Haulotte Vertical Mast STAR 10-26J Maintenance Book 4001180330 - PDF DOWNLOAD

STAR 10 - STAR 26J

Maintenance Book

MAINTENANCE BOOK

STAR 10 - STAR 26J USA

4001180330

E 10.22

USA / GB

STAR 10 - STAR 26J

2

4001180330

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Electric Shock Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Explosion / Fire Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

CONTENTS

2 - Maintenance and repair training . . . . . . . . . . . 14 2.1 2.2 2.3 2.4 2.5 2.6 2.7 -

Owner's responsability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Technician's responsability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 HAULOTTE Services®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Product modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Product information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3 - Conditions of warranty . . . . . . . . . . . . . . . . . . 15

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Maintenance Book

C Familiarization 1 - Primary machine components . . . . . . . . . . . . 18 1.1 - Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1.2 - Ground control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 1.2.1 1.2.2 -

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ACTIV'Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.3 - Platform control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 1.3.1 -

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2 - List of actuators and sensors . . . . . . . . . . . . . 32 2.1 - Sensors and actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3 - Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . 34 4 - Ingredient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 4.1 - Hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5 - Lubrication diagram . . . . . . . . . . . . . . . . . . . . . 35 6 - Greasing points localization . . . . . . . . . . . . . . 36 7 - Machine specifications . . . . . . . . . . . . . . . . . . 37 7.1 - Movement speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

D Inspection and maintenance schedule 1 - Inspection program . . . . . . . . . . . . . . . . . . . . . 39 2 - Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . 39 3 - Preventive maintenance . . . . . . . . . . . . . . . . . 40 4 - Periodic inspection . . . . . . . . . . . . . . . . . . . . . 44 5 - Major inspection . . . . . . . . . . . . . . . . . . . . . . . . 46

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Maintenance Book

Machine sheet MS0001 - Structural part inspection . . . . . . . . . . . . . . . 47 MS0002 - Pins and bearing inspection . . . . . . . . . . . . . 51 MS0003 - Cylinder inspection . . . . . . . . . . . . . . . . . . . . 55 MS0004 - Braking test procedure . . . . . . . . . . . . . . . . . 59 MS0005 - Torque Values . . . . . . . . . . . . . . . . . . . . . . . . 61 MS0010 - Slew ring inspection . . . . . . . . . . . . . . . . . . . 65 MS0012-2 - Condition of the cables inspection - Criteria of replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 MS0020 - Hoses inspection - Replacement . . . . . . . . . 75 MS0042 - Inspection of the condition of the chains -

Criteria of replacement . . . . . . . . . . . . . . . . . . . . . . . . 77 MS0044 - Tires (Tyres) and pressures - Wheel

replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 MS0045 - Lubrication - Jib cylinder - Steering cylinder Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 MS0046 - Dismantling / Reassembling wheels reducer89 MS0047 - Replacing the wheel pivot. . . . . . . . . . . . . . . 93 MS0048 - Steering cylinder removal . . . . . . . . . . . . . . 103 MS0049 - Hydraulic oil - Level Replacement . . . . . . . 107 MS0050 - Hydraulic filter cartridge Replacement . . . 109 MS0052 - Battery (ies) . . . . . . . . . . . . . . . . . . . . . . . . . 111 MS0053 - Return cables . . . . . . . . . . . . . . . . . . . . . . . . 117

CONTENTS

MS0054 - Specific adjustment procedure

STAR 10 - STAR 26J . . . . . . . . . . . . . . . . . . . . . . . . . 119 MS0059 - Electrical wiring . . . . . . . . . . . . . . . . . . . . . . 125 MS0061 - Clearance procedure . . . . . . . . . . . . . . . . . . 127 MS0062 - Inspection of the slack chain sensors . . . . 129 MS0085 - Overriding function reset . . . . . . . . . . . . . . 135 MS0097 - Calibration steering . . . . . . . . . . . . . . . . . . . 139 MS0133 - Universal plug . . . . . . . . . . . . . . . . . . . . . . . 143 MS0242 - Check of tilt sensor . . . . . . . . . . . . . . . . . . . 145 MS0245 - Dismantling/Reassembling the Tilt Sensor 151 MS0343 - Visual inspection of the baseplate fastening screws on the casings of booms 1 and 2 . . . . . . . 159

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Maintenance Book

E Trouble shooting and diagram 1 - Trouble shooting . . . . . . . . . . . . . . . . . . . . . . 167 1.1 - Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 1.2 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 1.3 - Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

2 - Electric diagram . . . . . . . . . . . . . . . . . . . . . . . 180 3 - Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . 186

F Records 1 - Intervention register . . . . . . . . . . . . . . . . . . . . 187

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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.

Symbol Symbol

Description Danger : Risk of injury or death Caution : Risk of material damage Prohibition relating to work safety and quality Reminder to use good practice or follow pre-operation checks Cross-reference to another part of the manual Cross-reference to another manual Cross-reference to repair (contact HAULOTTE Services®) Maintenance sheet Recommended tools Recommended part Safety

N.B. :

8

Additional technical information

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A - Preface - Foreword Decals Color

Title

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

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

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

Notice : Indicates practices not related to personal injury.

Procedure : Indicates a maintenance operation.

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

1.

Place the machine on firm, level ground.

2.

Stow the machine completely.

3.

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

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.

1.2 -

Pull the E-stop button.

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.

• Fold the machine with the mast fully retracted and lowered and the jib aligned.

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

• Ensure all compartments are closed and secured.

• Chock the wheels.

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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.

Minimum safe approach distances

Electric voltage

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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B - Safety Notes

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C - Familiarization Familiarization

Notes

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C - Familiarization 1-

Primary machine components 1.1 -

LAYOUT STAR 10 - STAR 26J

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C - Familiarization Marking

Description

Marking

Description

C1

Chassis

C47

Battery isolation switch

C4

Jib

C50

Battery charger socket

C6

Platform

C54

Telescopic mast

C7

Platform control box

C58

Pothole protection

C10

Slew ring

C59

Platform entry (hinged rail)

C11

Turntable assembly

C64

Tilt sensor

C20

Tie-down (and/or forklift loading)

C74

Jib leveling cylinder

C27

Ground control box + Universal plug

C76

Guardrail

C33

Counterweight

C90

Batteries pack

C34

Drive wheels

C136

Steer wheels

C35

Document holder

C170

Brake release switch

C42

Foot Switch (For Japan only) Universal plug

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C - Familiarization 1.2 -

GROUND CONTROL BOX 1.2.1 - Layout General view

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C - Familiarization Controls and indicators Marking

Name

Description

15

SB801

E-stop button

SA901

Control box activation key switch

Function Pulled out : E-stop activated Pushed in : E-stop deactivated Move upwards : Platform control box energized

92

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

Beacon light 1

105 127

SA520

Mast telescoping selector

128

SA250

Turret rotation switch

129

SA620

Jib raising / lowering switch

253

CN03

258

Move to the right : Flashing light is turned on Move to the left : Flashing light is turned off Move upwards : Mast lifting Move downwards : Mast retraction Move to the left : Clockwise (CW) rotation Move to the right : Counter clockwise (CCW) rotation Move upwards : Jib raising Move downwards : Jib lowering

Diagnostic tool socket Brake release telecommand connection2

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

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C - Familiarization 1.2.2 - 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.

Indicators

254

ACTIV’Screen

255 245

256

!

228 4000274010 B

252

6

Controls and indicators Marking

22

Description

6

Platform overload indicator : Intermittently lit in case of overload

228

Enable Switch : Press and hold Enable Switch

245

"Overriding system" control : Emergency lowering system in case of overload

252

Machine fault indicator : Intermittently lit in the event of an operation malfunction

254

Navigation buttons

255

Validation Button

256

Cancel Button

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C - Familiarization Activ'Screen Icon

Description

Function

Icon

Description

Function

Activ'Screen ACTIV’Screen

!

4000274010 B

Navigation buttons - Above Activ'Screen display

Up Navigation

Permits scrolling up through the screen (if present)

Permits allows scrolling down through Down Navigation the screen and onto the following screen (if present)

Cancel Button

Used to refuse or cancel a selection within the menu

Validation Button

Used to confirm selection within the menus

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.

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C - Familiarization Controls and indicators Icon

Description

Function

Icon

Description

Function

Home screen (dashboard) (Will be visible - depending on the machine)

1

2

3

24

Battery status

• Display battery charge status

Maintenance use

• Maintenance required display

Alarm

• Alarm detected display

Hourmeter

• Display total machine running hours

Machine Model

• The timer flashes if the engine is switched on and the hourmeter increases.

Ready

• Machine ready, displayed when no failures and no other machine state icons is active

Machine date and time

• Display machine date and time

Machine ready

• Machine ready, displayed when no failures and no other machine state icons is active

Functional information zone

Information text

Machine status zone

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C - Familiarization Controls and indicators Icon

Description

Function

Icon

Description

Function

Home screen (dashboard) (Will be visible - depending on the machine)

Information text

Software part number

• Display machine software code

2

Information text

Software version + Screen software version + Screen version

• Display software version, screen software and screen

3

Information text

Screen identification + Screen software version

• Display of screen ID and screen software version

4

Information text

Machine serial number

• Machine serial number displayed

1

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C - Familiarization Controls and indicators Icon

Description

Function

Icon

Description

Function

Home screen (dashboard) (Will be visible - depending on the machine)

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Access code

• 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

Tilt

• Display software version, screen software and screen

Overload

• Display of screen ID and screen software version

Low battery

• Machine serial number displayed

Recharge the batteries

• Fully recharge the batteries To perform a full recharge, the battery level must be less than 70 %.

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C - Familiarization Icon

Description

Function

Icon

Description

Low battery water level

Function

• Check the level

Low water tank level • Check the level

Present fault

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• Display machine fault code

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C - Familiarization 1.3 -

PLATFORM CONTROL BOX 1.3.1 - Layout General view

Controls and indicators Marking

Name

Description

Function

27

HL800

Tilt indicator

Machine on excessive slope

30

HL802

Platform overload indicator

Platform overload

43

SA907

Horn button

Press and hold the horn button to sound the horn Sound stops when the horn button is released Pulled out : Platform control box energized 46

SB802

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

132

28

SA200

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Enable Switch / Turret rotation control

Press in and hold : Validation of turret rotation selection Release : Cancellation of turret rotation selection

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C - Familiarization Marking

Name

Description

Function

100%

Battery charged

135

HL904

Battery charging indicator 40%

Flashing : Batteries have 40 % charge left

20%

Constantly on : Batteries have only 20 % charge left 146

HL903

Machine fault indicator

Machine operating fault

Press in button ( 250 ) to select either the drive or steer movement Move forward : Forward drive Drive and steering joystick

Move backwards : Reverse drive Press right side of button : Right-hand steering Press left side of button : Left-hand steering

244

SM901

Press button ( 251 ) to select Mast extend / retract movement Move forward : Mast lifting Joystick as mast movement function Move backwards : Mast retraction Press button ( 252 ) to select Jib raising or lowering movement

249

250

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Jib movement joystick

Move forward : Jib raising

Turret rotation selector

Move to the right : Counter-clockwise turret rotation

Move backwards : Jib lowering

Move to the left : Clockwise turret rotation

Drive and steer control

Pressed down (activated) : Movement selection (Without activating the joystick ( 244 ), under 8 s, the movement is cancelled.)

Drive and steering indicator mode

On : Activated mode

SA102

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C - Familiarization Marking

251

252

30

Name

Description

Function

Mast extension / retraction control

Pressed down (activated) : Movement selection (Without activating the joystick ( 244 ), under 8 s, the movement is cancelled.)

Mast movement indicator mode

On : Activated mode

Jib raising / lowering control

Pressed down (activated) : Movement selection (Without activating the joystick ( 244 ), under 8 s, the movement is cancelled.)

Jib movement indicator mode

On : Activated mode

SA500

SA600

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C - Familiarization Notes

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C - Familiarization 2-

List of actuators and sensors 2.1 -

SENSORS AND ACTUATORS Sensors and actuators

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C - Familiarization Name

Description

SP601

Jib pressure transducer (Weighing)

SQ530

Position sensor mast lowered

SQ534

Position sensor mast raised

SQ800

Sensor - Tilt 3°

SQ801

Sensor - chain tension detection 1

SQ802

Sensor - chain tension detection 2

SR150 or SR150_1

Sensor - Steering angle

SR601

Jib angle transducer (Weighing)

YB100

Right rear brake-release solenoid valve

YB101

Left rear brake-release solenoid valve

YV150L

Left steering electro-distributor

YV150R

Right steering electro-distributor

YV250L

Mast left electro-distributor rotation

YV250R

Mast right electro-distributor rotation

YV520D

Mast lowering solenoid valve

YV520U

Mast raising solenoid valve

YV620U

Jib raising solenoid valve

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C - Familiarization 3-

Consumables Consumable

HAULOTTE® code

Hydraulic filter cartridge

4-

2505000970

Ingredient Ingredient

HAULOTTE® code

Hydraulic oil

2420801310

Hydraulic oil (Winter option)

2505002640

Biological hydraulic oil

2820304310

4.1 -

HYDRAULIC OIL Hydraulic oils must comply with the following requirements : • Oil filterability must be compatible with absolute filters • Have properties such as : • Antifoam and deaeration • Anti-wear, anti-shear and antioxydant • Rust and corrosion inhibitors (copper)

The recommended viscosity grades depending on the environmental conditions are as follows : Environmental conditions

ISO Viscosity grade

Ambient temperature between - 15° C (- 9° F) and + 40° C (+ 104° F)

HV 46

Ambient temperature between - 35° C (- 31° F) and + 35° C (+ 95° F)

HV 32

Ambient temperature between 0° C (32° F) and + 45° C (+ 113° F)

HV 68

Biodegradable oils may be used if they comply with the following requirements : • Ambient operating temperature between - 15° C (- 9° F) and + 40° C (+ 104° F) • HEES type biodegradable oil only according to standards ISO 15380 and VDMA 24568 • Necessary characteristics : Viscosity grade

ISO Viscosity grade

Viscosity at + 40° C (+ 104° F)

46 +/- 3 mm² / s

Viscosity at + 100° C (+ 260° F)

> 8 mm² / s

Viscosity index

> 160

Flashpoint

> 220° C (> 572° F)

Pour point

< - 40° C (> - 104° F)

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Lubrication diagram

9

3 DANGER

4

3 6

6

5

4

List of ingredients Marking

Ingredient

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

5

Extreme-pressure lithium grease

2820304320

Lead-free grease - Aerosol 0,4 l(0.1 gal US)

2820304330

Lead-free grease - Can 5 l(1,32 gal US)

2820304340

3

6

9

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High-pressure lubricant

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C - Familiarization 6-

Greasing points localization • Slew ring.

• Wheel steering pivots : 2 on the chassis.

Lubricate the pivots with lead-free grease.

• Mast lubrication :

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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 8 - STAR 22J

STAR 10 - STAR 26J

Micro drive speed

0,6 km/h / 0.4 mph

High drive speed

5 km/h / 3.1 mph

Maximum towing speed

5 km/h / 3.1 mph

Time for mast lifting

28 s

30 s

Time for mast lowering

38 s

30 s

Time for jib lifting

27 s

Time for jib descent

25 s

27 s

Time for lifting at maximum height

59 s

57 s

Time for lowering to minimum height

64 s

57 s

Time for continue turntable rotation

60 s

D

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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

Person-in-charge

Stakeholder

Type

Documentation

Before each hire

Owner

On-site technician

Daily inspection

Operator's manual

Before each use or each change of user

Operator

Operator

Daily inspection

Operator's manual

At intervals recommended

by HAULOTTE®

Owner

On-site technician, qualified HAULOTTE Services® technician

Preventive maintenance

Maintenance Book

Before sale

Owner

On-site technician, qualified HAULOTTE Services® technician

Periodic inspection

Maintenance Book

Annually ( 1 year) (*)

Owner

On-site technician, qualified HAULOTTE Services® technician

Periodic inspection

Maintenance Book

After 10 years then every 5 years

Owner

Qualified technician HAULOTTE Services®

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.

Symbol meanings Oil change

To check by test

Tightening

Levelling

Visual inspection

Functional adjustments / Checks / Cleaning

Lubrication-Lubrication

Systematic replacement

Page or associated procedure

OK NOK

Corrected

First 50H

First 50H

Preventive Maintenance Level 1 - First 50H

Comments

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

Hydraulic : oils, filters and hoses Replace the hydraulic filter

Mast ; Boxes Control chains state and tension Check the condition and tension of the return cables

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D - Inspection and maintenance schedule OK NOK

Corrected

Page or associated procedure

Every 2 weeks

Every 2 weeks

Preventive Maintenance Level 1 – Every 2 weeks

Comments

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

OK

NOK

Corrected

Page or associated procedure

Every 6 months or 250H

Every 6 months or 250H

Preventive Maintenance Level 1 - Every 6 months or 250H

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

Slew ring Grease the turntable slew ring

Mast ; Boxes Grease mast

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 Page or associated procedure

OK NOK

Corrected

Every 1 year or 500H

Every 1 year or 500H

Preventive Maintenance Level 2 - Every 1 year or 500H

Comments

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

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

Slew ring Tighten the slew ring

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

Mast ; Boxes Check the pads-Replacement if necessary Control chains state and tension Control cables state and tension Check the cylinder baseplate fastening screws of the lifting cylinder on the 1 tube Check the 2 tube baseplate fastening screws

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Corrected

Page or associated procedure

Every 2 years or 1000H

Every 2 years or 1000H

Preventive Maintenance Level 2 - Every 2 years or 1000H

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

Slew ring Check the slew ring clearance

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

OK NOK

Corrected

Page or associated procedure

Every 10 years

Every 10 years

Preventive Maintenance Level 2 - Every 10 years

Comments

Mast ; Boxes Cables replacement

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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.

Page or associated procedure

OK NOK

Corrected

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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OK NOK

Corrected

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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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 Means of protection to be used when implementing the range

Appropriate workwear

Gloves

Safety shoes

3-

You will need • Standard tool kit

4001180330

• Place barriers around the perimeter of the work area

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General data Structural part inspection

MS0001 4-

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

4.1 -

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

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

• Absence of deformation and visible damage.

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

• Absence of excessive gap to the articulations and slides.

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

• No screws or missing part loosened or unscrew.

• Anchorage points firmly fixed and not damaged.

The list of part to check are define Section Familiarization.

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.

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General data Structural part inspection

MS0001 Example

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

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

Refer to spare part catalog for additional information if needed.

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

4.3 -

FUNCTIONAL TESTS The following tests must be performed periodically

Section D - Inspection and maintenance schedule :

• An important technical intervention.

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

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

The results of the tests must be entirely documented.

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

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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.

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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 Means of protection to be used when implementing the range

Appropriate workwear

Gloves

Safety shoes

3-

You will need • Standard tool kit

4001180330

• Place barriers around the perimeter of the work area

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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 : Recommended Values

C

A

D

E B F

G

Marking

Description

A

At least 0,5 times the nominal diameter

B

Make a chamfer

C

Nominal diameter of the bearing - 0,2 / - 0,3 mm (-7874 µ in / -11810 µ in)

D

Bearing drift

E

Diameter of the bearing guide - 0,20 / - 0,25 mm (-7874 µ in / -9843 µ in)

F

Bearing

G

Housing

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

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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 Means of protection to be used when implementing the range

Appropriate workwear

Gloves

Safety shoes

3-

You will need • Standard tool kit

4001180330

• 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 :

58

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 Means of protection to be used when implementing the range

Appropriate workwear

Gloves

Safety shoes

3-

You will need • Standard tool kit

4001180330

• Place barriers around the perimeter of the work area

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59

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

Nm

2.4 4.07

44 80

5 9.1

41 69

4.63 7.87

54 93

6.18 10.5

68 118

7.7 58 6.63 78 8.84 13.4 100 11.3 132 15

79 139

9 68 7.75 91 10.3 15.7 116 13.2 155 17.6

Dull dry

14 27.9 48.6 77.4 125 171 243 331 420

19.1 37.8 66 105 170 233 330 450 570

18.8 37.2 64.9 103 166 229 325 442 562

25.5 23.6 32 50.5 47.2 64 88 81.8 111 140 131.28 178 226 205.04 278 311 283.2 384 441 401.2 544 600 551.7 748 762 690.3 936

20.1 39.9 69.7 110 173 238 337 458 583

27.3 54.1 94.5 150 235 323 458 622 791

26.9 36.5 28 38 23.6 32 31.4 42.6 53.2 72.2 55 75 46.7 63.3 62.3 84.4 92.2 125 95.9 130 81 110 108 147 147 200 154.15 209 129 175 172 234 230 313 239.7 325 202 274 269 365 317 430 331 449 278 377 371 503 450 610 469.8 637 394 535 525 713 612 830 645.3 875 536 727 715 970 778 1055 807.6 1095 682 925 909 1233

USA / GB

61

Nm

9.88 16.2 22 19.6 32.45 44 34.1 56 76 54.3 89.24 121 84.8 139.4 189 117 192.5 261 165 272.9 370 225 345.4 509 285 469.8 637

E 10.22

ft-lbs

7.2 14.4 25.1 40 62.5 86.2 121 166 210

Nm

ft-lbs

ft-lbs

Nm

7.41 14.7 25.6 40.8 63.6 87.5 124 169 214

Nm

ft-lbs

ft-lbs

Nm

5.4 10.8 19.8 30.1 46.9 64.5 91 124 157

Nm

Nm

8 5.9 8 10 12.17 16.5 12 20.65 28 14 33.19 45 16 52.37 71 18 72.28 98 20 102.5 139 22 140.87 191 24 176.27 239

4001180330

ft-lbs

ft-lbs

Dry

Nm

Lubed

ft-lbs

Dull dry

Nm

Dry

Nm

Lubed

ft-lbs

Dull dry

Nm

Dry

ft-lbs

Lubed

Nm

Dull dry

Nm

Nm

in-lbs

Nm

21 36

Nm

in-lbs

in-lbs

Nm

1.8 3.05

Yellow dry

in-lbs

in-lbs

16 19

Nm

Nm

2 3.4

Lubed

in-lbs

in-lbs

17.7 30

ft-lbs

5 6

ft-lbs

Nm

Yellow dry

in-lbs

Lubed

Nm

Dull dry

in-lbs

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

Nm

Lubed (B)

in-lbs

Dull dry (A)

Nm

Yellow dry (C)

Class 12.9

in-lbs

Dull dry (A) Lubed (B)

Class 8.8

Size (mm)

Size (mm)

Class 4.6

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

Thread

Lubed in-lbs

1/4

Dry

Nm

in-lbs

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

62

Lubed Nm

in-lbs

Dry

Nm

Lubed

in-lbs

Nm

in-lbs

Nm

20

80

9

100

11.3

110

12.4

140

15.8

130

14.7

28

90

10.1

120

13.5

120

13.5

160

18

140

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

18

13

17.6

17

23

18

24

25

33.9

21

28.4

24

14

19

19

25.7

20

27.1

27

36.6

24

32.5

16

23

31.2

31

42

33

44.7

44

59.6

38

51.5

24

26

35.2

35

47.4

37

50.1

49

66.4

43

58.3

14

37

50.1

49

66.4

50

67.8

70

94.7

61

62.7

20

41

55.5

55

74.5

60

81.3

80

108.4

68

92.1

13

57

77.3

75

101.6

80

108.4

110

149

93

126

20

64

86.7

85

115

90

122

120

162

105

142

12

80

108.4

110

149

120

162

150

203

130

176

18

90

122

120

162

130

176

170

230

140

189

11

110

149

150

203

160

217

210

284

180

244

18

130

176

170

230

180

244

240

325

200

271

10

200

271

270

366

280

379

380

515

320

433

16

220

298

300

406

310

420

420

569

350

474

9

320

433

490

583

450

610

610

827

510

691

14

350

474

470

637

500

678

670

908

560

759

8

480

650

640

867

680

922

910

1233

770

1044

12

530

718

710

962

750

1016

990

1342

840

1139

7

590

800

790

1071

970

1315

1290

1749

1090

1477

12

670

908

890

1206

1080

1464

1440

1952

1220

1654

7

840

1138

1120

1518

1360

1844

1820

2467

1530

2074

12

930

1260

1240

1681

1510

2047

2010

2725

1700

2304

6

1460

1979

1950

2643

2370

3213

3160

4284

2670

3620

12

1640

2223

2190

2969

2670

3620

3560

4826

3000

4067

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General data Torque Values

MS0005 3-

Hydraulic couplings and hoses tightening torque charts Hydraulic fitting torque (Tolerance = 0 / +10%) BSPP threads according to ISO1179 Torque

Thread 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

ft-lbs

Nm

15 30 33 59 100 136 199 251 306

20 40 45 80 135 185 270 340 415

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).

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General data Torque Values

MS0005 Hydraulic hose torque (Minimum / Maximum) JIC torque Hose size

ORFS torque

JIC thread

ORFS thread ft-lbs

Nm

ft-lbs

Nm

DN06 - 1/4"

7/16-20

11-15

15-21

9/16-18

18-21

25-28

DN10 - 3/8"

9/16-18

22-31

30-42

11/16-16

30-33

40-45

DN12 - 1/2"

3/4-16

37-52

50-70

13/16-16

41-44

55-60

DN16 - 5/8"

7/8-14

51-69

69-94

1"-14

59-66

80-90

DN19 - 3/4"

1"1/16-12

72-99

98-133

1"3/16-12

85-96

115-130

DN25 - 1"

1"5/16-12

103-140

140-190

1"7/16-12

111-125

150-170

DN32 - 1"1/4

1"5/8-12

155-210

210-285

1"11/16-12

148-166

200-225

DN38 - 1"1/2

1"7/8-12

214-280

290-380

2"-12

221-243

300-330

DN50 - 2"

2"1/2-12

332-443

450-600

2"1/2-12

367-406

500-550

4-

STAR 10 - STAR 26J Sub-assemblies

Concerned elements Wheels

32 Nm

Wheel studs / Driving reducer Chassis

Loctite 243 - Normal threadlocker

Wheel steering pivots

115 Nm

Steering cylinder / Chassis

115 Nm

Safety block - Emergency lowering : • Cartridge • Nut Slew ring

Torque

39 - 51 Nm 3 - 4 Nm

Slew ring / Chassis

135 Nm

Turntable / Slew ring

195 Nm

Hydraulic motor / Slew ring

76 Nm

ECU

ECU / Carrier

10 Nm

Engine

Screw fastening elastic coupling / Flywheel

35 Nm

Counterweight

Counterweight / Turntable

320 Nm

Upper and lower front pads

30 Nm Medium threadlocker

Mast

Lift cylinder : • Cartridge • Nut

34 - 41 Nm 3 - 4 Nm

Platform control box

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Chassis and turret Slew ring inspection

MS0010 Chassis and turret Slew ring inspection

1-

You will need

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

For safety reasons, imperatively respect the following stages during the tests : • Put the machine in stowed position.

• Do not smoke.

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.

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Chassis and turret Slew ring inspection

MS0010 3-

Lubrication The maintenance of the slew ring is essential for the safety of the machine and to guarantee its service life. Whatever the type of system installed on the machine, interior or external teeth, follow the recommendations of greasing as indicated in the program.

• Grease the (internal and external) crown gear teeth.

• Grease the raceways (access to greasers via the holes situated on the turntable, until the oil escapes from the crown lip seal).

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Chassis and turret Slew ring inspection

MS0010 3.1 -

FOR HA16RTJ - HA16RTJ O - HA16RTJ PRO - HA46RTJ O - HA46RTJ PRO ONLY • 2 by tie rod (B)

B Slew ring : • 2 nipples on the raceways inside the slew ring

• 3 nipples on the worm screw

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Chassis and turret Slew ring inspection

MS0010 • Greasing the crown gear teeth

• Greasing the sidewall telescope

4-

Tightening To ensure safety operation, tightening check should be performed on slew ring.

Please refer to follow value for this procedure using a torque wrench.

Machine type

Metric torque value

Imperial torque value

HT23RTJ O - HT23RTJ O SW HT67RTJ O - HT23RTJ PRO HT23RTJ PRO SW - HT67RTJ PRO

215 Nm

158.6 lb ft

HA16RTJ

215 Nm

158.6 lb ft

HA32PX - HA100JRT

215 Nm

158.6 lb ft

HA41PX-NT - HA130JRT-NT

215 Nm

158.6 lb ft

STAR 10 - STAR 26J - Ring on plate

135 Nm

100 lb ft

STAR 10 - STAR 26J - Plate on mast foot

195 Nm

144 lb ft

STAR 10 - STAR 26J - Ring on chassis

135 Nm

100 lb ft

68

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Chassis and turret Slew ring inspection

MS0010 5-

Slew ring inspection Section D Inspection and maintenance schedule.

5.1 -

VISUAL AND SOUND CHECK • Check for the presence of all the locating bolts.

• Check that the accessible screws are not loosened. If necessary, tighten the screws. (Refer to the "tightening torque" table. ) • Visually check the presence of the teeth and gear (if possible).

• Check the appearance of the teeth.

A tight spot or grinding sound during rotation or the presence of metal particles escaping from the lip seal are signs of abnormal wear in the raceway (Contact HAULOTTE Services®).

Replace slew ring in the following cases : • Abnormal noise during the turret rotation.

• Movement jolts during the rotation of the turret.

• Gear teeth missing or damaged.

• Presence of metal particles in the grease.

• Wear on gear teeth.

• Abnormal clearance of the gear ring.

5.2 -

MEASUREMENT OF THE CLEARANCE Place the machine in the following conditions : • On flat ground, Set up barriers to define the test area.

• No load in the platform.

• From the ground control box, align the turret at 90 ° to the chassis.

• Retract the mast.

• Jib in horizontal position (if fitted).

From the magnetic comparator, note the clearance ( J1) between chassis (or turret) and the slew ring.

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Chassis and turret Slew ring inspection

MS0010 Clearance between chassis (or turret) and slew ring

J1

After having carried out the measurement : • Jib in horizontal position(if fitted).

In its new configuration, note the clearance ( J1) between chassis (or turret) and the slew ring as previously.

• If the difference between two measurements does not exceed 2 mm (0.08 in) : the test validates correct operation.

• Otherwise, contact HAULOTTE Services® to repair the system.

70

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Mast Condition of the cables inspection - Criteria of replacement

MS0012-2 Mast Condition of the cables inspection - Criteria of 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 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-

Control wire rope system To guarantee a full safety use of the machine , Haulotte recommends respecting the following inspections :

3.1 -

DAILY CHECK • To position the machine on a flat and firm ground.

• To put the machine under tension and select the ground control box.

• Carry out a lifting / lowering cycle.

• To check the synchronization and the symmetry of the movements and the absence of abnormal noises.

If these phenomena occur, carry out a reinforced control (see paragraph below).

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Mast Condition of the cables inspection - Criteria of replacement

MS0012-2 3.2 -

PERIODIC CONTROL To reach the elements : • To position the machine on a flat and firm ground.

• Dismount the inspection door and/or covers.

• To put the machine under tension and select the ground control box.

• To check the presence and the tightening of the fastenings of the cables on the visible points of fixing. To raise the masts unit to the doors inspection.

• To extend the structure to obtain an access to the wire rope : Using a flash light, perform a visual inspection of the following items : • Check that cables are properly aligned with one another.

• Check that the cables under are equal tension.

• Check that the pulleys are properly aligned with the cables.

• Check that the cable is properly seated in the pulley.

• Check that nothing blocks the chain guides.

• Check the condition of the cables. If any of the following defects are observed, replace the pair of cables.

Replace defective parts with genuine HAULOTTE® replacements.

72

Machine

Original diameter

STAR 6 - STAR 13 - STAR 8 - STAR 22J STAR 10 - STAR 22J

3 mm

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Mast Condition of the cables inspection - Criteria of replacement

MS0012-2 • No broken strands must be observed, in particular at the ends.

• Replacement is compulsory when 3 strands or more are broken along the length of the cable.

• Replacement is compulsory when 1 strand is broken near the ends.

• No deformed folds or frayed strands must be observed.

• No signs of corrosion must be observed.

4-

Tension checking Section D Inspection and maintenance schedule.

For the particular procedures of adjustment untreated in maintenance book, it is necessary to contact HAULOTTE Services®.

5-

Criteria of replacement • Machine operates in a particularly hostile environment.

• Abnormal noises are produced during movement of structure.

• Machine has been in storage for more than 6 months.

• Machine has been submitted to an abusive load or serious collision.

• Machine has been exposed to an electrical arc.

Contact Haulotte Services for further advice.

Cables and cable elements are made from case hardened steel in a high-quality process. Deliver any scrap cables or cable elements to a dealer specialised in metal recycling in compliance with regulations.

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Mast Condition of the cables inspection - Criteria of replacement

MS0012-2

Notes

74

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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.

Tightening torque table 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.

76

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Upper boom Inspection of the condition of the chains - Criteria of replacement

MS0042 Upper boom Inspection of the condition of the chains - Criteria of 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 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 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.

N.B.-:-TELESCOPING OPERATIONS MAY BE NECESSARY TO ACCESS ELEMENTS. Before applying new lubricant, remove any foreign particles from the chain. Use recommended lubricants Section B 1Recommendations-Lubrication diagram.

When cleaning chains, follow regulations concerning the environment.

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Upper boom Inspection of the condition of the chains - Criteria of replacement

MS0042 3.1 -

CHECK THE CONDITION OF THE CHAINS To carry out the following operations, perform a complete telescoping.

• Check that the lifting chains and safety chains are clean.

• Check that there are no foreign particles on the chains and guide.

• Check that there are no signs of corrosion on chain elements.

Chains with any of the defects described below must be replaced.

• Check for elongation wear : • Elongation of up to 2 %, over 12 segments, of the original chain length is permitted.

• Measure the value of (3) using an appropriate method. Compare with the value of *1 indicated in the table below.

Machine

Link width (2)

Length of 12 links (4)

STAR 6 - STAR 13 STAR 10 - STAR 26J HA32/41PX-NT H28TJ+/H43TPX

11.5 mm

152.40 mm

STAR 10 - STAR 26J

14.50 mm

190.50 mm

HTL 4014/17 - HTL 3614/17

24 mm

304.80 mm

• Check for external wear on rollers and links : • External wear must not measure more than 2 % from the section of the original link (2), see table above.

• Measure the value of (1) using an appropriate method.

• Check that no line or element is damaged or missing.

78

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Upper boom Inspection of the condition of the chains - Criteria of replacement

MS0042 • Check that links are not distorted, deformed or broken.

Crack

Distortion

Break Wedging

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

3.2 -

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

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Upper boom Inspection of the condition of the chains - Criteria of replacement

MS0042 4-

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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Chassis and turret Tires (Tyres) and pressures - Wheel replacement

MS0044 Chassis and turret Tires (Tyres) and pressures - 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

Solideal

Type

Solid tires/tyres

Drive wheel mass

18,5 kg - 41 lb

Steer wheel mass

20,6 kg - 45 lb

Size

406 mm / 100 mm (16 in / 4 in)

Torque

115 Nm (84.81 ft lbs)

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Chassis and turret Tires (Tyres) and pressures - Wheel replacement

MS0044 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%

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 and turret Tires (Tyres) and pressures - Wheel replacement

MS0044 5-

Wheel replacement Procedure of replacement : • Loosen the wheel nuts on the wheel to be removed.

• Raise the machine using a jack or a hoist.

• Remove the wheel nuts.

• Remove the wheel.

• Install the new wheel.

• Lower the machine to the ground.

• Tighten the wheel nuts to the recommended torque Refer to maintenance and repair manuals.

Component

Standard wheel

Reference number

Solideal

Type

Solid tires/tyres

Drive wheel mass

18,5 kg - 41 lb

Steer wheel mass

20,6 kg - 45 lb

Size

406 mm / 100 mm (16 in / 4 in)

Torque

115 Nm (84.81 ft lbs)

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Chassis and turret Tires (Tyres) and pressures - Wheel replacement

MS0044

Notes

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Chassis and turret Lubrication - Jib cylinder - Steering cylinder - Lift cylinder

MS0045 Chassis and turret Lubrication - Jib cylinder - 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.

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Chassis and turret Lubrication - Jib cylinder - Steering cylinder - Lift cylinder

MS0045 3-

Lubrication Jib cylinder In order to maintain the lifting cylinder in good condition and avoid any internal or external corrosion during prolonged storage (inside or outside), proceed as follows : • Machine stowed Carry out the movements to lift and descend of jib or platforme every 2 or 3 days to lubricate cylinder tube.

• Machine unfolded Using a brush, apply multipurpose grease (of mineral type) to all the chrome and unpainted parts of the cylinder ( 1 ).

1

Lubricate the cylinder rod 1 once a month ( 1 ).

Do not use synthetic grease. Synthetic grease can damage the seals of cylinder.

Before operating the machine, remove the grease from the cylinder rod.

Do not high pressure wash the cylinder as this could cause damage to the cylinder rod, as well as penetration of water into the guide seal (corrosion, contamination, seizing).

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Chassis and turret Lubrication - Jib cylinder - Steering cylinder - Lift cylinder

MS0045 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.

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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Chassis and turret Lubrication - Jib cylinder - Steering cylinder - Lift cylinder

MS0045

Notes

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Chassis and turret Dismantling / Reassembling wheels reducer

MS0046 Chassis and turret Dismantling / Reassembling wheels reducer

1-

You will need

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

• Standard tool kit • Torque wrench • Place barriers around the perimeter of the work area • Strap (Capacity : 500 kg / 1100 lb) • Bridge crane 1000 kg(2200 lb) (minimum) • Grease • Hydraulic oil Exclusively use tools and auxiliary average adapted. Always wear necessary safety clothing. This procedure is to be carried out after the first 50 hours and then every 250 hours.

2-

Level of knowledge required It is important that the person performing the work on the machine knows all the relative safety information contained in the instruction manual.

Only an authorized and qualified technician can work on HAULOTTE® machines.

3-

Safety instructions • The technician should take all steps to protect themselves or others against all risks of injury related to this intervention.

• The technician should ensure 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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Chassis and turret Dismantling / Reassembling wheels reducer

MS0046 4-

Removal • Cut off the main power supply at the battery master switch.

• Disconnect all energy sources connected to the machine (e.g. battery charger).

• Identify the motor to be replaced.

Arrière droit / Rear right

• Disconnect the U/V/W cables and the temperature and speed sensors).

Arrière gauche / Rear left

3 connectors (braking,

• Place the machine on resistant and stable wedges. Dismantle the relevent wheel.

• Unscrew the 6 CHC M10X30 fastening screws and the 6 M10 flat washers.

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Chassis and turret Dismantling / Reassembling wheels reducer

MS0046 • Sling the gear motor assembly using a 500 kg(1100 lb) sling and a bridge crane.

N.B.-:-IF THE GEAR MOTOR NEEDS TO BE DISMANTLED, UNSCREW 4 FASTENING SCREWS.

THE

5-

Reinstall • Reposition the assembly in the notch.

• Push the motor into the highest position.

• Attach the assembly using screws and washers.

• Tighten to the recommended torque : 57 Nm. • Mark with a pen as shown.

• Reconnect all the U/V/W cables and the 3 connectors.

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Chassis and turret Dismantling / Reassembling wheels reducer

MS0046

• Tighten to the recommended torque on the above procedure (4,8 Nm).

• Refit the wheel.

• Tighten the wheel using the 6 screws.

• Tighten to the recommended torque : 115 Nm. • Mark with a pen as shown.

6-

Additional operations • Check the wheel gear oil level.

• If missing, perform the filling (Typ Shell SPIRAX 80W90 Quantity 0,68 l).

7-

Checks • Switch the machine on.

• Engage drive in forward and then reverse (high and low drive speed).

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Chassis and turret Replacing the wheel pivot

MS0047 Chassis and turret Replacing the wheel pivot

1-

You will need

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

• Standard tool kit • Strap (Capacity : 500 kg / 1100 lb) • Bridge crane 1000 kg(2200 lb) (minimum) • Place barriers around the perimeter of the work area • Torque wrench (10 Nm - 115 Nm) • Wrench and sockets up to diameter 36 mm • Mounting punches (50 - 70 mm) • Grease Exclusively use tools and auxiliary average adapted. Always wear necessary safety clothing. This procedure is to be carried out after the first 50 hours and then every 250 hours.

2-

Level of knowledge required It is important that the person performing the work on the machine knows all the relative safety information contained in the instruction manual.

Only an authorized and qualified technician can work on HAULOTTE® machines.

3-

Safety instructions • The technician should take all steps to protect themselves or others against all risks of injury related to this intervention.

• The technician should ensure 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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Chassis and turret Replacing the wheel pivot

MS0047 4-

Removal The procedure is identical for the front left and front right pivots.

Front right pivot

Front left pivot

• Cut off the main power supply at the battery master switch.

• Disconnect all energy sources connected to the machine (e.g. battery charger).

• Remove the covers.

• Remove the wheel.

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Chassis and turret Replacing the wheel pivot

MS0047 • Lift the machine using a hoist (or a jack). Place chocks under the chassis to ensure the machine is safely immmobilised.

• Remove the V4X45 pin and M18 flat washer.

• Unscrew the fastening plate from the steering pivots (right or left depending on the pivot to be changed).

Left stop (Screw ringHE 6X16)

Right stop (Screw ringCHC 6X16)

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Chassis and turret Replacing the wheel pivot

MS0047 • Use a mallet to knock the assembly out of its seating.

• Sling the hub.

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Chassis and turret Replacing the wheel pivot

MS0047 5-

Reinstall 5.1 -

HUB • Lubricate the interior of the 2 bores.

View from large bore side

View from small bore side

• Separate the ball bearings from the ring.

• Fit the ring into the hub.

• Proceed in the same way on the large bore side.

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Chassis and turret Replacing the wheel pivot

MS0047 • Lubricate the inner and outer rings and slide the assembly into the cage, as shown.

• Fit the seal into its seating.

Take care it is mounted the right way round.

• Lubricate the pivot at 3 points as shown.

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Chassis and turret Replacing the wheel pivot

MS0047 • Slide on the wheel hub.

• Using a punch, insert the wheel hub up to the stop.

Do not force it.

• Using a punch, insert the small bearing into its cage.

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Chassis and turret Replacing the wheel pivot

MS0047 • Position the M30 washer in the centre.

• Screw up the nut.

• Tighten with a torque wrench to a torque of 10 Nm. N.B.-:-IF NECESSARY, FINISH TIGHTENING WITH A RATCHET WRENCH TO LINE UP THE HOLE FOR THE PIN.

• Inser the V5X 50 pin around the M24 nut.

• Using a punch, fill the 62 mm diameter cap with grease and install it.

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Chassis and turret Replacing the wheel pivot

MS0047 5.2 -

WHEEL STEERING PIVOTS • Lubricate the shaft of the pivot.

• Apply grease to the 2 sides of the washer.

• Position the washer at the stop.

• Position the chamfer on the top as shown.

• Lubricate the ring on the chassis.

• Lubricate the shaft of the pivot connecting to the steering tierod.

• Insert the pivot into its seating.

• Refit the washer and pin on the axle.

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Chassis and turret Replacing the wheel pivot

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

• Refit the wheel.

• Tighten to the recommended torque : 115 Nm. • Lower the machine to the ground.

• Tighten the wheel nuts to the recommended torque : 115 Nm

6-

Checks • Switch the machine on.

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

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Chassis and turret Steering cylinder removal

MS0048 Chassis and turret Steering cylinder removal

1-

You will need

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

• Standard tool kit • Place barriers around the perimeter of the work area • Strap (Capacity : 500 kg / 1100 lb) • Bridge crane 1000 kg(2200 lb) (minimum) • Grease Exclusively use tools and auxiliary average adapted. Always wear necessary safety clothing. This procedure is to be carried out after the first 50 hours and then every 250 hours.

2-

Level of knowledge required It is important that the person performing the work on the machine knows all the relative safety information contained in the instruction manual.

Only an authorized and qualified technician can work on HAULOTTE® machines.

3-

Safety instructions • The technician should take all steps to protect themselves or others against all risks of injury related to this intervention.

• The technician should ensure 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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Chassis and turret Steering cylinder removal

MS0048 4-

Removal • Cut off the main power supply at the battery master switch.

• Disconnect all energy sources connected to the machine (e.g. battery charger).

• Remove the covers.

• Lift the machine using a hoist (or a jack).

• Stabilize the machine correctly.

• Remove the front wheels.

• On each side of the cylinder, remove the V4X45 pin and the M18 flat washer in order to free the steering tie-rods.

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Chassis and turret Steering cylinder removal

MS0048 • Remove the 4 HM12x40 cl 10.8 fastening screws using a 16 mm diameter wrench in order to remove the cylinder assembly and the 2 steering tie-rods.

• Extend the cylinder.

• Remove the V4X45 pin and the M16 flat washer from each side.

• Remove the 3/8 BSPP male unions from the cylinder and refit them on the new cylinder.

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Chassis and turret Steering cylinder removal

MS0048 5-

Reinstall • Refit the tie-rods.

Take care that the yoke shoulder is the right way round.

• Re-build the actuator.

• Attach the cylinder to the wheel pivots.

• Refit the wheels.

• Tighten to the recommended torque : 115 Nm. • Lower the machine to the ground.

6-

Checks • Switch the machine on.

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

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Hydraulics Hydraulic oil - Level Replacement

MS0049 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 .

2

Top up the oil level, if necessary : 1.

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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

MS0049 4-

Replacement of hydraulic oil Hydraulic oil must be replaced all the 2000 hours or 2 years. This periodicity can be modified so important interventions and/or anomaly was noted.

The state of cleanliness of the oil filter cartouche is another indicator of purging of the system : • Dismount the cartouche of the oil filter.

• Check the absence of rubber, plastic or metal shaving.

4.1 -

CONSUMABLE Use only oils whose features correspond to HAULOTTE® recommendations (Section C - Familiarization Consumable) or contact HAULOTTE Services®.

Not mix two different characteristics oils. If necessary, purge and clean the circuit.

4.2 -

FILLING To fill the system correctly; respect the following stages : • The machine must be completely folded (for the machines equipped: raised stabilizers).

• Fill the tank.

• Carry out a complete cycle (to go/return) of each cylinder.

• Fill the tank if necessary (never more than the maximum level).

• Repeat stages 1 and 2 for each cylinder of the machine.

When filling, it is forbidden to remove the strainer filter.

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Hydraulics Hydraulic filter cartridge Replacement

MS0050 Hydraulics Hydraulic filter cartridge 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.

All hydraulic components (pump, tanks….) except cylinders must be subjected to periodic visual inspections such as defined below.

Section D Inspection and maintenance schedule : • Absence of leakage (pump, tanks, hydraulic block, connections…).

• Absence of rust on the hydraulic blocks.

• Absence of deformations, damage, crack on tanks, pump and block hydraulics.

• Absence of foreign objects on all surfaces.

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

• Hydraulic oil level (to supplement if necessary, machine in folded up position).

• Presence and good state of the hydraulic oil filter (absence of filling).

2-

Hydraulic filter cartridge Replacement Before dismantling, ensure that the oil circuit is no longer under pressure and that the oil temperature is not too high.

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1.

Loosen and remove plug ( 1 ).

2.

Remove the cartridge.

3.

Install a new cartridge.

4.

Refit and tighten plug .

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Hydraulics Hydraulic filter cartridge Replacement

MS0050

Notes

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Electric Battery (ies)

MS0052 Electric Battery (ies)

1-

You will need

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

• Standard tool kit • Place barriers around the perimeter of the work area • Strap (Capacity : 500 kg / 1100 lb) • Bridge crane 1000 kg(2200 lb) (minimum) 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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Electric Battery (ies)

MS0052 4-

Removal • Lift the mast slightly.

• Cut off the main power supply at the battery master switch.

• Disconnect all energy sources connected to the machine (e.g. battery charger).

Overview - Batteries

• Remove the covers.

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Electric Battery (ies)

MS0052 • Disconnect all the cables connected to the battery elements.

• Disconnect the centralized filling pipes.

• Loosen and remove the 2 fastening screws .

• Disconnect the water level (1) (SL901) and temperature (2) (ST309) sensors.

• Remove the upper cover bracket.

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Electric Battery (ies)

MS0052 • Remove the battery compartment using a bridge crane.

5-

Reinstall • Refit a the new battery pack.

• Re-attach and reconnect all the cables and pipes to the centralized filling system.

Take care with the connections.

• Switch the machine on.

• Check the levels and top up as required.

• Recharge the batteries.

• Once charging is finished, check the voltage and density.

The density level is approximately 1,28 kg/l to 20°.

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Electric Battery (ies)

MS0052 6-

Checks • Switch the machine on.

• Test the movements from the platform and ground control boxes.

• Check no alarms are present.

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Electric Battery (ies)

MS0052

Notes

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Mast Return cables

MS0053 Mast Return cables

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 Return cables

MS0053 4-

Control on STAR 8 - STAR 22J and STAR 10 - STAR 22J only : Replace in case of : • Broken wire ( C ) C

• Broken strand ( B ) Jeu Gap 1 mm max.

• Kinked cable

B A

• Wear on lugs • Abnormal stretching of the cabel making it impossible to adjust play at the threaded end

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Mast Specific adjustment procedure STAR 10 - STAR 26J

MS0054 Mast Specific adjustment procedure STAR 10 - STAR 26J

1-

You will need

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

• Standard tool kit • A tape-measure, a ruler • Ratchet wrench + socket S22.HLA and S24.HLA • Place barriers around the perimeter of the work area • Spanner 4, 10, 13, 14, 24 • Flat pliers • Ratchet version 10 flat wrench • 5 BTR wrench 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 Specific adjustment procedure STAR 10 - STAR 26J

MS0054 4-

Inspection of chain adjustment From the ground control box : • Lift the mast so that tube 1 extends 300 mm beyond the foot of the mast (+/- 2 mm).

4

306 mm +/- 2 mm

3

300 mm +/- 2 mm

2

300 mm +/- 2 mm

1

300 mm +/- 2 mm

Pied de mât / Mast foot

• Check the height of the tubes : For STAR 10 - STAR 26J : • Tube 1 : 300 mm (+/- 2 mm) • Tube 2 : 300 mm (+/- 2 mm) • Tube 3 : 300 mm (+/- 2 mm) • Tube 4 : 306 mm (+/- 2 mm) For STAR 8 - STAR 22J : • Tube 1 : 300 mm (+/- 2 mm) • Tube 2 : 300 mm (+/- 2 mm) • Tube 3 : 312 mm (+/- 2 mm)

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Mast Specific adjustment procedure STAR 10 - STAR 26J

MS0054 • If not compliant : Carry out the operations from the ground control box.

Before adjusting the chains, check that the return cables are not tight.

Adjust the chains on tube 1 to adjust the height of tube 2 : • Screw or unscrew the nuts A located under the machine with a ratchet wrench and a long 24 socket • Check via the inspection hatch at the foot of the mast located on tube 1 that the chains are not twisted.

Adjust the chains on tube 2 to adjust the height of tube 3 : • Screw or unscrew the nuts B located on tube 1 with a ratchet wrench and a long 22 socket • Hold the chain yolks with a 24 flat wrench.

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Mast Specific adjustment procedure STAR 10 - STAR 26J

MS0054 Adjust the chains on tube 3 to adjust the height of tube 4 : • Screw or unscrew the nuts C located on tube 2 with a ratchet wrench and a long 22 socket.

• Hold the chain yolks with a 14 flat wrench.

C

5-

Inspection of chain adjustment From the ground control box : • Lift the mast so that tube 1 extends 100 mm beyond the foot of the mast (+/- 20 mm).

100 mm +/- 20 mm

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Mast Specific adjustment procedure STAR 10 - STAR 26J

MS0054 Inspect the 6 return cables ( 4 for the STAR 8). The clearance between the washer and the foot of the mast or tube must be 2 mm.

2 mm

• If not compliant :

For the cables at the foot of the mast and tube 1 : • Hold the cable lub with a 4 flat wrench • Adjust the cable tension : Screw or unscrew the M6 locknut, preferably with a ratchet version 10 flat wrench For the cables on tube 3 : • Remove the left chain from tube 3 so as to free access to the return cable • Adjust the clearance to 2 mm for both chains • Refit the chaine once the adjustment has been made • Check that both chains have the same tension.

For chain adjustment : Only remove one chain from tube 3 at a time.

Check the height of the tubes again after refitting the chains.

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Mast Specific adjustment procedure STAR 10 - STAR 26J

MS0054

Notes

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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

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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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Mast Inspection of the slack chain sensors

MS0062 Mast Inspection of the slack chain sensors

1-

You will need

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

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

MS0062 4-

Procedure • Lift the machine to a height of 1 m(3 ft3 in) using a hoist.

Sensor SQ801 : • Place an insulating element between the sensor and the chain rod.

• The sensor should switch off and a fault should be displayed on the screen (ground control box).

• Check the appearance of the "Chain break" message on the screen.

N.B.-:-THE APPEARANCE OF THE "CHAIN BREAK" MESSAGE MEANS THAT THE SENSOR IS WORKING. Sensor SQ802 : • Place an insulating element between the sensor and the chain rod.

• The sensor should switch off and a fault should be displayed on the screen (ground control box).

• Check the appearance of the "Chain break" message on the screen.

N.B.-:-THE APPEARANCE OF THE "CHAIN BREAK" MESSAGE MEANS THAT THE SENSOR IS WORKING. Perform the same operation for the 2 sensors at the same time.

• Check the appearance of the "Chain break" message on the screen.

N.B.-:-THE APPEARANCE OF THE "CHAIN BREAK" MESSAGE MEANS THAT THE SENSORS ARE WORKING. If the "Chain break" message does not appear, start the slack chain sensor adjustment procedure again.

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MS0062 5-

Slack chain detector adjustment procedure Installation of the SQ801 and SQ802 detectors SQ801 (Left)

SQ802 (Right)

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MS0062 Figure 1

Distance between the edge of the sensor and the Belleville washers : 5 mm Figure 2

Distance between the edge of the sensor and the Belleville washers : 3 mm Adjustment : • Using a mallet, position the 2 threaded rods at the bottom of the 20 diameter hole (See direction of the arrows on figure 1).

• Adjust the detectors to 5 mm • Hit with the mallet again in the opposite direction (See direction of the arrows on figure 2)to recentre the rods and bring them closer to the detectors (approx. 3 mm).

During mounting, the detectors must be in the top position to detect the Belleville washers and not the nut.

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Mast Inspection of the slack chain sensors

MS0062 The oblong holes must be reduced in height so that the bottom position is not permitted.

N.B.-:-THE DETECTOR CONNECTORS MUST BE AT 90 % AND NOT STRAIGHT AS THEY TOUCH THE SLEW RING.

Detection of the washers whatever the position of the threaded rod :

The detectors remain on even if the threaded rod is completely to the left (1 mm) or right (5 mm).

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Mast Inspection of the slack chain sensors

MS0062

Notes

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Overriding system Overriding function reset

MS0085 Overriding system Overriding function reset

1-

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

• Place barriers around the perimeter of the work area

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-

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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Overriding system Overriding function reset

MS0085 4-

Overriding function reset If the Overriding function has been requested, the machine displays the following screen at startup :

4.1 -

PROCEDURE • Enter the access code level 2 or 3.

• Select the menu : 3. Machine settings.

• Select the menu : 3.3 Machine config.

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Overriding system Overriding function reset

MS0085 • Enter menu "Option settings".

• Move down to the line "Emergency mode not reset".

• Press the button

to deselect the option.

• Return to the welcome screen.

The Overriding function is reset.

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Overriding system Overriding function reset

MS0085

Notes

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Chassis Calibration steering

MS0097 Chassis Calibration steering

1-

You will need • Place barriers around the perimeter of the work area

• Standard tool kit • Protective goggles • Gloves

1 person

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

2-

Level of knowledge required The use of this card implies that its user is trained on this kind of machine and that this training was delivered by Haulotte or an authorised representative.

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-

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.

• The worker must make sure to have the EPI (Personal Protective Equipment) suited to the work and to the environment's specific conditions in which the equipment is located (see safety information specific to the work site.

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

• Mark out the work area.

• Switch off the ignition and remove the ignition key.

• Software version : 4001079910 - V3.03 or above.

• Put a "DO NOT USE" decal near the start/stop button to inform personnel that work is currently in progress on the equipment.

• 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.

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

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Chassis Calibration steering

MS0097 4-

Steering calibration procedure In the ACTIV'Screen (or using HaulotteDiag) navigate to the calibration menu and enter Steering calibration Sensor SR150

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Chassis Calibration steering

MS0097 Sensor SR150_1

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Chassis Calibration steering

MS0097 5-

Checks Turn on the machine and test the steer function- the pump motor should stop when the steering is at mechanical limit and the steering switch is held on : Sensor SR150_1 Valid range

Angle sensors

142

Calibration pts

V (approx.)

SR150_1

Left (-75.00°) Counter clockwise (CCW)

[330: 360]

[4.134: 4.410]

SR150_1

Right (+44.1°) Clockwise (CW)

[70: 100]

[1.282: 1.590]

SR150_1

Center (+0°)

[245: 255]

[2.350: 2.677]

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Turntable Universal plug

MS0133 Turntable Universal plug

1-

You will need • The tracker with its cable.

• A clamp to strip the wires.

• A clamp to crimp the wires.

• Place barriers around the perimeter of the work area

1 person

2-

Procedure Step 1 : • Disconnect the plug 2.

• Remove the caps on the plug.

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

• Strip the wires of the tracker.

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

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.

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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 Means of protection to be used when implementing the range

3-

Appropriate workwear

Gloves

Safety shoes

Safety goggles

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

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Chassis Check of tilt sensor

MS0242 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.

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

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Chassis Check of tilt sensor

MS0242 • Check the X and Y axis : Axis X

Axis 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

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Chassis Check of tilt sensor

MS0242

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Chassis Check of tilt sensor

MS0242

Notes

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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 Means of protection to be used when implementing the range

3-

Appropriate workwear

Gloves

Safety shoes

Safety goggles

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

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Chassis Dismantling/Reassembling the Tilt Sensor

MS0245 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.

• 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).

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Chassis Dismantling/Reassembling the Tilt Sensor

MS0245 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

• Menu : Calibration

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Chassis Dismantling/Reassembling the Tilt Sensor

MS0245 • Menu : Slope sensor on flat ground

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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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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 : Axis X

Axis Y

• Procedure to verify the tilt angle using the screen Activ' Screen :

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Chassis Dismantling/Reassembling the Tilt Sensor

MS0245 • In the main menu select : Machine settings > Calibration > Tilt > Check of tilt sensor.

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Chassis Dismantling/Reassembling the Tilt Sensor

MS0245

Notes

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Mast Visual inspection of the baseplate fastening screws on the casings of booms 1 and 2

MS0343 Mast Visual inspection of the baseplate fastening screws on the casings of booms 1 and 2

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 Means of protection to be used when implementing the range

3-

Appropriate workwear

Gloves

Safety shoes

Safety goggles

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

• Place barriers around the perimeter of the work area

1 person

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Mast Visual inspection of the baseplate fastening screws on the casings of booms 1 and 2

MS0343 4-

Procedure • 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).

• Affix a "DO NOT USE" label to the ground control box to let personnel know that the equipment is undergoing maintenance.

4.1 -

INSPECTION OF FASTENING SCREWS ON THE LIFTING CYLINDER BASEPLATE OF HOUSING 1 Inspection flap access at the foot of the mast. : • Open the inspection hatch.

• Raise the mast to approximately 5 m (height of the bottom of the lowered platform-jib).

Visual inspection only, do not put your hands inside the housings (through the hatches).

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Mast Visual inspection of the baseplate fastening screws on the casings of booms 1 and 2

MS0343 • Check that there is no clearance between the cylinder base ( 1 ) and the housing 1 ( 2 ) (if necessary raise or lower the mast slightly) Visual inspection only, do not put your hands inside the housings (through the hatches)

Particular case : • On some machines, at the factory the adjustment of the masts required the installation of adjustment wedges ( 1 ). In this case, check that there is no clearance ( J = 0 ) between the housing ( 2 ) and the adjustment wedge ( 1 ).

N.B.-:-IF IN DOUBT OR ANY OTHER PARTICULAR SITUATION, PLEASE CONTACT HAULOTTE SERVICES®

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Mast Visual inspection of the baseplate fastening screws on the casings of booms 1 and 2

MS0343 • Visually check that the 4 baseplate screws of the cylinder are not loosened.

Visual inspection only, do not put your hands inside the housings (through the hatches). Do not tighten the assembled screws with threadlocker.

•

: 3 required conditions :

• All of the screws are present.

• No play between the baseplate of the cylinder and the casing.

• All of the screws are tightened.

• If no anomalies are detected, continue the procedure.

• If inspection reveals an anomaly, shut down this machine and immediately get in touch with your local contact HAULOTTE Services®.

• Close the inspection hatch.

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Mast Visual inspection of the baseplate fastening screws on the casings of booms 1 and 2

MS0343 4.2 -

INSPECTION OF THE FASTENING SCREWS OF THE BASEPLATE OF HOUSING NO 2 Inspection flap access for mast tube 1 : • Raise the mast to approximately 5 m (height of the bottom of the lowered platform-jib).

• Open the inspection flap for tube 1 (counterweight side).

Visual inspection only, do not put your hands inside the housings (through the hatches).

• Visually check that there is no play (J=0) between the housing 2 (1) and its baseplate ( 2 ).

Visual inspection only, do not put your hands inside the housings (through the hatches). Do not tighten the assembled screws with threadlocker.

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Mast Visual inspection of the baseplate fastening screws on the casings of booms 1 and 2

MS0343

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Mast Visual inspection of the baseplate fastening screws on the casings of booms 1 and 2

MS0343

•

: 3 required conditions :

• All of the screws are present.

• No play between the baseplate of the cylinder and the casing.

• All of the screws are tightened.

• If no anomaly is detected, end of procedure.

• If the inspection reveals an anomaly (abnormal play, loosened screw, abnormal noise) : Contact HAULOTTE Services®.

• Close the inspection hatch.

E

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Mast Visual inspection of the baseplate fastening screws on the casings of booms 1 and 2

MS0343

Notes

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STAR 10 - STAR 26J

E - Trouble shooting and diagram Trouble shooting and diagram 1-

Trouble shooting 1.1 -

RECOMMENDATIONS If a malfunction occurs, check the following points : • Sufficient hydraulic oil in the tank.

• Batteries are charging.

• Control box E-stop push-buttons are pulled out.

• The control box selector key is set to platform or ground control box.

• Control box relays are engaged.

• Fuse status.

• Ground control box solenoid valve status.

If the malfunction persists, consult the troubleshooting table to identify the problem.

IF you cannot identify the problem, contact HAULOTTE Services®.

1.2 -

DESCRIPTION The FAILURES function describes the requirements relative to failures : monitoring, information recording, information reading.

1.3 -

REQUIREMENTS

Requirements

Definition

FAIL_xx_001

An ACTIVE failure ( A ) signals that the failure is stive active

FAIL_xx_002

A DETECTED failure ( D ) signals the cause of the failure has been valid one at least power on, but is inactive

FAIL_xx_003

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)

FAIL_xx_004

At power on, the failure log and failure counter are not changed for a failure which was already active at power off

FAIL_xx_005

The failure log and failure counter are changed for a failure which internal code is changed

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

4001180330

E 10.22

USA / GB

167

STAR 10 - STAR 26J

E - Trouble shooting and diagram Failures

N

C

Description

1

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 : The driver of the electromechanical brake coil is not able to drive the load

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 startup

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 : Connection problem of electric brake 1

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

Inverter

F01.01 Inverter Master

F01.05 Pump failure

A

A

F01.06 Overheating

A

F01.08 Low Battery

A

F01.09 Electrical park brake 1

F01.10 Electrical park brake 2

168

A

A

4001180330

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 : Connection problem of electric brake 2 E 10.22

USA / GB

STAR 10 - STAR 26J

E - Trouble shooting and diagram Failures

N

C

Description

Inverter

F01.11 Inverter Slave

A

F01.12 Wrong Controller Hardware

D

Failures

N

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 Vor >3 V)

1

COMBIACX is not a power version

2

ACEX is not a power version

C

Description

1

Zapi failure code 20 on COMBIACX : The driver of main contactor drive coil is shorted, or its coil is disconnected

2

Zapi failure code 24 on COMBIACX : The main contactor coil has been driven but main contactor does not close

4

Zapi failure code 46 on COMBIACX : Main contactor contact is stuck (always closed)

8

Supervisor status: alarm or wait reset and main contactor is not forced open by a Zapi failure

Contactor

F02.04 Power Contactor SB801

4001180330

D

E 10.22

USA / GB

169

STAR 10 - STAR 26J

E - Trouble shooting and diagram Failures

N

C

Description

Relay F03.07 Relay failure

1

Relay KAH stuck

2

Relay KAH2 stuck

D

1

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

N

C

Description

D

F03.15 Water refill pump control relay KA911

Failures Electrovalves

1

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

YV150L/YV150R

2

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

F04.03 Turret rotation

1

Turret rotation left valve YV250L failure (short circuit) and orientation setpoint active : --> YV250L = FAIL & STP(Orientation)

2

Turret rotation right valve YV250R failure (short circuit) and orientation setpoint active : --> V250R = FAIL & STP(Orientation)

1

Jib lift valve YV620U failure (short circuit) and jib setpoint active : --> YV620U = FAIL & STP(Jib)

2

Jib valve YV620 open circuit failure or jib valve YV620 short circuit failure and jib setpoint active : --> YV620 = OPEN-CIRCUIT || (YV620 = SHORT-CIRCUIT & STP(Jib))

1

Mast lift valve YV520U failure (short circuit) and mast setpoint active : --> YV520D = FAIL & STP(Mast)

2

Mast descent valve YV520D open circuit failure or Mast descent valve YV520D short circuit failure and mast setpoint active : --> YV520U = OPEN-CIRCUIT || (YV520U = SHORT-CIRCUIT & STP(Mast))

F04.01 Steering

D

D

YV250L/YV250R

F04.07 Jib

D

YV620/YV620U

F04.39 Mast

D

YV520D/YV520U

170

4001180330

E 10.22

USA / GB

STAR 10 - STAR 26J

E - Trouble shooting and diagram Failures

N

C

Description Joysticks

F05.01 Drive joystick

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)

1

Analog signal SM902 of orientation joystick SM902 out of range : --> SM902 < 0,2V | SM902 > 4,8V

2

Incoherence between analog and out of neutral signals of orientation joystick SM902 : --> SM902HN = 1 & (2,45V < SM902 < 2,55V) --> or SM902HN =0 & (SM902 < 2V | SM902 > 3V)

D

SM902

F05.11 Joystick neutral

Analog signal SM901Y of main joystick SM901 out of range : --> SM901Y < 0,2V | SM901Y > 4,8V

D

SM901

F05.05 Turret Joystick

1

A

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

A

Neutral position of orientation joystick SM902 not detected after power on : --> SM902 < 2.35V | SM902 > 2.65V

SM901

F05.12 Joystick neutral SM902

Failures

N

C

Description

Overload F06.01 No Loading Cal

A

Angle/pressure weighting system missing or not calibrated and EU|AU|RUK

Calibration required

4001180330

E 10.22

USA / GB

171

STAR 10 - STAR 26J

E - Trouble shooting and diagram Failures

N

C

Description

Sensors F07.02 Broken Chain

D

SB801/SB802

F07.05 Motor Temperature F07.21 Pressure sensor

SQ801=1

2

SQ802=1

1

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

2

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

1

SP601<20pts (Open circuit)

2

SP601>4000pts (Short circuit)

D

D

SR601

F07.22 Jib Angle

1

Analog signal calibrated SR601 of arm angle sensor calibrated and out of range [-58.40° to 71.50°] : --> (SR601 <min(pts)-500 | SR601 >max(pts+500) & calibrated

D

SR601

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°]

F07.33 Steer Angle

D

1

If the sensor is SR150_1 the error will appear if :

SR150

• Analog signal of steering angle sensor is out of range (only if calibrated) : • & F10.14=0

F07.35 Motor encoder

D

F07.36 ECU temperature

D

F07.44 Tilt sensor not calibrated

A

F07.46 Tilt sensor error

172

D

4001180330

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 : The internal thermal sensor is out of range

2

Zapi failure code 37 on ACEX : The internal thermal sensor is out of range

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

16

Supply voltage > 28V

32

Temperature > 90°C

E 10.22

USA / GB

STAR 10 - STAR 26J

E - Trouble shooting and diagram Failures

N

C

Description

1

Zapi failure code 18 on COMBIACX : Power capacitors voltage does not increase at startup

2

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

4

Zapi failure code 36 on COMBIACX : At start-up, the battery voltage is too low or too high (< 0.8 Vbattor > 1.2 Vbatt)

8

Zapi failure code 60 on COMBIACX : A low logic level of Key-Off has been detected during start-up diagnosis

16

Zapi failure code 18 on ACEX : Power capacitors voltage does not increase at start-up

32

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

64

Zapi failure code 36 on ACEX : At start-up, the battery voltage is too low or too high (< 0.8 Vbattor > 1.2 Vbatt)

128

Zapi failure code 60 on ACEX : A low logic level of Key-Off has been detected during startup diagnosis

1

Supply on but no control box signal (SA901B=SA901T=0)

2

Both control box signal present (SA901B=SA901T=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

Zapi failure code 38 on ACEX and Zapi failure code 38 on COMBIACX : Internal Smart driver KO

2

Zapi failure code 24 on COMBIACX : Low voltage on power line

3

Zapi failure code 46 on ACEX : Main contactor contact is stuck (always closed)

1

Phase 1 timeout

2

Phase 2 timeout

4

Phase 3 timeout

8

Batteries over temperature

16

Charger failure (check charger internal failure code in reference)

32

Temperature sensor failure

64

Flash memory corrupted

Electric circuit

F08.04 Supply

F08.07 Control Box incoherence F08.09 Common outputs supply F08.10 Power supply

F08.13 Power supply

A

A

A

D

D

128 Not an original HAULOTTE® charger

F08.16 Power supply F08.19 Battery Voltage drop too deept

4001180330

D

A

1

Incoherence between Request and Acknowledge (index or sub-index)

2

Acknowledge control error (0x80)

4

Acknowledge timeout (no response within 1s)

8

Wrong charge settings CRC between screen and main ECU (Restart machine)

1

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 10.22

USA / GB

173

STAR 10 - STAR 26J

E - Trouble shooting and diagram Failures

N

C

Description

F10.14 Steering angle not calibrated

D

1

Steer angle not calibrated

F10.15 Jib angle not calibrated

D

1

Jib 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

F10.21 Battery water refill system

N

F10.22 Battery water refill needed

N

Battery water level is low

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

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

Failures

N

C

Description

Internal faults

F12.01 CAN Fault

A

Check wires

F12.02 E2P Read/Write Error

D

Change calc.

F12.04 E2P Param Reset

D

Check settings

174

4001180330

1

Cantiller RX failure

2

Screen RX failure

4

CAN failure of ACEX (Zapi failure code 39 on COMBIACX or no information received from the ACEX) : Module does not receive any CAN messages from another module

8

CAN failure of COMBIACX (Zapi failure code 39 on ACEX) : Module does not receive any CAN messages from another module

16

No time (date/hour) update (problem with screen communication)

32

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

1

EEPROM failure status error

2

EEPROM failure stack full

4

Zapi failure code 25 on COMBIACX : EEPROM failure

8

Zapi failure code 69 on COMBIACX : EEPROM failure

16

Zapi failure code 25 on ACEX : EEPROM failure

32

Zapi failure code 69 on ACEX : EEPROM failure

64

Read EEPROM during init failed 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)

E 10.22

USA / GB

STAR 10 - STAR 26J

E - Trouble shooting and diagram Failures

N

C

Description

Internal faults

F12.05 E2P Param Not Set

F12.07 ECU software version incoherence

F12.08 ECU fault (master)

F12.09 ECU fault (slave)

F12.10 Wrong default parameters

4001180330

A

A

1

Model not set

2

Country not set

4

Serial number = 0

8

At least one of the parameter used and not set

16

At least one option used and not set

32

At least one config not set

1

Zapi software version different on COMBIACX and on ACEX

2

Wrong version of HAULOTTE® software on the ACEX

4

Wrong HAULOTTE® code software on the ACEX

1

Zapi failure code 34 on COMBIACX : Client software watchdog

2

Zapi failure code 41 on COMBIACX : Problem on the A/D conversion of uC

4

Zapi failure code 42 on COMBIACX : Watchdog circuit output became high due to hardware or software problem

8

Zapi failure code 43 on COMBIACX : Watchdog circuit output became high due to hardware or software problem

16

Zapi failure code 54 on COMBIACX : Current gain acquisition has not been performed or EEPROM damaged

32

Zapi failure code 63 on COMBIACX : Wrong client software

64

Zapi failure code 68 on COMBIACX : RAM checksum failed ( RAM warning)

128

Zapi failure code 73 on COMBIACX : Timeout of client function (execution time exceed maximum allowable time)

1

Zapi failure code 34 on ACEX : Client software watchdog

2

Zapi failure code 41 on ACEX : Problem on the A/D conversion of uC

4

Zapi failure code 42 on ACEX : Watchdog circuit output became high due to hardware or software problem

8

Zapi failure code 43 on ACEX : Watchdog circuit output became high due to hardware or software problem

16

Zapi failure code 54 on ACEX : Current gain acquisition has not been performed or EEPROM damaged

32

Zapi failure code 63 on ACEX : Wrong client software

64

Zapi failure code 68 on ACEX : RAM checksum failed ( RAM warning)

128

Zapi failure code 73 on ACEX : Timeout of client function (execution time exceed maximum allowable time)

/

Incoherence of the ZAPI parameter table ; restart the machine, it will restore the correct table

A

A

A

E 10.22

USA / GB

175

STAR 10 - STAR 26J

E - Trouble shooting and diagram Failures

N

C

Description

Internal faults

F12.16 Internal error of diagnostic system (request)

A

Check diagnostic system configuration

F12.16 Internal error of diagnostic system (set)

A

Check diagnostic system configuration

176

4001180330

4

Maintenance log

6/7

Events log

193

Failure

196

Machine parameter (speed or ramp)

197

Machine calibration

198

Option

199

Country

200

Machine configuration

201

Machine Model

205

Security settings

206

Machine state

207

Inputs/Outputs

209

Internal function

210

Internal cut-out

211

Machine maintenance

212

Event counters

213

Internal version

4

Maintenance log

6/7

Events log

193

Failure

196

Machine parameter (speed or ramp)

197

Machine calibration

198

Option

199

Country

200

Machine configuration

201

Machine Model

205

Security settings

206

Machine state

207

Inputs/Outputs

209

Internal function

210

Internal cut-out

211

Machine maintenance

212

Event counters

213

Internal version

E 10.22

USA / GB

STAR 10 - STAR 26J

E - Trouble shooting and diagram Failures

N

C

Description

Switches

F13.01 Lower Box Switches

D

1

Incoherence between the 2 signals of jib lifting switch of turret box (both active) : --> SA620U = 1 & SA620D = 1

2

Incoherence between the 2 signals of jib lifting switch of turret box (both active) : --> SA250L = 1 & SA250R = 1

4

Incoherence between the 2 signals of jib lifting switch of turret box (both active) : --> SA520U = 1 & SA520D = 1

1

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

1

Neutral position of jib lifting switch of turret box not detected after power on : --> SA620U = 1 | SA620D = 1

2

Neutral position of mast orientation switch of turret box not detected after power on : --> SA250L = 1 | SA620R = 1

4

Neutral position of mast lifting switch of turret box not detected after power on : --> SA520U = 1 | SA520D = 1

8

Neutral position of Foot Switch of turret box not detected after power on : --> SA905 = 1

16

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

32

Neutral position of horn option switch of turret box not detected after power on : --> SA907T = 1

Check switches

F13.02 Platform Switches

D

Check switches

F13.10 Neutral switch Check chassis switches

4001180330

A

E 10.22

USA / GB

177

STAR 10 - STAR 26J

E - Trouble shooting and diagram Failures

N

C

Description

Switches

F13.11 Switches neutral 2

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 orientation selection of platform box not detected after power on and no Foot Switch configuration activated : --> (SA200 = 1 && CFG[DeadmanPedal]=0)

8

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

16

Neutral position of jib selection switch of platform box not detected after power on : --> SA102 = 1

32

Neutral position of mast selection switch of platform box not detected after power on : --> SA500= 1

64

Neutral position of orientation selection switch of platform box not detected after power on : --> SA600 = 1

128

Neutral position of orientation selection of platform box not detected after power on and Foot Switch configuration activated : --> (SB800 = 1 && CFG[DeadmanPedal]=1)

A

Check plat. switches

Failures

1

N

C

D

1

Description

CAN J1939 F15.06 J1939

178

4001180330

Error on J1939

E 10.22

USA / GB

STAR 10 - STAR 26J

E - Trouble shooting and diagram Failures

N

C

Description

Engine F16.01 Overheating F16.02 Speed problem

F16.03 Motor supply

A

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

A

A

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

4001180330

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

E 10.22

USA / GB

179

STAR 10 - STAR 26J

E - Trouble shooting and diagram 2-

Electric diagram Electricity part 4001025550D - folio 1

180

4001180330

E 10.22

USA / GB

STAR 10 - STAR 26J

E - Trouble shooting and diagram Variable speed drive part 4001025550D - folio 2

4001180330

E 10.22

USA / GB

181

STAR 10 - STAR 26J

E - Trouble shooting and diagram Variable speed drive part 4001025550D - folio 3

182

4001180330

E 10.22

USA / GB

STAR 10 - STAR 26J

E - Trouble shooting and diagram Cage part 4001025550D - folio 4

4001180330

E 10.22

USA / GB

183

STAR 10 - STAR 26J

E - Trouble shooting and diagram Options 4001025550D - folio 5

184

4001180330

E 10.22

USA / GB

STAR 10 - STAR 26J

E - Trouble shooting and diagram Options 4001025550D - folio 6

4001180330

E 10.22

USA / GB

185

STAR 10 - STAR 26J

E - Trouble shooting and diagram 3-

Hydraulic diagram

P U

F

186

4001180330

E 10.22

USA / GB

STAR 10 - STAR 26J

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

Type of intervention

4001180330

E 10.22

Number of hours

Intervenor

HAULOTTE Services® intervention number

USA / GB

187

STAR 10 - STAR 26J

F - Records Date

188

Type of intervention

4001180330

Number of hours

E 10.22

Intervenor

HAULOTTE Services® intervention number

USA / GB