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.
STAR 8 - STAR 22J - STAR 10 - STAR 26J - 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.
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Preface - Foreword D e c a l s Color Title Description Danger : Indicates a hazardous situation which if not avoided, WILL result in death or serious injury.
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Preface - Foreword Notes 4000414930 E 10.15 USA / GB...
STAR 8 - STAR 22J - STAR 10 - STAR 26J - 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.
STAR 8 - STAR 22J - STAR 10 - STAR 26J - Safety 1.3 - ELECTROCUTION HAZARDS The machine is not electrically insulated and does not provide protection from contact or proximity to electrically charged conductors. Always position the lift at a safe distance from electrically charged conductors to ensure that no part of the machine is within an unsafe area.
STAR 8 - STAR 22J - STAR 10 - STAR 26J - Safety 1.4 - EXPLOSION / FIRE HAZARDS Always wear protective clothing and eye wear when working with batteries and power sources/systems. N.B.-:-A CID IS NEUTRALIZED WITH SODIUM BICARBONATE AND WATER •...
Only authorized and qualified operators may operate HAULOTTE® machines. 2.3 - HAULOTTE SERVICES® The HAULOTTE Group is at your service in all 5 continents of the world via an extensive network of its own factory trained technicians, who are ready to respond to your every need.
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.
• If damage is caused by modifications that do not comply with HAULOTTE® specifications. • If lubricants, hydraulic oils or fuels that do not comply with HAULOTTE® recommendations are used. • If the machine is incorrectly repaired or used by the customer.
HAULOTTE® will not accept any claims concerning cleaning of the fuel circuit, filter, injection pump or any other equipment in direct contact with fuel or lubricants.
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Safety Notes 4000414930 E 10.15 USA / GB...
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Familiarization Familiarization Notes 4000414930 E 10.15 USA / GB...
STAR 8 - STAR 22J - STAR 10 - STAR 26J - Familiarization 1.2.2 - ACTIV'Screen I n d i c a t o r s ACTIV’Screen 4000274010 B Marking Description Platform overload indicator : Intermittently lit in case of overload 'Enable Switch' selector : Press and hold 'Enable switch' button "Overriding system"...
STAR 8 - STAR 22J - STAR 10 - STAR 26J - Familiarization 1.3 - PLATFORM CONTROL BOX 1.3.1 - Layout G e n e r a l v i e w 4000414930 E 10.15 USA / GB...
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Familiarization C o n t r o l s a n d i n d i c a t o r s Marking Description Function Tilt indicator Machine on excessive slope...
STAR 8 - STAR 22J - STAR 10 - STAR 26J - Familiarization 2 - Device layout 2.1 - SENSORS AND ACTUATORS S e n s o r s a n d a c t u a t o r s 4000414930 E 10.15...
STAR 8 - STAR 22J - STAR 10 - STAR 26J - Familiarization 5 - Lubrication diagram DANGER L i s t i n g r e d i e n t s Marking Ingredient Symbol HAULOTTE® code Hydraulic oil (Standard) - Barrel 209 l(55,2 gal US)
STAR 8 - STAR 22J - STAR 10 - STAR 26J - Familiarization 5.1 - GREASING POINTS LOCALIZATION • Slew ring. • Wheel axles : 2 on the chassis. Lubricate the pivots with lead-free grease. • Mast lubrication : 4000414930 E 10.15...
STAR 8 - STAR 22J - STAR 10 - STAR 26J - Familiarization 6 - Machine specifications 6.1 - MOVEMENT SPEED To allow checking operation, refer to the following table about originally time per movement. If the values measured by test are not equal to the following : •...
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Familiarization Notes 4000414930 E 10.15 USA / GB...
STAR 8 - STAR 22J - STAR 10 - STAR 26J - Inspection and maintenance schedule Inspection and maintenance schedule 1 - Maintenance Schedule There are a number of factors which can affect the design life including but not limited to, severity of operating conditions/routine maintenance.
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Inspection and maintenance schedule Intervals Area After 125 h After 250 h After 1500 h After 5000 h Daily (hours) or 1 year (hours) or 1 year (hours) or 3 years...
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Inspection and maintenance schedule Intervals Area After 125 h After 250 h After 1500 h After 5000 h Daily (hours) or 1 year (hours) or 1 year (hours) or 3 years...
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Inspection and maintenance schedule Intervals Area After 125 h After 250 h After 1500 h After 5000 h Daily (hours) or 1 year (hours) or 1 year (hours) or 3 years...
Country of use but no less than once a year. The purpose of the inspection is to detect any defect which could lead to an accident during routine use of the machine. HAULOTTE Services® requires Reinforced and Major Inspections to be carried out on the product to extend its service life.
STAR 8 - STAR 22J - STAR 10 - STAR 26J - Inspection and maintenance schedule 3 - Daily inspection The content and method of inspection must be conducted by operators before using the machine, it includes a visual inspection and functional and security systems testing of the machine.
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Inspection and maintenance schedule Daily inspection Visual inspection without disassembly Check level To check by test Corrected applicable Manuals and displays. Clean or replace if necessary. Presence, cleanliness and legibility of the...
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Inspection and maintenance schedule Extending structure (jib, mast) No cracks, broken weld, paint chipped No deterioration and visible damage No screws missing / loose parts No foreign material / impurities in joints or slides...
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Inspection and maintenance schedule Battery electrolyte level Level of centralized battery refilling No screws missing / loose parts Presence and good condition of hydraulic hose Presence and good condition of engine components Presence and good condition of the batteries: terminations and clamps, electrolyte level ...
Otherwise or in addition, use the detailed program below. This inspection is the responsibility of the owner, and must be conducted by a qualified technician. To ensure safe use and improve the life of machine, HAULOTTE® recommends performing this inspection at every 125 hours intervals.
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Inspection and maintenance schedule Periodic inspection In addition to the daily inspection program Area Type of intervention Area Type of intervention Mast assembly Functions and controls Platform control box (indicators, Chains etc.)
Reinforced periodic inspection is a thorough inspection of the machine structure and to ensure proper functionality. It must be performed every 1500 h or every 3 years, whichever occurs first. This inspection is the responsibility of the owner, and it must be conducted by a HAULOTTE Services® technician or a qualified company or person.
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Inspection and maintenance schedule Reinforced inspection In addition to daily and periodic inspections Area Type of intervention Area Type of intervention Mast assembly Functions and controls Platform control box (indicators, Chains etc.)
5 years, whichever occurs first, and subsequently every 5 years thereafter. This inspection is the responsibility of the owner, and it must be conducted by a HAULOTTE Services® technician or by a qualified and authorized company or person.
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Inspection and maintenance schedule Major inspection In addition with daily, periodic, and reinforced inspections Area Type of intervention Area Type of intervention Platform assembly Functions and controls Platform control box (indicators, Platform etc.)
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Inspection and maintenance schedule Machine sheet N.B.-:-T HAULOTTE HE LIST OF AINTENANCE NSPECTION HEETS IS NOT EXHAUSTIVE ONTACT ® ERVICES FOR ADDITIONAL OTHER SHEETS 4000414930 E 10.15 USA / GB...
General data Structural part inspection MS0001 General data Structural part 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 : •...
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General data Structural part inspection MS0001 3 - Control and maintenance To guarantee the integrity of the machine, it is necessary to carry out periodical controls on the mechanical structure such as defines hereafter. 3.1 - DAILY INSPECTION All the accessible structural part without disassembling must be subjected to a fast visual inspection.
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General data Structural part inspection MS0001 3.2 - MAJOR INSPECTION A thorough inspection of the structural parts must be realized all the 5000 h or 10 years with disassembling of the element to check the entirety of the welding. All structural part listed Section Familiarization must be disassembled and all weldsmust be review using non-destructive checks.
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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.
General data Pins and bearing inspection MS0002 General data Pins and bearing 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. 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.
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General data Pins and bearing inspection MS0002 3 - Control and maintenance The control of pins, stop pins, bushes and bearing must be carried out according to the following recommendations : • Every day before use : Fast visual inspection without disassembling. •...
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General data Pins and bearing inspection MS0002 5 - Procedure of reassembly 5.1 - PINS AND BUSHES For OPTIMUM 8 - OPTIMUM 1931 E only : Never grease the pins and rings of scissor arms. When reassembling bearings and pins ensure that : •...
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General data Pins and bearing inspection MS0002 5.2 - BEARINGS For the reassembly of bearings, respect the following stages : • Clean boring and/or the pins to remove all the foreign bodies. • Slightly lubricate boring and/or pins. • Lubricate the ring of the bearing slightly. •...
General data Cylinder inspection MS0003 General data Cylinder 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 : •...
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• 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 : •...
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General data Cylinder inspection MS0003 3.3 - MAJOR INSPECTION A thorough inspection of the structural parts must be realized all the 5000 h or 10 years with disassembling of the element to check the entirety of the welding. Each Cylinder must be disassembled and must be review using non-destructive checks.
• Stopped machine, measure the distance between the wheel axles and traced reference mark on the ground : • If the distance lies between 0.2 m (0ft 8in) and 2,7 m (8 ft 11 in), the test is validated. • If not, Contact HAULOTTE Services® to repair the system. 4000414930 E 10.15...
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General data Breaking test procedure MS0004 Notes 4000414930 E 10.15 USA / GB...
Torque Values 1 - Metric torque chart For screws HAULOTTE®, use columns ( A ), ( B ) and ( C ) : • Screw ( 1 ) grey dull dry, use colums ( A ) • Screw ( 1 ) grey dull greasy, use column ( B ) •...
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General data Torque Values MS0005 2 - SAE fastener torque chart SAE fastener torque chart This charts is to be used as a guide only unless noted elsewhere in this manual A574 High Grade 5 Grade 8 strength black oxide bolts Size Thread Lubed...
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General data Torque Values MS0005 3 - STAR 8 - STAR 22J - STAR 10 - STAR 26J Sub-assemblies Concerned elements Torque Chassis Wheels 32 Nm Wheel studs / Driving reducer Loctite 243 - Normal threadlocker Wheel axles 115 Nm...
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General data Torque Values MS0005 Notes 4000414930 E 10.15 USA / GB...
Chassis and turntable Slew ring inspection MS0010 Chassis and turntable 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 : •...
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Chassis and turntable 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.
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158.6 lb ft STAR 8 - STAR 22J - Ring on plate 135 Nm 100 lb ft STAR 8 - STAR 22J - Plate on mast foot 195 Nm 144 lb ft STAR 8 - STAR 22J - Ring on chassis...
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• 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 : •...
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In its new configuration, note the clearance ( J1) between chassis (or turret) and the slew ring as previously. • If the difference between two measurements does not exceed 2 mm (0.08 in) : the test validates correct operation. • Otherwise, contact HAULOTTE Services® to repair the system. 4000414930 E 10.15...
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Chassis and turntable Slew ring inspection MS0010 Notes 4000414930 E 10.15 USA / GB...
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 •...
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• 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. 4000414930 E 10.15...
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Condition of the cables inspection - Criteria of replacement MS0012 Machine Original diameter STAR 6 - STAR 13 - STAR 8 - STAR 22J - STAR 10 - STAR 22J 3 mm H21TX - H23TPX - H25TPX 9 mm HA16JRT...
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• for STAR all 250 hours or 3 months. • for the other machines all 250 h hours or 6 months. For the particular procedures of adjustment untreated in maintenance book, it is necessary to contact HAULOTTE Services®. MS0018 Boom adjustment procedure.
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.
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Hydraulics Hoses inspection - Replacement MS0020 3 - Hoses Disassembling For safety reasons, respect imperatively the following conditions of disassembling : • Fold the machine on a flat and released ground : • The machine is not in slope. • The boom is horizontal. •...
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.
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Electric Electrical wiring MS0059 Notes 4000414930 E 10.15 USA / GB...
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 •...
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• Measure the value of (3) using an appropriate method. Compare with the value of *1 indicated in the table below. Machine Link width (2) Length of 12 links (4) STAR 6 - STAR 13 - STAR 8 - STAR 22J - STAR 10 - STAR 26J HA32/41PX-NT 11.5 mm 152.40 mm H28TJ+/H43TPX STAR 8 - STAR 22J - STAR 10 - STAR 26J 14.50 mm...
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Upper boom Inspection of the condition of the chains - Criteria of replacement MS0042 • Check for external wear on rollers and links : • External wear must not measure more than 2 % from the section of the original link (2), see table above. •...
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3.2 - CHECK THE TENSION OF THE CHAINS Refer to the technical data sheet for your product following this sheet. To make any other adjustments not detailed in this maintenance logbook : Contact Haulotte Services for further advice. 4 - Replacing the chains The chains must imperatively be changed every 10 years.
Chassis and turntable Tires (Tyres) and pressures - Wheel replacement MS0044 Chassis and turntable Tires (Tyres) and pressures - Wheel replacement 1 - You will need • Standard tool kit • Protective goggles • Gloves • Place barriers around the perimeter of the work area •...
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• 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.
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Chassis and turntable 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. •...
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Chassis and turntable Tires (Tyres) and pressures - Wheel replacement MS0044 Notes 4000414930 E 10.15 USA / GB...
Chassis and turntable Lubrication - Jib cylinder - Steering cylinder - Lift cylinder MS0045 Chassis and turntable Lubrication - Jib cylinder - Steering cylinder - Lift cylinder 1 - You will need • Standard tool kit • Brush • Multipurpose grease (of mineral type) •...
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Chassis and turntable 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 : •...
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Chassis and turntable 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 : •...
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Chassis and turntable Lubrication - Jib cylinder - Steering cylinder - Lift cylinder MS0045 Lift cylinder In order to maintain the lifting cylinder in good condition and avoid any internal or external corrosion during prolonged storage (inside or outside), proceed as follows : •...
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.
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Chassis and turntable 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 gauche / Arrière droit / Rear right...
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Chassis and turntable Dismantling / Reassembling wheels reducer MS0046 • Sling the gear motor assembly using a 500 kg(1100 lb) sling and a bridge crane. N.B.-:-I F THE GEAR MOTOR NEEDS TO BE DISMANTLED UNSCREW THE FASTENING SCREWS 4000414930 E 10.15 USA / GB...
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Chassis and turntable Dismantling / Reassembling wheels reducer MS0046 5 - Reinstall • Reposition the assembly in the notch. • Push the motor into the highest position. • Attach the assembly using screws and washers. • Tighten to the recommended torque : 32 Nm. •...
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Chassis and turntable Dismantling / Reassembling wheels reducer MS0046 • Tighten to the recommended torque on the above procedure (4,8 Nm). • Refit the wheel. • Attach the wheel using the 5 screws and washers. • Tighten to the recommended torque : 115 Nm. •...
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Chassis and turntable Dismantling / Reassembling wheels reducer MS0046 Notes 4000414930 E 10.15 USA / GB...
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.
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Chassis and turntable Replacing the wheel pivot MS0047 4 - Removal The procedure is identical for the front left and front right pivots. F r o n t r i g h t p i v o t F r o n t l e f t p i v o t •...
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Chassis and turntable 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).
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Chassis and turntable Replacing the wheel pivot MS0047 L e f t s t o p ( S c r e w r i n g H E 6 X 1 6 ) R i g h t s t o p ( S c r e w r i n g C H C 6 X 1 6 )
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Chassis and turntable Replacing the wheel pivot MS0047 5 - Reinstall 5.1 - HUB • Lubricate the interior of the 2 bores. V i e w f r o m l a r g e b o r e s i d e V i e w f r o m s m a l l...
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Chassis and turntable Replacing the wheel pivot MS0047 • Lubricate the inner and outer rings and slide the assembly into the cage, as shown. • Fit the seal into its seating. Take care it is mounted the right way round. •...
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Chassis and turntable Replacing the wheel pivot MS0047 • Slide on the wheel hub. • Using a punch, insert the wheel hub up to the stop. Do not force it. • Using a punch, insert the small bearing into its cage. 4000414930 E 10.15 USA / GB...
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Chassis and turntable 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.-:-I F NECESSARY FINISH TIGHTENING WITH A RATCHET WRENCH TO LINE UP THE HOLE FOR THE PIN •...
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Chassis and turntable Replacing the wheel pivot MS0047 5.2 - WHEEL AXLES • Lubricate the shaft of the pivot. • Apply grease to the 2 sides of the washer. • Position the washer at the stop. • Position the chamfer on the top as shown. •...
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Chassis and turntable 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 •...
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.
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Chassis and turntable Steering cylinder replacement 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). •...
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Chassis and turntable Steering cylinder replacement 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. •...
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Chassis and turntable Steering cylinder replacement 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. •...
Hydraulics Hydraulic oil - Level Replacement MS0049 Hydraulics Hydraulic oil - Level Replacement 1 - You will need • Standard tool kit • Place barriers around the perimeter of the • Protective goggles 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 : •...
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• 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.
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.
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Hydraulics Hydraulic filter cartridge Replacement MS0050 Notes 4000414930 E 10.15 USA / GB...
Electric Battery (ies) MS0051 Electric Battery (ies) 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 Remove the battery cover.
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Electric Battery (ies) MS0051 3 - Centralized battery refilling The machine is delivered with the centralized filling tank empty. When using the machine for the first time, the user must fill the tank with demineralized water up to the maximum level. •...
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Electric Battery (ies) MS0051 4 - Filling the batteries manually In cold weather conditions, centralized battery filling does not function. Perform battery filling manually. Loosen the caps located on the top of the battery. If the level of electrolyte is below the level of the plates : Top up with distilled water.
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• The charger settings are adjusted in the factory using its own cable. If the cable needs changing, the HAULOTTE® factory must be contacted to obtain authorisation. How to charge the batteries ? : Before charging the batteries, switch the machine off.
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Electric Battery (ies) MS0051 When there is a fault, the LED indicator flashes in various colours depending on the type of alarm : State of flashing indicator Type of alarm Description (Action) Battery not connected or not compliant : Check connection or Battery presence rated voltage.
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Electric Battery (ies) MS0051 B a t t e r y c h a r g e s t a t u s a c c o r d i n g d e n s i t y a n d t e m p e r a t u r e Do not store machines, outside and in cold weather conditions, when batteries are discharged : Risk of damaging batteries.
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Electric Battery (ies) MS0051 L o s s c a p a c i t y d u r i n g p r o l o n g e d s t o r a g e .0015 perdu par semaine lors d'un stockage à une T° de 6°C .0015 per week loss in prolonged storage at 42°F .005 perdu par semaine lors d'un stockage à...
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Electric Battery (ies) MS0051 Notes 4000414930 E 10.15 USA / GB...
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.
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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). O v e r v i e w B a t t e r i e s •...
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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 . • Remove the upper cover bracket. • Remove the battery compartment using a bridge crane. 4000414930 E 10.15 USA / GB...
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Electric Battery (ies) MS0052 5 - Reinstall • Refit a the new battery pack. • Re-attach and reconnect all the cables and pipes to the centralized filling system. Take care with the connections. • Switch the machine on. • Check the levels and top up as 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.
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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 ) • Broken strand ( B ) • Kinked cable 1 mm max.
Mast Specific adjustment procedure STAR 8 - STAR 20J - STAR 10 - STAR 26J MS0054 Mast Specific adjustment procedure STAR 8 - STAR 20J - STAR 10 - STAR 26J 1 - You will need • PPE (Personal Protective Equipment: glove, safety shoe, glasses, etc…)
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Mast Specific adjustment procedure STAR 8 - STAR 20J - 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).
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Mast Specific adjustment procedure STAR 8 - STAR 20J - 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.
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• Lift the mast so that tube 1 extends 100 mm beyond the foot of the mast (+/- 20 mm). 100 mm +/- 20 mm Inspect the 6 return cables ( 4 for the STAR 8). The clearance between the washer and the foot of the mast or tube must be 2 mm.
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Mast Specific adjustment procedure STAR 8 - STAR 20J - STAR 10 - STAR 26J MS0054 2 mm • If not compliant : For the cables at the foot of the mast and tube 1 : • Hold the cable lub with a 4 flat wrench •...
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Mast Specific adjustment procedure STAR 8 - STAR 20J - STAR 10 - STAR 26J MS0054 Notes 4000414930 E 10.15 USA / GB...
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.
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Mast Tube wedging 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...
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.
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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. •...
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Mast Inspection of the slack chain sensors MS0062 5 - Slack chain detector adjustment procedure Installation of the SQ801 and SQ802 detectors S Q 8 0 1 ( L e f t ) S Q 8 0 2 ( R i g h t ) 4000414930 E 10.15 USA / GB...
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Mast Inspection of the slack chain sensors MS0062 F i g u r e Distance between the edge of the sensor and the Belleville washers : 5 mm F i g u r e Distance between the edge of the sensor and the Belleville washers : 3 mm Adjustment : •...
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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.-:-T 90 % HE DETECTOR CONNECTORS MUST BE AT 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 4000414930 E 10.15 USA / GB...
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.
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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. •...
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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. 4000414930 E 10.15 USA / GB...
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Overriding system Overriding function reset MS0085 Notes 4000414930 E 10.15 USA / GB...
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - 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.
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Trouble shooting and diagram Failure Code Description F01 : Inverter Zapi failure code 17 on Combiacx Zapi failure code 23 on Combiacx Zapi failure code 31 on Combiacx Inverter Master F01.01 (A)
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Trouble shooting and diagram Failure Code Description F04 : Electrovalves Steering front left valve YV150L failure (short circuit) and steering setpoint active - YV150L = FAIL & STP (Steering) Steering F04.01 (D)
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Trouble shooting and diagram Failure Code Description F07 : Sensors SQ801 = 1 Broken Chain F07.02 (D) SB801/SB802 SQ802 = 1 Zapi failure code 61 on Combiacx Motor Temperature F07.05 (D)
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Trouble shooting and diagram Failure Code Description F12 : Internal faults Cantiller RX failure Screen RX failure Zapi failure code 39 on Combiacx or no information received CAN Fault F12.01 (A)
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Trouble shooting and diagram Failure Code Description F13 : Switches Incoherence between the 2 signals of jib lifting switch of turret box (both active) • SA620U = 1 & SA620D = 1...
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Trouble shooting and diagram Failure Code Description F15 : J1939 Failure J1939 F15.06 (D) Error on J1939 Failure Code Description F16 :Motor Zapi failure code 35 on Combiacx Overheating F16.01 (A)
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Trouble shooting and diagram 2 - Electric diagram E l e c t r i c i t y p a r t 03-17 03-17 03-2 02-1 02-1...
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Trouble shooting and diagram V a r i a b l e s p e e d d r i v e p a r t 01-22 01-22...
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Trouble shooting and diagram C a g e p a r t 4000414930 E 10.15 USA / GB...
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Trouble shooting and diagram 3 - Hydraulic diagram 4000414930 E 10.15 USA / GB...
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Trouble shooting and diagram Notes 4000414930 E 10.15 USA / GB...
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - 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 HAULOTTE S ®...
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Records Number of HAULOTTE Services® Date Type of intervention Intervenor hours intervention number 4000414930 E 10.15 USA / GB...
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Records Number of HAULOTTE Services® Date Type of intervention Intervenor hours intervention number 4000414930 E 10.15 USA / GB...
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Records Number of HAULOTTE Services® Date Type of intervention Intervenor hours intervention number 4000414930 E 10.15 USA / GB...
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Records Number of HAULOTTE Services® Date Type of intervention Intervenor hours intervention number 4000414930 E 10.15 USA / GB...
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STAR 8 - STAR 22J - STAR 10 - STAR 26J - Records Number of HAULOTTE Services® Date Type of intervention Intervenor hours intervention number 4000414930 E 10.15 USA / GB...
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