinder inspection

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

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

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

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

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

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

Type of cylinders

Maximum drift authorised due to an internal leak of the cylinder

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

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

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

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

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

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

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

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

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

Steering cylinder

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

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

These tests must be made in conditions of equivalent temperatures.

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General data Cylinder inspection

MS0003 4.3 -

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

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

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

Check :

62

1.

Pipe weld connection.

2.

Rod weld connection.

3.

Ring.

4.

Rod.

5.

Piston.

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General data Braking test procedure

MS0004 General data Braking test procedure

1-

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

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

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

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

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

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

2-

Risk prevention M e a n s

o f

p r o t e c t i o n

Appropriate workwear

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

w h e n

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

Gloves

Safety shoes

3-

You will need • Standard tool kit

4001033900

• Place barriers around the perimeter of the work area

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General data Braking test procedure

MS0004 4-

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

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

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

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

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

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

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

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General data Torque Values

MS0005 General data Torque Values

1-

Metric torque chart For screws HAULOTTE®, use columns ( A ), ( B ) and ( C ) :

1

• Screw ( 1 ) grey dull dry, use colums ( A )

2

3

• 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

in-lbs

in-lbs

Nm

Nm

Nm

in-lbs

ft-lbs

23.6

32

31.4 42.6

46.7 63.3 62.3 84.4

12 20.65

28 19.8 25.6 25.1 34.1

76

48.6

81.8

111 69.7 94.5 92.2 125

95.9

130

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

365

18 72.28

98 64.5 87.5 86.2 117 192.5 261 171 233 229 311

81

Nm

Nm

38 75

Nm

28 55

Nm

20.1 27.3 26.9 36.5 39.9 54.1 53.2 72.2

Nm

32 64

Nm

23.6 47.2

Nm

19.1 18.8 25.5

Nm

14

27.9 37.8 37.2 50.5

Nm

22

Nm

ft-lbs

Dry

44

88

ft-lbs

in-lbs

Nm

Lubed

5.4 7.41 7.2 9.88 16.2

64.9

ft-lbs

Dull dry

8

66

ft-lbs

Dry

10 12.17 16.5 10.8 14.7 14.4 19.6 32.45 56

ft-lbs

Lubed

Nm

ft-lbs

Dull dry

ft-lbs

ft-lbs

9 68 7.75 91 10.3 15.7 116 13.2 155 17.6

ft-lbs

Dry

79 139

Nm

Lubed

7.7 58 6.63 78 8.84 13.4 100 11.3 132 15

Nm

5.9

Dull dry

Yellow dry

in-lbs

8

Yellow dry

Lubed

ft-lbs

Dull dry

Dull dry

Nm

41 4.63 54 6.18 68 69 7.87 93 10.5 118

Nm

5 9.1

Lubed

in-lbs

in-lbs

2 16 1.8 21 2.4 44 3.4 19 3.05 36 4.07 80

Nm

17.7 30

Nm

5 6

Nm

in-lbs

Yellow Yellow Dull dry (A) Lubed (B) dry (C) dry (C)

Nm

in-lbs

Lubed (B)

in-lbs

Dull dry (A)

Nm

Yellow dry (C)

in-lbs

Lubed (B)

Class 12.9

ft-lbs

Dull dry (A)

in-lbs

Class 8.8

Size (mm)

Size (mm)

Class 4.6

173

235

230

313

239.7

325

202 274 269

283.2

384

238

323

317

430

331

449

278 377 371

503

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

20 102.5 139

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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 Grade 5 Size

1/4

Thread

20 28

Lubed

Dry

3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 1/2

66

18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12

Lubed

Dry

Lubed

in-lbs

Nm

in-lbs

Nm

in-lbs

Nm

in-lbs

Nm

in-lbs

Nm

80 90

9 10.1

100 120

11.3 13.5

110 120

12.4 13.5

140 160

15.8 18

130 140

14.7 15.8

Lubed

5/16

A574 High strength black oxide bolts

Grade 8

Dry

Lubed

Dry

Lubed

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

13 14 23 26 37 41 57 64 80 90 110 130 200 220 320 350 480 530 590 670 840 930 1460 1640

17.6 19 31.2 35.2 50.1 55.5 77.3 86.7 108.4 122 149 176 271 298 433 474 650 718 800 908 1138 1260 1979 2223

17 19 31 35 49 55 75 85 110 120 150 170 270 300 490 470 640 710 790 890 1120 1240 1950 2190

23 25.7 42 47.4 66.4 74.5 101.6 115 149 162 203 230 366 406 583 637 867 962 1071 1206 1518 1681 2643 2969

18 20 33 37 50 60 80 90 120 130 160 180 280 310 450 500 680 750 970 1080 1360 1510 2370 2670

24 27.1 44.7 50.1 67.8 81.3 108.4 122 162 176 217 244 379 420 610 678 922 1016 1315 1464 1844 2047 3213 3620

25 27 44 49 70 80 110 120 150 170 210 240 380 420 610 670 910 990 1290 1440 1820 2010 3160 3560

33.9 36.6 59.6 66.4 94.7 108.4 149 162 203 230 284 325 515 569 827 908 1233 1342 1749 1952 2467 2725 4284 4826

21 24 38 43 61 68 93 105 130 140 180 200 320 350 510 560 770 840 1090 1220 1530 1700 2670 3000

28.4 32.5 51.5 58.3 62.7 92.1 126 142 176 189 244 271 433 474 691 759 1044 1139 1477 1654 2074 2304 3620 4067

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General data Torque Values

MS0005 3-

Hydraulic couplings and hoses tightening torque charts H y d r a u l i c

f i t t i n g

t o r q u e

( T o l e r a n c e

=

0

/

+ 1 0 % )

BSPP threads according to ISO1179 Torque

Thread G1/4 G3/8 G1/2 G3/4 G1" G1"1/4 G1"1/2

ft-lbs

Nm

26 52 66 133 229 332 398

35 70 90 180 310 450 540

UNF threads according to ISO11926-2/3 Torque

Thread 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1"1/16-12 1"5/16-12 1"5/8-12 1"7/8-12

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Nm

15 30 33 59 100 136 199 251 306

20 40 45 80 135 185 270 340 415

USA / GB

67

General data Torque Values

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

Thread M10x1,0 M12x1,5 M14x1,5 M16x1,5 M18x1,5 M20x1,5 M22x1,5 M26x1,5 M33x2,0 M42x2,0

Torque DIN 3852-1

ft-lbs

Nm

ft-lbs

Nm

18 26 30 51 66 92 100 133 229 332

25 35 40 70 90 125 135 180 310 450

18 26 33 41 52 59 74 125 229 243

25 35 45 55 70 80 100 170 310 330

N.B.-:- ISO6149: SEALING WITH O-RING WITHOUT ANY RETAINING RING (OR FORM). ISO9974 / DIN3852: SEALING WITH O-RING AND RETAINING RING (OR FORM).

H y d r a u l i c Hose size

JIC thread

DN06 - 1/4" DN10 - 3/8" DN12 - 1/2" DN16 - 5/8" DN19 - 3/4" DN25 - 1" DN32 - 1"1/4 DN38 - 1"1/2 DN50 - 2"

7/16-20 9/16-18 3/4-16 7/8-14 1"1/16-12 1"5/16-12 1"5/8-12 1"7/8-12 2"1/2-12

68

4001033900

h o s e

t o r q u e

JIC torque ft-lbs

Nm

11-15 22-31 37-52 51-69 72-99 103-140 155-210 214-280 332-443

15-21 30-42 50-70 69-94 98-133 140-190 210-285 290-380 450-600

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( M i n i m u m ORFS thread 9/16-18 11/16-16 13/16-16 1"-14 1"3/16-12 1"7/16-12 1"11/16-12 2"-12 2"1/2-12

/

M a x i m u m ) ORFS torque ft-lbs

Nm

18-21 30-33 41-44 59-66 85-96 111-125 148-166 221-243 367-406

25-28 40-45 55-60 80-90 115-130 150-170 200-225 300-330 500-550

USA / GB

Hydraulics Hoses inspection - Replacement

MS0020 Hydraulics Hoses inspection - Replacement

1-

You will need

• Standard tool kit • Protective goggles • Place barriers around the perimeter of the work area • Gloves Exclusively use tools and auxiliary average adapted. Always wear necessary safety clothing.

2-

Control and inspections The state of hoses devices plays a significant role in the safety of the machines.

Section D - Inspection and maintenance schedule : • Check the absence of leakage to the junctions of the hoses.

• Check that all the hoses are correctly tightened.

• Check the absence of tear and crack of the external hoses.

• Check that the shielding of the hose is not apparent.

• Check the absence of chemical aggression of the membrane of the hose.

If anomalies are noted, it is necessary to replace the elements by respecting the following recommendations.

3-

Hoses Disassembling For safety reasons, respect imperatively the following conditions of disassembling : • Fold the machine on a flat and released ground : • The machine is not in slope.

• The boom is horizontal.

• Put the turret (if equipped) in the axis.

• Carry out a beaconing of the sector (maximum risk zone = machine height).

• Locate the hoses and their connections points to guarantee the good performance of the machine after intervention.

• Locate the hoses course to facilitate the reassembly.

To recover oil, use an oils container in order not to pollute the environment.

Unscrew the flexible device slowly in order to make fall residual water pressure.

It is imperative to secure and maintain cylinders when removing hoses cylinders. An analysis of the hydraulic system is imperative.

After disassembling : • Close the hose openings and the hydraulic components to avoid the pollution of the hydraulic system.

• Check the cleanliness of the hoses and the hydraulic components : • Absence of plastic, rubber or metal shaving.

• If necessary, purge and clean the circuit (tank included).

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Hydraulics Hoses inspection - Replacement

MS0020 4-

Hoses Reassembly For safety reasons, respect imperatively the following conditions of reassembly : • Using the reference marks carried out previously; carry out the courses of hoses.

• During the fixing of the hoses, respect the tightening torques below.

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) Hose 3/8" (diameter 10mm) Hose 1/2" (diameter 12mm) Hose 5/8" (diameter 16mm) Hose 3/4" (diameter 19)

1,5 daN.m(11,08 lbf.ft) 3,5 daN.m(25,86 lbf.ft) 5 daN.m(36,95 lbf.ft) 8 daN.m(59,12 lbf.ft) 10 daN.m(73,91 lbf.ft)

2,6 daN.m(19,22 lbf.ft) 4,2 daN.m(31,04 lbf.ft) 5,7 daN.m(42,12 lbf.ft) 8,5 daN.m(62,82 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.

70

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Electric Electrical wiring

MS0059 Electric Electrical wiring

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.

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.

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Electric Electrical wiring

MS0059

Notes

72

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Mast Clearance procedure

MS0061 Mast Clearance procedure

1-

You will need

• Standard tool kit • Protective goggles • Place barriers around the perimeter of the work area • Gloves Exclusively use tools and auxiliary average adapted. Always wear necessary safety clothing.

2-

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

• Position the machine on a flat ground, stabilized and in a released environment.

• 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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Mast Clearance procedure

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.

Fastening screw torque : 4 Nm.

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Chassis Steering cylinder removal

MS0086 Chassis Steering cylinder removal

1-

You will need • PPE (Personal Protective Equipment: glove, safety shoes, glasses, etc ...)

• Standard tool kit • Grease

• Place barriers around the perimeter of the work area

1 person Exclusively use tools and auxiliary average adapted. Always wear necessary safety clothing.

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

• Position the machine on a flat ground, stabilized and in a released environment.

• 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.

4-

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.

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Chassis Steering cylinder removal

MS0086 5-

Removal N.B.-:-DETATCH THE PLATFORM CONTROL BOX AND KEEP IT WITH YOU. YOU WILL REQUIRE THIS LATER TO OPERATE THE STEERING. • Raise the telescoping mast upto 1,20 m(3 ft11 in) (Tube 1).

• Insert the safety prop ( 1 ) in the hole to lock the mast.

To avoid any crushing hazard, insert the safety prop in the designated hole to lock the mast.

• Steer the machine so the wheels are straight ahead.

• Remove the central cover.

• Remove the circlip from the rod end of the cylinder (fixed to the pivot), the washer and extract the pin.

• Turn the steering towards the left side, to retract the steering cylinder.

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Chassis Steering cylinder removal

MS0086 • Disconnect the 2 hoses from the cylinder, fit plugs and caps to the hose and cylinder.

• Remove the circlip from the bore end (front left) of the cylinder, the washer and extract the pin.

• Remove the cylinder.

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Chassis Steering cylinder removal

MS0086 6-

Reinstall • Install the bore end (front side) pivot pin, refit the washer and circlip.

• Re-connect the hoses to the cylinder.

• Operate the steering towards the right side, to align the cylinder with the pivot.

• If you cannot align easliy with the pump, turn the wheels slightly by kicking them ir tapping with a soft hammer.

• Install the rod end pin of the cylinder (fixed to the pivot), refit the washer and circlip.

• Refit the top cover plate.

• Remove the safety support and lower the mast.

7-

Checks • Switch the machine on.

• Engage drive and steering. Check there are no leaks or abnormal noises.

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Chassis Pothole cylinder replacement

MS0087 Chassis Pothole cylinder replacement

1-

You will need • PPE (Personal Protective Equipment: glove, safety shoes, glasses, etc ...)

• Standard tool kit • Grease

• Place barriers around the perimeter of the work area

1 person Exclusively use tools and auxiliary average adapted. Always wear necessary safety clothing.

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

• Position the machine on a flat ground, stabilized and in a released environment.

• 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.

4-

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.

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Chassis Pothole cylinder replacement

MS0087 5-

Removal Drive then lift the machine just for a brief moment, to put the potholes in a "mid way" position, between fully retracted and fully extended. This is to remove any pressure from the pivot pins and make removal easier.

• Open the battery trays on either side of the machine.

• Remove the circlips and washers from the pivot pins at both ends and slide the cylinder off the pins.

• Disconnect the hydraulic hoses, plug and cap the hoses and fittings.

6-

Reinstall • Reverse the above procedure.

N.B.-:-TO ALIGN THE CYLINDER WITH THE PINS ON THE POTHOLE SYSTEM, IT MAY BE NECESSARY TO OPERATE THE DRIVE (TO RETRACT THE POTHOLE CYLINDER) OR LIFT (TO EXTEND THE POTHOLE CYLINDER).

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Chassis Tires (Tyres) - Wheel replacement

MS0102 Chassis Tires (Tyres) - Wheel replacement

1-

You will need • Standard tool kit • Protective goggles • Gloves • Jack • Hoist • Torque wrench

2-

• Place barriers around the perimeter of the work area

Preliminary operation For safety reasons, imperatively respect the following stages during the tests : • To set up a beaconing of safety around the test area.

• Put the machine in stowed position.

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.

3-

Technical specifications Component

Standard wheel

Reference number Type Wheel mass Size Torque

4001033900

Solideal Solid tires/tyres 19 kg - 42 lbs 316 mm / 108 mm (12,5 in / 4,25 in) 250 Nm (184 ft lbs)

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Chassis Tires (Tyres) - Wheel replacement

MS0102 4-

Wheel and tires/tyres inspections Replace the wheels and the tires if any of the following conditions exist : • Presence of cracks, damage, deformation or other faults on the hub • Damage to the tire : • Cut or hole > 3 cm (2 in) in the rubber side wall.

• Blister or pronounced lump on the external and lateral wall.

• Damaged wheel stud.

• Damage or wear on the side wall to the extent that the reinforcing wire is visible.

• Consistent wear of the ground contact surface greater than 25% • Check that the pin 2352101250 is present and in good condition - Replace as necessary.

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.

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Chassis Tires (Tyres) - Wheel replacement

MS0102 5-

Procedure of replacement • Slightly lift the machine using a forklift.

• Place a wooden spacer under the frame to support the machine after lifting off the ground.

• Remove the pin ( 1 ), the wheel nut ( 2 ) and the flat washer(3).

• Remove the wheel.

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Chassis Tires (Tyres) - Wheel replacement

MS0102 R e a s s e m b l y

Marking 1 2 3 4 5

84

o f

t h e

w h e e l

Description Wheel Washer Nut Pin Motor shaft

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Chassis Tires (Tyres) - Wheel replacement

MS0102 • Use a new flat washer (2700500110).

• Use a new nut (4000503700).

1.

Check that the shaft key is well positioned in the motor shaft.

2.

Mount the wheel on the motor shaft.

3.

Install the washer first then the nut.

4.

Tighten the wheel nut to the recommended torque : 250 Nm (184 ft.lbs).

5.

Add tightening until a groove of the nut is in coincidence with one hole of the shaft of the motoreducer.

6.

Insert the pin (2352101250) into its seating.

7.

Bend over the cotter pin legs to secure the nut.

N.B.-:-LOCK IN PLACE WITH A NEW PIN.

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Chassis Tires (Tyres) - Wheel replacement

MS0102

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Hydraulics Hydraulic oil - Level Replacement

MS0103 Hydraulics Hydraulic oil - Level Replacement

1-

You will need

• Standard tool kit • Protective goggles • Place barriers around the perimeter of the work area • Gloves Exclusively use tools and auxiliary average adapted. Always wear necessary safety clothing.

2-

Preliminary operation For safety reasons, imperatively respect the following stages during the tests : • To set up a beaconing of safety around the test area.

• Put the machine in stowed position.

• Use safety straps.

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.

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 .

Top up the oil level, if necessary :

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1.

Loosen and remove the tank cap (2).

2.

Top up the oil level.

3.

Refit and tighten the tank cap (2).

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Hydraulics Hydraulic oil - Level Replacement

MS0103 4-

Replacement of hydraulic oil 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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Chassis - Mast Lubrication - Steering cylinder - Lift cylinder

MS0104 Chassis - Mast Lubrication - Steering cylinder - Lift cylinder

1-

You will need

• Standard tool kit • Brush • Multipurpose grease (of mineral type) • Place barriers around the perimeter of the work area • Protective goggles • Gloves Exclusively use tools and auxiliary average adapted. Always wear necessary safety clothing.

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.

3-

Lubrication Steering 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 : • 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.

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Chassis - Mast Lubrication - Steering cylinder - Lift cylinder

MS0104 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).

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.

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Ground control box HAULOTTE Activ'Screen

MS0106 Ground control box HAULOTTE Activ'Screen

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.

Upon starting and during operation of the machine, the LCD screen "Activ'Screen" located on the ground control box displays in real time the machine operating status.

2-

Simplified menus Main menu

Submenu 1

0. Home screen 0b. Information 0c. Information 0d. Access codes settings 1. Failures

1.1. Current failures 1.2. Failures log

2. Access code 3. Machine settings

3.1. Speeds and Ramps 3.2. Calibration 3.3. Machine configuration 3.4. Save / restore parameters 3.5. Advanced settings

4. Diagnostic

4.1. Functions 4.2. Machine state

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MS0106 Main menu

Submenu 1 4.3. Inputs / Outputs 4.4. System test

5. Maintenance

5.1. Maintenance to be done 5.2. Maintenance log 5.3. Events log 5.4. Usage log 5.5. Upload software 5.6. Software versions 5.7. Event counters

6. Tools

6.1. Upload software 6.2. Camera 6.3. Wifi 6.4. Photos 6.5. General settings 6.6. Files manager

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Ground control box HAULOTTE Activ'Screen

MS0106 3-

Detailed menus

Main menu

1. Failures

Submenu 1

Submenu 2

1.1. Current failures

(Detected failures list)

1.2. Failures log

(Failure history) By date

(Failure history by date)

By counters

(Failure history by counters)

Enter HAULOTTE® Acces Code (

2. Access code

+ ENTER)

Drive forward Min speed Max speed Max speed micro Acceleration Deceleration Drive reverse Min speed Max speed 3. Machine settings

Max speed micro

3.1. Speeds and Ramps

Acceleration Deceleration Steering left Max speed Steering right Max speed Potholes extend Max speed Potholes retract Max speed

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MS0106

Main menu

Submenu 1

Submenu 2 Mast raise Min speed Max speed raise Acceleration raise

3.1. Speeds and Ramps 3. Machine settings

Deceleration raise Mast descent Min speed Max speed raise Acceleration raise Deceleration raise

3.2. Calibration

Main menu

Submenu 1

Steering angle Load management system

Submenu 2 Option setting Buzzer Flashing light Tracking system Drive restriction when lifted User identification inhibited Platform protection

3. Machine settings

3.3. Machine configuration

Country selection Standard USA Australia Russia / Ukraine ECU Date and hour Automatic setting Manual setting

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Ground control box HAULOTTE Activ'Screen

MS0106

Main menu

3. Machine settings

Main menu

Submenu 1

Submenu 2

3.4. Save / restore parameters

Save parameters Restore parameters Components configuration Battery types Mast descent valve Machine Model STAR 6 (STAR 13) STAR 6P (STAR 13P) STAR 8S (STAR 20) Serial number Hourmeter Security settings Machine checking

3.5. Advanced settings

Submenu 1

4.1. Functions

4. Diagnostic

4.2. Machine state

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Submenu 2 Drive micro speed Drive high speed Forward steering Mast Picking plate (only on STAR 6P (STAR13P)) Machine Active control box Chassis control box Platform control box Picking control box (only on STAR 6P (STAR13P)) Machine unfolded Tilt Hourmeter Platform Foot Switch state Chassis enable switch state Battery level Battery voltage Unbraking enabled User identified User identification Running calibration

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MS0106

Main menu

Submenu 1

Submenu 2 ECU Max number of EEPROM queries (R/W) into the stack Current number of EEPROM queries (R/W) into the stack Current EEPROM status Number of EEPROM stack errors Number of EEPROM status errors Execution time of 4 ms task

4. Diagnostic

4.2. Machine state

Execution time of 8 ms task Execution time of 32 ms task Execution time of 128 ms task Execution time of 1000 ms task ZAPI network failure present on ECU CombiACX ZAPI network failure present on ECU ACEX Software version CAN Tiller Number of initialization tries

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Ground control box HAULOTTE Activ'Screen

MS0106

Main menu

Submenu 1

Submenu 2 Driving Drive movement setpoint Drive movement slowdown Drive forward cuttings Drive reverse cuttings Drive movement control Drive speed Speed reduction Brake release switch (Driving) Right motor speed setpoint

4. Diagnostic

4.2. Machine state

Left motor speed setpoint Steering Steering movement setpoint Steering movement slowdown Steering left cuttings Steering right cuttings Steering movement control Wheels steering angle Steering left limit Steering right limit Steering angle calibration performed

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Ground control box HAULOTTE Activ'Screen

MS0106

Main menu

Submenu 1

Submenu 2 Potholes Potholes movement setpoint Potholes out cuttings Potholes in cuttings Potholes movement control Mast Mast movement setpoint Mast movement slowdown Mast raise cutouts Mast descent cutouts

4. Diagnostic

4.2. Machine state

Mast movement control Picking machine (only on STAR 6P (STAR13P)) Picking tray movement setpoint Picking tray movement cutouts Picking tray movement control Threshold of the picking overload Instantaneous picking overload alarm Overload alarm of the picking Maximum current during a picking movement Current drawn by the picking motor Offset current Mean current during a picking movement

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MS0106

Main menu

Submenu 1

4. Diagnostic

DIGITAL INPUTS ( TOR) SB801 - Emergency stop (turntable/frame) SQ800 - Slope sensor SA901TU - Control box selector - Turntable SA901PF - Control box selector - Platform SA907TU - Horn switch - Turntable ST903 - Extrem ambiant temperature sensor SA103 - Brake release switch SQ144_145 - Potholes left/right position sensors SR120 - Chassis inclination detector 1 SR121 - Chassis inclination detector 2 SM901EN - Enable switch - Enable Switch SM901L - Joystick steering rocker - Left SM901R - Joystick steering rocker - Right SA907 - Horn switch SM901N - Drive/Arm joystick - Enable Switch 4.3. Inputs / Outputs SA908a - Drive/Arm movement selection switch - Direction a SA908b - Drive/Arm movement selection switch - Direction b SQ700_701 - Platform doors position sensors SQ920 - Platform protection detector SA520U - Mast switch (picking) up-Raise (only on STAR 6P (STAR13P)) SA520D - Mast switch (picking) down-Descent (only on STAR 6P (STAR13P)) SB806 - Enable switch (only on STAR 6P (STAR13P)) SA110 - Drive speed selection SWITCH1 - Top arm SWITCH2 - Bottom arm SWITCH3 - Enable switch SWITCH5 - Navigation Up SWITCH6 - Navigation Down SWITCH7 - Navigation Confirm SWITCH8 - Navigation Cancel

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Ground control box HAULOTTE Activ'Screen

MS0106

Main menu

Submenu 1

Submenu 2 Outputs TOR KAH - Supply holding relay YV150R - Front right steering valve YV150L - Front left steering valve HA901 - Buzzer (Turntable) YV144 - Pothole lift down YV145 - Potholes lift up KA1 - Horn relay YV903 - Pump unloading valve

4. Diagnostic

4.3. Inputs / Outputs

KA2 - Flashing light relay HL420 - Indicator light - Lifting mode HL100 - Indicator light - Driving selection HL802 - Indicator light - Overload platform HL904 - Indicator light - Low Battery HL800 - Indicator light - Tilt HL903 - Indicator light - Impacting Machine Behaviour Failure(s) SA723S - Picking tray switch - Supply voltage (only on STAR 6P (STAR13P)) EL909 - Indicator light - Road light 4

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MS0106

Main menu

Submenu 1

Submenu 2 ANALOG INPUTS MOT_D_I - Right engine current SV300 - Motor speed sensor 1 ST302 - Motor temperature sensor 1 ECU_TEMP - ECU internal temperature PUMP_I - Pump current SI900 - Picking motor current consumption (only on STAR 6P (STAR13P)) SR150 - Front wheels angle sensor

4. Diagnostic

4.3. Inputs / Outputs

MOT_G_I - Left engine current SV301 - Motor speed sensor 2 ST303 - Motor temperature sensor 2 ECU_TEMP - ECU internal temperature SM901 - Drive/Arm joystick SA723 - Picking tray switch (only on STAR 6P (STAR13P)) AU_INFO - Emergency stop (platform) status Analogic output YV520 - Mast valve

4.4. System test

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Ground control box HAULOTTE Activ'Screen

MS0106

Main menu

Submenu 1

Submenu 2 Hydraulic oil filter change

Lubrication - Lubricant system 5.1. Maintenance to Hydraulic tank oil change be done Replacement : Chains, pulleys, wear pads Replacement : Pins, rings, bearings 5.2. Maintenance log

(Maintenance done history) By event By date Machine tilt and unfolded Country changes (EEPROM) Parameter changes (EEPROM)

5.3. Events log 5. Maintenance

Software version changes Updated hourmeter Overload alarm (only on STAR 6P (STAR13P)) Change of the calibration values of the Picking load system (only on STAR 6P (STAR13P)) 5.4. Usage log

(Usage machine history : Date and hourmeter)

5.5. Upload software

From local drive From USB drive HAULOTTE® Application CombiACX

5.6. Software versions

ACEX Can Tiller Activ'Screen

102

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MS0106

Main menu

Submenu 1

Submenu 2

5. Maintenance

5.7. Event counters

Hourmeter Mast movement Drive movements Picking plate movement Turret control box selection Platform control box selection Picking control box selection (only on STAR 6P (STAR13P)) Maximum right inverter temperature Maximum right engine temperature Maximum left inverter temperature Maximum left engine temperature Mast raising movement Mast descent movement Drive movements Steering movement Picking plate movement Turret control box selection Platform control box selection Picking control box selection (only on STAR 6P (STAR13P)) Steering movement Overload Picking usage (only on STAR 6P (STAR13P))

Main menu

Submenu 1

Submenu 2

6. Tools

By event By date 6.2. Camera (Camera history) 6.3. Wifi (Wifi history) 6.4. Photos (Photos history) Language Brightness 6.5. General settings Date & Time format HAULOTTE DIAG Update System properties 6.6. Files manager File manager history 6.1. Upload software

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Ground control box HAULOTTE Activ'Screen

MS0106 3.1 -

SCREEN ACCESS CODE SETTINGS 3.1.1 - Screen 0d This screen allows the access to the following screens. When this state is active, there is no scrolling with other possible states. Only the "screen saver" is active. In this screen, it is possible to enter a level code from 1 to 3 : • Level 1 : 1250 User code • Level 2 : 2031 • Level 3 : "Turning" code. Based on the date and the machine serial number.

Screen_Acces_code Username : • Press the validation button ( 4 ).

• Press the up ( 3 ) or down ( 8 ) navigation button to increment / decrement the digits.

• Press the ( 4 ) validation button in order to pass to the next digit.

• The return/cancel key returns to the previous digit, without erasing, or to the previous menu if the first digit is selected.

104

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Ground control box HAULOTTE Activ'Screen

MS0106 Screen_Acces_level_x Username : • Press the validation code ( 4 ) to validate the entered code.

Screen_Bad_code Username : • The screen 1 access (faults) after 1s if the entered code corresponds to an access level.

• Otherwise, stay on this screen to allow the user to enter a new code.

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Ground control box HAULOTTE Activ'Screen

MS0106

Notes

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Picking tray chain Control-Lubrication

MS0112 Picking tray chain Control-Lubrication

1-

You will need

• Standard tool kit • Protective goggles • Place barriers around the perimeter of the work area • Gloves Exclusively use tools and auxiliary average adapted. Always wear necessary safety clothing.

2-

Preliminary procedure All disassembly operations, if possible, must only be performed on equipment that has been completely deactivated and only by personnel with the necessary technical knowledge.

In addition to the safety precautions indicated in these instructions, follow all regulations concerning safety and accident prevention that are generally applicable.

Every precaution must be taken before working on or near the machine.

After work has been completed, all casings and safety devices must be restored completely and operational.

3-

Lubrication Section D Inspection and maintenance schedule. 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.

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.

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Picking tray chain Control-Lubrication

MS0112 4-

Check the condition of the chains • 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 3 %, over 12 segments, of the original chain length is permitted.

• Measure the value of (3) using an appropriate method. Compare with the value of ( 4 ) indicated in the table below.

Machine

Link width (2)

Length of 12 links (4)

Star 6 P Star 13 P

12.7 mm

152,4 mm

• Check for external wear on rollers and links : • External wear must not measure more than 3 % 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.

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Picking tray chain Control-Lubrication

MS0112

Crack

Distortion

Break Wedging

• Check the connection points of links (the lines must be parallel).

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Picking tray chain Control-Lubrication

MS0112 5-

Check the tension of the chains • Position the picking plate at the top without load.

• A "slack" strand ( A ) forms under the plate, between it and the bottom sprocket.

• Push (or pull) this slack strand without forcing it at a distance of 500 mm (+/- 5 mm) above the gearmotor support using a finger.

• Measure the minimal internal distance between the 2 chain strands.

N.B.-:-THE VALUE TO BE ACHIEVED IS 41 MM (+/- 1 MM).

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Picking tray chain Control-Lubrication

MS0112 • To reach this value, it is necessary to act on the 2 nuts ( 1 ) after having fully screwed in the locknuts ( 2 ).

• .

N.B.-:-ENSURE THAT THE AXIS OF THE TOP SPROCKET REMAINS HORIZONTAL AFTER ADJUSTMENT: BALANCE THE NUMBER OF SCREW TURNS. • Move the picking plate up/down a few times to ensure that it is working correctly.

• Tighten the lock nuts2.

6-

Replacing the chains Section D Inspection and maintenance schedule.

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.

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Picking tray chain Control-Lubrication

MS0112

Notes

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Electric Battery (ies) - Standard machine

MS0113 Electric Battery (ies) - Standard machine

1-

You will need

• Standard tool kit • Protective goggles • Place barriers around the perimeter of the work area • Gloves Exclusively use tools and auxiliary average adapted. Always wear necessary safety clothing.

2-

Control 1.

Open battery compartments.

2.

Loosen the caps located on the top of the battery.

The level of electrolyte in the battery must be approx. 0,01 m(0 ft39 in) above the plates.

3-

Filling-up Loosen the caps located on the top of the battery.

If the level of electrolyte is below the level of the plates :

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Top up with distilled water.

2.

Refit and tighten the battery caps.

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Electric Battery (ies) - Standard machine

MS0113 4-

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%

When should the batteries be charged? : • Do not let the battery discharge to below 20 %.

• 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.

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Electric Battery (ies) - Standard machine

MS0113 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 - 20 Ah 220 V single phase 50 Hz 120 V single phase 60 Hz 80 V single phase 50 - 60 Hz

Electric power supply Delivered voltage

24 V

Charging time

Approximately 10 h for batteries discharged to 80 %

Mains connection

Standard plug

How to maintain battery autonomy ? : • Do not charge the batteries in cold temperatures.

• The battery life is reduced when the machine is used in cold temperatures (< 0 °C(32 °F) ).

• If the machine is not going to be used for a length of time, shut-off the power with battery isolation switch.

• Do not let the battery discharge to below 20 %.

• If batteries are deeply discharged (<10%); standard battery charger may not be enough to recharge battery.

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

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Electric Battery (ies) - Standard machine

MS0113 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)

Red

Battery presence

Battery not connected or not compliant : Check connection or rated voltage.

Yellow

Temperature probe

Temperature probe disconnected while charging or outside the functional range : Check connection and measure battery temperature.

Green

Specified time

Phase 1 or 2 is longer than the maximum allowed time : Check battery capacity

Red-Yellow

Battery current

Loss of output current control : Faulty control logic.

Red-Green

Battery voltage

Loss of output voltage control : Battery disconnected or faulty 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 supply.

• 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.

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Electric Battery (ies) - Standard machine

MS0113 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 e m p e r a t u r e

t o

d e n s i t y

a n d

Do not store machines, outside and in cold weather conditions, when batteries are discharged : Risk of damaging batteries.

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Electric Battery (ies) - Standard machine

MS0113 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

Densité acide Specific gravity

Capacitérestant restanten en% % Capacité %Capacity Capacityremaining remaining %

.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 perdu par semaine lors d'un stockage à une T° de 30°C .0075 per week loss in prolonged storage at 86°F

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 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

118

d e n s i t y

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)

4001033900

E 01.23

USA / GB

Turntable Universal plug

MS0133 Turntable Universal plug

1-

You will need • The tracker with its cable.

• A clamp to strip the wires.

• A clamp to crimp the wires.

• Place barriers around the perimeter of the work area

1 person

2-

Procedure Step 1 : • Disconnect the plug 2.

• Remove the caps on the plug.

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

• Strip the wires of the tracker.

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

Step 3 : • Take the wedgelock off the plug.

• Thread the wires in the positions regarding the information.

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Turntable Universal plug

MS0133 C1

Universal connector

Pin 1

+ permanent battery

Pin 2

GND (0 V)

Pin 3

+ battery voltage

Pin 4

• Machine with engine : Engine ON information.

• Electrical machine : Movement and driving information.

Pin 5

Power ON information

Pin 6 Pin 7

Movement information (Flashing light option activation)

Pin 8

Driving information

Pin 9

CAN 1 H

Pin 10

CAN 1 L

Pin 11

CAN 2 H

Pin 12

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

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

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

Step 5 : • Reconnect the plugs.

• Mount the tracker.

• The tracking device is operational.

120

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Chassis Check of tilt sensor

MS0242 Chassis Check of tilt sensor

1-

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

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

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

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

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

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

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

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

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

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

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

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

2-

Risk prevention M e a n s

4001033900

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Safety goggles

E 01.23

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121

Chassis Check of tilt sensor

MS0242 3-

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

• Place barriers around the perimeter of the work area

1 person

4-

Check of tilt sensor • Put the machine in stowed position.

• Position the machine on an incline that is greater than the maximum permitted incline.

• Check that the tilt indicator is on ( 27).

• Fit the platform and ensure that movement is off and the buzzer is triggered.

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

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

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

• Switch off the ignition and remove the ignition key.

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

122

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Chassis Check of tilt sensor

MS0242 • Position the electronic level under the chassis and note the values displayed on the X and Y axis.

• Check the X and Y axis : A x i s

X

A x i s

Y

• Turn on ignition key and start up engine.

• Compare the tilt values X and Y of the machine with an electronic level to those displayed on the screen Activ' Screen.

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Chassis Check of tilt sensor

MS0242 • In the main menu select : Machine settings > Calibration > Tilt > Check of tilt sensor :

For each axis ( X and Y) : The difference in values between the electronic level and those displayed on the Activ' Screen display must not exceed 0,5 °.

• If the gap is > 0,5°, carry out a new calibration (Refer to

124

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MS0245 - Dismantling/Reassembling the Tilt Sensor).

USA / GB

Chassis Check of tilt sensor

MS0242

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125

Chassis Check of tilt sensor

MS0242

Notes

126

4001033900

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Chassis Dismantling/Reassembling the Tilt Sensor

MS0245 Chassis Dismantling/Reassembling the Tilt Sensor

1-

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

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

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

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

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

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

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

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

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

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

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

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

2-

Risk prevention M e a n s

4001033900

o f

p r o t e c t i o n

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

w h e n

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

Appropriate workwear

Gloves

Safety shoes

Safety goggles

E 01.23

USA / GB

127

Chassis Dismantling/Reassembling the Tilt Sensor

MS0245 3-

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

• Place barriers around the perimeter of the work area

1 person

4-

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

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

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

• Switch off the ignition and remove the ignition key.

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

128

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Chassis Dismantling/Reassembling the Tilt Sensor

MS0245 • Cut the COLSON tie holding the tilt cable.

• Unscrew the 2 fixing screws (1).

5-

Reassembly • Reverse the above procedure.

• Tighten the brake nuts to a torque of 10 Nm then mark the screws with the sealing.

• Fasten the tilt cable with a COLSON tie onto the sleeve clamp.

• Carry out the calibration procedure(Refer to the illustrations below).

6-

Calibration Tilt calibration must be performed on perfectly flat ground.

Using an electronic level, check the level of the chassis and calibration of the machine if necessary ( +/-0.3° for each axis).

• On the Activ'Screen screen, enter the level 2 access code.

• Menu : Machine settings

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129

Chassis Dismantling/Reassembling the Tilt Sensor

MS0245 • Menu : Calibration

• Menu : Slope sensor on flat ground

130

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Chassis Dismantling/Reassembling the Tilt Sensor

MS0245

Lateral angle (sensor Y axis) : Lateral angle decreases in this direction : –Y : Lateral angle increases in this direction : +Y : Longitudinal angle (sensor X axis) : Longitudinal angle decreases in this direction : –X : Longitudinal angle increases in this direction : +X :

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Chassis Dismantling/Reassembling the Tilt Sensor

MS0245 7-

Additional operations • Position the machine on an incline that is greater than the maximum permitted incline.

• Fit the platform and ensure that movement is off and the buzzer is triggered.

• Check that the tilt values in X and Y displayed on the screen Activ' Screen are identical to the current machine values (check using an electronic level on the chassis) +/-0.3°.

The position of the electronic tilt : A x i s

X

A x i s

Y

• Procedure to verify the tilt angle using the screen Activ' Screen : • In the main menu select : Machine settings > Calibration > Tilt > Check of tilt sensor.

132

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Chassis Dismantling/Reassembling the Tilt Sensor

MS0245

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133

Chassis Dismantling/Reassembling the Tilt Sensor

MS0245 E

Notes

134

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STAR 6P - STAR 13P

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 A DETECTED failure ( D ) signals the cause of the failure has been valid one at least power on, but is inactive A code CODE is linked to failures which have several causes of activation to identify the one of activation (if many conditions are active the code are added) At power on, the failure log and failure counter are not changed for a failure which was already active at power off The failure log and failure counter are changed for a failure which internal code is changed

FAIL_xx_002 FAIL_xx_003 FAIL_xx_004 FAIL_xx_005

N.B.-:- VAR[ACTIVEFAILURE] = 1 IF ONE OR MORE OF THE FOLLOWING FAILURES ARE IN ACTIVE STATE

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E- Trouble shooting and diagram 1.4 -

FAILURES LIST

Failures

N

C

Description

Inverter

F01.01 Inverter Master

F01.05 Pump failure

F01.06 Overheating

A

F01.08 Low Battery

A

136

4001033900

Zapi failure code 17 on COMBIACX : Failure in the high current hardware protection circuit

2

Zapi failure code 23 on COMBIACX : When no current is applied to the traction motor, the current feedbacks are out of permitted standby range

4

Zapi failure code 31 on COMBIACX : Driver of line contactor coil is damaged (not able to close)

8

Zapi failure code 40 on COMBIACX : Auxiliary output driver opened

16

Zapi failure code 59 on COMBIACX : Pump current sensor out of range (at start-up or standby)

32

Zapi failure code 67 on COMBIACX : At start-up, the amplifiers voltage (used to measure the motor voltage) is too low or too high (< 2 V or >3 V)

1

Zapi failure code 44 on COMBIACX : The software waits for the motor pump to stop at start-up

2

Zapi failure code 51 on COMBIACX : Pump driving voltage different than the expected one

4

Zapi failure code 55 on COMBIACX : The pump motor output voltage is lower than expected, considering the PWM applied

8

Zapi failure code 56 on COMBIACX : The pump motor output voltage is higher than expected, considering the PWM applied

16

Zapi failure code 57 on COMBIACX : The pump current sensor feedback is always 0 A, even if pump motor is running

1

Zapi failure code 32 on COMBIACX : The controller has reached thermal cutout (temperature of the controller base plate is higher than 85° C)

2

Zapi failure code 32 on ACEX : The controller has reached thermal cutout (temperature of the controller base plate is higher than 85° C)

1

Zapi failure code 33 on COMBIACX : Low battery (lower than 10%)

1

Zapi failure code 16 on COMBIACX : Short circuit on main contactor or electric brake coil

2

Zapi failure code 26 on COMBIACX : The driver of the electromechanical brake is shorted to -Vbatt

4

Zapi failure code 29 on COMBIACX : The driver of the electromechanical brake is shorted to +Vbatt

8

Zapi failure code 45 on COMBIACX : A short circuit on the power outputs of the controller has been detected

16

Zapi failure code 66 on COMBIACX : Voltage on power electric brake present but not expected

32

Zapi failure code 38 on COMBIACX and no Zapi failure code 38 on ACEX : Internal Smart driver KO

A

A

F01.09 Electrical park brake 1

1

A

E 01.23

USA / GB

STAR 6P - STAR 13P

E- Trouble shooting and diagram Failures

N

C

Description

1

Zapi failure code 16 on ACEX : Short circuit on main contactor or electric brake coil

2

Zapi failure code 26 on ACEX : The driver of the electromechanical brake is shorted to -Vbatt

4

Zapi failure code 29 on ACEX : The driver of the electromechanical brake is shorted to +Vbatt

8

Zapi failure code 45 on ACEX : A short circuit on the power outputs of the controller has been detected

16

Zapi failure code 66 on ACEX : Voltage on power electric brake present but not expected

32

Zapi failure code 38 on ACEX and no Zapi failure code 38 on COMBIACX : Internal Smart driver KO

1

Zapi failure code 17 on ACEX : Failure in the high current hardware protection circuit

2

Zapi failure code 23 on ACEX : When no current is applied to the traction motor, the current feedbacks are out of permitted standby range

4

Zapi failure code 31 on ACEX : Driver of line contactor coil is damaged (not able to close)

8

Zapi failure code 40 on ACEX : The driver of the electromechanical brake coil is not able to drive the load

32

Zapi failure code 67 on ACEX : At start-up, the amplifiers voltage (used to measure the motor voltage) is too low or too high (< 2 V or > 3 V)

1

COMBIACX is a power version

2

ACEX is a power version

Inverter

F01.10 Electrical park brake 2

F01.11 Inverter Slave

F01.12 Wrong controller hardware

4001033900

A

A

D

E 01.23

USA / GB

137

STAR 6P - STAR 13P

E- Trouble shooting and diagram Failures

N

C

Description

Contactor 1

F02.04 Power Contactor

2 D 4

SB801

8

Failures

Zapi failure code 20 on COMBIACX : The driver of main contactor drive coil is shorted, or its coil is disconnected Zapi failure code 24 on COMBIACX : The main contactor coil has been driven but main contactor does not close Zapi failure code 46 on COMBIACX : Main contactor contact is stuck (always closed) Supervisor status: alarm or wait reset and main contactor is not forced open by a Zapi failure

N

C

Description

D

1

Automatic refill pump KA911 control relay failure : --> KA911: Check relay output status.

N

C

Description

Contactor F03.15 Water refill pump control relay KA911

Failures Electrovalves F04.01 Steering

1 D

YV150R/YV150L1

F04.11 Principal movement valve

2

D

1

Unload valve YV903 failure (short circuit) and setpoint which need its activation active : --> YV903 = FAIL & (STP(Steering)|| STP(MastUp)|| STP(Potholes))

D

1

Mast descent valve YV520 open circuit failure or Mast descent valve YV520 short circuit failure and mast setpoint active : --> YV520 = OPEN-CIRCUIT || (YV520 = SHORT-CIRCUIT & STP(Mast))

YV903

F04.39 Mast YV520

1

F04.40 Potholes

D

YV144/YV1452

Steering front left valve YV150R failure (short circuit) and steering setpoint active : --> YV150R = FAIL & STP(Steering) Steering front right valve YV150L failure (short circuit) and steering setpoint active : --> YV150L = FAIL & STP(Steering)

2

Potholes in valve YV145 failure (short circuit) and potholes setpoint active : --> YV145 = FAIL & STP(Potholes) Potholes Out valve YV144 open circuit failure or Potholes Out valve YV144 short circuit failure and potholes setpoint active : --> YV144 = OPEN-CIRCUIT || (YV144 = SHORT-CIRCUIT & STP(Potholes))

1. Only on STAR 6 - STAR 13 - STAR 6 P - STAR 13 P - STAR 8 S - STAR 20 2. Only on STAR 6 - STAR 13 - STAR 6 P - STAR 13 P - STAR 8 S - STAR 20

138

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STAR 6P - STAR 13P

E- Trouble shooting and diagram Failures

N

C

Description

Joysticks

F05.01 Drive joystick

Analog signal SM901Y of main joystick SM901 out of range : --> SM901Y < 0.2V | SM901Y > 4.8V

2

Incoherence between analog and out of neutral signals of main joystick SM901 : --> SM901N = 1 & (2.45V < SM901Y < 2.55V) --> or SM901N = 0 & (SM901Y < 2V | SM901Y > 3V)

D

SM901

F05.11 Joystick neutral

1

Neutral position of main joystick SM901 not detected after power on : --> SM901 < 2.35V | SM901 > 2.65V

A

SM901

Failures

N

C

Description

F06.01 Overload not calibrated

A

1

Picking overload not calibrated

A

2

Load Management System not calibrated

F06.03 Load Cells out of range

D

1

Gauge value or temperature 1 and/or 2 of sensor 1 out of range - Check sensor 1.

D

2

Gauge value or temperature 1 and/or 2 of sensor 2 out of range - Check sensor 2.

F06.04 Load Cells incoherence

D

1

Gauge value 1 and/or 2 of sensor 1 are frozen - Check sensor 1.

D

2

Gauge value 1 and/or 2 of sensor 2 are frozen - Check sensor 2.

F06.05 Overload low power

D

1

Supply voltage of gauge sensor 1 out of range - Check sensor 1 supply.

D

2

Supply voltage of gauge sensor 2 out of range - Check sensor 2 supply.

Overload

F06.09 Negative load

4001033900

A

Load into the platform below -40kg for more than 500ms when machine is unfolded.

To acknowledge the underload alarm flag, the computed load must go under -30kg during 2 seconds (hysteresis to avoid flickering of underload alarm flag).

E 01.23

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139

STAR 6P - STAR 13P

E- Trouble shooting and diagram Failures

N

C

Description

Sensors F07.05 Motor Temperature

F07.33 Steer Angle

1

Zapi failure code 61 on COMBIACX : The drive motor temperature sensor is not correctly connected or damaged

4

Zapi failure code 61 on ACEX : The drive motor temperature sensor is not correctly connected or damaged

1

If the sensor is SR150 the error will appear if : • Analog signal calibrated SR150 of steer angle sensor calibrated and out of range [-44.1° to 75.0°] If the sensor is SR150_1 the error will appear if : • Analog signal of steering angle sensor is out of range (only if calibrated) : • & F10.14=0

1

Zapi failure code 47 on COMBIACX : Problem on the encoder

2

Zapi failure code 47 on ACEX : Problem on the encoder

1

Zapi failure code 37 on COMBIACX : Controller temperature sensor is faulty

2

Zapi failure code 37 on ACEX : Controller temperature sensor is faulty

1

Potholes are seen out but the IN timer is finished

1

No movement is asked and a current is present (short circuit of the sensor or stuck relay) : CTRL[Plate]=0 && VAR[MotorCurrent]>32.5A

2

The neutral current is less than the expected value (sensor in open circuit or stuck relay) : CTRL[Plate]=0 && VAR[MotorCurrent]<42.5A

1

Tilt sensor is not calibrated. Perform the calibration.

1

Checksum failure

2

Fault detected on X - axis

4

Fault detected on Y - axis

8

Supply voltage < 8V

D

D

SR1501

F07.35 Motor encoder

D

F07.36 ECU temperature

D

F07.38 Potholes not in2

D

F07.41 Overload Picking3

F07.44 Tilt sensor not calibrated

F07.46 Tilt sensor error

D

A

D

16

Supply voltage > 28V

32

Temperature > 90°C

1. Only on STAR 6 - STAR 13 - STAR 6 P - STAR 13 P - STAR 8 S - STAR 20 2. Only on STAR 6 - STAR 13 - STAR 6 P - STAR 13 P - STAR 8 S - STAR 20 3. Only on STAR 6 P - STAR 13 P

140

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STAR 6P - STAR 13P

E- Trouble shooting and diagram Failures

N

C

Description

Electric circuit

1

Zapi failure code 18 on COMBIACX : Power capacitors voltage does not increase at start-up Zapi failure code 27 on COMBIACX : The controller detects an overvoltage or undervoltage condition : • Overvoltage threshold is 35 V, under voltage threshold is 9.5 V Zapi failure code 36 on COMBIACX : At start-up, the battery voltage is too low or too high (< 0.8 Vbatt or > 1.2 Vbatt) Zapi failure code 60 on COMBIACX : A low logic level of Key-Off has been detected during start-up diagnosis Zapi failure code 18 on ACEX : Power capacitors voltage does not increase at startup Zapi failure code 27 on ACEX : The controller detects an overvoltage or undervoltage condition • Overvoltage threshold is 35 V, under voltage threshold is 9.5 V Zapi failure code 36 on ACEX : At start-up, the battery voltage is too low or too high (< 0.8 Vbatt or > 1.2 Vbatt) Zapi failure code 60 on ACEX : A low logic level of Key-Off has been detected during start-up diagnosis SA901B=0 & SA901C=0

2

SA901B=1 & SA901C=1

1

Zapi failure code 50 on COMBIACX : Low voltage of the electrovalves common (B2)

2

Zapi failure code 50 on ACEX : Low voltage of the electrovalves common (B2)

1 2 4

F08.04 Supply

8 A 16 32 64 128

F08.07 Control Box incoherence F08.09 Common outputs supply

A

D

1

F08.10 Power supply

D

F08.13 Power supply

D

F08.16 Power supply

D

F08.19 Battery Voltage drop too deept

A

4001033900

2 3 1 2 4 8 16 32 64 128 1 2 4 8 1

Zapi failure code 38 on ACEX and Zapi failure code 38 on COMBIACX : Internal Smart driver KO Zapi failure code 24 on COMBIACX : Main contactor opened Zapi failure code 46 on ACEX : Main contactor contact is stuck (always closed) Phase 1 timeout Phase 2 timeout Phase 3 timeout Batteries over temperature Charger failure (check charger internal failure code in reference) Temperature sensor failure Flash memory corrupted Not an original HAULOTTE® charger Incoherence between Request and Acknowledge (index or sub-index) Acknowledge control error (0x80) Acknowledge timeout (no response within 1s) Wrong charge settings CRC between screen and main ECU (Restart machine) The critical battery level flag is active before the low battery level flag is active This failure is maintained active until switch off the electric circuit - F08.19(A)

E 01.23

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141

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E- Trouble shooting and diagram Failures

N

C

Description

D

1

Steer angle not calibrated

1

Detector SL911 indicates low level in automatic refill tank

2

Battery water refill needed but temperature is too cold (<3°C)

Functions F10.14 Steering angle not calibrated1 F10.21 Battery water refill system

N

F10.22 Battery water refill needed

N

Battery water level is low

D

Check the functional state of refill system components : • Check ambient temperature is beyond 3° • Check refill system circuit pipes: no leakage, no blockage • KA911: Check functional state of refill tank electric pumps • SL911: Check refill tank water level detector and the presence of demineralized water in the tank

F10.24 Incoherence between water level in refill tank and water level in batteries

1. Only on STAR 6 - STAR 13 - STAR 6 P - STAR 13 P - STAR 8 S - STAR 20

142

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E- Trouble shooting and diagram Failures

N

C

Description

1 2

Cantiller RX failure Screen RX failure Zapi failure code 39 on COMBIACX : Module does not receive any CAN messages from another module Zapi failure code 39 on ACEX : Module does not receive any CAN messages from another module No time (date/hour) update (problem with screen communication) CAN frame not received from tilt sensor or stagnant transmission (timestamp not updated anymore).

Check that resistance wires 1001 ( CAN high) and 1002 ( CAN low) is nearly 60 ohms, machine switched off.

CAN frame not received from strain gauge 1 CAN frame not received from strain gauge 2 EEPROM failure status error EEPROM failure stack full Zapi failure code 25 on COMBIACX : EEPROM failure Zapi failure code 69 on COMBIACX : EEPROM failure Zapi failure code 25 on ACEX : EEPROM failure Zapi failure code 69 on ACEX : EEPROM failure Read EEPROM during init failed

Internal faults

4

F12.01 CAN Fault

8 A

16

Check wires 32

F12.02 E2P Read/Write Error

D

Change calc.

F12.04 E2P Param Reset

D

64 128 1 2 4 8 16 32 64

ID of software loaded into machine is different from the ID stored into EEPROM: all machine parameters have been reset and must then be set again (speeds, ramps, options, configs, access code level 2, failure counters and calibration data)

1

Check settings

F12.05 E2P Param Not Set

A

1 2 4 8 16 32

Model not set Country not set Serial number = 0 At least one of the parameter used and not set At least one option used and not set At least one config not set Wrong machine model : STAR6 selected and strain gauges are present on CAN bus - Select STAR8 / STAR6W.

64

F12.07 ECU software version incoherence

A

1

Zapi software version different on COMBIACX and on ACEX

1 2

Zapi failure code 34 on COMBIACX : Client software watchdog Zapi failure code 41 on COMBIACX : Problem on the A/D conversion of uC Zapi failure code 42 on COMBIACX : Watchdog circuit output became high due to hardware or software problem Zapi failure code 43 on COMBIACX : Watchdog circuit output became high due to hardware or software problem Zapi failure code 54 on COMBIACX : Current gain acquisition has not been performed or EEPROM damaged Zapi failure code 63 on COMBIACX : Wrong client software Zapi failure code 68 on COMBIACX : RAM checksum failed ( RAM warning) Zapi failure code 73 on COMBIACX : Timeout of client function (execution time exceed maximum allowable time)

4

F12.08 ECU fault (master)

8 A 16 32 64 128

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E- Trouble shooting and diagram Failures

N

C

Description

1 2

Zapi failure code 34 on ACEX : Client software watchdog Zapi failure code 41 on ACEX : Problem on the A/D conversion of uC Zapi failure code 42 on ACEX : Watchdog circuit output became high due to hardware or software problem Zapi failure code 43 on ACEX : Watchdog circuit output became high due to hardware or software problem Zapi failure code 54 on ACEX : Current gain acquisition has not been performed or EEPROM damaged Zapi failure code 63 on ACEX : Wrong client software Zapi failure code 68 on ACEX : RAM checksum failed ( RAM warning) Zapi failure code 73 on ACEX : Timeout of client function (execution time exceed maximum allowable time) Incoherence of Battery Parameters ; new value forced, restart mandatory Incoherence of Motor Accessories Parameters ; new value forced, restart mandatory Incoherence of Motor Parameters ; new value forced, restart mandatory Incoherence of Option Parameters ; new value forced, restart mandatory Incoherence of Input Output Parameters ; new value forced, restart mandatory Incoherence of Machine Parameters ; new value forced, restart mandatory A parameter has changed and a restart is mandatory No parameters verification Wrong parameter : out of expected range Wrong parameter : EEPROM problem or RAM problem Wrong parameter : parameter current value is different from parameter initialized value Wrong parameter : incoherence between master and slave parameter source Invalid Maintenances Log ID Invalid Events log ID Invalid Events log ID Invalid Failure ID Invalid Machine Parameter (Speed or Ramp) ID Invalid Machine Calibration ID Invalid Option ID Invalid Country ID Invalid Machine Configuration ID Invalid Machine Model ID Invalid Security Setting ID Invalid Machine State ID Invalid Input/Output ID Invalid Internal Function ID Invalid Internal Version ID Invalid Machine Maintenance ID Invalid Event Counter ID Invalid Internal Version ID

Internal faults

4

F12.09 ECU fault (slave)

8 A 16 32 64 128

F12.10 Wrong default parameters

A

F12.11 Parameters reload

A

Restart machine

F12.16 Internal error of diagnostic system (request)

144

4001033900

A

1 2 4 8 16 32 64 128 1 2 4 8 4 6 7 193 196 197 198 199 200 201 205 206 207 209 210 211 212 213

E 01.23

USA / GB

STAR 6P - STAR 13P

E- Trouble shooting and diagram Failures

N

C

Description

A

4 6 7 193 196 197 198 199 200 201 205 206 207 209 210 211 212 213

Internal faults

F12.16 Internal error of diagnostic system (set)

4001033900

Invalid Maintenances Log ID Invalid Events log ID Invalid Events log ID Invalid Failure ID Invalid Machine Parameter (Speed or Ramp) ID Invalid Machine Calibration ID Invalid Option ID Invalid Country ID Invalid Machine Configuration ID Invalid Machine Model ID Invalid Security Setting ID Invalid Machine State ID Invalid Input/Output ID Invalid Internal Function ID Invalid Internal Version ID Invalid Machine Maintenance ID Invalid Event Counter ID Invalid Internal Version ID

E 01.23

USA / GB

145

STAR 6P - STAR 13P

E- Trouble shooting and diagram Failures

N

C

Description

D

1

Incoherence between the 2 signals of front steering switch of platform box (both active) : --> SM901L = 1 & SM901R = 1

1

Neutral position of mast lifting switch of chassis box not detected after power on : --> Screen_button1=1 | Screen_button2=1

2

Neutral position of Foot Switch of chassis box not detected after power on : --> Screen_button3= 1

4

Neutral position of unbraking of chassis box not detected after power on : --> SB100 = 1

8

Neutral position of horn option switch of chassis box not detected after power on : --> SA907C = 1

1

Neutral position of front steering switch of platform box not detected after power on : --> SM901L = 1 | SM901R = 1

2

Neutral position of Foot Switch of platform box not detected after power on : --> SM901DM = 1

4

Neutral position of horn switch of platform box not detected after power on : --> SA907 = 1

8

Neutral position of drive selection switch of platform box not detected after power on : --> SA908D= 1

16

Neutral position of mast selection switch of platform box not detected after power on : --> SA908M= 1

32

Neutral position of Foot Switch of picking box not detected after power on : --> SA806 = 1

64

Neutral position of lift mast of picking box not detected after power on : --> SA520U = 1 | SA520D = 1

128

Neutral position of lift plate of picking box not detected after power on : --> SA723 = 1

Switches F13.02 Platform switches Check switches

F13.10 Neutral switch

A

Check chassis switches

F13.11 Switches neutral 2

A

Check plat. switches

Failures

N

C

D

1

Description

CAN J1939 F15.06 J1939

146

4001033900

Error on J1939

E 01.23

USA / GB

STAR 6P - STAR 13P

E- Trouble shooting and diagram Failures

N

C

Description

Engine F16.01 Overheating

F16.02 Speed problem

F16.03 Motor supply

4001033900

1

Zapi failure code 35 on COMBIACX : Motor maximum temperature reached

2

Zapi failure code 35 on ACEX : Motor maximum temperature reached

1

Zapi failure code 52 on COMBIACX : The drive motor has been detected stalled or the encoder is not working

2

Zapi failure code 52 on ACEX : The drive motor has been detected stalled or the encoder is not working

1

Zapi failure code 19 on COMBIACX : Motor output voltage is lower than expected while running

2

Zapi failure code 22 on COMBIACX : Motor output voltage is higher than expected while running

4

Zapi failure code 28 on COMBIACX : Motor voltage feedback circuits are damaged

8

Zapi failure code 71 on COMBIACX : The motor output voltage is lower than expected, before main contactor drive switch is ON

16

Zapi failure code 72 on COMBIACX : The motor output voltage is higher than expected, before main contactor drive switch is ON

32

Zapi failure code 19 on ACEX : Motor output voltage is lower than expected while running

64

Zapi failure code 22 on ACEX : Motor output voltage is higher than expected while running

128

Zapi failure code 28 on ACEX : Motor voltage feedback circuits are damaged

256

Zapi failure code 71 on ACEX : The motor output voltage is lower than expected, before main contactor drive switch is ON

512

Zapi failure code 72 on ACEX : The motor output voltage is higher than expected, before main contactor drive switch is ON

A

A

A

E 01.23

USA / GB

147

STAR 6P - STAR 13P

E- Trouble shooting and diagram 2-

Electric diagram E l e c t r i c i t y

148

4001033900

p a r t

4 0 0 1 0 1 6 9 5 0

E 01.23

A

-

f o l i o

0 1

USA / GB

STAR 6P - STAR 13P

E- Trouble shooting and diagram V a r i a b l e

4001033900

s p e e d

d r i v e

E 01.23

p a r t

4 0 0 1 0 1 6 9 5 0

A

-

USA / GB

f o l i o

0 2

149

STAR 6P - STAR 13P

E- Trouble shooting and diagram V a r i a b l e

150

4001033900

s p e e d

d r i v e

p a r t

E 01.23

4 0 0 1 0 1 6 9 5 0

A

-

f o l i o

0 3

USA / GB

STAR 6P - STAR 13P

E- Trouble shooting and diagram C a g e

4001033900

p a r t

E 01.23

4 0 0 1 0 1 6 9 5 0

A

-

f o l i o

0 4

USA / GB

151

STAR 6P - STAR 13P

E- Trouble shooting and diagram O p t i o n

152

-

4001033900

W e i g h i n g

s y s t e m

E 01.23

4 0 0 1 0 1 6 9 5 0

A

-

f o l i o

0 5

USA / GB

STAR 6P - STAR 13P

E- Trouble shooting and diagram O p t i o n

4001033900

-

L i t h i u m

E 01.23

b a t t e r y

4 0 0 1 0 1 6 9 5 0

A

-

f o l i o

USA / GB

0 6

153

STAR 6P - STAR 13P

E- Trouble shooting and diagram 3-

Hydraulic diagram

F

154

4001033900

E 01.23

USA / GB

STAR 6P - STAR 13P

F- Records Records 1-

Intervention register

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

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

Date

4001033900

Type of intervention

E 01.23

Number of hours

Intervenor

HAULOTTE Services® intervention number

USA / GB

155

STAR 6P - STAR 13P

F- Records Date

156

Type of intervention

4001033900

Number of hours

E 01.23

Intervenor

HAULOTTE Services® intervention number

USA / GB