Haulotte Articulating Booms STAR 6P – STAR 13P Maintenance Book Manual –  PDF DOWNLOAD

Haulotte Articulating Booms STAR 6P – STAR 13P Maintenance Book Manual –  PDF DOWNLOAD

FILE DETAILS:

Haulotte Articulating Booms STAR 6P – STAR 13P Maintenance Book Manual –  PDF DOWNLOAD

Language : English
Pages :156
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Haulotte Articulating Booms STAR 6P – STAR 13P Maintenance Book Manual –  PDF DOWNLOAD

Maintenance Book 1
STAR 6P – STAR 13P 1
USA 1
A 3
Preface – Foreword 3
1 – Symbols and colors 8 3
B 3
Safety 3
1 – General safety rules 11 3
11 – Maintenance implementation 11 3
12 – Uncontrolled movement Hazard 12 3
13 – Electric Shock Hazards 13 3
14 – Explosion / Fire Hazards 14 3
2 – Maintenance and repair training 15 3
21 – Owner’s responsability 15 3
22 – Technician’s responsability 15 3
23 – HAULOTTE Services® 15 3
24 – Training 15 3
25 – Product modification 16 3
26 – After Sales Service 16 3
27 – Product information 16 3
3 – Conditions of warranty 16 3
C 4
Familiarization 4
1 – Primary machine components 18 4
11 – Layout 18 4
12 – Maintenance support 20 4
13 – Picking tray 21 4
131 – Description 21 4
132 – Safety precautions 21 4
133 – Pre-use inspection 21 4
134 – Loading instructions 21 4
135 – Special decal 22 4
136 – Operation 22 4
137 – Cold weather operational recommendation 22 4
14 – Ground control box 23 4
141 – Layout 23 4
142 – HAULOTTE Activ’Screen 24 4
1421 – LCD screen 25 4
15 – Platform control box 30 4
151 – Layout 30 4
16 – Auxiliary control box 32 4
161 – Layout 32 4
2 – List of actuators and sensors 34 4
21 – Sensors and actuators 34 4
3 – Consumables 36 4
4 – Ingredient 36 4
41 – Hydraulic oil 36 4
42 – Marine protection 37 4
5 – Lubrication diagram 37 4
6 – Greasing points localization 38 4
7 – Machine specifications 39 4
71 – Movement speed 39 4
D 4
Inspection and maintenance schedule 4
1 – Inspection program 41 4
2 – Daily inspection 41 4
3 – Preventive maintenance 42 4
4 – Periodic inspection 47 4
5 – Major inspection 49 4
Machine sheet 5
MS0001 – Structural part inspection 51 5
MS0002 – Pins and bearing inspection 55 5
MS0003 – Cylinder inspection 59 5
MS0004 – Braking test procedure 63 5
MS0005 – Torque Values 65 5
MS0020 – Hoses inspection – Replacement 69 5
MS0059 – Electrical wiring 71 5
MS0061 – Clearance procedure 73 5
MS0086 – Steering cylinder removal 75 5
MS0087 – Pothole cylinder replacement 79 5
MS0102 – Tires (Tyres) – Wheel replacement 81 5
MS0103 – Hydraulic oil – Level Replacement 87 5
MS0104 – Lubrication – Steering cylinder – Lift cylinder 89 5
MS0106 – HAULOTTE Activ’Screen 91 5
MS0112 – Control-Lubrication 107 5
MS0113 – Battery (ies) – Standard machine 113 5
MS0133 – Universal plug 119 5
MS0242 – Check of tilt sensor 121 5
MS0245 – Dismantling/Reassembling the Tilt Sensor 127 5
E 6
Trouble shooting and diagram 6
1 – Trouble shooting 135 6
11 – Recommendations 135 6
12 – Description 135 6
13 – Requirements 135 6
14 – Failures list 136 6
2 – Electric diagram 148 6
3 – Hydraulic diagram 154 6
F 6
Records 6
1 – Intervention register 155 6
Preface – Foreword 7
You have just purchased a HAULOTTE® product and we would like to thank you for your business 7
The Aerial Work Platform is a mechanical device primarily designed and manufactured with the intent to position people with the necessary tools and material to overhead elevated temporary workplaces All other uses or alterations/modifications to the 7
This manual shall be considered a permanent component of the machine and shall be kept with the aerial work platform in the designated Manual Holder, at all times 7
Safe operation of this product can only be assured if you follow the operating instructions contained in this manual are followed To ensure proper and safe use of this equipment, it is strongly recommended that only trained and authorized personnel 7
We would particularly like to draw your attention to 2 essential points : 7
• Compliance with safety instruction (machine, use, environment) 7
• Use of the equipment within the performance limits 7
With regard to the designation of our equipment, we stress that this is purely for commercial purposes and not to be confused with the technical specifications Only the specifications in this manual should be used to study the suitability of the equ 7
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 7
It is the on-site maintenance technician’s duty to carry out the regular maintenance work recommended by HAULOTTE Services® 7
This maintenance work is essential for correct machine operation 7
If regular maintenance is not carried out, this may : 7
• Void the warranty 7
• Cause machine malfunction 7
• Reduce machine reliability and shorten its service life 7
• Jeopardize operator safety 7
To ensure that the regular maintenance requirements are fully satisfied, contact HAULOTTE Services® 7
HAULOTTE Services® technicians are specially trained to carry out extensive repairs, interventions or adjustments on the safety systems or elements of HAULOTTE® machines They carry genuine HAULOTTE spare parts and tools as required, and also provi 7
1 – Symbols and colors 8
Symbols and colors are used to alert the operator of safety precautions and/or to highlight important safety information 8
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 8
Symbol 8
Decals 9
B 9
Safety 11
1 – General safety rules 11
11 – Maintenance implementation 11
Your safety and the safety of the people around are essential 11
Make sure the work area is clean in order to not to pollute the system of the machine 11
Before performing any maintenance interventions, place the machine in maintenance configuration 11
The maintenance stand must be in place before any maintenance operation is begun 11
Placing the machine in maintenance configuration : 11
Putting in use position : 11
Never leave the hydraulic cylinders fully extended before switching off the machine, or when stationary for an extended period of time Keep the elements of the machine in configuration of maintenance thanks to mechanics devices 12
Report that the machine is under maintenance by tagging the platform and ground control boxes 12
Note : 12
12 – Uncontrolled movement Hazard 12
Be aware of uncontrolled movement and always respect the following : 12
13 – Electric Shock Hazards 13
The machine is not electrically insulated and does not provide protection from contact or proximity to electrically charged conductors 13
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 13
Respect the local rules and the minimum safety distance from power lines 13
Minimum safe approach distances 13
Do not operate the machine : 13
Keep away from the machine if it contacts energized power lines Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut off 13
In the event of accidental contact with a high voltage line, wait for the power to the line be de-energized before attempting to operate the machine 13
14 – Explosion / Fire Hazards 14
Always wear protective clothing and eye wear when working with batteries and power sources/systems 14
2 – Maintenance and repair training 15
21 – Owner’s responsability 15
The owner (or hirer) has the obligation to inform technician of the instructions contained in the Operator Manual and Maintenance Book 15
The owner (or hirer) has the obligation to renew all manuals or decals that are either missing or in bad condition 15
Additional copies can be ordered from HAULOTTE Services® 15
The owner (or hirer) is responsible for applying the local regulations regarding maintenance of the machine 15
22 – Technician’s responsability 15
The technician must read and understand the contents of this manual, operators manuals and the decals affixed on the machine 15
The technician must inform the owner (or hirer) if the manual or any decals are missing or in poor condition, and of any malfunction of the machine 15
23 – HAULOTTE Services® 15
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 15
24 – Training 15
Whether you want to just service your equipment or carry out a complete overhaul, HAULOTTE® can provide you with a structured training program or we can tailor a program to suit your specific requirements or circumstances Training can cover the ge 15
25 – Product modification 16
In a constant effort to improve the quality of machines, HAULOTTE continually monitors technical improvements that enable to develop products with improved safety and greater reliability The target being that HAULOTTE® always work to build confiden 16
These improvements will be shared via the following documents : 16
26 – After Sales Service 16
Our HAULOTTE Services® After Sales Service is at your disposal throughout your machine’s service life to ensure the optimum use of your HAULOTTE product : 16
27 – Product information 16
Without the written permission from Haulotte, modifying a HAULOTTE® product is a Safety concern Any modification may violate Haulotte design parameters, local regulations and industry standards 16
If you desire a modification to the product, submit a request in writing to HAULOTTE 16
With the utmost care to ensure enhanced reliability and greater safety of the HAULOTTE® products, it is pertinent that when a “Service or Safety Bulletin” is issued, action is taken immediately Once the bulletin has been addressed, make sure that t 16
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 16
3 – Conditions of warranty 16
Our warranty conditions and extension contracts are now available on the websites of our sales network : wwwhaulottecom 16
C 16
Familiarization 17
1 – Primary machine components 18
11 – Layout 18
STAR 6 P – STAR 13 P 18
Universal plug 19
12 – Maintenance support 20
The maintenance stand must be in place before any maintenance operation is begun 20
Placing the machine in maintenance configuration : 20
Putting in use position : 20
13 – Picking tray 21
131 – Description 21
This picking tray is designed as an attachment to the platform to transport parcels to and from elevated heights 21
132 – Safety precautions 21
Before using machine in the picking mode : 21
133 – Pre-use inspection 21
134 – Loading instructions 21
135 – Special decal 22
136 – Operation 22
refer to Section B 36 Auxiliary control box to perform the picking tray and mast movements 22
137 – Cold weather operational recommendation 22
For temperatures between 0 °C(32 °F) and – 20 °C(- 4 °F) : 22
14 – Ground control box 23
141 – Layout 23
General view 23
Controls and indicators 23
142 – HAULOTTE Activ’Screen 24
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 24
HAULOTTE Activ’Screen 24
Controls and indicators 24
At startup : 25
At startup with the ground or platform controls selected; system initiates a self check : 25
Alarm status : 27
Alarm status displayed as applicable – samples shown below 27
Tilt : 27
Overload : 27
Low battery : 27
Recharge the batteries : 27
Fully recharge the batteries 27
Low battery water level : 28
Low water tank level : 28
Present fault : 28
15 – Platform control box 30
151 – Layout 30
General view – STAR 6 P – STAR 13 P 30
Controls and indicators 31
16 – Auxiliary control box 32
161 – Layout 32
General view 32
Controls and indicators 33
2 – List of actuators and sensors 34
21 – Sensors and actuators 34
Sensors and actuators – STAR 6 P – STAR 13 P 34
3 – Consumables 36
4 – Ingredient 36
41 – Hydraulic oil 36
Hydraulic oils must comply with the following requirements : 36
• Antifoam and deaeration 36
• Anti-wear, anti-shear and antioxydant 36
• Rust and corrosion inhibitors (copper) 36
The recommended viscosity grades depending on the environmental conditions are as follows : 36
Biodegradable oils may be used if they comply with the following requirements : 36
42 – Marine protection 37
In harsh environments (high levels of salinity in the atmosphere: close to the sea, industrial environment with chloride emissions and/or humidity > 70%), we recommend applying the following protection process : 37
5 – Lubrication diagram 37
List of ingredients 37
6 – Greasing points localization 38
• Wheel steering pivots : 2 on the chassis 38
Lubricate the pivots with lead-free grease 38
• Mast lubrication : 38
Picking tray chain : 38
• Remove the plate 1 38
Apply oil to the top sprocket after cleaning the chain 38
7 – Machine specifications 39
71 – Movement speed 39
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 : 39
Always check speed movement from the ground control box 39
D 39
Inspection and maintenance schedule 41
1 – Inspection program 41
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 41
Inspections and maintenance must be carried out by a qualified company or person chosen by the owner of the machine 41
The results of these visits must be recorded in a safety register created by the owner This register as well as the list of competent repair persons must made available to the work inspector, government inspector and company safety committee at any 41
(*) Or according to local regulations 41
2 – Daily inspection 41
The daily inspection must be performed every day, before the start of a new work shift and at every change of user 41
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 41
A description of the daily inspection can be found in the machine’s user manual 41
We recommend these forms to be completed daily and stored to assist with your maintenance schedule 41
3 – Preventive maintenance 42
Maintenance operations must be carried out by a qualified technician chosen by the owner and ensure that the machine operates correctly 42
Severity of operating conditions may require a reduction in time between maintenance periods 42
Maintenance operations performed must be recorded in a register / log book of the machine 42
Symbol meanings 42
Preventive Maintenance Level 1 – First 50H 43
Preventive Maintenance Level 1 – Every 2 weeks 43
Preventive Maintenance Level 1 – Every 6 months or 250H 44
Preventive Maintenance Level 2 – Every 1 year or 500H 45
Preventive Maintenance Level 2 – Every 2 years or 1000H 46
4 – Periodic inspection 47
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 47
This intervention must take place after : 47
• Extensive dismantling and reassembly 47
• Repairs involving the machine’s essential components 47
• Any accident causing stress to the machine 47
This inspection is the responsibility of the owner, and must be conducted by a qualified technician 47
Under no circumstances may this inspection replace the control required by local regulations 47
Use the detailed program below 47
5 – Major inspection 49
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 49
This inspection is the responsibility of the owner and must be carried out by a technician HAULOTTE Services® or an authorized and qualified person 49
In order to carry it out, contact the subsidiary HAULOTTE® or the authorized distributor 49
Machine sheet 49
General data 51
1 – Warning 51
2 – Risk prevention 51
Means of protection to be used when implementing the range 51
3 – You will need 51
4 – Control and maintenance 52
To guarantee the integrity of the machine, it is necessary to carry out periodical controls on the mechanical structure such as defines hereafter 52
41 – Daily inspection 52
All the accessible structural part without disassembling must be subjected to a fast visual inspection 52
If anomalies are noted, according to the list below, a reinforced control will have to be carried out to judge conformity of the part : 52
The list of part to check are define Section Familiarization 52
42 – Major inspection 52
All structural part listed Section Familiarization must be disassembled and all weldsmust be review using non-destructive checks Section D – Inspection and maintenance schedule 52
The criteria quoted above are applicable 52
The main items to be inspected are : 52
Example 53
In the event of suspicion of crack, a cleaning and a sweating are to be carried out to guarantee the integrity of the part before reassembly 53
Check presence and torque of each bolts and screw used to assembly part listed in Section Familiarization Refer to spare part catalog for additional information if needed 53
43 – Functional tests 53
The following tests must be performed periodically Section D – Inspection and maintenance schedule : 53
The following tests must be realized by a qualified staff under secure conditions 53
The results of the tests must be entirely documented 53
To avoid the swing of the machine during the test, it is imperative that a device of reserve (chain, not of anchoring) is used during the test 53
44 – Dynamic tests 54
The machine must be place on level and firm ground 54
With 100% of the maximum allowed load, operate from ground control box (or emergency control box) all the movements ; the platform floor must reach a height of about 1 above the ground 54
The functional tests must show the following facts : 54
Refer to the user manual for the description of the safety device and technical characteristics to be reached 54
45 – Structural test 54
The following test shows that the structure of the machine is in conformity with the safety requirements 54
The machine must be place on level and firm ground 54
With 100% of the maximum allowed load, operate from ground control box (or emergency control box) all the movements ; the platform floor must reach a height of about 1 above the ground : 54
If the difference between two measurements does not exceed 4 cm (1575 in) : the test is validated 54
If the difference between two measurements exceeds 4 cm (1575 in), to contact HAULOTTE Services® or to carry out the additional tests described below MS0003 – § 32 Cylinder inspection 54
General data 55
1 – Warning 55
2 – Risk prevention 55
Means of protection to be used when implementing the range 55
3 – You will need 55
4 – Control and maintenance 56
Inspection of the pins, stop pins, bushings and bearings must be carried out according to the recommendations Section D – Inspection and maintenance schedule : 56
• Fast visual inspection without disassembling Section D – Inspection and maintenance schedule : 56
• Check the presence of the pins and visible stops pins without disassembling 56
• Check the presence of the screws 56
• Check absence of deformations, cracks or breakage of pins and/or stops pins 56
• Check absence of heavy abrasion, wear or oxidation of the pins, stops pins 56
• Reinforced visual inspection with disassembling of certain elements to reach the bushes or bearing Section D – Inspection and maintenance schedule : In addition to the above cited criteria, verify the following : 56
• Check the presence and the position of the bushes and bearings 56
• Check the absence of shaving in periphery of the pins 56
• Check the absence of heavy abrasion, wear or oxidation of the bushes and bearing 56
• Check the absence of deformations, cracks or breakage of the bushes and bearing 56
• Check the absence of radial gap > 0,5 mm (19690 µ in) on the pins 56
• Complete disassembling of the pins, bushes and bearing Section D – Inspection and maintenance schedule : In complement of the inspections above cited, it is necessary to check : 56
• For the stages : 56
• Check the presence of material of friction 56
• For the bearings : 56
• After disassembling, protect the bearing from pollution and shocks 56
• Clean the bearing with a suitable solvent 56
• Check the absence of shaving in the housing of the bearing and/or the bearing 56
• Check the absence of heavy abrasion, wear, oxidation, deformations of the balls (or rollers) and the ball races 56
The periodicity can evolve under the following conditions Section D – Inspection and maintenance schedule : 56
• Abnormal noise during movements of the structure 56
• Prolonged storage of the machine ( 6 months) 56
• Specific storage and use Environment (strong moisture and salinity of the air) 56
5 – Criteria of replacement 56
The pins, stop pins, bushes and bearing must be replaced as soon as one of the anomalies quoted above is noted Bearing and bushes must be imperatively changed at the end of 10 years of use 56
6 – Procedure of reassembly 57
61 – Pins and bushes 57
When reassembling bearings and pins ensure that : 57
Recommended Values 57
62 – Bearings 58
For the reassembly of bearings, respect the following stages : 58
General data 59
1 – Warning 59
2 – Risk prevention 59
Means of protection to be used when implementing the range 59
3 – You will need 59
4 – Control and maintenance 60
41 – Visual inspections 60
The hydraulic actuating cylinders must be subjected to visual inspections periodic all the 250 hours or 6 months such as defined below : 60
42 – Functional tests 60
To guarantee an optimal level of performance and safety, functional tests must be realized all the 250 hours or 6 months 60
The periodicity can evolve under the following conditions : 60
Generic Control : 60
• Lift Arm hydraulic cylinder : Lift the arm to approximately half full height The telescopic boom should be fully extended and in the horizontal position (For machines fitted with) 60
• Boom lifting cylinder or Jib cylinder : Lift the concerned equipment (boom or jib) of approximately half way Extend the telescope to its maximum 60
• Telescoping cylinder : Lift the boom to its maximum angle and telescope approximately 50 cm (1969 in) 60
• If the difference between two measurements does not exceed 4 cm (1575 in) : the test validates correct operation 60
• If the difference between two measurements exceeds 4 cm (1575 in), contact HAULOTTE Services® or carry out the additional tests described below 60
Control cylinder by cylinder : 61
• Attach the body of the comparator on the cylinder rod 61
• The needle of the comparator must be in contact with the end of the casing of the cylinder 61
• The target is to measure the creep of the cylinder rod 61
43 – Major inspection 62
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 62
The criteria quoted above are applicable : 62
Check : 62
1 Pipe weld connection 62
2 Rod weld connection 62
3 Ring 62
4 Rod 62
5 Piston 62
General data 63
1 – Warning 63
2 – Risk prevention 63
Means of protection to be used when implementing the range 63
3 – You will need 63
4 – Test procedure 64
The brake system is a significant component of the safety of the machine The following tests must be performed periodically Section D – Inspection and maintenance schedule 64
High speed : 64
• On a flat ground or slightly inclined (always lower than the authorized slope: see plate manufacturer) 64
• Trace on the ground, a line being used as reference mark of stop 64
• Roll moving front until reaching maximum speed : 64
• Between 3 km/h (19 mph) and 6,5 km/h (4,039 mph) according to the machines 64
• Release the manipulator as soon as the wheels axles are on the level of the traced reference mark 64
• Stopped machine, measure the distance between the wheel axles and traced reference mark on the ground : 64
• If the distance lies between 02 m (0ft 8in) and 2,7 m (8 ft 11 in), the test is validated 64
• If not, Contact HAULOTTE Services® to repair the system 64
General data 65
1 – Metric torque chart 65
For screws HAULOTTE®, use columns ( A ), ( B ) and ( C ) : 65
• Screw ( 1 ) grey dull dry, use colums ( A ) 65
• Screw ( 1 ) grey dull greasy, use column ( B ) 65
• Screw ( 2 ) yellow dry, use column ( C ) 65
• Screw ( 2 ) yellow greasy, use column ( B ) 65
• Screw ( 3 ) grey bright dry, use column C 65
• Screw ( 3 ) grey bright greasy, use column ( B ) 65
2 – SAE fastener torque chart 66
3 – Hydraulic couplings and hoses tightening torque charts 67
Hydraulic fitting torque (Tolerance = 0 / +10%) 67
Hydraulic hose torque (Minimum / Maximum) 68
Hydraulics 69
1 – You will need 69
2 – Control and inspections 69
The state of hoses devices plays a significant role in the safety of the machines 69
Section D – Inspection and maintenance schedule : 69
• Check the absence of leakage to the junctions of the hoses 69
• Check that all the hoses are correctly tightened 69
• Check the absence of tear and crack of the external hoses 69
• Check that the shielding of the hose is not apparent 69
• Check the absence of chemical aggression of the membrane of the hose 69
If anomalies are noted, it is necessary to replace the elements by respecting the following recommendations 69
3 – Hoses Disassembling 69
For safety reasons, respect imperatively the following conditions of disassembling : 69
• Fold the machine on a flat and released ground : 69
• The machine is not in slope 69
• The boom is horizontal 69
• Put the turret (if equipped) in the axis 69
• Carry out a beaconing of the sector (maximum risk zone = machine height) 69
• Locate the hoses and their connections points to guarantee the good performance of the machine after intervention 69
• Locate the hoses course to facilitate the reassembly 69
To recover oil, use an oils container in order not to pollute the environment 69
After disassembling : 69
• Close the hose openings and the hydraulic components to avoid the pollution of the hydraulic system 69
• Check the cleanliness of the hoses and the hydraulic components : 69
• Absence of plastic, rubber or metal shaving 69
• If necessary, purge and clean the circuit (tank included) 69
4 – Hoses Reassembly 70
For safety reasons, respect imperatively the following conditions of reassembly : 70
• Using the reference marks carried out previously; carry out the courses of hoses 70
• During the fixing of the hoses, respect the tightening torques below 70
Tightening torque table 70
Once all the hoses are correctly tight : 70
• Put the machine in operational configuration 70
• Carry out some movements implementing the hoses concerned in order to purge the hydraulic system 70
• Check the absence of leakage 70
• Control the level of hydraulic oil tank 70
• Check the pressures 70
Electric 71
1 – You will need 71
Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt, chafed, corroded or pinched wires could result in unsafe operating conditions and may cause component damage 71
• Open the side covers 71
• Inspect the following areas for burnt, chafed, corroded and loose wires : 71
• Cable carrier cat track 71
• Engine wiring harness 71
• Hydraulic manifold wiring 71
• Gear ring rotation block 71
• Mast lowering emergency block 71
Mast 73
1 – You will need 73
2 – Level of knowledge required 73
It is important that the person performing the work on the machine knows all the relative safety information contained in the instruction manual 73
3 – Safety instructions 73
4 – Procedure 74
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 74
If the mast jams when being extended, increase the clearance 74
If the distribution of the wedges cannot be equivalent on each side of a tube, wedge the right and rear sides more according to the red dots on the diagram below 74
The maximum wedging authorised per pad is 2 mm 74
The pads must be attached with pre-coated CHC M6x20 screws and M6 contact washers 74
Fastening screw torque : 4 Nm 74
Chassis 75
1 – You will need 75
2 – Level of knowledge required 75
It is important that the person performing the work on the machine knows all the relative safety information contained in the instruction manual 75
3 – Safety instructions 75
4 – Preliminary operation 75
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 75
Respect, in addition to the instructions appearing in the present instructions, the legal tendencies generally applicable for safety accident prevention 75
All the precautions must be done in work before intervening on and near the machine 75
After completion of work, all the covers and safety devices must be positioned back completely and operational 75
5 – Removal 76
• Raise the telescoping mast upto 1,20 m(3 ft11 in) (Tube 1) 76
• Insert the safety prop ( 1 ) in the hole to lock the mast 76
• Steer the machine so the wheels are straight ahead 76
• Remove the central cover 76
• Remove the circlip from the rod end of the cylinder (fixed to the pivot), the washer and extract the pin 76
• Turn the steering towards the left side, to retract the steering cylinder 76
• Disconnect the 2 hoses from the cylinder, fit plugs and caps to the hose and cylinder 77
• Remove the circlip from the bore end (front left) of the cylinder, the washer and extract the pin 77
• Remove the cylinder 77
6 – Reinstall 78
• Install the bore end (front side) pivot pin, refit the washer and circlip 78
• Re-connect the hoses to the cylinder 78
• Operate the steering towards the right side, to align the cylinder with the pivot 78
• If you cannot align easliy with the pump, turn the wheels slightly by kicking them ir tapping with a soft hammer 78
• Install the rod end pin of the cylinder (fixed to the pivot), refit the washer and circlip 78
• Refit the top cover plate 78
• Remove the safety support and lower the mast 78
7 – Checks 78
• Switch the machine on 78
• Engage drive and steering Check there are no leaks or abnormal noises 78
Chassis 79
1 – You will need 79
2 – Level of knowledge required 79
It is important that the person performing the work on the machine knows all the relative safety information contained in the instruction manual 79
3 – Safety instructions 79
4 – Preliminary operation 79
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 79
Respect, in addition to the instructions appearing in the present instructions, the legal tendencies generally applicable for safety accident prevention 79
All the precautions must be done in work before intervening on and near the machine 79
After completion of work, all the covers and safety devices must be positioned back completely and operational 79
5 – Removal 80
Drive then lift the machine just for a brief moment, to put the potholes in a “mid way” position, between fully retracted and fully extended This is to remove any pressure from the pivot pins and make removal easier 80
• Open the battery trays on either side of the machine 80
• Remove the circlips and washers from the pivot pins at both ends and slide the cylinder off the pins 80
• Disconnect the hydraulic hoses, plug and cap the hoses and fittings 80
6 – Reinstall 80
• Reverse the above procedure 80
Chassis 81
1 – You will need 81
2 – Preliminary operation 81
For safety reasons, imperatively respect the following stages during the tests : 81
• To set up a beaconing of safety around the test area 81
• Put the machine in stowed position 81
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 81
Respect, in addition to the instructions appearing in the present instructions, the legal tendencies generally applicable for safety accident prevention 81
All the precautions must be done in work before intervening on and near the machine 81
After completion of work, all the covers and safety devices must be positioned back completely and operational 81
3 – Technical specifications 81
4 – Wheel and tires/tyres inspections 82
Replace the wheels and the tires if any of the following conditions exist : 82
• Presence of cracks, damage, deformation or other faults on the hub 82
• Damage to the tire : 82
• Cut or hole > 3 cm (2 in) in the rubber side wall 82
• Blister or pronounced lump on the external and lateral wall 82
• Damaged wheel stud 82
• Damage or wear on the side wall to the extent that the reinforcing wire is visible 82
• Consistent wear of the ground contact surface greater than 25% 82
• Check that the pin 2352101250 is present and in good condition – Replace as necessary 82
5 – Procedure of replacement 83
• Slightly lift the machine using a forklift 83
• Place a wooden spacer under the frame to support the machine after lifting off the ground 83
• Remove the pin ( 1 ), the wheel nut ( 2 ) and the flat washer(3) 83
• Remove the wheel 83
Reassembly of the wheel 84
• Use a new flat washer (2700500110) 85
• Use a new nut (4000503700) 85
1 Check that the shaft key is well positioned in the motor shaft 85
2 Mount the wheel on the motor shaft 85
3 Install the washer first then the nut 85
4 Tighten the wheel nut to the recommended torque : 250 Nm (184 ftlbs) 85
5 Add tightening until a groove of the nut is in coincidence with one hole of the shaft of the motoreducer 85
6 Insert the pin (2352101250) into its seating 85
7 Bend over the cotter pin legs to secure the nut 85
Hydraulics 87
1 – You will need 87
2 – Preliminary operation 87
For safety reasons, imperatively respect the following stages during the tests : 87
• To set up a beaconing of safety around the test area 87
• Put the machine in stowed position 87
• Use safety straps 87
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 87
Respect, in addition to the instructions appearing in the present instructions, the legal tendencies generally applicable for safety accident prevention 87
All the precautions must be done in work before intervening on and near the machine 87
After completion of work, all the covers and safety devices must be positioned back completely and operational 87
3 – Level control 87
Each day before use, check the hydraulic oil level to ensure safety operation 87
The oil level (1) must be between the upper and lower markers 87
Top up the oil level, if necessary : 87
1 Loosen and remove the tank cap (2) 87
2 Top up the oil level 87
3 Refit and tighten the tank cap (2) 87
4 – Replacement of hydraulic oil 88
The state of cleanliness of the oil filter cartouche is another indicator of purging of the system : 88
• Dismount the cartouche of the oil filter 88
• Check the absence of rubber, plastic or metal shaving 88
41 – Consumable 88
Use only oils whose features correspond to HAULOTTE® recommendations (Section C – Familiarization – Consumable) or contact HAULOTTE Services® 88
Not mix two different characteristics oils If necessary, purge and clean the circuit 88
42 – Filling 88
To fill the system correctly; respect the following stages : 88
Chassis – Mast 89
1 – You will need 89
2 – Preliminary operation 89
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 89
Respect, in addition to the instructions appearing in the present instructions, the legal tendencies generally applicable for safety accident prevention 89
All the precautions must be done in work before intervening on and near the machine 89
After completion of work, all the covers and safety devices must be positioned back completely and operational 89
3 – Lubrication 89
Steering cylinder 89
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 : 89
• Wheels aligned 89
Lift cylinder 90
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 : 90
• Store the machine with retracted mast 90
Ground control box 91
1 – You will need 91
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 91
2 – Simplified menus 91
3 – Detailed menus 93
31 – Screen access code settings104
311 – Screen 0d104
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 :104
Screen_Acces_code Username :104
Screen_Acces_level_x Username :105
Screen_Bad_code Username :105
Picking tray chain107
1 – You will need107
2 – Preliminary procedure107
All disassembly operations, if possible, must only be performed on equipment that has been completely deactivated and only by personnel with the necessary technical knowledge107
In addition to the safety precautions indicated in these instructions, follow all regulations concerning safety and accident prevention that are generally applicable107
Every precaution must be taken before working on or near the machine107
After work has been completed, all casings and safety devices must be restored completely and operational107
3 – Lubrication107
Section D Inspection and maintenance schedule The frequency of application depends on surrounding conditions and conditions of use The frequency of application must ensure that a sufficient quantity of fluid oil is present in the chain links107
If the chain has been exposed to corrosive fluids, clean the chain immediately and apply lubricant107
Before applying new lubricant, remove any foreign particles from the chain Use recommended lubricants Section B 1Recommendations-Lubrication diagram107
When cleaning chains, follow regulations concerning the environment107
4 – Check the condition of the chains108
• Check that the lifting chains and safety chains are clean108
• Check that there are no foreign particles on the chains and guide108
• Check that there are no signs of corrosion on chain elements108
Chains with any of the defects described below must be replaced108
• Check for elongation wear :108
• Elongation of up to 3 %, over 12 segments, of the original chain length is permitted108
• Measure the value of (3) using an appropriate method Compare with the value of ( 4 ) indicated in the table below108
• Check for external wear on rollers and links :108
• External wear must not measure more than 3 % from the section of the original link (2), see table above108
• Measure the value of (1) using an appropriate method108
• Check that no line or element is damaged or missing108
• Check that links are not distorted, deformed or broken108
• Check the connection points of links (the lines must be parallel)109
5 – Check the tension of the chains110
• Position the picking plate at the top without load110
• A “slack” strand ( A ) forms under the plate, between it and the bottom sprocket110
• Push (or pull) this slack strand without forcing it at a distance of 500 mm (+/- 5 mm) above the gearmotor support using a finger110
• Measure the minimal internal distance between the 2 chain strands110
• To reach this value, it is necessary to act on the 2 nuts ( 1 ) after having fully screwed in the locknuts ( 2 )111
• 111
• Move the picking plate up/down a few times to ensure that it is working correctly111
• Tighten the lock nuts2111
6 – Replacing the chains111
Section D Inspection and maintenance schedule111
Contact Haulotte Services for further advice111
Les chains and chain elements are made from case hardened steel in a high-quality process Deliver any scrap chains or chain elements to a dealer specialised in metal recycling in compliance with regulations111
Electric113
1 – You will need113
2 – Control113
1 Open battery compartments113
2 Loosen the caps located on the top of the battery113
The level of electrolyte in the battery must be approx 0,01 m(0 ft39 in) above the plates113
3 – Filling-up113
Loosen the caps located on the top of the battery113
If the level of electrolyte is below the level of the plates :113
1 Top up with distilled water113
2 Refit and tighten the battery caps113
4 – Battery charge114
Battery charger status114
Ground control box :114
The indicator (90) indicates charge status114
• Green indicator : Battery charged 100 %114
• Yellow LED : Battery charged 80 %114
• Red LED : Battery in initial charging phase114
Platform control box :114
The indicator (135) indicates charge status114
• Battery charged :114
• Flashing : Batteries have 40% charge left :114
• Constantly on : Batteries have only 20% charge left :114
When should the batteries be charged? :114
• Do not let the battery discharge to below 20 %114
• When the batteries are discharged to between 35 % and 80 % of their nominal capacity114
• If installing new batteries, recharge them after 3 or 4 hours of use 3 to 5 times114
• After a long period of non-use114
• Never leave the batteries discharged114
• Do not put off recharging the batteries in cold weather as the electrolyte may freeze114
How to charge the batteries ? :115
• Use the machine’s on-board charger The charger has a charge rate compatible to the battery capacity115
• Ensure that the mains supply is compatible to the charger’s consumption115
• Top up the batteries with distilled water to the minimum electrolyte level if any of the elements are below this minimum level115
• Work in a clean and well-ventilated area away from naked flames115
How to maintain battery autonomy ? :115
• Do not charge the batteries in cold temperatures115
• The battery life is reduced when the machine is used in cold temperatures (< 0 °C(32 °F) )115
• If the machine is not going to be used for a length of time, shut-off the power with battery isolation switch115
• Do not let the battery discharge to below 20 %115
• If batteries are deeply discharged (<10%); standard battery charger may not be enough to recharge battery115
Start-up is automatic as soon as the mains connection is established The charger is fitted with a LED indicator placed near the special holding frame :115
• Green indicator : Battery charged 100 %115
• Yellow LED : Battery charged 80 %115
• Red LED : Charger in the intitial charge phase115
When there is a fault, the LED indicator flashes in various colours depending on the type of alarm :116
In case of an alarm, the charger stops supplying power116
During charging :116
• The machine’s electric system is automatically deactivated while the external power supply is connected to the machine116
• Ensure that the battery are at a temperature not exceeding 45 °C(113 °F) (be careful in summer or in places with a high ambient temperature)116
• Do not remove or open the caps on the elements116
Charge interruption :116
• To turn off the charger, disconnect it from the mains supply116
• Should the machine need to be operated during a charging cycle, first diconnect the charger This may reduce the life span of the batteries Re-connect the charger once the operation is over116
After charging :116
• Top up the electrolyte level, if necessary116
• Avoid overflowing116
• Wash the top of the batteries without removing the caps116
• Dry with compressed air or clean cloths116
• Oil the terminals116
Battery charge status according to density and temperature117
Loss of capacity during prolonged storage118
Electrolyte freezing point according to the density of the acid and state of charge118
Turntable119
1 – You will need119
2 – Procedure119
Step 1 :119
• Disconnect the plug 2119
• Remove the caps on the plug119
Step 2 :119
• Pick up the pins in the plastic bag119
• Strip the wires of the tracker119
• Crimp the wires with the pins with a crimping clamp119
Step 3 :119
• Take the wedgelock off the plug119
• Thread the wires in the positions regarding the information119
Step 4 :120
• Put the wedgelock back on the plug to fix the pins120
Step 5 :120
• Reconnect the plugs120
• Mount the tracker120
• The tracking device is operational120
Chassis121
1 – Warning121
2 – Risk prevention121
Means of protection to be used when implementing the range121
3 – You will need122
4 – Check of tilt sensor122
• Put the machine in stowed position122
• Position the machine on an incline that is greater than the maximum permitted incline122
• Check that the tilt indicator is on ( 27)122
• Fit the platform and ensure that movement is off and the buzzer is triggered122
• Position the machine on a flat and firm surface, clear of obstructions (beware of power lines)122
• Mark out the work area (barriers, cones, marking tape)122
• Restrict access to the area (restricted access sign)122
• Switch off the ignition and remove the ignition key122
• Place a do not operate tag at the start/stop switch location to inform personnel that the equipment is being worked on122
• Position the electronic level under the chassis and note the values displayed on the X and Y axis123
• Check the X and Y axis :123
Axis X123
Axis Y123
• Turn on ignition key and start up engine123
• Compare the tilt values X and Y of the machine with an electronic level to those displayed on the screen Activ’ Screen123
• In the main menu select : Machine settings > Calibration > Tilt > Check of tilt sensor :124
• If the gap is > 0,5°, carry out a new calibration (Refer to MS0245 – Dismantling/Reassembling the Tilt Sensor)124
Chassis127
1 – Warning127
2 – Risk prevention127
Means of protection to be used when implementing the range127
3 – You will need128
4 – Dis-assembly128
• Position the machine on a flat and firm surface, clear of obstructions (beware of power lines)128
• Mark out the work area (barriers, cones, marking tape)128
• Restrict access to the area (restricted access sign)128
• Switch off the ignition and remove the ignition key128
• Place a do not operate tag at the start/stop switch location to inform personnel that the equipment is being worked on128
• Cut the COLSON tie holding the tilt cable129
• Unscrew the 2 fixing screws (1)129
5 – Reassembly129
• Reverse the above procedure129
• Tighten the brake nuts to a torque of 10 Nm then mark the screws with the sealing129
• Fasten the tilt cable with a COLSON tie onto the sleeve clamp129
• Carry out the calibration procedure(Refer to the illustrations below)129
6 – Calibration129
• On the Activ’Screen screen, enter the level 2 access code129
• Menu : Machine settings129
• Menu : Calibration130
• Menu : Slope sensor on flat ground130
7 – Additional operations132
• Position the machine on an incline that is greater than the maximum permitted incline132
• Fit the platform and ensure that movement is off and the buzzer is triggered132
• Check that the tilt values in X and Y displayed on the screen Activ’ Screen are identical to the current machine values (check using an electronic level on the chassis) +/-03°132
The position of the electronic tilt :132
Axis X132
Axis Y132
• Procedure to verify the tilt angle using the screen Activ’ Screen :132
• In the main menu select : Machine settings > Calibration > Tilt > Check of tilt sensor132
E134
Trouble shooting and diagram135
1 – Trouble shooting135
11 – Recommendations135
If a malfunction occurs, check the following points :135
If the malfunction persists, consult the troubleshooting table to identify the problem135
IF you cannot identify the problem, contact HAULOTTE Services®135
12 – Description135
The FAILURES function describes the requirements relative to failures : monitoring, information recording, information reading135
13 – Requirements135
14 – Failures list136
2 – Electric diagram148
Electricity part 4001016950 A – folio 01148
Variable speed drive part 4001016950 A – folio 02149
Variable speed drive part 4001016950 A – folio 03150
Cage part 4001016950 A – folio 04151
Option – Weighing system 4001016950 A – folio 05152
Option – Lithium battery 4001016950 A – folio 06153
3 – Hydraulic diagram154
F154
Records155
1 – Intervention register155
The intervention register keeps a record of maintenance and repair work carried out inside or outside the maintenance programme155

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