Haulotte STAR 8 Product guide

Maintenance book
STAR 8 - STAR 22J - STAR 10 - STAR 26J
4000414930 E 10.15 USA / GB
Maintenance book
STAR 8 - STAR 22J - STAR 10 - STAR 26J
USA

2 4000414930 E 10.15 USA / GB
STAR 8 - STAR 22J - STAR 10 - STAR 26J

3
CONTENTS
Maintenance book
CONTENTS
A
Preface -
Foreword
1 - Symbols and colors . . . . . . . . . . . . . . . . . . . . . . 8
B
Safety
1 - General safety rules . . . . . . . . . . . . . . . . . . . . . 11
1.1 - Maintenance implementation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 - Uncontrolled movement Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 - Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4 - Explosion / Fire Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 - Maintenance and repair training . . . . . . . . . . . 14
2.1 - Owner's responsability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 - Technician's responsability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 - HAULOTTE Services®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 - Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5 - Product modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6 - After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.7 - Product information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 - Manufacturer's warranty . . . . . . . . . . . . . . . . . 16
3.1 - Warranty acceptance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 - Warranty period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 - Conditions of warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 - Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4
Maintenance book
C
Familiarization
1 - Primary machine components . . . . . . . . . . . . 20
1.1 - Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2 - Ground control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.2 - ACTIV'Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3 - Platform control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 - Device layout . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.1 - Sensors and actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3 - Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4 - Ingredient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 - Hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5 - Lubrication diagram . . . . . . . . . . . . . . . . . . . . . 29
5.1 - Greasing points localization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6 - Machine specifications . . . . . . . . . . . . . . . . . . 31
6.1 - Movement speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
D
Inspection and
maintenance
schedule
1 - Maintenance Schedule. . . . . . . . . . . . . . . . . . . 33
2 - Inspection program . . . . . . . . . . . . . . . . . . . . . 37
3 - Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . 38
4 - Periodic inspection . . . . . . . . . . . . . . . . . . . . . 42
5 - Reinforced inspection . . . . . . . . . . . . . . . . . . . 44
6 - Major inspection . . . . . . . . . . . . . . . . . . . . . . . . 46

5
CONTENTS
Maintenance book
Machine sheet
MS0001 - Structural part inspection . . . . . . . . . . . . . . . 49
MS0002 - Pins and bearing inspection . . . . . . . . . . . . . 53
MS0003 -
Cylinder inspection . . . . . . . . . . . . . . . . . . . . 57
MS0004 -
Breaking test procedure . . . . . . . . . . . . . . . . 61
MS0005 - Torque Values . . . . . . . . . . . . . . . . . . . . . . . . 63
MS0010 -
Slew ring inspection . . . . . . . . . . . . . . . . . . . 67
MS0012 -
Condition of the cables inspection - Criteria of
replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
73
MS0020 -
Hoses inspection - Replacement . . . . . . . . . 77
MS0059 - Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . 79
MS0042 -
Inspection of the condition of the chains -
Criteria of replacement . . . . . . . . . . . . . . . . . . . . . . . .
81
MS0044 -
Tires (Tyres) and pressures - Wheel
replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85
MS0045 -
Lubrication - Jib cylinder - Steering cylinder -
Lift cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89
MS0046 -
Dismantling / Reassembling wheels reducer 93
MS0047 -
Replacing the wheel pivot. . . . . . . . . . . . . . . 99
MS0048 - Steering cylinder replacement . . . . . . . . . . 109
MS0049 -
Hydraulic oil - Level Replacement . . . . . . . 113
MS0050 -
Hydraulic filter cartridge Replacement . . . 115
MS0051 - Battery (ies) . . . . . . . . . . . . . . . . . . . . . . . . . 117
MS0052 -
Battery (ies) . . . . . . . . . . . . . . . . . . . . . . . . . 125
MS0053 -
Return cables . . . . . . . . . . . . . . . . . . . . . . . . 129
MS0054 - Specific adjustment procedure STAR 8 -
STAR 20J - STAR 10 - STAR 26J . . . . . . . . . . . . . . . 131
MS0061 - Tube wedging procedure . . . . . . . . . . . . . . 137
MS0062 -
Inspection of the slack chain sensors . . . . 139
MS0085 -
Overriding function reset . . . . . . . . . . . . . . 145

6
Maintenance book
E
Trouble
shooting and
diagram
1 - Trouble shooting . . . . . . . . . . . . . . . . . . . . . . 149
1.1 - Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.2 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.3 - Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2 - Electric diagram . . . . . . . . . . . . . . . . . . . . . . . 156
3 - Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . 159
F
Records
1 - Intervention register. . . . . . . . . . . . . . . . . . . . 161

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A - Preface - Foreword
Preface - Foreword
You have just purchased a HAULOTTE® product and we would like to thank you for your business.
The Aerial Work Platform is a mechanical device primarily designed and manufactured with the intent to position people
with the necessary tools and material to overhead elevated temporary workplaces. All other uses or alterations/modifi-
cations to the aerial work platform must be approved by HAULOTTE®.
This manual shall be considered a permanent component of the machine and shall be kept with the aerial work platform
in the designated Manual Holder, at all times.
Safe operation of this product can only be assured if you follow the operating instructions contained in this manual are
followed. To ensure proper and safe use of this equipment, it is strongly recommended that only trained and authorized
personnel operate and maintain the aerial work platform.
We would particularly like to draw your attention to 2 essential points :
Compliance with safety instruction (machine, use, environment).
Use of the equipment within the performance limits.
With regard to the designation of our equipment, we stress that this is purely for commercial purposes and not to be con-
fused with the technical specifications. Only the specifications in this manual should be used to study the suitability of
the equipment for the intended use.
This maintenance and repairs book is specific to the HAULOTTE® products listed on the cover page of this manual. The
maintenance book is intended for the on-site maintenance technician.
It is the on-site maintenance technician's duty to carry out the regular maintenance work recommended by HAULOTTE
Services®.
This maintenance work is essential for correct machine operation.
If regular maintenance is not carried out, this may :
Void the warranty.
Cause machine malfunction.
Reduce machine reliability and shorten its service life.
Jeopardize operator safety.
To ensure that the regular maintenance requirements are fully satisfied, contact HAULOTTE Services®.
HAULOTTE Services® technicians are specially trained to carry out extensive repairs, interventions or adjustments on
the safety systems or elements of HAULOTTE® machines. They carry genuine HAULOTTE spare parts and tools as
required, and also provide fully documented reports on all work completed.

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A - Preface - Foreword
1 - Symbols and colors
Symbols and colors are used to alert the operator of safety precautions and/or to highlight important safety
information.
The following safety symbols are used throughout this manual to indicate specific hazards and the hazard
severity level when operating or maintaining the Aerial Work Platform.
Symbol
Symbol Description
Danger : Risk of injury or death
Caution : Risk of material damage
Prohibition relating to work safety and quality
Reminder to use good practice or follow pre-operation checks
Cross-reference to another part of the manual
Cross-reference to another manual
Cross-reference to repair (contact HAULOTTE Services®)
Maintenance sheet
Time required for intervention
Recommended tools
Recommended part
Safety
N.B. : Additional technical information

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A - Preface - Foreword
Decals
N.B.-:-THE FOLLOWING SAFETY ADVISORIES ARE USED THROUGHOUT THIS MANUAL TO INDICATE SPECIFIC
HAZARDS WHEN OPERATING OR MAINTAINING THE MACHINE.
Color Title Description
Danger : Indicates a hazardous situation which if not avoided,
WILL result in death or serious injury.
Warning : Indicates a hazardous situation which if not avoided,
COULD result in death or serious injury.
Caution : Failure to comply could result in minor or moderate
injury.
Notice : Indicates practices not related to personal injury.
Procedure : Indicates a maintenance operation.

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A - Preface - Foreword
Notes

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B - Safety
Safety
1 - General safety rules
1.1 - MAINTENANCE IMPLEMENTATION
Your safety and the safety of the people around are essential.
Make sure the work area is clean in order to not to pollute the system of the machine.
Before performing any maintenance interventions, place the machine in maintenance configuration.
1. Place the machine on firm, level ground.
2. Stow the machine completely.
3. Push the E-stop push-button to cut off the electricity supply.
Never leave the hydraulic cylinders fully extended or retracted before switching off the machine, or when
stationary for an extended period of time. Keep the elements of the machine in configuration of
maintenance thanks to mechanics devices.
Report that the machine is under maintenance by tagging the platform and ground control boxes.
Note :
• Using the machine during maintenance is strictly forbidden.
• Do not climb onto the covers.
• The handling of parts must be carried out using appropriate equipment (Chains, Lifting slings, Lifting
anchors).
• Plug the end of any hoses removed, and cap any open ports to prevent contamination during
maintenance.
1. Pull the E-stop button.
1.2 - UNCONTROLLED MOVEMENT HAZARD
Be aware of uncontrolled movement and always respect the following :
• Maintain clearance from high voltage lines.
• Maintain clearance from generators, radar, electromagnetic fields.
• Never expose the batteries or electrical components to water (high pressure washer, rain).
• Never tow the machine over extended distances.
• In case of a machine breakdown, it is possible to tow short distance to load it onto a trailer.
• Never leave the hydraulic cylinders fully extended or retracted before switching off the machine, or
when stationary for an extended period of time.
• Fold the machine with the mast fully retracted and lowered and the jib aligned.
• Select a safe parking location, on a firm level surface, clear of obstruction and traffic.
• Ensure all compartments are closed and secured.
• Chock the wheels.

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B - Safety
1.3 - ELECTROCUTION HAZARDS
The machine is not electrically insulated and does not provide protection from contact or proximity to
electrically charged conductors.
Always position the lift at a safe distance from electrically charged conductors to ensure that no part of
the machine is within an unsafe area.
Respect the local rules and the minimum safety distance from power lines.
Minimum safe approach distances
N.B.-:-THIS TABLE IS APPLICABLE, EXCEPT WHEN THE LOCAL REGULATIONS ARE MORE STRICT.
Electric voltage Minimum safety distance
Mètre Feet
0 - 300 V Avoid contact
300 V - 50 kV 310
50 - 200 kV 515
200 - 350 kV 620
350 - 500 kV 825
500 - 750 kV 11 35
750 - 1000 kV 14 45
Do not operate the machine :
• Do not operate the machine when close to live power lines, consider the
movement of the machine and the sway of the electric power lines particularly in
windy conditions.
• Do not operate the machine during lightning, thunderstorms, snow/ice or any
weather condition that could compromise operator safety.
• Do not operate the machine during lightning or storms.
• Do not use the machine as a welding earth.
• Do not wash electrical components with a high pressure washer.
• Do not weld on the machine without first disconnecting the battery terminals.
• The machine must not be used while charging the batteries.
• When using the platform AC power line, ensure it is protected with a circuit
breaker.
Keep away from the machine if it contacts energized power lines. Personnel on the
ground or in the platform must not touch or operate the machine until energized
power lines are shut off.
In the event of accidental contact with a high voltage line, wait for the power to the
line be de-energized before attempting to operate the machine.

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B - Safety
1.4 - EXPLOSION / FIRE HAZARDS
Always wear protective clothing and eye wear when working with
batteries and power sources/systems.
N.B.-:-ACID IS NEUTRALIZED WITH SODIUM BICARBONATE AND WATER.
• Do not start the engine if you smell or detect liquid propane gas
(LPG), gasoline, diesel fuel or other explosive substances.
• Do not work in an explosive or flammable atmosphere / environment.
• Do not touch hot components.
• Do not bridge the battery terminals with metallic objects.
• Do not service the battery in proximity of spark, open flame, lit
cigarettes.

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B - Safety
2 - Maintenance and repair training
2.1 - OWNER'S RESPONSABILITY
The owner (or hirer) has the obligation to inform technician of the instructions contained in the Operator
Manual and Maintenance Book.
The owner (or hirer) has the obligation to renew all manuals or decals that are either missing or in bad
condition.
Additional copies can be ordered from HAULOTTE Services®.
The owner (or hirer) is responsible for applying the local regulations regarding maintenance of the
machine.
2.2 - TECHNICIAN'S RESPONSABILITY
The technician must read and understand the contents of this manual, operators manuals and the
decals affixed on the machine.
The technician must inform the owner (or hirer) if the manual or any decals are missing or in poor
condition, and of any malfunction of the machine.
2.3 - HAULOTTE SERVICES®
The HAULOTTE Group is at your service in all 5 continents of the world via an extensive network of
its own factory trained technicians, who are ready to respond to your every need.
2.4 - TRAINING
Whether you want to just service your equipment or carry out a complete overhaul, HAULOTTE® can
provide you with a structured training program or we can tailor a program to suit your specific
requirements or circumstances. Training can cover the general operation of the equipment,
breakdowns, engine maintenance and repairs and electrical/hydraulic/mechanical repairs and trouble
shooting.
Only authorized and qualified operators may operate HAULOTTE® machines.

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B - Safety
2.5 - PRODUCT MODIFICATION
In a constant effort to improve the quality of machines, HAULOTTE Group continually monitors
technical improvements that enable to develop products with improved safety and greater reliability.
The target being that HAULOTTE® always work to build confidence in the relationships with our
customers.
These improvements will be shared via the following documents :
• OI : Obligatory Intervention, Safety information requiring immediate action (take into account
by HAULOTTE®).
• NI : Technical improvement requiring immediate action (take into account by HAULOTTE®).
• RI : Improvement proposed to customers to take into account during maintenance operation.
• PI : Product information for knowledge.
2.6 - AFTER SALES SERVICE
Our HAULOTTE Services® After Sales Service is at your disposal throughout your machine's service
life to ensure the optimum use of your HAULOTTE product :
• When contacting our After Sales Service, ensure that you provide the machine model and serial
number.
• When ordering any consumables or spare parts, please use this manual and the HAULOTTE®
Essential catalogue to receive your genuine HAULOTTE® spare parts, your only guarantee of parts
interchangeability and correct machine operation.
• If there is an equipment malfunction involving a HAULOTTE® product, then contact HAULOTTE
Services® immediately even if the malfunction does not involve material and/or bodily damage.
2.7 - PRODUCT INFORMATION
Without the written permission from Haulotte, modifying a HAULOTTE® product is a Safety concern.
Any modification may violate Haulotte design parameters, government regulations and industry
standards.
If you desire a modification to the product, submit a request in writing to HAULOTTE Group.
With the utmost care to ensure enhanced reliability and greater safety of the HAULOTTE® products, it
is pertinent that when a "Service or Safety Bulletin" is issued, action is taken immediately. Once the
bulletin has been addressed, make sure that the completed form is submitted to HAULOTTE Services®.
Do not hesitate to contact HAULOTTE Services® , should you have any questions relating to the issued
bulletin(s) or with questions on the policy itself.

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B - Safety
3 - Manufacturer's warranty
3.1 - WARRANTY ACCEPTANCE
On reception of his machine, the owner or rental company must check the machine's condition and fill
out the machine reception slip provided.
3.2 - WARRANTY PERIOD
The present warranty is valid for a period of 12 months or up to a maximum of 1000 operating hours for
lifting and handling equipment and 2000 operating hours for public works machinery, starting from
delivery and terminating when the first limit is reached.
Spare parts are covered by a 6 month warranty.
3.3 - CONDITIONS OF WARRANTY
HAULOTTE® guarantees its products against defects, faults or manufacturing defects when the owner
or rental company has informed HAULOTTE® of the defect.
The warranty does not cover the consequences of normal wear, nor any defects, failure or damage
resulting from poor maintenance or abnormal usage, in particular overloading, impact by an external
source, faulty installation or any modification made to products marketed by HAULOTTE® and
performed by the owner or rental company.
In the event of operation or use which does not comply with the instructions or recommendations in the
maintenance book, warranty claims will not be accepted.
The machine utilisation period must be recorded by reading the engine hour meter whenever an
intervention is made. The engine hour meter must be maintained in good working order to guarantee
maximum working life and to justify maintenance at the recommended time.
Warranty obligations for the time period stated above will cease immediately in situations where the
defect is due to the following reasons :
• Use of spare parts that are not HAULOTTE® originals.
• If elements or products other than those recommended by the manufacturer are used.
• If the HAULOTTE® name, serial numbers or identification marks are removed or altered.
• After an unreasonably long delay before reporting a manufacturing problem.
• If the owner or rental company continues to use the machine despite problems.
• 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.
If no particular agreement has been made, any claims made after the previously established warranty
period has expired will be refused.

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B - Safety
The present warranty does not cover damage that may result directly or indirectly from any flaws or
defects covered by the latter :
• Consumables : No claims will be accepted for objects or parts replaced in the context of normal
machine usage.
• Settings : Adjustments of all sorts may become necessary at any time. Therefore adjustments are
considered a part of normal machine usage conditions and are not covered by the warranty.
• Hydraulic and fuel circuit contamination : Every possible precaution is taken to ensure that fuel and
hydraulic liquid delivered is clean. On the other hand, in certain cases it is possible to contaminate fuel
and hydraulic circuits, especially when fuel and lubricants are stored on the work site. Moreover,
irregular or poor cleaning of the decanting device may also cause fuel/hydraulic circuit contamination
and therefore damage the parts in direct contact with these liquids. 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.
• Wearing parts (pads, bearings, tires/tyres, connections, etc.) : These parts are, by definition, subject
to deterioration during the period of operation. Wearing parts will therefore not be covered by the
warranty agreement.
3.4 - WARRANTY CONDITIONS
To benefit from the warranty, the owner or rental company must inform the nearest HAULOTTE®
subsidiary or the subsidiary that delivered the machine (the only dealer authorised to carry out an
intervention under the manufacturer's warranty agreement) of the defect in writing as quickly as
possible.
The subsidiary will decide whether to repair or replace the part that proves to be faulty.
The owner or rental company must present the duly completed maintenance book supplied with the
machine as proof that the maintenance operations recommended by the manufacturer have been
carried out.
The owner or rental company must ensure that the defect covered by the HAULOTTE® warranty is
reported to and acknowledged by the HAULOTTE® subsidiary the only dealer authorised to carry out
work covered by the warranty) as rapidly as possible or must report the defect in writing.
Work carried out under the HAULOTTE® warranty will be performed by the subsidiary which delivered
the machine, wherever possible.

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B - Safety
Notes

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C - Familiarization
Notes
Familiarization

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C - Familiarization
1 - Primary machine components
1.1 - LAYOUT
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