Page 1 Maintenance Book Maintenance Book OPTIMUM 8 - OPTIMUM 1931 E 4001069810 E 12.19 USA / GB...
Page 2 OPTIMUM 8 - OPTIMUM 1931 E 4001069810 E 12.19 USA / GB...
Page 3: Table Of Contents
2.3 - HAULOTTE Services®........
Page 4 Layout ..........1.4.2 - HAULOTTE Activ'Screen ......1.4.2.1 - LCD screen .
Page 5 Calibration arm angle sensors ..MS0099 - HAULOTTE Activ'Screen ....MS0106 - Universal plug ..... . .
Page 6 Maintenance Book Trouble shooting and diagram 1 - Trouble shooting ..... . 1.1 - Recommendations......... . . 1.2 - Description .
Page 7: Preface - Foreword
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.
Page 8: Symbols And Colors
OPTIMUM 8 - OPTIMUM 1931 E - 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.
Page 9 OPTIMUM 8 - OPTIMUM 1931 E - Preface - Foreword D e c a l s Color Title Description Danger : Indicates a hazardous situation which if not avoided, WILL result in death or serious injury. Warning : Indicates a hazardous situation which if not avoided, COULD result in death or serious injury.
Page 10 OPTIMUM 8 - OPTIMUM 1931 E - Preface - Foreword Notes 4001069810 E 12.19 USA / GB...
Page 11: Safety
OPTIMUM 8 - OPTIMUM 1931 E - Safety Safety 1 - General safety rules 1.1 - AINTENANCE 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.
Page 12: Uncontrolled Movement Hazard
OPTIMUM 8 - OPTIMUM 1931 E - Safety 1.2 - NCONTROLLED MOVEMENT AZARD 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).
Page 13: Electrocution Hazards
OPTIMUM 8 - OPTIMUM 1931 E - Safety 1.3 - LECTROCUTION AZARDS 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.
Page 14: Explosion / Fire Hazards
OPTIMUM 8 - OPTIMUM 1931 E - Safety 1.4 - XPLOSION AZARDS 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 • Do not work in an explosive or flammable atmosphere / environment.
Page 15: Maintenance And Repair Training
2.3 - HAULOTTE S ® ERVICES 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 - RAINING Whether you want to just service your equipment or carry out a complete overhaul, HAULOTTE®...
Page 16: Product Modification
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.
Page 17: Manufacturer's Warranty
• 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.
Page 18: Warranty Conditions
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.
Page 19 OPTIMUM 8 - OPTIMUM 1931 E - Familiarization Familiarization Notes 4001069810 E 12.19 USA / GB...
Page 20: Primary Machine Components
OPTIMUM 8 - OPTIMUM 1931 E - Familiarization 1 - Primary machine components 1.1 - AYOUT O P T I M U M O P T I M U M 1 9 3 1 C142 C171 C168 C141 C20 C2 C78 C58...
Page 21 OPTIMUM 8 - OPTIMUM 1931 E - Familiarization Marking Description Marking Description Chassis Platform access ladder Front drive wheels Compartment locking latch Platform Sliding guardrail Platform control box Extension deck lock pin Tie-down (and/or forklift loading) Scissors Ground control box + Universal plug...
Page 22: Maintenance Support
OPTIMUM 8 - OPTIMUM 1931 E - Familiarization 1.2 - AINTENANCE SUPPORT The maintenance stand must be in place before any maintenance operation is begun. Placing the machine in maintenance configuration : • Lift scissor arms to a sufficient height (floor of the platform at around 2,5 m / 8 ft 2 in from the ground).
Page 23: Extension Deck
OPTIMUM 8 - OPTIMUM 1931 E - Familiarization 1.3 - XTENSION DECK N.B.-:-D O NOT LOAD THE EXTENSION DECK FOR EASE OF MANOEUVRING Ensure that gate or sliding bar is in it’s proper closed position. Perform the extending and retracting operations of the extension deck on flat, horizontal ground.
Page 24: Ground Control Box
OPTIMUM 8 - OPTIMUM 1931 E - Familiarization 1.4 - ROUND CONTROL BOX 1.4.1 - Layout G e n e r a l v i e w ACTIV’ Screen C o n t r o l s a n d...
Page 25: Haulotte Activ'screen
OPTIMUM 8 - OPTIMUM 1931 E - Familiarization 1.4.2 - HAULOTTE Activ'Screen Upon starting and during operation of the machine, the LCD screen "Activ'Screen" located on the ground control box displays in real time the machine operating status. H A U L O T T E...
Page 26: Lcd Screen
OPTIMUM 8 - OPTIMUM 1931 E - Familiarization 1.4.2.1 - LCD screen At startup : At startup with the ground or platform controls selected; system initiates a self check : • Bar gets filled up. • Home screen comes on with status icon of the machine - okay to proceed functioning the controls.
Page 27 OPTIMUM 8 - OPTIMUM 1931 E - Familiarization • After pressing on Symbol Description Software part number Software version + Screen software version + Screen version Screen identification + Screen software version Machine serial number displayed • After again pressing on •...
Page 28 OPTIMUM 8 - OPTIMUM 1931 E - Familiarization Alarm status : Alarm status displayed as applicable - samples shown below Tilt : Overload : Low battery : 4001069810 E 12.19 USA / GB...
Page 29 OPTIMUM 8 - OPTIMUM 1931 E - Familiarization Recharge the batteries : Fully recharge the batteries. Low battery water level : Low water tank level : Present fault : 4001069810 E 12.19 USA / GB...
Page 30: Platform Control Box
OPTIMUM 8 - OPTIMUM 1931 E - Familiarization 1.5 - LATFORM CONTROL BOX 1.5.1 - Layout G e n e r a l v i e w C o n t r o l s a n d i n d i c a t o r s...
Page 31 OPTIMUM 8 - OPTIMUM 1931 E - Familiarization Marking Item Description Function 100% Battery charged HL904 Battery charging indicator Flashing : Batteries have 40 % charge left Constantly on : Batteries have only 20 % charge left Move forward : Forward drive or platform raising...
Page 32: List Of Actuators And Sensors
OPTIMUM 8 - OPTIMUM 1931 E - Familiarization 2 - List of actuators and sensors 2.1 - ENSORS AND ACTUATORS S e n s o r s a n d a c t u a t o r s 4001069810 E 12.19...
Page 33 OPTIMUM 8 - OPTIMUM 1931 E - Familiarization Name Description SP400 Pressure sensor SQ144 Pothole limit sensor SQ145 Pothole limit sensor SQ800 Tilt sensor SR150 Steering potentiometer SR420 Tilt sensor low position SR722 Arm angle sensor YV120 6 tracks / 2 positions for potholes or steering switch (priority for potholes)
Page 34: Sensors Detail
OPTIMUM 8 - OPTIMUM 1931 E - Familiarization 2.2 - ENSORS DETAIL 2.2.1 - Limit switchs for potholes Marking Item Description SQ144 Sensors = 1 when potholes are retracted SQ145 4001069810 E 12.19 USA / GB...
Page 35: Steering Potentiometer
OPTIMUM 8 - OPTIMUM 1931 E - Familiarization 2.2.2 - Steering potentiometer Marking Item Description Value 2.5 O, supply in 12 VDC (coming from ACEX variator) Before to launch the calibration, the pre-setting has to be done at mid-range SR150...
Page 36: Angle Transducers
OPTIMUM 8 - OPTIMUM 1931 E - Familiarization 2.2.3 - Angle transducers Marking Item Description Analogic sensor (0.5/4.5VDC), detection of low position SR420 Value adjustable according to scissors angle (~ 74 – 535 pts) Calibration system angle/pressure through consoles or active screen...
Page 37: Pressure Transducer
OPTIMUM 8 - OPTIMUM 1931 E - Familiarization 2.2.4 - Pressure transducer Marking Item Description Analogic transducer (4-20mA), value variable depends of the pressure on big SP400 chamber of the lifting cylinder Calibration system angle/pressure through consoles or active screen 4001069810 E 12.19...
Page 38: Slope Sensor
OPTIMUM 8 - OPTIMUM 1931 E - Familiarization 2.2.5 - Slope sensor Marking Item Description Tilt Y = 1.5° / X =3° (wire 12 = Vbat if machine on flat surface) SQ800 1=red=+Batt / 2=white=signal / 3=black=GND 2.2.6 - Battery charger...
Page 39: Fuses And Relays
OPTIMUM 8 - OPTIMUM 1931 E - Familiarization 2.2.7 - Fuses and relays Marking Item Description Protection electrovalve circuit (10A) Protection main circuit (10A) Protection accessories circuit (10A) SA103 Toggle switch for manual brake release function Relay for horn Relay for main modules power supply 4001069810 E 12.19...
Page 40: Consumables
OPTIMUM 8 - OPTIMUM 1931 E - Familiarization 3 - Consumables Consumable HAULOTTE® code Hydraulic filter cartridge 2505000970 4 - Ingredient Ingredient HAULOTTE® code Hydraulic oil 2420801310 Hydraulic oil (Winter option) 2505002640 Biological hydraulic oil 2820304310 4.1 - YDRAULIC OIL Hydraulic oils must comply with the following requirements : •...
Page 41: Lubrication Diagram
OPTIMUM 8 - OPTIMUM 1931 E - Familiarization 5 - Lubrication diagram 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)
Page 42: Greasing Points Localization
OPTIMUM 8 - OPTIMUM 1931 E - Familiarization 5.1 - REASING POINTS LOCALIZATION • Front-right wheel pivot greasing • Front-left wheel pivot greasing 4001069810 E 12.19 USA / GB...
Page 43: Machine Specifications
OPTIMUM 8 - OPTIMUM 1931 E - Familiarization 6 - Machine specifications 6.1 - OVEMENT 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 : •...
Page 44 OPTIMUM 8 - OPTIMUM 1931 E - Familiarization Notes 4001069810 E 12.19 USA / GB...
Page 45: Inspection Program
OPTIMUM 8 - OPTIMUM 1931 E - 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.
Page 46: Daily Inspection
OPTIMUM 8 - OPTIMUM 1931 E - Inspection and maintenance schedule 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.
Page 47: Preventive Maintenance
OPTIMUM 8 - OPTIMUM 1931 E - 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.
Page 48 OPTIMUM 8 - OPTIMUM 1931 E - Inspection and maintenance schedule P r e v e n t i v e M a i n t e n a n c e L e v e l E v e r y...
Page 49 OPTIMUM 8 - OPTIMUM 1931 E - Inspection and maintenance schedule P r e v e n t i v e M a i n t e n a n c e L e v e l E v e r y...
Page 50: Periodic Inspection
OPTIMUM 8 - OPTIMUM 1931 E - 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.
Page 51 OPTIMUM 8 - OPTIMUM 1931 E - Inspection and maintenance schedule Page or Periodic associated Comments procedure 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...
Page 52: 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.
Page 53: Ms0001 - Structural Part Inspection
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 : •...
Page 54 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 - AILY INSPECTION All the accessible structural part without disassembling must be subjected to a fast visual inspection.
Page 55 General data Structural part inspection MS0001 3.2 - AJOR 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 : •...
Page 56 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.
Page 57: Ms0002 - Pins And Bearing Inspection
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.
Page 58 General data Pins and bearing inspection MS0002 3 - 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 : •...
Page 59: Assembly
5.1 - INS AND BUSHES For OPTIMUM 8 - OPTIMUM 1931 E only : Never grease the pins and rings of scissor arms. When reassembling bearings and pins ensure that : • Lightly lubricate the housing into which the bearing is to be installed.
Page 60 General data Pins and bearing inspection MS0002 5.2 - EARINGS 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. •...
Page 61: Ms0003 - Cylinder Inspection
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 : •...
Page 62 • 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.
Page 63 General data Cylinder inspection MS0003 • If the creep of the cylinder rod is higher than the values indicated in the table below, replace the cylinder. Maximum drift authorised due to an internal leak of Type of cylinders the cylinder Lift cylinder arm or boom (Machine with working heights After 10 mn, creep After 60 mn, creep...
Page 64 General data Cylinder inspection MS0003 3.3 - AJOR 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.
Page 65: Ms0004 - Braking Test Procedure
• 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. 4001069810 E 12.19...
Page 66 General data Braking test procedure MS0004 Notes 4001069810 E 12.19 USA / GB...
Page 67: Ms0005 - Torque Values
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 ) •...
Page 68 General data Torque Values MS0005 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 Lubed...
Page 69 General data Torque Values MS0005 3 - Hydraulic couplings and hoses tightening torque charts H y d r a u l i c f i t t i n g t o r q u e ( T o l e r a n c e + 1 0 % ) BSPP threads according to ISO1179 Torque...
Page 70 General data Torque Values MS0005 Metric threads according to ISO 6149-2/3 or ISO9974 / DIN 3852-1 Torque Torque ISO 6149-2/3 DIN 3852-1 Thread ft-lbs ft-lbs M10x1,0 M12x1,5 M14x1,5 M16x1,5 M18x1,5 M20x1,5 M22x1,5 M26x1,5 M33x2,0 M42x2,0 N.B.-:- ISO6149: S ). ISO9974 / DIN3852: EALING WITH O RING WITHOUT ANY RETAINING RING OR FORM...
Page 71 General data Torque Values MS0005 4 - OPTIMUM 8 - OPTIMUM 1931 E Sub-assemblies Concerned elements Torque Axles Wheels 320 Nm Wheel studs / Driving reducer Loctite 243 - Normal threadlocker Hydraulic motor / Driving reducer 50 Nm Wheel reducer / Chassis...
Page 72 General data Torque Values MS0005 Notes 4001069810 E 12.19 USA / GB...
Page 73: Ms0020 - Hoses Inspection - Replacement
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.
Page 74 Hydraulics Hoses inspection - Replacement MS0020 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. •...
Page 75: Ms0025 - Electrical Wiring
Electric Electrical wiring MS0025 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.
Page 76 Electric Electrical wiring MS0025 Notes 4001069810 E 12.19 USA / GB...
Page 77: Ms0072 - Pressure Adjustment
Hydraulics Pressure adjustment MS0072 Hydraulics Pressure adjustment 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.
Page 78 Hydraulics Pressure adjustment MS0072 4 - Pressure plug location G e n e r a l p r e s s u r e i n t a k e Marking Description Pressure reading Pressure relief valve 4001069810 E 12.19 USA / GB...
Page 79: Ms0073 - Scissor Arms Screw - Periodical Checks
Scissor arm Scissor arms screw - Periodical checks MS0073 Scissor arm Scissor arms screw - Periodical checks 1 - You will need • Standard tool kit • Protective goggles • Place barriers around the perimeter of the work area • Gloves •...
Page 80 Scissor arm Scissor arms screw - Periodical checks MS0073 Notes 4001069810 E 12.19 USA / GB...
Page 81 Chassis Removal / Replacement of motor reducer assembly MS0084 Chassis Removal / Replacement of motor reducer assembly 1 - You will need • Standard tool kit • Place barriers around the perimeter of the work area • Protective goggles • Gloves •...
Page 82 Chassis Removal / Replacement of motor reducer assembly MS0084 4 - Removal N.B.-:-T HIS PROCEDURE IS EXPLAINED WITHOUT REMOVING OF THE REAR COUNTERWEIGHT AS PERHAPS ). B PERFORMED IN THE FIELD UT REMOVAL OF THE REAR STEP COUNTERWEIGHT MAKES THE ACCESS MUCH BETTER AND IS RECOMMENDED WHEN POSSIBLE F THE COUNTERWEIGHT IS REMOVED THERE IS NO NEED TO RAISE THE...
Page 83 Chassis Removal / Replacement of motor reducer assembly MS0084 • Disconnect the 3 power cables from the motor (U - V - W). • Disconnect the plug for the brake unit ( YB101 or YB100 depending on the side). • Disconnect the plug for the speed sensor ( SV301 or SV300, depending on the side).
Page 84 Chassis Removal / Replacement of motor reducer assembly MS0084 5 - Reinstall • Lift the motor into place, and refit the 4 bolts by hand. • Tighten the 4 bolts in X pattern with the top bolts in X patter, with a top bole First.
Page 85: Assembly
Chassis Removal / replacement of steering pivot assembly MS0090 Chassis Removal / replacement of steering pivot assembly 1 - You will need • Standard tool kit • Place barriers around the perimeter of the work area • Protective goggles • Gloves •...
Page 86 Chassis Removal / replacement of steering pivot assembly MS0090 3 - Removal N.B.-:-T HIS PROCEDURE WAS COMPLETED USING AN OVERHEAD CRANE BUT COULD EQUALLY BE PERFORMED USING A FORKLIFT N.B.-:-I F THE WHEEL IS GOING TO BE REMOVED THE NUT MUST BE LOOSENED BEFORE THE MACHINE IS LIFTED OFF THE GROUND IF NOT IT IS DIFFICULT TO HOLD THE WHEEL •...
Page 87 Chassis Removal / replacement of steering pivot assembly MS0090 Removing the steering bar from the pivot : • Remove the circlip and washer. • Slide the bar up off the pin. 4001069810 E 12.19 USA / GB...
Page 88 Chassis Removal / replacement of steering pivot assembly MS0090 Removing the steering pivot : • Place a block under the pivot (or wheel) so the assembly does not fall out on the ground when the upper plate is unscrewed. • Unscrew the 2 cap head bolts on the top of the pivot. Attention, the pivot is no longer fixed in the chassis.
Page 89 Chassis Removal / replacement of steering pivot assembly MS0090 N.B.-:-T HIS STEP IS ONLY POSSIBLE IF THE WHEEL IS ALREADY REMOVED Removing the axle from the pivot : • Place the assembly face down on a flat surface. • Using a screwdriver and soft hammer, remove the dust cover. •...
Page 90 Chassis Removal / replacement of steering pivot assembly MS0090 4 - Reinstall The mounting procedure is the opposite of the removal, with attention to the following nut tensions : • Nut on the inner axle 250 Nm • 6 cap head screws on the top of the wheel pivot 10 Nm •...
Page 91: Ms0095 - Removal / Replacement Of Platform Assembly
• 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.
Page 92 Platform Removal / replacement of platform assembly MS0095 4 - Removal • Cut the 3 cable ties under the platform that hold the platform wiring loom to the underside of the platform ( 1 near plug and 2 under platform). •...
Page 93 Platform Removal / replacement of platform assembly MS0095 • Attach the slings to the mid rail of the platform front and rear like shown on the following foto : 1 x sling 2 m / 6 ft 7 in, 500 kg / 1,103 lb minimum 2 x sling 1 m / 3 ft 3 in, 500 kg / 1,103 lb minimumSlings are passed through the interior of the platform.
Page 94 Platform Removal / replacement of platform assembly MS0095 • Using the overhead crane, slide the platform towards the rear. N.B.-:-A FTER THE PLATFORM IS MORE THAN LOWER THE CRANE GENTLY TO RAISE THE FRONT OF THE PLATFORM • If the platform isn’t low enough at the rear side, it will contact and be stuck on the inner scissor arms (Clearance necessary).
Page 95 Platform Removal / replacement of platform assembly MS0095 • The platform assembly can now be lifted clear and placed on a pallet. 5 - Reinstall • The installation procedure is the exact reverse of the removal procedure. N.B.-:-E NSURE THE PLATFORM IS LIFTED WITH THE REAR OF THE PLATFORM LOWER HIS WILL MAKE ALIGNMENT EASIER 6 - Complementary operations...
Page 96 Platform Removal / replacement of platform assembly MS0095 Notes 4001069810 E 12.19 USA / GB...
Page 97: Ms0096 - Removal / Replacement Of Scissor Pack
Scissors Removal / replacement of Scissor pack MS0096 Scissors Removal / replacement of Scissor pack 1 - You will need • Standard tool kit • Place barriers around the perimeter of the work area • Protective goggles • Gloves • Torque wrench for 21 Nm •...
Page 98 Scissors Removal / replacement of Scissor pack MS0096 3 - Removal N.B.-:-T HIS PROCEDURE IS EXPLAINED WITHOUT REMOVING OF THE REAR COUNTERWEIGHT AS PERHAPS ). B PERFORMED IN THE FIELD UT REMOVAL OF THE REAR STEP COUNTERWEIGHT MAKES THE ACCESS MUCH BETTER AND IS RECOMMENDED WHEN POSSIBLE F THE COUNTERWEIGHT IS REMOVED THERE IS NO NEED TO RAISE THE...
Page 99 Scissors Removal / replacement of Scissor pack MS0096 • Open the right side swing out tray, and disconnect the 2 hydraulic hoses (pressure and return) that go up the scissor frame to the lift cylinder. Plug and cap the hoses. •...
Page 100 Scissors Removal / replacement of Scissor pack MS0096 • Remove the fixation screws that hold the keeper plates on the lower front scissor frame pin and remove the keeper plates. • Take 2 slings (2 m x 1000 kg / 6 ft 7 in x 2,205 lb) and attach them to the platform.
Page 101 Scissors Removal / replacement of Scissor pack MS0096 • Lift the scissor assembly so the front clears the counterweight on the chassis, and slide towards the rear until the rear wear pads come free of the chassis. • Pay attention to the hosing that it does not get caught on the chassis. Otherwise pull the hoses and cabling to the top of the scissor.
Page 102 Scissors Removal / replacement of Scissor pack MS0096 4 - Reinstall • Attach the slings to the scissor assembly in the same manner as for the removal. • Lift the assembly, and position behind the chassis so as to slide the scissor assembly into the chassis rails.
Page 103 Scissors Removal / replacement of Scissor pack MS0096 • The NORDLOCK washer is made up of 2 different washers. • These must be assembled in the right order. • The Side of the washer that goes towards the bolt head has markings on it. Installation order of the NORDLOCK washer : •...
Page 104 Scissors Removal / replacement of Scissor pack MS0096 Tighten the keeper bolts as follows : • Tighten the screw ( 1 ) then ( 2 ) to 22 Nm. • Re tighten the screw ( 1 ) then ( 2 ) to 22 Nm. •...
Page 105 Scissors Removal / replacement of Scissor pack MS0096 5 - Complementary operations • Reinstall the platform : See MS0095 - Removal / replacement platform. • Verify the hydraulic oil level. • The lift cylinder may contain air. Complete several lift/lower cycles to remove any air from the system. •...
Page 106 Scissors Removal / replacement of Scissor pack MS0096 Notes 4001069810 E 12.19 USA / GB...
Page 107: Ms0097 - Calibration Steering
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 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.
Page 108 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. 4 - Steering calibration procedure t h e...
Page 109 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 : • When wheels steer to the left the steer angle decreases : Its limit is set to + 47,6° •...
Page 110 Chassis Calibration steering MS0097 Notes 4001069810 E 12.19 USA / GB...
Page 111: Ms0098 - Calibration Load Management System
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. 4001069810 E 12.19...
Page 112 Platform Calibration Load management system MS0098 4 - Load management calibration Procedure Before starting the calibration, check that the sensors are correctly mounted : • The sensors are mounted parallel with the front edge of the support for the sensors. •...
Page 113 Platform Calibration Load management system MS0098 Sensors Low position Upper position SR420 environ 74 pts environ 530 pts SR722 environ 420 pts environ 135 pts • Place the 250 kg / 550 lb load in the middle of the platform 4001069810 E 12.19 USA / GB...
Page 114 Platform Calibration Load management system MS0098 t h e A C T I V ' S c r e e n ( o r u s i n g H a u l o t t e D i a g ) n a v i g a t e t h e c a l i b r a t i o n...
Page 115 Platform Calibration Load management system MS0098 5 - Checks • Turn the machine off then on, and test the lift function. • Check that the function is stopped over 3 m / 9 ft 10 in with 250 kg / 550 lb in platform. •...
Page 116 Platform Calibration Load management system MS0098 Notes 4001069810 E 12.19 USA / GB...
Page 117: Ms0099 - Calibration Arm Angle Sensors
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. 4001069810 E 12.19...
Page 118 Scissors Calibration arm angle sensors MS0099 4 - Procedure of load management system calibration Before starting the calibration, check that the sensors are correctly mounted : • The sensors are mounted parallel with the front edge of the support for the sensors. •...
Page 119 Scissors Calibration arm angle sensors MS0099 N.B.-:-B EFORE LAUNCHING THE CALIBRATION CHECK AND ADJUST IF NECESSARY THE SENSORS VALUE Sensors Calibration Valid range (V) SR420 Low (0°) [0.65 ; 1.10] SR722 Low (0°) [4.05 ; 4.40] SR420 High (57°) [3.35 ; 3.80] SR722 High (57°) [1.30 ;...
Page 120 Scissors Calibration arm angle sensors MS0099 t h e A C T I V ' S c r e e n ( o r u s i n g H a u l o t t e D i a g ) n a v i g a t e t h e c a l i b r a t i o n...
Page 121: Ms0106 - Haulotte Activ'screen
Ground control box HAULOTTE Activ'Screen MS0106 Ground control box HAULOTTE Activ'Screen 1 - You will need • Standard tool kit • Protective goggles • Place barriers around the perimeter of the work area • Gloves Exclusively use tools and auxiliary average adapted. Always wear necessary safety clothing.
Page 122 Ground control box HAULOTTE Activ'Screen MS0106 Main menu Submenu 1 4.3. Inputs / Outputs 4.4. System test 5. Maintenance 5.1. Maintenance to be done 5.2. Maintenance log 5.3. Events log 5.4. Usage log 5.5. Upload software 5.6. Software versions 5.7. Event counters 6.
Page 123 1.2. Failures log (Failure history) 1. Failures By date (Failure history by date) By counters (Failure history by counters) Enter HAULOTTE® Acces Code ( + ENTER) 2. Access code Drive forward Min speed Max speed Max speed micro Acceleration...
Page 124 Ground control box HAULOTTE Activ'Screen MS0106 Main menu Submenu 1 Submenu 2 Mast raise Min speed Max speed raise Acceleration raise Deceleration raise 3.1. Speeds and Ramps Mast descent 3. Machine settings Min speed Max speed raise Acceleration raise Deceleration raise Steering angle 3.2.
Page 125 Ground control box HAULOTTE Activ'Screen MS0106 Main menu Submenu 1 Submenu 2 Save parameters 3.4. Save / restore parameters Restore parameters Components configuration Battery types Mast descent valve Machine Model 3. Machine settings STAR 6 (STAR 13) 3.5. Advanced STAR 6P (STAR 13P)
Page 126 Ground control box HAULOTTE Activ'Screen MS0106 Main menu Submenu 1 Submenu 2 Drive micro speed Drive high speed 4.1. Functions Forward steering Mast Picking plate (only on STAR 6P (STAR13P)) Machine Active control box Chassis control box Platform control box Picking control box (only on STAR 6P (STAR13P)) 4.
Page 127 Ground control box HAULOTTE Activ'Screen MS0106 Main menu Submenu 1 Submenu 2 Max number of EEPROM queries (R/W) into the stack Current number of EEPROM queries (R/W) into the stack Current EEPROM status Number of EEPROM stack errors Number of EEPROM status errors Execution time of 4 ms task 4.
Page 128 Ground control box HAULOTTE Activ'Screen MS0106 Main menu Submenu 1 Submenu 2 Driving Drive movement setpoint Drive movement slowdown Drive forward cuttings Drive reverse cuttings Drive movement control Drive speed Speed reduction Brake release switch (Driving) Right motor speed setpoint 4.
Page 129 Ground control box HAULOTTE Activ'Screen MS0106 Main menu Submenu 1 Submenu 2 Potholes Potholes movement setpoint Potholes out cuttings Potholes in cuttings Potholes movement control Mast Mast movement setpoint Mast movement slowdown Mast raise cutouts Mast descent cutouts Mast movement control 4.
Page 130 Ground control box HAULOTTE Activ'Screen MS0106 Main menu Submenu 1 Submenu 2 DIGITAL INPUTS ( TOR) SB801 - Emergency stop (turntable/frame) SQ800 - Slope sensor SA901TU - Control box selector - Turntable SA901PF - Control box selector - Platform SA907TU - Horn switch - Turntable...
Page 131 Ground control box HAULOTTE Activ'Screen MS0106 Main menu Submenu 1 Submenu 2 Outputs TOR KAH - Supply holding relay YV150R - Steering front right valve YV150L - Steering front left valve HA901 - Buzzer (Turntable) YV144 - Pothole lift down...
Page 132 Ground control box HAULOTTE Activ'Screen MS0106 Main menu Submenu 1 Submenu 2 ANALOG INPUTS MOT_D_I - Right engine current SV300 - Motor speed sensor 1 ST302 - Motor temperature sensor 1 ECU_TEMP - ECU internal temperature PUMP_I - Pump current...
Page 133 Ground control box HAULOTTE Activ'Screen MS0106 Main menu Submenu 1 Submenu 2 Hydraulic oil filter change Lubrication - Lubricant system 5.1. Maintenance to Hydraulic tank oil change be done Replacement : Chains, pulleys, wear pads Replacement : Pins, rings, bearings 5.2.
Page 134 Ground control box HAULOTTE Activ'Screen MS0106 Main menu Submenu 1 Submenu 2 Hourmeter Mast movement Drive movements Picking plate movement Turret control box selection Platform control box selection Picking control box selection (only on STAR 6P (STAR13P)) Maximum right inverter temperature...
Page 135 6.2. Camera (Camera history) 6.3. Wifi (Wifi history) 6.4. Photos (Photos history) 6. Tools Language Brightness 6.5. General Date & Time format settings HAULOTTE DIAG Update System properties 6.6. Files manager File manager history 4001069810 E 12.19 USA / GB...
Page 136 Ground control box HAULOTTE Activ'Screen MS0106 3.1 - CREEN ACCESS CODE SETTINGS 3.1.1 - Screen 0d This screen allows the access to the following screens. When this state is active, there is no scrolling with other possible states. Only the "screen saver" is active. In this screen, it is possible to enter a level code from 1 to 3 : •...
Page 137 Ground control box HAULOTTE Activ'Screen MS0106 Screen_Acces_level_x Username : • Press the validation code ( 4 ) to validate the entered code. Screen_Bad_code Username : • The screen 1 access (faults) after 1s if the entered code corresponds to an access level.
Page 138 Ground control box HAULOTTE Activ'Screen MS0106 Notes 4001069810 E 12.19 USA / GB...
Page 139: Ms0133 - Universal Plug
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 2 - Procedure Step 1 : •...
Page 140 Turntable Universal plug MS0133 Step 3 : • Take the wedgelock off the plug. • Thread the wires in the positions regarding the information. Universal connector Pin 1 + permanent battery Pin 2 GND (0 V) Pin 3 + battery voltage •...
Page 141 Turntable Universal plug MS0133 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. 4001069810 E 12.19 USA / GB...
Page 142 Turntable Universal plug MS0133 Notes 4001069810 E 12.19 USA / GB...
Page 143: Ms0174 - Platform Extension Lock Assembly
Platform Platform extension lock assembly MS0174 Platform Platform extension lock assembly 1 - You will need • Standard tool kit • Place barriers around the perimeter of the work area • Protective goggles • Gloves • EPI (Personal protective equipment) Kit 4000502080 which contains : •...
Page 144 • 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.
Page 145 Platform Platform extension lock assembly MS0174 4 - Procedure • Take the plate ( 1 ) : 4000468460 and insert the lever ( 2 ) : 4000468340. • Install the compressed spring ( 3 ) : 2421808300 between the lever and the plate.
Page 146 Platform Platform extension lock assembly MS0174 • In the platform, unscrew the 4 screw ( 13 ) HM8x12 from the old pedal plate. • Loosen the screw ( 14 ) HM10 for the top roller. • Remove the old pedal plate, and slide the new plate into place. •...
Page 147: Ms0175 - Removal - Replacement Of The Motor/Pump Assembly
• 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.
Page 148 Chassis Removal - Replacement of the motor/pump assembly MS0175 4 - Removal • Open the swing out trays on both sides. • To work in security, disconnect the battery cable to isolate the machine. • Disconnect the plugs from the 3 electrical coils on the motor pump group as shown below.
Page 149 Chassis Removal - Replacement of the motor/pump assembly MS0175 • The motor / Pump group can now be removed. • Remove the 2 M10 bolts ( 1 ) that fix the motor/pump group to the tray (they are access from underneath the tray). •...
Page 150 Chassis Removal - Replacement of the motor/pump assembly MS0175 5 - Reinstall Re-installation is a reversal of the removal procedure, with the following important points : • Ensure that the spacer plate (shown below) is positioned correctly under the motor/pump group. •...
Page 151: Ms0176 - Hydraulic Filter
• 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.
Page 152 Chassis Hydraulic filter MS0176 4 - Removal N.B.-:-Y OU CAN EMPTY THE RESERVOIR VIA THE FILLER PLUG BEFORE REMOVING THE FILTER BUT IT IS EASIER TO DO AFTER THE MOTOR PUMP IS REMOVED • Stand the motor/pump group vertically and loosen the band clamp. •...
Page 153 Chassis Hydraulic filter MS0176 • Use a large screwdriver (or flat blade) to carefully separate the block from the tank. N.B.-:-T AKE CARE TO NOT MARK THIS SURFACE 4001069810 E 12.19 USA / GB...
Page 154 Chassis Hydraulic filter MS0176 • Remove the motor/pump group from the reservoir. • The filter can now be removed- it simply slides onto the pick-up tube. • There is a secondary filter on the pickup side, this can be washed with cleaner if required.
Page 155 Chassis Hydraulic filter MS0176 5 - Reinstall • Reverse the above procedure. 6 - Complementary operations • Refit the hydraulic unit and refill the oil reservoir. 7 - Checks • Test the machine. • Check the oil level and top up if necessary. •...
Page 156 Chassis Hydraulic filter MS0176 Notes 4001069810 E 12.19 USA / GB...
Page 157: Ms0177 - Assembly Electro-Brake Unit
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. 4001069810 E 12.19...
Page 158 Chassis Assembly electro-brake unit MS0177 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.
Page 159 Chassis Assembly electro-brake unit MS0177 4 - Removal If fitted with dust protection kit : • Remove the plastic cover ( A ), and the rubber ring cover ( B ). • Unscrew the 3 mounting screws progressively. • Remove the brake magnet ( 1 ), the friction disk ( 2 ) and the inner flange ( 3 ).
Page 160 Chassis Assembly electro-brake unit MS0177 N.B.-:-T HE FOLLOWING IS ONLY REQUIRED IF YOU WISH TO REPLACE THE GEAR • Remove the circlip from the end of the shaft. • Remove the gear from the shaft using a shaft puller. 4001069810 E 12.19 USA / GB...
Page 161 Chassis Assembly electro-brake unit MS0177 5 - Reinstall N.B.-:-T HESE FIRST STEP IS ONLY REQUIRED IF THE GEAR WAS REPLACED • Install the key in the shaft, and then use a press to install the gear onto the motor shaft. •...
Page 162 Chassis Assembly electro-brake unit MS0177 • Check that the wires are correctly positioned as shown below. • Install the backing plate ( 1 ) and then install the rotor disk ( 2 ). • Check the alignment of the backing plate, so it is aligned with the holes. •...
Page 163 Chassis Assembly electro-brake unit MS0177 • Install the brake uni onto the motor. • Do not forget to install the washer onto the mounting bolts. • Position the brake electromagnet onto the motor, and align it so the wiring is just next to the "U" wire as shown below. 4001069810 E 12.19 USA / GB...
Page 164 Chassis Assembly electro-brake unit MS0177 • Remove the threaded bars, and insert the bolts. • Tension the bolts to 2,66 Nm +/-10% . • Remove the plastic wedges which hold the adjusting screws in position. • Check the air gap at 3 points. •...
Page 165 Chassis Assembly electro-brake unit MS0177 • To reset the airgap ( A ), undo the adjustment bolts ( B ) and adjust to obtain the necessary gap size. • Measure the airgap at several points. • Cycle the brake a number of times then re-check. If using dust cover : •...
Page 166 Chassis Assembly electro-brake unit MS0177 • The installation is complete. 6 - Complementary operations • For instructions on installing the motor-reducer assembly to the machine : See MS0084 - Removal / Replacement of motor reducer assembly. 7 - Checks • After installation, verify the correct drive operation in both directions. •...
Page 167: Ms0178 - Brake Unit Protection Installation
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. 4001069810 E 12.19...
Page 168 Chassis Brake unit protection installation MS0178 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.
Page 169 Chassis Brake unit protection installation MS0178 4 - Removal 4.1 - EMOVE THE COUNTERWEIGHT • Remove the counterweight thread cover, connect M16 eye bolts ( 1 ) and attach slings. • Loosen and remove the counterweight fixing screw ( 2 ) on each side.
Page 170 Chassis Brake unit protection installation MS0178 • Remove the counterweight then open the motor cover. • Counterweight is about 250 kg (551 lbs). • Treating a stuck brake. 4001069810 E 12.19 USA / GB...
Page 171 Chassis Brake unit protection installation MS0178 4.2 - REATING A STUCK BRAKE • Slightly loosen the three screws ( 3 ) on the back of each motor. • Tap, very softly, the brake with a rubber hammer this will release the stuck brake.
Page 172 Chassis Brake unit protection installation MS0178 5 - Reinstall 5.1 - NSTALLING THE PROTECTION KIT • Remove the plastic cover ( A ), and the rubber ring cover ( B ). • Assemble the rubber ring. • Assemble the plastic cover. 4001069810 E 12.19 USA / GB...
Page 173 Chassis Brake unit protection installation MS0178 • Reconnect the plugs for YB100 and YB101. 5.2 - EINSTALL THE COUNTERWEIGHT • Step 1 : Refit the motor cover and pose the counterweight in. • Step 2 : Tighten the counterweight screw on both side to 190 •...
Page 174 Chassis Brake unit protection installation MS0178 Notes 4001069810 E 12.19 USA / GB...
Page 175: Ms0179 - Assembly Moto - Reducer
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. 4001069810 E 12.19...
Page 176 Chassis Assembly moto - reducer MS0179 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.
Page 177 Chassis Assembly moto - reducer MS0179 • Grease the reducer and motor with 1/3 of the grease supplied. • Install the shaft key, with the round side facing down. • Take the 8 studs and add a small amount of the thread locking agent. 4001069810 E 12.19 USA / GB...
Page 178 Chassis Assembly moto - reducer MS0179 • Glue and screw the studs to the motor. • Tighten the studs to 6 Nm. • Install the paper gasket. • If necessary, clean up all traces of thread lock before installing the paper gasket. 4001069810 E 12.19 USA / GB...
Page 179 Chassis Assembly moto - reducer MS0179 Assemble the crown gear with the 26 needle rollers : • Align the N°51 stamped on the reducer with the electrical terminal on the motor as shown ( A ). • Grease the needle rollers and the housing with another 1/3 of the grease from the kit.
Page 180 Chassis Assembly moto - reducer MS0179 • Insert the bearing ( 3 ). • The references on both, the disk and the bearing, need to be facing upward. • Insert the shim spacer ( 4 ). • Install the second disk ( 5 ). •...
Page 181 Chassis Assembly moto - reducer MS0179 • Install the 8 dowel pins ( 6 ). • Each dowel pin must fit in without effort and not protrude above the height of the upper disk. • Install the shim spacer ( 7 ). •...
Page 182 Chassis Assembly moto - reducer MS0179 • Apply the remaining of the grease. • Install the paper gasket. • Clean the surface if needed, to ensure there is no grease on the gasket surface. • Install the housing with axle shaft. •...
Page 183 Chassis Assembly moto - reducer MS0179 • Install and tighten the 2 flat nuts that hold the housing. • Mark a red paint straight line on the stud, the nut and the main housing. 4001069810 E 12.19 USA / GB...
Page 184 Chassis Assembly moto - reducer MS0179 • Position the mounting plate ( 9 ) on the motor - reducer. • Install the spring washers ( 10 ). • Tighten the nuts ( 11 ). • Pay attention to the position ( E ) of the cutouts at ( 90° ) to the electric terminal.
Page 185 Chassis Assembly moto - reducer MS0179 • Mark a red paint straight line between the stud, the nut and the mounting plate. 5 - Complementary operations • For instructions on installing on the machine : See MS0084 - Removal / Replacement of motor reducer assembly.
Page 186 Chassis Assembly moto - reducer MS0179 Notes 4001069810 E 12.19 USA / GB...
Page 187: Ms0242 - Check Of Tilt Sensor
• 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.
Page 188 Chassis Check of tilt sensor MS0242 3 - You will need • "DO NOT OPERATE" tag • Personal protective equipment • Place barriers around the perimeter of the work area • Standard tool kit • Electronic level 4 - Check of tilt sensor •...
Page 189 Chassis Check of tilt sensor MS0242 • Position the electronic level under the chassis and note the values displayed on the X and Y axis. • Check the X and Y axis : A x i s A x i s •...
Page 190 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 °.
Page 191 Chassis Check of tilt sensor MS0242 • If the gap is > 0,5°, carry out a new calibration (Refer to MS0245 - Dismantling/Reassembling the Tilt Sensor). 4001069810 E 12.19 USA / GB...
Page 192 Chassis Check of tilt sensor MS0242 Notes 4001069810 E 12.19 USA / GB...
Page 193 • 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.
Page 194 Chassis Dismantling/Reassembling the Tilt Sensor MS0245 3 - You will need • "DO NOT OPERATE" tag • Personal protective equipment • Place barriers around the perimeter of the work area • Standard tool kit • Electronic level 4 - Dis-assembly •...
Page 195 Chassis Dismantling/Reassembling the Tilt Sensor MS0245 • Cut the COLSON tie holding the tilt cable. • Unscrew the 2 fixing screws (1). 5 - Reassembly • Reverse the above procedure. • Tighten the brake nuts to a torque of 10 Nm then mark the screws with the sealing. •...
Page 196 Chassis Dismantling/Reassembling the Tilt Sensor MS0245 • Menu : Calibration • Menu : Slope sensor on flat ground 4001069810 E 12.19 USA / GB...
Page 197 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 : 4001069810 E 12.19...
Page 198 Chassis Dismantling/Reassembling the Tilt Sensor MS0245 7 - Additional operations • Position the machine on an incline that is greater than the maximum permitted incline. • Fit the platform and ensure that movement is off and the buzzer is triggered. •...
Page 199 Chassis Dismantling/Reassembling the Tilt Sensor MS0245 4001069810 E 12.19 USA / GB...
Page 200 Chassis Dismantling/Reassembling the Tilt Sensor MS0245 4001069810 E 12.19 USA / GB...
Page 201 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. 4001069810 E 12.19...
Page 202 Chassis Assembly electro-brake unit (For the Asia-Pacific market only) MS0283 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.
Page 203 Chassis Assembly electro-brake unit (For the Asia-Pacific market only) MS0283 • Remove the brake magnet ( 1 ), the friction disk ( 2 ) and the inner flange ( 3 ). N.B.-:-T HE FOLLOWING IS ONLY REQUIRED IF YOU WISH TO REPLACE THE GEAR •...
Page 204 Chassis Assembly electro-brake unit (For the Asia-Pacific market only) MS0283 5 - Reinstall N.B.-:-T HESE FIRST STEP IS ONLY REQUIRED IF THE GEAR WAS REPLACED • Install the key in the shaft, and then use a press to install the gear onto the motor shaft.
Page 205 Chassis Assembly electro-brake unit (For the Asia-Pacific market only) MS0283 • Check that the wires are correctly positioned as shown below. • Install the backing plate ( 1 ) and then install the rotor disk ( 2 ). • Check the alignment of the backing plate, so it is aligned with the holes. •...
Page 206 Chassis Assembly electro-brake unit (For the Asia-Pacific market only) MS0283 • Install the brake uni onto the motor. • Do not forget to install the washer onto the mounting bolts. • Position the brake electromagnet onto the motor, and align it so the wiring is just next to the "U"...
Page 207 Chassis Assembly electro-brake unit (For the Asia-Pacific market only) MS0283 • Remove the threaded bars, and insert the bolts. • Tension the bolts to 2,66 Nm +/-10% . • Remove the plastic wedges which hold the adjusting screws in position (If present).
Page 208 Chassis Assembly electro-brake unit (For the Asia-Pacific market only) MS0283 • To reset the airgap ( A ), undo the adjustment bolts ( B ) and adjust to obtain the necessary gap size. • Measure the airgap at several points. •...
Page 209 Chassis Assembly electro-brake unit (For the Asia-Pacific market only) MS0283 6 - Complementary operations • For instructions on installing the motor-reducer assembly to the machine : See MS0084 - Removal / Replacement of motor reducer assembly. 7 - Checks • After installation, verify the correct drive operation in both directions. •...
Page 210 Chassis Assembly electro-brake unit (For the Asia-Pacific market only) MS0283 Notes 4001069810 E 12.19 USA / GB...
Page 211 • 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 - ESCRIPTION The FAILURES function describes the requirements relative to failures : monitoring, information recording, information reading.
Page 212 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram Failure Code Description F01 : Inverter COMBIACX : Failure in the high current hardware protection circuit. • Internal fault. • Replace the inverter. COMBIACX : When no current is applied to the traction motor, the current feedbacks are out of permitted standby range.
Page 213 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram Failure Code Description F01 : Inverter COMBIACX : The software waits for the motor pump to stop at start-up. • If the motor connected to "-P" is still moving, wait for it to be still.
Page 214 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram Failure Code Description F01 : Inverter Low battery voltage ( estimated value < 10%). • Check for damaged batteries, battery cables or connections. • Recharge batteries. Low Battery F01.08 (A) •...
Page 215 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram Failure Code Description F01 : Inverter ACEX: Short circuit detected on electromechanical brake or main contactor output (overcurrent). • Main contactor drive coil : Check connections and wiring for interruptions between controller and coil.
Page 216 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram Failure Code Description F02 : Contactor The driver of main contactor drive coil is shorted, or its coil is disconnected. • Ensure there is no short or low-impedance pull-down between MC and -Vbatt.
Page 217 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram Failure Code Description F04 : Electrovalves Short circuit detected on steering front left electrovalve : Steering --> YV121 = FAIL YV121 / F04.01 (D) Short circuit detected on steering front right electrovalve : YV122 -->...
Page 218 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram Failure Code Description F07 : Sensors COMBIACX : The motor temperature sensor is not correctly connected or damaged. Key OFF / ON. Motor Check wiring. Temperature F07.05 (D) ACEX : The motor temperature sensor is not correctly connected or damaged.
Page 219 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram Failure Code Description F08 : Electric circuit COMBIACX : Power capacitors voltage does not increase at start-up • Ensure that no external device is connected to the batteries. • Check battery, power cables and connections.
Page 220 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram Failure Code Description F08 : Electric circuit ACEX : At start-up, the battery voltage is too low or too high ( < 0.8 Vbatt or > 1.2 Vbatt) • Check that the controller SET BATTERY parameter value matches the battery nominal voltage ( 24VDC ).
Page 221 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram Failure Code Description F11 : Safeties Arm raise is controlled and arm angle is decreasing, out of calibration process (arm angle or F11.09 (D) pressure angle table). incoherence Check YV903 valve (wiring and connection).
Page 222 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram Failure Code Description 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).
Page 223 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram Failure Code Description ACEX: Software watchdog active. • Key OFF/ON. ACEX: Problem on the Analog/Digitial conversion of micro controller. • Key OFF/ON. ACEX: Watchdog circuit output became high due to hardware or software problem (WDG1).
Page 224 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram Failure Code Description F13 : Switches Incoherence between the 2 signals of front steering switch of platform box (both active) Lower Box --> SM901L = 1 & SM901R = 1 Switches F13.01 (D)
Page 225 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram Failure Code Description F16 :Motor COMBIACX: During drive, motor output voltage is lower than expected. • Check the motor power wiring and connections. • Check the motor phases for proper insulation with the chassis.
Page 226 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram 2 - Legend 2.1 - YSTEM ARCHITECTURE S y s t e m a r c h i t e c t u r e 4001069810 E 12.19 USA / GB...
Page 227 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram 2.1.1 - Power circuit P o w e r c i r c u i t 4001069810 E 12.19 USA / GB...
Page 228 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram 2.1.2 - Control circuit C o n t r o l c i r c u i t 4001069810 E 12.19 USA / GB...
Page 229 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram 3 - Electric diagram E l e c t r i c i t y p a r t 4 0 0 0 8 2 2 7 6 0...
Page 230 OPTIMUM 8 - OPTIMUM 1931 E - 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 4 0 0 0 8 2 2 7 6 0...
Page 231 OPTIMUM 8 - OPTIMUM 1931 E - 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 4 0 0 0 8 2 2 7 6 0...
Page 232 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram C a g e p a r t 4 0 0 0 8 2 2 7 6 0 f o l i o 4001069810 E 12.19 USA / GB...
Page 233 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram O p t i o n s 4 0 0 0 8 2 2 7 6 0 f o l i o 4001069810 E 12.19 USA / GB...
Page 234 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram O p t i o n L i t h i u m b a t t e r y 4 0 0 0 8 2 2 7 6 0...
Page 235 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram 4 - Hydraulic diagram 4001069810 E 12.19 USA / GB...
Page 236 OPTIMUM 8 - OPTIMUM 1931 E - Trouble shooting and diagram Notes 4001069810 E 12.19 USA / GB...
Page 237 OPTIMUM 8 - OPTIMUM 1931 E - 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 ® N THE CASE OF A...
Page 238 OPTIMUM 8 - OPTIMUM 1931 E - Records HAULOTTE Number of Date Type of intervention Intervenor Services® hours intervention number 4001069810 E 12.19 USA / GB...

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