CE MATS ANG E10.07

Maintenance book
TELESCOPIC MASTS
Maintenance book
TELESCOPIC MASTS
STAR 6 (STAR 13) - STAR 8NG
(STAR 22J) - STAR 9 - STAR 10NG
(STAR 26J) - STAR 11 - STAR 12 EN
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Telescopic masts
2 24203 3352 0 E 10 07 EN
Maintenance book
CONTENTS
1 - Maintenance book . . . . . . . . . . . . . . . . . . . . . . . 5
2 - After Sales Service . . . . . . . . . . . . . . . . . . . . . . . 5
3 - Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
A
SAFETY PRECAUTIONS
1 - Recommendations . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 - Maintenance book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 - Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 - Label colours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 - Manufacturer's warranty . . . . . . . . . . . . . . . . . 10
2.1 - Warranty acceptance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 - Warranty period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 - Conditions of warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 - Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 - Scope of intervention . . . . . . . . . . . . . . . . . . . . 12
4 - Instructions for intervention . . . . . . . . . . . . . . 13
B
CONTENTS
RECOMMENDATIONS
1 - Lubrication diagram . . . . . . . . . . . . . . . . . . . . . 15
2 - Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3 - Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 - Classification plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1.1 - Red labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1.2 - Orange labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1.3 - Yellow labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.1.4 - Other labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.1.5 - Green labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2 - Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
C
MAINTENANCE
1 - General programme . . . . . . . . . . . . . . . . . . . . . 39
2 - Detailed programme . . . . . . . . . . . . . . . . . . . . . 45
3 - Maintenance sheets . . . . . . . . . . . . . . . . . . . . 126
3.1 - Placing in maintenance configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.2 - Placing in operating configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
E001 - Oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
E003 - Hydraulic filter cartridge . . . . . . . . . . . . . . 129
E005 - Rotation crown gear. . . . . . . . . . . . . . . . . . 131
E006 - Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
E007 - Screws, bolts and nuts . . . . . . . . . . . . . . . 139
3
Maintenance book
E010 - Steering wheel pivots . . . . . . . . . . . . . . . . 141

E016 - Cables and chains . . . . . . . . . . . . . . . . . . . 143
E027 - Return cables . . . . . . . . . . . . . . . . . . . . . . . 145
E028 - Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
E029 - Traction battery . . . . . . . . . . . . . . . . . . . . . 149
D
DIAGNOSIS ASSISTANCE
1 - Recommendations . . . . . . . . . . . . . . . . . . . . . 155
2 - Finding the failure . . . . . . . . . . . . . . . . . . . . . 156
E
ELECTRIC CIRCUIT
1 - Wiring diagramMain components . . . . . . . . . 165
2 - Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3 - Relays and terminals . . . . . . . . . . . . . . . . . . . 167
4 - Locations and functions of the main safety
features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
5 - Buzzers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
6 - LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
F
HYDRAULIC CIRCUIT
1 - Hydraulic diagramMain components . . . . . . 171
2 - Solenoid valves . . . . . . . . . . . . . . . . . . . . . . . 171
G
INTERVENTION LOG
1 - Intervention log. . . . . . . . . . . . . . . . . . . . . . . . 175
4
Telescopic masts
You have just bought a HAULOTTE® telescopic
handler and we would like to thank you for your
trust.
1 - Maintenance book
As indicated on the delivery slip, this maintenance book is part of the documents in our on-board case
supplied on delivery of your machine.
In order to guarantee you full satisfaction, you must scrupulously follow the operating instructions
contained in this manual. The life time of your machine depends upon it.
We would like to draw your attention in particular to 2 essential points :
• Compliance with the safety precautions (machine, operation, environment).
• Use within the equipment performance limits.
2 - After Sales Service

Our HAULOTTE Services® After Sales Service is completely at your disposal during and beyond the
warranty period to provide the service you require.
• Contact our After Sales Service, specifying the exact machine type and its serial number.
• When ordering any consumables or spare parts, please use this manual and the Haulotte Essential
catalogue to receive original spare parts, the only guarantee of interchangeability and perfect
operation.
• In the event of malfunctions or incidents involving a HAULOTTE® machine, contact HAULOTTE
Services® immediately even if no material or bodily damage is observed and we will intervene as
soon as possible.
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Telescopic masts
3 - Conformity
We remind you that HAULOTTE® machines comply with the provisions of the directives currently
applicable to this type of machine.
Any modification without having obtained written authorization from HAULOTTE®, renders this
conformity null.
HAULOTTE® cannot be held liable for the technical specifications contained in this manual.
HAULOTTE® reserves the right to make improvements or modifications to the machine without
modifying this manual.
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A - Safety precautions
A
Safety precautions
1 - Recommendations B
1.1 - MAINTENANCE BOOK
The maintenance book is intended for the on-site maintenance technician.
It is the duty of the on-site maintenance technician to carry out the regular maintenance work
C
recommended by HAULOTTE Services®.
This maintenance work is essential for correct machine operation.
If regular maintenance work is not carried out this may :

• Invalidate the warranty. D
• Cause machine malfunction.
• Reduce machine reliability and shorten its lifetime.
• Cause operator safety problems.
To ensure that the regular maintenance requirements are fully satisfied, contact HAULOTTE
Services®.
E
HAULOTTE Services® technicians are specially trained to the requirements of our machines
and have genuine spare parts, all the necessary documentation and tools required.
24203 3352 0 E 10 07 EN 7
Telescopic masts
1.2 - SYMBOLS USED
Symbols are used to alert the operator of the safety precautions or to highlight practical
information.
S y m b o l m e a n i n g s
Symbol Meaning
Danger : Risk of injury or death (work safety)
Caution : Risk of material damage (work quality)
Prohibition relating to work safety and quality
Reminder : No identified risk but a reminder of common sense, good

practice or pre-action prerequisites
Cross-reference to another part of the manual (see section or sheet)
Cross-reference to another manual (see manual)
Cross-reference to repairs (contact HAULOTTE Services®)
Maintenance sheet
Time required for intervention
Recommended tools
Recommended part
Safety
N.B. : Additional technical information
8 24203 3352 0 E 10 07 EN
Telescopic masts
A
1.3 - LABEL COLOURS
The potential dangers and specific regulations are indicated on the machine by labels and
identification plates.
B
The labels must be kept in good condition. Additional labels can be obtained from HAULOTTE Services®.
L a b e l
Familiarize yourself with the labels and their respective color codes.
c o l o r c o d e - C E - A S
C
Labels Color Meaning
Red Potentially fatal danger
Orange Risk of serious injury

D
Yellow Risk of material damage and/or minor injury
Other Additional technical information E

L a b e l c o l o r c o d e - A N S I - C S A
Labels Color Meaning

F
Red Potentially fatal danger
Orange Risk of serious injury
Yellow Risk of material damage and/or minor injury G

Other Additional technical information
Green CSA maintenance operation or information

H
24203 3352 0 E 10 07 EN 9
Telescopic masts
2 - Manufacturer's warranty
2.1 - WARRANTY ACCEPTANCE
On reception of his machine, the owner or rental company must check the condition of the
machine and fill out the machine reception slip provided.
2.2 - WARRANTY PERIOD
The present warranty is granted for a period of 12 months or a limit of 1000 hours for lifting and
handling equipment and 2000 hours for public works machinery, to run from delivery and
terminating with the first term to be reached.
Spare parts are covered by a 6 month warranty.
2.3 - CONDITIONS OF WARRANTY
HAULOTTE® guarantees its products against defects, faults or constructional 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 case of operation or use which does not comply with the instructions or recommendations
in this maintenance book, claims will not be accepted.
The machine utilisation period must be recorded by reading the engine hour meter each time
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 which 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 in spite of problems.
• If damage is caused by modifications which do not comply with HAULOTTE® specifications.
• If lubricants, hydraulic oils or fuels are used which do not comply with HAULOTTE®
recommendations.
• If the machine is incorrectly repaired or used by the customer or in case of an accident caused by a
third party.
10 24203 3352 0 E 10 07 EN
Telescopic masts
A
If no particular agreement has been made, any claims made after the warranty period
previously established has expired will be refused..
The present warranty does not cover damage which may result directly or indirectly from any
flaws or defects covered by the latter.
B
The present warranty does not cover damage which 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 usage
of the machine.
• Adjustments : Adjustments of all sorts may become necessary at any moment. This means that
C
adjustments are 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 imperfect cleaning of the decanting device may also cause fuel circuit contamination and
therefore damage the parts in direct contact with the fuel. HAULOTTE® will not accept any claims
D
concerning cleaning of the fuel circuit, filter, injection pump or any other equipment in direct contact
with fuel or lubricants.
• Wearing parts (pads, rings, tyres, connections, etc) : These pieces are, by definition, subject to
deterioration during the period of use. Wearing parts will therefore not be covered by the warranty
agreement.
E
2.4 - WARRANTY CONDITIONS
To benefit from the present warranty, the owner or rental company must inform the nearest
HAULOTTE® branch or the branch which delivered the machine (the only dealer authorised
to carry out an intervention under the manufacturer's warranty agreement)of the defect in F
writing and as rapidly as possible.
The branch will decide whether to repair or replace the part which proves to be faulty.
The owner or rental company will present the maintenance book supplied with the machine,
duly completed as proof that the maintenance operations recommended by the manufacturer
have indeed been carried out.
G
The owner or rental company must ensure that the defect covered by the HAULOTTE®
warranty is acknowledged by the HAULOTTE® branch (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 branch which
participated in delivery of the machine, wherever possible.
H
24203 3352 0 E 10 07 EN 11
Telescopic masts
3 - Scope of intervention
The inspection and maintenance table identifies the role and the responsibilities of each party in regular
machine maintenance.
If the machine is operated in a hostile environment or intensively, increase the frequency of maintenance.
I n s p e c t i o n s a n d m a i n t e n a n c e
Type of Reference
Frequency Person-in-charge Intervenor
intervention document
Before each delivery
Pre-delivery Qualified HAULOTTE
of sold, hired or Owner (or hirer) Operator manual
inspection Services® technician
resold equipment
Before operation or
Pre-operation
when the operator Operator Operator Operator manual
inspection
changes
At the specified On-site technician or
Regular preventive
intervals (250 h or 1 Owner (or hirer) qualified HAULOTTE Maintenance book
maintenance
year) Services® technician
Organization or
technician approved
2 times a year or at
by the employer or by
the latest 6 months
the intermediary
after the last regular
Regular visit Owner (or hirer) of HAULOTTE Maintenance book
visit, and according
Services® in
to the local
accordance with
regulations
the HAULOTTE
Services® contract
12 24203 3352 0 E 10 07 EN
Telescopic masts
A
4 - Instructions for intervention
Do not use the machine during maintenance work.
B
For any intervention on the power sources, wear glasses and protective clothes (acid spray).
N.B.-:-ACID IS NEUTRALISED WITH SODIUM BICARBONATE AND WATER. C

Never operate the machine in the following situations :
• Do not work in an explosive or inflammable ambience (spark, flame, etc.).
• Do not touch the hot parts of the motorization system (engine, filters, etc.).
• Do not use a tool to make contact between the battery terminals.
• Do not manipulate the battery close to a spark, flame, glowing tobacco (emission of gas).
D
• Never expose the batteries or electrical components to water (pressure cleaner, rain).
• Never neutralize the securities.
• Do not climb on the hoods.
• Do not fill up the fuel tank, when the engine is running and/or close to a naked flame.
E
Use a recipient to collect oil to avoid polluting the environment.
24203 3352 0 E 10 07 EN 13
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14 24203 3352 0 E 10 07 EN
Telescopic masts
B - Recommendations
A
Recommendations
1 - Lubrication diagram B
D i a g r a m S T A R 6 ( S T A R 1 3 )
3 3 D
9 4 4 9
D i a g r a m S T A R 8 ( S T A R 2 2 J ) - S T A R 9 - S T A R 1 0
( S T A R 2 6 J ) - S T A R 1 1 - S T A R 1 2
9
E
3 F
4
Seulement pour
STAR8-10
Only for STAR22-26J
3 G
5 6 6 4
Excepté pour
STAR8-10
Except for STAR22-26J
24203 3352 0 E 10 07 EN 15
Telescopic masts
B - Recommendations
L i s t o f i n g r e d i e n t s
HAULOTTE®
Marking Ingredient Symbol
code
Engine oil - Can 20 l (5,3 gal US) 2420801360
1 Engine oil - Barrel 209 l (55,2 gal US) 2420801350
Engine oil ( +30° / -20°) 2820305670
Box oil - Can 20 l (5,3 gal US) 2420801370
2
Box oil - Barrel 209 l (55,2 gal US) 2420801380
Hydraulic oil (Standard) - Barrel 209 l (55,2 gal US) 2420801310
3
Hydraulic oil (Winter option) 2505002640
4 Biological hydraulic oil - Barrel 209 l (55,2 gal US) 2820304310
5 Lithium exteme pressure grease 2820304320
Lead-free grease - Aerosol 0,4 l (0.1 gal US) 2820304330

6
Lead-free grease - Can 5 l (1,32 gal US) 2820304340
7 Molybdenum grease
8 Oil
9 High pressure lubricant
2 - Consumables
L i s t o f c o n s u m a b l e s
HAULOTTE®
Consumable Applicability
code
• STAR 8 (STAR 22J)
Hydraulic filter cartridge 2505000970
• STAR 10 (STAR 26J)
16 24203 3352 0 E 10 07 EN
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B - Recommendations
A
3 - Labels
3.1 - CLASSIFICATION PLAN
B
3.1.1 - Red labels
The red labels indicate a potentially fatal danger.

C
C o m m o n l a b e l s
R7 R3 R5 R8 R21 R31
S p e c i f i c l a b e l s S T A R 6 ( S T A R 1 3 ) E
R1 R9 R2 R39
24203 3352 0 E 10 07 EN 17
Telescopic masts
B - Recommendations
S p e c i f i c l a b e l s S T A R 8 ( S T A R 2 2 J )
R1 R9 R4 R30
R32
S p e c i f i c l a b e l s S T A R 9
R1 R4 R30 R33
18 24203 3352 0 E 10 07 EN
Telescopic masts
B - Recommendations
A
S p e c i f i c l a b e l s S T A R 1 0 ( S T A R 2 6 J )
R1 R4 R30
B
R32 R9
C
D
S p e c i f i c l a b e l s S T A R 1 1
R1 R4 R30 R33
E
F
S p e c i f i c l a b e l s S T A R 1 2
R1 R4 R30 R33
G
24203 3352 0 E 10 07 EN 19
Telescopic masts
B - Recommendations
3.1.2 - Orange labels
The orange labels indicate a risk of serious injury.
O1 O4 O5
O1 O4 O5
O1 O4 O5
20 24203 3352 0 E 10 07 EN
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B - Recommendations
A
3.1.3 - Yellow labels
The yellow labels indicate a risk of material damage and/or minor injury. B
J3 J10
a
D
S p e c i f i c l a b e l s S T A R 6 ( S T A R 1 3 )
J6 J22 J23 E
+
24203 3352 0 E 10 07 EN 21
Telescopic masts
B - Recommendations
S p e c i f i c l a b e l s S T A R 8 ( S T A R 2 2 J ) - S T A R 9 - S T A R
1 0 ( S T A R 2 6 J ) - S T A R 1 1 - S T A R 1 2
J4 J13 J14 J15
J23 J24
3.1.4 - Other labels
The other labels provide additional technical information.
A1 A5 A8 A32
A1 A1
A16
A9
T OP
S
START
A3
A2 A2 A11 A12
A4
A2
Battery Level
100%
80% 80%
START
S
T OP
A7 A15
0
1 2
7813 744 a 7813 743 a
S p e c i f i c l a b e l s S T A R 9 - S T A R 1 1 - S T A R 1 2
A53 A54
22 24203 3352 0 E 10 07 EN
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B - Recommendations
A
S p e c i f i c l a b e l s A S
R16 R22 R15 R19

B
S p e c i f i c l a b e l s A N S I
C
A22 O3 A35 A30
D
S p e c i f i c l a b e l s A N S I : S T A R 6 ( S T A R 1 3 )
A23 A27
A4
E
S p e c i f i c l a b e l s A N S I : S T A R 8 ( S T A R 2 2 J )
A23 A29 A32 F

A27
A34
G
S p e c i f i c l a b e l s o p t i o n
A8
H
24203 3352 0 E 10 07 EN 23
Telescopic masts
B - Recommendations
3.1.5 - Green labels
Green labels provide maintenance operation or information( CSA standard).
3.2 - IDENTIFICATION
L o c a l i z a t i o n : S T A R 6 ( S T A R 1 3 ) - C E
R31 A1 A12 A11 A11 A12 R1 J10 J4 O1
R22 R15 Only for Australia

R2
R3 Only for Australia
R2
R7
R39
A3
A7
J22
A16
A16 A5
J3
J3
R2
R9
R31 R21
A5 A8 - A9
R16 J6
Only for Australia
O4
R9 O4 R16 Only for Australia
O5 A4 O5 R31 R9 J23 O5 A4 O5 A2 R9 O4 R16 R19 Only for Australia
R16 Only for Australia
Only for Australia
24 24203 3352 0 E 10 07 EN
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B - Recommendations
A
L o c a l i z a t i o n : S T A R 8 ( S T A R 2 2 J ) - S T A R 9 - S T A R
1 0 ( S T A R 2 6 J ) - S T A R 1 1 - S T A R 1 2 - C E
Only for Star9 A54

R5
Only for Star8
Star10
A32 R31 R1
R15Only for Australia
B
Star11-Star12
A53
R33 Only for Star9
Star11-Star12
J4
A15
O1
R4
A2
A7
C
J3 A5
R3
R8
A16
R9 R1 J13 O5
O5 R5 J15 R9 A11
A3
O4 J23 J3
R16 O4 R7
J14
R30
J24
Only for Australia
J10
D
A1
A15
A32
E
J3
O4
R16
F
Only for Australia
R19
Only for Australia
A16 J24 O5 R3 R9 O4 A5
R30 R9 A8 - A9 O5 A12 R4 R21
G
R16
Only for Australia
24203 3352 0 E 10 07 EN 25
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B - Recommendations
L a b e l d e s c r i p t i o n s - C E
STAR 6
Color Marking Description Quantity STAR 9
(STAR 13)
Red R1 Height of the floor and load 1 3078152630 3078149980
Red R2 Driving direction 4 3078152670
Red R3 Risk of crushed hands 1 3078149010 3078149010
Red R4 Risk of body crushing 1 3078143630
Red R5 Danger of electrocution 1 3078144470 3078144470
Red R7 Do not park in the work area 2 3078144240 3078144240
Red R8 Close the removable midrail 1 3078153510 3078153510
Red R9 Wheel load 4 3078152950
Red R21 Protective clothing required 1 3078143610 3078143610
Red R30 Vertical crushing of the body 1 3078144440
Red R31 Driving direction 3 3078152650 3078148790
Red R33 Brake release 1 3078146840
Red R39 Do not climb onto the tool box 1 307P218750
Orange O1 Operation instructions 1 3078149610 3078149610
Orange O4 Machine anchorage points 4 3078145110 3078145110
Orange O5 Position of the lift truck forks 4 3078143830 3078143830
Yellow J3 Do not place your foot on the hood 2 3078143640 3078143640
Do not use the machine as a solder
Yellow J4 1 3078143600
mass
Yellow J6 Tilt verification 1 3078144650
Yellow J10 Socket 1 3078143540 3078143540
Yellow J13 Battery verification 1 3078143510
Using the machine during battery
Yellow J14 1 3078144460
charging is forbidden
Yellow J15 Battery charger socket 1 3078144480
Yellow J22 Battery use 1 3078152620
Yellow J23 Emergency mast lowering 1 3078152660 307P200120
Yellow J24 Emergency jib lowering 1 3078144420
Other A1 Upper console 1 3078152460
Other A2 Lower console 1 3078152680
Other A3 Identification plate 1 307P219020 307P219020
Other A4 Machine name logo 2 3078152090
Other A5 Small format HAULOTTE® logo 2 307P217410 307P217410
Other A7 Read the operation manual 1 3078143680 3078143680
Other A8 Hydraulic oil 1 3078143520 3078143520
Other A8 Biodegradable oil 1 3078148890 3078148890
Other A9 Upper and lower oil level 1 3078143590 3078143590
Other A11 Front green boom 1 3078148820 3078148820
Other A12 Rear red boom 1 3078148830 3078148830
Other A15 Harness location 2 307P216290 307P216290
Other A16 Yellow and black adhesive tape 2 2421808660 2421808660
Other A32 Vertical machine name logo 1 307P217390
Other A53 ON 1 3078142000
Other A54 OFF 1 3078142010
26 24203 3352 0 E 10 07 EN
Telescopic masts
B - Recommendations
A
Color
Red
Marking
R1
Description
Height of the floor and load

Quantity
2
STAR 8
(STAR 22J)
307P219210
STAR 10
(STAR 26J)
307P216420
B
Red R4 Risk of body crushing 2 3078143630 3078143630
Red
Red
R8
R9
Close the removable midrail
Wheel load
1
4
3078153510
307P219220
3078153510
307P216430
C
Red R30 Vertical crushing of the body 2 3078144440 3078144440
Red R32 Emergency stop push button 1 3078148800 3078148800
Orange
Orange
Orange
O1
O4
O5
Operation instructions
Machine anchorage points
Position of the lift truck forks
1
4
4
3078149610
3078145110
3078143830
3078149610
3078145110
3078143830
D
Yellow J4 2 3078143600 3078143600
mass
Yellow J10 Socket 1 3078143540 3078143540
Yellow
Yellow
J13
J14
Battery verification
1
1
3078143510
3078144460
3078143510
3078144460
E
Yellow J15 Battery charger socket 1 3078144480 3078144480
Yellow J23 Emergency mast lowering 1 307P218900 307P218900
Yellow J24 Emergency jib lowering 1 3078144420 3078144420
Other
Other
Other
A1
A2
A3
Upper console
Lower console
Identification plate
1
1
1
3078148280
3078148300
307P219020
3078148280
3078148300
307P219020
F
Other
Other
A9
A11
Upper and lower oil level
Front green boom
1
1
3078143590
3078148820
3078143590
3078148820
G
Other A32 Vertical machine name logo 1 307P217430 307P217400
24203 3352 0 E 10 07 EN 27
Telescopic masts
B - Recommendations
Color Marking Description Quantity STAR 11 STAR 12

Red R1 Height of the floor and load 2 3078149990 3078150000
Red R33 Brake release 1 3078146840 3078146840
Yellow J4 2 3078143600 3078143600
mass
Yellow J10 Socket 1 3078143540 3078143540
Yellow J13 Battery verification 1 3078143510 3078143510
Yellow J14 1 3078144460 3078144460
Other A1 Upper console 1 3078148280 3078148280
Other A2 Lower console 1
Other A53 ON 1 3078142000 3078142000
Other A54 OFF 1 3078142010 3078142010
28 24203 3352 0 E 10 07 EN
Telescopic masts
B - Recommendations
A
L o c a l i z a t i o n : S T A R 6 ( S T A R 1 3 ) - A S
R31 A1 A12 A11 A11 A12 R1 J10 J4 O1
R2
R3
R22
Only for Australia
R15 Only for Australia B
R2
R7
R39
A3
J22
A7 C
A16
A16 A5
J3
J3
R2
R9
R31 R21
D
A5 A8 - A9
R16 J6
Only for Australia
O4
R9 O4 R16 Only for Australia
O5 A4 O5 R31 R9
R16
J23
Only for Australia
O5 A4 O5 A2 R9 O4 R16 R19 Only for Australia
Only for Australia E
24203 3352 0 E 10 07 EN 29
Telescopic masts
B - Recommendations
L o c a l i z a t i o n : S T A R 8 ( S T A R 2 2 J ) - S T A R 9 - S T A R
1 0 ( S T A R 2 6 J ) - S T A R 1 1 - S T A R 1 2 - A S
Only for Star8
Star10
R5 A32 R31 R1
Only for Star9 A54 R15Only for Australia
Star11-Star12
A53
R33 Only for Star9
Star11-Star12
J4
A15
O1
A7
R4
A2
J3 A5
R3
R8
A16
A3 J14
R9 R1 J13 O5 O4 J23 J3 R30
O5 R5 J15 R9 A11 R16 O4 R7 J24 J10
Only for Australia
A1
A15
A32
J3
O4
R16
Only for Australia
R19
Only for Australia
A16 J24 O5 R3 R9 O4 A5
R30 R9 A8 - A9 O5 A12 R4 R21
R16
Only for Australia
30 24203 3352 0 E 10 07 EN
Telescopic masts
B - Recommendations
A
L a b e l d e s c r i p t i o n s - A S
Color
Red
Marking
R1
Description

Quantity
1
STAR 6
(STAR 13)
3078152630
STAR 9
3078149980
B
Red
Red
R7
R8
Do not park in the work area
Close the removable midrail
2
1
3078144240
3078153510
3078144240
3078153510
C
Red R15 Harness use 1 3078144520 3078144520
Red R16 Load strength on each slings 1 3078144490 3078144490
Red R19 Fluid under pressure 1 3078145200 3078145200
Red
Red
R21
R22
Protective clothing required
Do not descend slopes at high
speed
1
1
3078143610
3078144360
3078143610
3078144360
D
Red R33 Brake release 1 3078146840
Red R39 Do not climb onto the tool box 1 307P218750
Orange
Orange
O1
O4
Operation instructions
1
4
3078149610
3078145110
3078149610
3078145110
E
Yellow J4 1 3078143600
mass
Yellow
Yellow
Yellow
J6
J10
J13
Tilt verification
Socket
Battery verification
1
1
1
3078144650
3078143540 3078143540
3078143510
F
Yellow J14 1 3078144460
Yellow
Yellow
J23
J24
Emergency mast lowering
Emergency jib lowering
1
1
3078152660 307P200120
3078144420
G
Other A4 Machine name logo 2 3078152090
Other
Other
A5
A7
Small format HAULOTTE® logo
Read the operation manual
2
1
307P217410
3078143680
307P217410
3078143680 H
Other
Other
Other
A12
A15
A16
Rear red boom
Harness location
Yellow and black adhesive tape
1
2
2
3078148830
307P216290
2421808660
3078148830
307P216290
2421808660
I
Other A53 ON 1 3078142000
Other A54 OFF 1 3078142010
24203 3352 0 E 10 07 EN 31
Telescopic masts
B - Recommendations
STAR 8 STAR 10
Color Marking Description Quantity
(STAR 22J) (STAR 26J)
Red R1 Height of the floor and load 2 307P219210 307P216420
Red R9 Wheel load 4 307P219220 307P216430
Red R15 Harness use 1 3078144520 3078144520
Red R16 Load strength on each slings 1 3078144490 3078144490
Red R22 1 3078144360 3078144360
speed
Red R32 Emergency stop push button 1 3078148800 3078148800
Yellow J4 2 3078143600 3078143600
mass
Yellow J10 Socket 1 3078143540 3078143540
Yellow J14 1 3078144460 3078144460
Other A2 Lower console 1 3078148300 3078148300
32 24203 3352 0 E 10 07 EN
Telescopic masts
B - Recommendations
A
Color
Red
Red
Marking
R1
R3
Description
Risk of crushed hands
Quantity
2
1
STAR 11
3078149990
3078143620
STAR 12
3078150000
3078143620
B
Red
Red
R15
R16
Harness use
Load strength on each slings
1
1
3078144520
3078144490
3078144520
3078144490
C
Red R22 1 3078144360 3078144360
speed
Red
Red
Red
R30
R31
R33
Vertical crushing of the body
Driving direction
Brake release
1
1
1
3078144440
3078148790
3078146840
3078144440
3078148790
3078146840
D
Yellow J4
mass
2 3078143600 3078143600 E
Yellow J10 Socket 1 3078143540 3078143540
Yellow J14 1 3078144460 3078144460
Yellow
Yellow
Yellow
J15
J23
J24
Battery charger socket
Emergency mast lowering
Emergency jib lowering
1
1
1
3078144480
307P200120
3078144420
3078144480
307P200120
3078144420
F
Other A2 Lower console 1
Other
Other
A7
A8
Read the operation manual
Hydraulic oil
1
1
3078143680
3078143520
3078143680
3078143520
G
Other
Other
A15
A16
Harness location
Yellow and black adhesive tape
2
2
307P216290
2421808660
307P216290
2421808660 H
Other A53 ON 1 3078142000 3078142000
Other A54 OFF 1 3078142010 3078142010
24203 3352 0 E 10 07 EN 33
Telescopic masts
B - Recommendations
L o c a l i z a t i o n : S T A R 6 ( S T A R 1 3 ) - A N S I - C S A
R31 A1 A12 A11 A11 A12 R1 J10 J4 O1

A22
R2
R3
R2
R7
R39
A23 A3
O3
A7
J22
A16
A16 A5
J3
J3
R2 A27
R9
R31 R21
A5 A8 - A9
A30 J6 - A35
O4
R9 O4 A30
O5 A4 A35 O5 R31 R9 J23 O5 A35 A4 O5 A2 R9 O4 A30
A30
34 24203 3352 0 E 10 07 EN
Telescopic masts
B - Recommendations
A
L o c a l i z a t i o n : S T A R 8 ( S T A R 2 2 J ) - A N S I - C S A
R32 A34 A32 R31 R1

R5 A29 A27 B
J4
O1 A15
A22
A7
R4
A2
J3 A5
C
R3
R8
A16
J14 A3
R9 R1 J13 O5
O5 R5 J15 R9 A11
O4 J23 J3
A30 O4 R7
R30
J24 J10 A23 D
A1
A15
A32
E
J3
F
O4
A30
R9
O3
A16 J24 O5 A35 R9 O4 A5
R30 A8 - A9 R3 O5 A12
A30
R4 R21
G
24203 3352 0 E 10 07 EN 35
Telescopic masts
B - Recommendations
L a b e l d e s c r i p t i o n s - A N S I - C S A
Color Marking Description Quantity STAR 6 (STAR 13)

Red R1 Height of the floor and load 1 3078152970
Red R3 Risk of crushed hands 1 3078147240
Red R5 Danger of electrocution 1 3078149300
Red R7 Do not park in the work area 2 3078147170
Red R8 Close the removable midrail 1 3078153630
Red R21 Protective clothing required 1 3078147350
Orange O1 Operation instructions 1 3078149050
Orange O3 Risks of explosion 1 3078148030
Orange O4 Machine anchorage points 4 3078147310
Orange O5 Position of the lift truck forks 4 3078146950
Yellow J3 Do not place your foot on the hood 2 3078147270
Yellow J6 Tilt verification 1 3078147090
Yellow J10 Socket 1 3078148900
Yellow J23 Emergency mast lowering 1 3078153010
Other A3 Identification plate 1 307P218930
Other A4 Machine name logo 2 307P217380
Other A5 Small format HAULOTTE® logo 2 307P217410
Other A7 Read the operation manual 1 3078147290
Other A8 Hydraulic oil 1 3078147140
Other A8 Biodegradable oil 1 3078148920
Other A9 Upper and lower oil level 1 3078147210
Other A11 Front green boom 1 3078148820
Other A12 Rear red boom 1 3078148830
Other A15 Harness location 2 3078147950
Other A16 Yellow and black adhesive tape 2 2421808660
Other A22 Voltage table 1 3078147890
Other A23 Symbol summary 1 3078153030
Other A27 Permissible load 1 3078153050
Other A30 Machine anchorage points 1 3078147930
Other A35 Socket connection 1 3078148630
36 24203 3352 0 E 10 07 EN
Telescopic masts
B - Recommendations
A
L a b e l d e s c r i p t i o n s - A N S I - C S A
Color
Red
Red
Marking
R1
R3
Description
Risk of crushed hands
Quantity
2
1
STAR 8 (STAR 22J)
307P219230
3078147240
B
Red R5 Danger of electrocution 1 3078149300
Red R7 Do not park in the work area 1 3078149310
Red R8 Close the removable midrail 1 3078153630
Red
Red
R9
R21
Wheel load
Protective clothing required
1
1
307P219240
3078147350
C
Orange O1 Operation instructions 1 3078149050
Orange O3 Risks of explosion 1 3078148030
Orange
Orange
O4
O5
Position of the lift truck forks
1
4
3078147310
3078146950 D
Yellow J3 Do not place your foot on the hood 2 3078147270
Yellow J4 2 3078147220
mass
Yellow J10 Socket 1 3078148900
Yellow J13 Battery verification 1 3078147330
Yellow J14
1 3078149280 E
Yellow J23 Emergency mast lowering 1 307P218920
Yellow J24 Emergency jib lowering 1 3078149380
Other A1 Upper console 1 307P203690
Other
Other
Other
A2
A3
A5
Lower console
Identification plate
Small format HAULOTTE® logo
1
1
2
3078148300
307P218930
307P217410
F
Other A7 Read the operation manual 1 3078147290
Other A8 Hydraulic oil 1 3078147140
Other A8 Biodegradable oil 1 3078148920
Other A9 Upper and lower oil level 1 3078147210
Other
Other
A11
A12
Front green boom
Rear red boom
1
1
3078148820
3078148830
G
Other A15 Harness location 1 3078147950
Other A16 Yellow and black adhesive tape 2 2421808660
Other A22 Voltage table 1 3078147890
Other A23 Symbol summary 1 307P201500
Other
Other
A27
A29
Permissible load
Summary safety instructions
2
1
307P211510
3078150870
H
Other A30 Machine anchorage points 2 3078147930
Other A34 Battery charger 1 3078148620
Other A35 Socket connection 1 3078148630
24203 3352 0 E 10 07 EN 37
Telescopic masts
B - Recommendations
38 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Maintenance
1 - General programme B
The time periods below are recommended for fuel-powered machines in normal use.
Symbol Meaning Symbol Meaning
Visual inspections
Systematic replacement
Operation requiring HAULOTTE
C
Services® authorisation
Visual inspection followed by
dismantling or replacement if
Check-Test See user manual or
machine maintenance book
(1)
necessary Operation
requiring HAULOTTE Services®
authorisation Increase in regular
D
inspections
Check level Tightening (bolt, etc.)
Lubrication-Lubrication Tightening (oil clearance) E

Static and dynamic tests For
countries in which machines are
Oil change
not subject to regular controlled
(2)
maintenance
1 - Increase in regular inspections

F
2 - For countries in which machines are not subject to regular controlled maintenance
Increase in regular inspections :
• Depending on the condition of critical components after 1000 h , the maintenance staff must reduce the
interval between regular inspections. If the decision is made not to replace, the part involved must be
recorded in the inspection schedule.
• Cylinders (welds, leakproofness)
G
• Welds
• Hoses and couplings
• Pins, rings and end-play take up
• Pulleys and pads H
• Bearings
• Caps and covers
• Rotation crown gear
I
24203 3352 0 E 10 07 EN 39
Telescopic masts
C - Maintenance
Intervals
Zone After 125 h or 1 After 250 h or 1 After 1500 h After 5000 h
Daily
years years or 3 years or 10 years
Platform assembly
Platform
Guardrail
Sliding mid-rail
Floor
Harness anchorage points
Mast assembly
Chains
(1)
Cables and tank bands
Turntable assembly
Rotation crown gear (3)
Orientation reducer
Chassis assembly
Tyres and rims
Wheel nuts and bolts
Wheel reducer
40 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Intervals
Daily
B
Wheel pivots
Functions and controls
Upper control console (indicators,

C
etc.)
Lower control console (indicators,

etc.) D
'Dead man' pedal
E
Emergency stop buttons (on all
consoles)
Circuit breaker and contactors

F
Overload
G
Speed
Brakes
H
Emergency lowering
LEDs, switches, joysticks and

selectors
I
24203 3352 0 E 10 07 EN 41
Telescopic masts
C - Maintenance
Intervals
Daily
Tilt
Limit switch ( PV, outreach limiter,

weighing)
Back to neutral for all joysticks,

selectors, etc
Motorisation system
Engine See manuacturer's guide
Batteries (terminals, cleanliness,

attachment)
Hydraulic and electrical assemblies
Hydraulic pump
Hydraulic tank, cap and sniffer
Hydraulic filter
Hydraulic oil
Electrical connections
Hydraulic unit motor commutator
(1)
Driving motor commutator

(1)
Variable speed drive

(1)
Common zones
42 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Intervals
Daily
B
Welds
(1)
Hoses and couplings

(1)
C
Pins, rings and end-play take up
(1)
D
Pulleys and pads
(1)
Bearings
E
Cylinders (welds, leakproofness) (2)
F
Caps and covers
General points
User manual and intervention log
Safety stickers and manufacturer's

plate
Mandatory inspection According to country G

Performance check on all functions
and safety devices
Lubrication according to the

maintenance plan H
General of the machine, paint, no
leaks, cracks or excessive distortion,
etc
Machine integrity, no modifications
without HAULOTTE Services®
I
authorisation

3 - Particular attention to be paid in crown gear checking
24203 3352 0 E 10 07 EN 43
Telescopic masts
C - Maintenance
Particular attention to be paid in crown gear checking :

• Visual appearence of interior and exterior floating or broken screws, etc).
• Check bolt tightness by testing a sample, making sure that the bolts are slightly loosened before
retightening with a torque wrench. Section C E005 Maintenance sheet
• Check the functional play in the crown gear (every-1500 h ). Consult the After Sales Service
44 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
2 - Detailed programme
The time periods below are recommended for fuel-powered machines in normal use.
B
Symbol Meaning Symbol Meaning
Systematic replacement
Visual inspections Operation requiring HAULOTTE
Services® authorisation C
Visual inspection followed by
dismantling or replacement if
Check-Test See user manual or necessary Operation
machine maintenance book requiring HAULOTTE Services®
(1)
authorisation Increase in regular
inspections D
Check level Tightening (bolt, etc.)
Lubrication-Lubrication Tightening (oil clearance)
Static and dynamic tests For

countries in which machines are
E
Oil change
not subject to regular controlled
(2)
maintenance

During the periodic inspection of the 5000 h (visual inspection with dismantling and exchange or
F
replacement if necessary), a record must be made of all parts that have been dismantled but not replaced
24203 3352 0 E 10 07 EN 45
Telescopic masts
C - Maintenance
125 h or 1 year service

Type of Type of
Zone Zone
intervention intervention
Mast assembly Functions and controls
Upper control console

Chains
(indicators, etc.)
Lower control console

(indicators, etc.)
Turntable assembly 'Dead man' pedal

Rotation crown gear
consoles)
Orientation reducer Circuit breaker and contactors
Overload
Speed
Chassis assembly Brakes
Wheel nuts and bolts Emergency lowering

Wheel pivots
selectors
Tilt
Limit switch ( PV, outreach

limiter, weighing)
Hydraulic and electrical assemblies Motorisation system
Hydraulic filter Engine See manuacturer's guide
Hydraulic oil
46 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B
Common zones General points
Pulleys and pads Mandatory inspection According to country C

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
HAULOTTE Services® contract number :
Intervention sheet number :
Signature :
I
24203 3352 0 E 10 07 EN 47
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Batteries (terminals,
Hydraulic oil
cleanliness, attachment)
Hydraulic unit motor

commutator
48 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Machine integrity, no
Cylinders (welds, modifications
leakproofness) without HAULOTTE Services®
authorisation D
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 49
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil
50 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
Signature :
I
24203 3352 0 E 10 07 EN 51
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil

commutator
52 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
authorisation D
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 53
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil
54 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
Signature :
I
24203 3352 0 E 10 07 EN 55
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil

commutator
56 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
authorisation D
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 57
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil
58 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
Signature :
I
24203 3352 0 E 10 07 EN 59
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil

commutator
60 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
authorisation D
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 61
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil
62 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
Signature :
I
24203 3352 0 E 10 07 EN 63
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil

commutator
64 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
authorisation D
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 65
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil
66 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
Signature :
I
24203 3352 0 E 10 07 EN 67
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone

Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic tank, cap and sniffer Engine See manuacturer's guide
Hydraulic filter
Hydraulic oil

commutator
68 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B
Pins, rings and end-play take up Mandatory inspection According to country C

Pulleys and pads
maintenance plan
modifications
D
Bearings
authorisation
Cylinders (welds,
leakproofness)
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 69
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil
70 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
Signature :
I
24203 3352 0 E 10 07 EN 71
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil

commutator
72 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
authorisation D
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 73
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil
74 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
Signature :
I
24203 3352 0 E 10 07 EN 75
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil

commutator
76 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
authorisation D
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 77
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil
78 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
Signature :
I
24203 3352 0 E 10 07 EN 79
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil

commutator
80 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
authorisation D
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 81
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil
82 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
Signature :
I
24203 3352 0 E 10 07 EN 83
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil

commutator
84 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
authorisation D
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 85
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil
86 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
Signature :
I
24203 3352 0 E 10 07 EN 87
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil

commutator
88 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
authorisation D
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 89
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil
90 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
Signature :
I
24203 3352 0 E 10 07 EN 91
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone

Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic filter
Hydraulic oil

commutator
92 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Pulleys and pads
maintenance plan
modifications
D
Bearings
authorisation
Cylinders (welds,
leakproofness)
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 93
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil
94 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
Signature :
I
24203 3352 0 E 10 07 EN 95
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil

commutator
96 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
authorisation D
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 97
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil
98 24203 3352 0 E 10 07 EN
Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
Signature :
I
24203 3352 0 E 10 07 EN 99
Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil

commutator
100 24203 3352 0 E 10 07 EN

Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
authorisation D
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 101

Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil
102 24203 3352 0 E 10 07 EN

Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
Signature :
I
24203 3352 0 E 10 07 EN 103

Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil

commutator
104 24203 3352 0 E 10 07 EN

Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
authorisation D
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 105

Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil
106 24203 3352 0 E 10 07 EN

Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
Signature :
I
24203 3352 0 E 10 07 EN 107

Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil

commutator
108 24203 3352 0 E 10 07 EN

Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
authorisation D
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 109

Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil
110 24203 3352 0 E 10 07 EN

Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
Signature :
I
24203 3352 0 E 10 07 EN 111

Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil

commutator
112 24203 3352 0 E 10 07 EN

Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
authorisation D
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 113

Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil
114 24203 3352 0 E 10 07 EN

Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
Signature :
I
24203 3352 0 E 10 07 EN 115

Telescopic masts
C - Maintenance

Type of Type of
Zone Zone

Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic filter
Hydraulic oil

commutator
116 24203 3352 0 E 10 07 EN

Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Pulleys and pads
maintenance plan
modifications
D
Bearings
authorisation
Cylinders (welds,
leakproofness)
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 117

Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil
118 24203 3352 0 E 10 07 EN

Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
Signature :
I
24203 3352 0 E 10 07 EN 119

Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil

commutator
120 24203 3352 0 E 10 07 EN

Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
authorisation D
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 121

Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Chains
(indicators, etc.)

(indicators, etc.)

Rotation crown gear
consoles)
Overload
Speed

Wheel pivots
selectors
Tilt

limiter, weighing)
Hydraulic oil
122 24203 3352 0 E 10 07 EN

Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B

Bearings
maintenance plan
Cylinders (welds,
leakproofness)
D
H
Date : Comments
Number of hours :
Intervenor :
Signature :
I
24203 3352 0 E 10 07 EN 123

Telescopic masts
C - Maintenance

Type of Type of
Zone Zone
Platform assembly Functions and controls
Platform
(indicators, etc.)

(indicators, etc.)
Mast assembly 'Dead man' pedal

Chains
consoles)
Circuit breaker and contactors
Turntable assembly Overload
Rotation crown gear Speed
Orientation reducer Brakes
Emergency lowering

selectors
Chassis assembly Tilt

Wheel nuts and bolts
limiter, weighing)
Wheel pivots
Hydraulic oil

commutator
124 24203 3352 0 E 10 07 EN

Telescopic masts
C - Maintenance
A
Zone
Type of
intervention
Zone
Type of
intervention B
Welds Mandatory inspection According to country C

Hoses and couplings
maintenance plan
modifications
Pins, rings and end-play take up
authorisation
D
Pulleys and pads
Bearings
Cylinders (welds,
leakproofness)
E
H
Date : Comments
Number of hours :
Intervenor :
I
Signature :
24203 3352 0 E 10 07 EN 125

Telescopic masts
C - Maintenance
3 - Maintenance sheets
Each specific procedure is described in the following maintenance sheets.
Before any maintenance intervention, place the machine in maintenance configuration.
Report that the machine is under maintenance on the upper and lower consoles.
Using the machine is strictly forbidden.
After maintenance return the machine to operating configuration.
3.1 - PLACING IN MAINTENANCE CONFIGURATION
1. Place the machine on firm, horizontal ground.

2. Stow the machine completely.
3. Press in the emergency push buttons to cut off the electricity supply.
3.2 - PLACING IN OPERATING CONFIGURATION
1. Pull the emergency stop push buttons.
126 24203 3352 0 E 10 07 EN

Control-Filling up
Oil tank
15 mn E001
Control-Filling up
Oil tank
1 - You will need

• Standard tool kit
• Protective goggles • Mark out the work area
• Gloves
2 - Preliminary procedure
1. Place the machine in maintenance configuration. 3.3.1-Placing in maintenance configuration
3 - Control
Check the oil level when cold (before beginning a new period of work).
The oil level ( 1 ) must be between the upper and lower markers .
4 - Filling up
For STAR 6 (STAR 13)
Top up the oil level if necessary :
1. Unscrew the tank cap .
2. Top-up the oil level.
3. Screw the tank cap back on.
For STAR 8 (STAR 22J)- STAR 10 (STAR 26J)

24203 3352 0 E 10 07 EN 127

Control-Filling up
Oil tank
15 mn E001
For STAR 9- STAR 11- STAR 12
5 - Additional operation
1. Place the machine in operating configuration. 3.3.2-Placing in operating configuration
128 24203 3352 0 E 10 07 EN

Replacement
Hydraulic filter cartridge
15 mn E003
Replacement
1 - You will need

• Gloves
3 - Replacement
• For STAR 8 (STAR 22J) and STAR 10 (STAR 26J) only :
Before dismantling, ensure that the oil circuit is no longer under pressure and that the oil temperature is
not too high.
1. Unscrew the cap ( 1 ).

2. Remove the cartridge.
3. Install a new cartridge.
4. Screw on the cap again .
1
24203 3352 0 E 10 07 EN 129

Replacement
15 mn E003
130 24203 3352 0 E 10 07 EN

Lubrication-Tightening-Clearance check
Rotation crown gear
15 mn E005
Rotation crown gear
1 - You will need

• Gloves
3 - Lubrication
External teeth - Internal teeth
1. Check the appearance of the teeth.
2. Oil the crown gear teeth (internal and external).
3. Oil the raceways (access to greasers via the holes lo-
cated on the turntable) until the oil comes out by the
crown lip seal.
24203 3352 0 E 10 07 EN 131

Rotation crown gear
15 mn E005
4 - Tightening
Machine type International system Imperial system
HA16PE 21,5 daN.m (. lbf.ft)
HA16SPX (HA46SJRT) 21,5 daN.m (158 lbf.ft)
HA16PX (HA46JRT) 21,5 daN.m (158 lbf.ft)
HA18SPX (HA51SJRT) 21,5 daN.m (158 lbf.ft)
H14TX (HB40) 8,7 daN.m (64 lbf.ft)
H16TPX (HB44J) 8,7 daN.m (64 lbf.ft)
H21TX (HB62) 21,5 daN.m (158 lbf.ft)
H23TPX (HB68J) 32 daN.m (236 lbf.ft)
H25TPX (HB76J) 21,5 daN.m (158 lbf.ft)
H28TPX (HB86JRT) 21,5 daN.m (158 lbf.ft)
H43TPX (HB135JRT) 21,5 daN.m (158 lbf.ft)
STAR 8 (STAR 22J) - Ring on plate 13,5 daN.m
STAR 8 (STAR 22J) - Plate on mast
195 daN.m
foot
STAR 8 (STAR 22J) - Ring on
13,5 daN.m
chassis
STAR 9 (N/A) - Ring on plate 79 daN.m
STAR 9 (N/A) - Plate on mast foot 198 daN.m
STAR 9 (N/A) - Ring on chassis 13,5 daN.m
STAR 10 (STAR 26J) - Ring on plate 13,5 daN.m
STAR 10 (STAR 26J) - Plate on mast
195 daN.m
foot
STAR 10 (STAR 26J) - Ring on
13,5 daN.m
chassis
132 24203 3352 0 E 10 07 EN

Rotation crown gear
15 mn E005
5 - Clearance check
N.B.-:-CONSULT THE AFTER SALES SERVICE HAULOTTE SERVICES®.
2. Rotate the crown through one complete turn.
A tight spot or grinding noise during rotation, or the presence of metallic particles emerging from the lip
seal are signs of abnormal wear in the raceway (Contactor HAULOTTE Services®).
24203 3352 0 E 10 07 EN 133

Rotation crown gear
15 mn E005
134 24203 3352 0 E 10 07 EN

Replacement-Tightening
Wheel
15 mn E006
Wheel
1 - You will need

• Protective goggles
• Gloves
• Mark out the work area
• Jack
• Hoist
• Torque spanner
24203 3352 0 E 10 07 EN 135

Wheel
15 mn E006
3 - Replacement
1. Loosen the fastening screws from the wheel to be re-
moved.
2. Raise the machine using a jack or hoist.
3. Remove the fastening screws.
4. Remove the wheel.
5. Mount a new wheel.
6. Lower the machine to the ground.
7. Tighten the fastening screws to the recommended tor-
que.
136 24203 3352 0 E 10 07 EN

Wheel
15 mn E006
4 - Torque
Machine type Wheel type Torque in N.m - lbf.ft
Drive wheel 250-184
HA12PX (HA33JRT)
Steering wheel 250-184
Drive wheel 320-236
HA16X
Drive wheel 320-236
HA16SPX (HA46SJRT)
Drive wheel 320-236
HA16PX (HA46JRT)
Drive wheel 320-236
HA18SPX (HA51SJRT)
Drive wheel 320-236
HA18PX (HA51JRT)
Drive wheel 320-236
HA20PX (HA61JRT)
Drive wheel 320-236
HA260PX (HA80JRT)
Drive wheel 650-479
HA32PX (HA100JRT)
Drive wheel 570-420
HA41PX (HA130JRT)
Drive wheel 320-236
H14TX (HB40)
Drive wheel 320-236
H16TPX (HB44J)
Drive wheel 320-236
H21TX (HB62)
Drive wheel 320-236
H23TPX (HB68J)
Drive wheel 320-236
H25TPX (HB76J)
Drive wheel 650-479
H28TPX (HB86JRT)
Drive wheel 570-420
H43TPX (HB135JRT)
Drive wheel 100-74
STAR 6 (STAR 13)
Drive wheel 80-59
STAR 8 (STAR 22J)
Drive wheel 15-11
STAR 9
Drive wheel 210-155
STAR 10 (STAR 26J)
Drive wheel 15-11
STAR 11
Drive wheel 15-11
STAR 12
24203 3352 0 E 10 07 EN 137

Wheel
15 mn E006
138 24203 3352 0 E 10 07 EN

Tightening
Screws, bolts and nuts
15 mn E007
Tightening
1 - Torque (course thread)

Nominal diameter Torque in N.m - lbf.ft
Class 8.8 Class 10.9 Class 12.9
M6x1 9 to 11-6,64 to 8,11 13 to 14-9,59 to 10,33 15 to 17-11,06 to 12,54
M7x1 15 to 19-11,06 to 14,01 21 to 24-15,49 to 17,7 26 to 28-19,18 to 20,65
M8x1.25 22 to 27-16,23 to 19,91 31 to 34-22,86 to 25,08 37 to 41-27,29 to 30,24
M10x1.5 43 to 45-31,72 to 33,19 61 to 67-44,99 to 49,42 73 to 81-53,84 to 59,74
M12x1.75 75 to 94-55,32 to 69,33 110 to 120-81,13 to 88,51 130 to 140-95,88 to 103,26
170 to 190-125,39 200 to 220-147,51
M14x2 120 to 150-88,51 to 110,63
to 140,14 to 162,26
190 to 230-140,14 260 to 290-191,77 320 to 350-236,02
M16x2
to 169,64 to 213,89 to 258,15
260 to 320-191,77 360 to 400-265,52 440 to 480-324,53
M18x2.5
to 236,02 to 295,02 to 354,03
520 to 570-383,53 620 to 680-457,29
M20x2.5 370 to 450-272,9 to 331,9
to 420,41 to 501,54
500 to 620-368,78 700 to 770-516,29 840 to 930-619,55
M22x2.5
to 457,29 to 567,92 to 685,93
630 to 790-464,66 890 to 990-656,43 1070 to 1180-789,19
M24.3x3
to 582,67 to 730,19 to 870,32
930 to 1150-685,93 1300 to 1400-958,83 1560 to 1730-1150,6
M27x3
to 848,2 to 1032,59 to 1275,98
1260 to 1570-929,33 1770 to 1960-1305,49 2200 to 2350-1622,64
M30x3.5
to 1157,97 to 1445,62 to 1733,27
24203 3352 0 E 10 07 EN 139

Tightening
15 mn E007
2 - Torque (fine thread)

Nominal diameter Torque in N.m - lbf.ft
Class 8.8 Class 10.9 Class 12.9
M8x1 24 to 29-17,7 to 21,39 33 to 37-24,34 to 27,29 40 to 44-29,5 to 32,45
M10x1.25 46 to 57-33,93 to 42,04 64 to 71-47,2 to 52,37 77 to 85-56,79 to 62,69
140 to 150-103,26
M12x1.25 83 to 100-61,22 to 73,76 120 to 130-88,51 to 95,88
to 110,63
180 to 200-132,76 220 to 240-162,26
M14x1.5 130 to 160-95,88 to 118,01
to 147,51 to 177,01
200 to 250-147,51 280 to 310-206,52
M16x1.5 340 to 370-250,77 to 272,9
to 184,39 to 228,64
290 to 360-213,89 490 to 540-361,41
M18x1.5 410 to 450-302,4 to 331,9
to 265,52 to 398,28
570 to 630-420,41 690 to 760-508,92
M20x1.5 410 to 510-302,4 to 376,16
to 464,66 to 560,55
550 to 680-405,66 920 to 1000-678,56
M22x1.5 780 to 870-575,3 to 641,68
to 501,54 to 737,56
970 to 1070-715,44 1160 to 1290-855,57
M24x1.5 690 to 860-508,92 to 634,3
to 789,19 to 951,46
1000 to 1300-737,56 1400 to 1560-1032,59 1690 to 1880-1246,48
M27x2
to 958,83 to 1150,6 to 1386,62
1400 to 1700-737,56 1960 to 2180-1032,59 2350 to 2610-1246,48
M30x2
to 958,83 to 1150,6 to 1386,62
140 24203 3352 0 E 10 07 EN

Lubrication
Steering wheel pivots
15 mn E010
Lubrication
1 - You will need

• Gloves
3 - Lubrication
For STAR 8 (STAR 22J), STAR 9, STAR 10 (STAR 26J),
STAR 11 and STAR 12 only :
Lubricate the pivots ( 1 ) with lead-free grease
24203 3352 0 E 10 07 EN 141

Lubrication
15 mn E010
142 24203 3352 0 E 10 07 EN

Control-Lubrication
Cables and chains
30 mn E016
Control-Lubrication
Cables and chains
1 - You will need

• Gloves
3 - Control
Carefully inspect each chain along its whole length :
• No corrosion must be visible on the chains, yokes and pins.
• The plates must not be cracked.
• The plate bolts must not have excessive play. The pins must not
have turned in their housing 1 1
• The plates must not be worn beyond 2% of their total height
A B
• If a chain seems faulty or worn it must be replaced.
Check the tension of the mast telescope chains and cables.
Check the alignment of the telescope assembly.
24203 3352 0 E 10 07 EN 143

Control-Lubrication
Cables and chains
30 mn E016
144 24203 3352 0 E 10 07 EN

Control
Return cables
30 mn E027
Control
Return cables
1 - You will need

• Gloves
3 - Control
For STAR 8 (STAR 22J) and STAR 10 (STAR 26J) only :
Replace in case of :
• Broken wire ( C ) C
• Broken strand ( B )
Jeu B
Gap
• Kinked cable 1 mm max.
A
• Wear on lugs
• Abnormal stretching of the cabel making it impossible to adjust
play at the threaded end
24203 3352 0 E 10 07 EN 145

Control
Return cables
30 mn E027
146 24203 3352 0 E 10 07 EN

Lubrication
Mast
15 mn E028
Lubrication
Mast
1 - You will need

• Gloves
3 - Lubrication
Lubricate the slides where the pads are (spatula).
Lubricate the pads at the rear of the machine.
24203 3352 0 E 10 07 EN 147

Lubrication
Mast
15 mn E028
148 24203 3352 0 E 10 07 EN

Control-Filling up-Battery charge
Traction battery
10 mn E029
Traction battery
1 - You will need

• Gloves
The battery manufacturer's safety instructions must be complied with.
3 - Control
Unscrew the caps located on the upper surface of the battery.
The level of electrolyte in the battery must be 0,01 m (0 ft 39 in) above the level of the plates.
24203 3352 0 E 10 07 EN 149

Traction battery
10 mn E029
4 - Filling up
Unscrew the caps located on the upper surface of the battery.
If the level of electrolyte is below the level of the plates : .

1. Top up with distilled water.
2. Screw the caps back on the battery.
150 24203 3352 0 E 10 07 EN

Traction battery
10 mn E029
5 - Battery charge
Battery charge status :

• This is shown on a graph.
• Each of the 10 % segments represents 10 % of the charge.
• Batteries are charged : All segements are highlighted.
• Batteries more than 70 % empty : Flashing. Batteries should be
recharged.
• Batteries more than 80 % empty : Only 2 segments are flashing.
The batteries must be recharged.
For STAR 8NG (STAR 22J)- STAR 9- STAR 10NG (STAR 26J)- STAR 11- STAR 12
• Batteries are charged : The green diodes are on( 1 ).
• Batteries being discharged : The diodes go out one after the 1
other( 1 ).
• Batteries discharged : The red diode is on, elevation is disabled
but driving and rotation are still possible( 2 ).
When should the batteries be charged? :

• Never discharge the batteries to more than than 80 % of their capacity in 5 h .
• When the batteries are discharged between 35 % and 80 % of their nominal capacity.
• If installing new batteries, recharge them after 3 or 4 hours of use 3 to 5 times
• After a long period out of use.
• Never leave the batteries discharged.
• Do not put off recharging the batteries in cold weather as the electrolyte may freeze.
• Do not recharge the batteries if the temperature of the electrolyte exceeds 40 °C (104 °F) . Allow to cool
down.
• Keep the top of the batteries clean and dry. Incorrect connection or corrosion may cause a high loss of
power
• The charger settings are adjusted in the factory using its own cable. If the cable needs changing,
the HAULOTTE® factory must be contacted to obtain authorisation.
24203 3352 0 E 10 07 EN 151

Traction battery
10 mn E029
How to change the batteries ? :
• Use the on-board charger. The charger has a charge rate adapted to the capacity of the batteries.
• Ensure that the mains supply is adapted to the charger.
• Top-up the batteries with distilled water to the minimum electrolyte level if any of the elements is below this
level.
• Work in a clean, well ventilated area away from flames.
24 V -
Charger type
30 A
Electric power supply 220 V single phase 50 Hz
Delivered voltage 24 V
Approximately 15 h for batteries discharged

Charging time
to 80 %
Mains connection Standard plug
For STAR 8NG (STAR 22J)- STAR 9- STAR 10NG (STAR 26J)- STAR 11- STAR 12
24 V -
Charger type
30 A
Electric power supply 220 V single phase 50 Hz
Delivered voltage 24 V
Approximately 8 h for batteries discharged

Charging time
to 80 %
Mains connection Standard plug
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 :
Green LED : Battery 100 % charged
Yellow LED : Battery 80 % charged
Red LED : Charger in the intitial charge phase
152 24203 3352 0 E 10 07 EN

Traction battery
10 mn E029
When there is a fault, the LED indicator flashes in various colours depending on the type of alarm :
State of flashing LED Type of alarm Description (Action)

Battery not connected or not
Red Battery presence compliant : Check connection or
rated voltage.
Temperature probe
disconnected while charging or
Yellow Temperature probe outside the functional failure :
Check connection and measure
battery temperature.
Phase 1 or 2 is longer than the

Green Specified time maximum allowed time : Check
battery capacity
Loss of output current control :

Red-Yellow Battery current
Faulty control logic.
Loss of output voltage control :

Red-Green Battery voltage Battery disconnected or faulty
control logic.
Overheating of semiconductors :
Red-Yellow-Green Temperature
Check fan operation.
In case of an alarm, the charger stops supplying power
During charging :
• The machine's electric system is automatically deactivated during charging
• Ensure that the temperature of the elements does not exceed 45 °C (113 °F) (be careful in summer or in a
place with a high ambient temperature)
• Do not remove or open the caps on the elements.
Charge interruption :
• To turn off the charger, disconnect it from the mains.
• 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 over.
After charging :
• Top up the electrolyte level if necessary.
• Avoid overflowing.
• Wash the top of the batteries without removing the caps.
• Dry with compressed air or clean cloths.
• Oil the terminals.
When the charger is connected to the mains for more than 48 h , a new charging cycle starts up at the end
of the previous charging cycle in order to offset self-discharge.
24203 3352 0 E 10 07 EN 153

Traction battery
10 mn E029
Place the machine in operating configuration. 3.3.2-Placing in operating configuration
To keep your batteries in good condition, test the density of each element once a month using a batttery
hydrometer, according to the temperature using the curves below :
S t a t e o f b a t t e r y c h a r g e a c c o r d i n g t o t h e d e n s i t y a n d
t e m p e r a t u r e
154 24203 3352 0 E 10 07 EN

Telescopic masts
D - Diagnosis assistance
A
Diagnosis assistance
1 - Recommendations B
If malfunction occurs, check the following points :
• There is sufficient fuel.
• Sufficient engine oil.
• Sufficient hydraulic oil in the tank.
C
• Batteries are charged.
• Console emergency stop buttons are pulled out.
• The console selector key is set to upper or lower console.
• Control console relays are connected. D
• Fuse status.
• Lower console solenoid valve status.
If the malfunction persists, consult the incidents table to identify the problem.
IF you cannot identify the problem, contact HAULOTTE Services®. E
24203 3352 0 E 10 07 EN 155

Telescopic masts
2 - Finding the failure

D i a g n o s i s S TA R 6 ( S TA R 1 3 )
Display
LED on
Incident Probable cause Solution
variable
Calibrator MDI
speed
drive
OK No No ON Operational traction No action is requested
RUNS
TESTING No ON Brief display on start up No action is requested
TESTS
Calibrator protocol wrongly Set the calibrator protocol to

PLEASE WAIT No No ON
positioned AUTO
Cut-off is triggered by the

Recharge the battery or
BDI CUTOUT BDI CUT F01004 7 flash(es) BDI according to the
batteries
programmed battery level
Check :
• Variable speed drive
THERMAL OVER mounting
No 8 flash(es) temperature exceeds 75
CUTBACK TEMP. • Surface cleanliness
°C (167 °F)
Allow the variable speed
drive to cool down
Check accelerator wiring

ACCEL. Accelerator pushed down Adjust the accelerator
ACCEL. FAULT F02001 6 flash(es)
FAULT before key-locking Recycle the 'Dead Man's
selector
Release the 'Dead man's'

'Dead man's' contact is
SEQUENCE SEQ. selector and the joystick
F04005 2 flash(es) closed and the joystick
FAULT FAULT Check the 'Dead man' signal
activated on start up
and the joystick instructions
2 directions selected at the

2 DIR. same time Check the wiring to the
2 DIR. FAULT No 2 flash(es)
FAULT Recycle the directions and direction switches
'Dead man's' selector
Battery level below the 'low

Check battery voltage
battery' setting
BATTERY LOW BAT. LOW No 7 flash(es) Recharge the battery or
Recycle the inverter or the
batteries
Battery level is above the

Check battery voltageB+ Not
BAT. 'high battery' setting
BATTERY HIGH No 7 flash(es) present on the variable
HIGH Recycle the inverter or the
speed drive
156 24203 3352 0 E 10 07 EN

Telescopic masts
A
Adjusting a parameter
PERS.
PERS. ERROR No 1 flash(es) outside the range (on key- Check settings
ERROR
CRC ERROR
CRC
No 1 flash(es)
locking)
One or more corrupted Check settings

B
ERROR settings Recycle the key
Check :
Short-circuited or badly • The coil is short-circuited
COIL S/C COIL S/C F05020 9 flash(es) connected contactor coil • The control is directly
Recycle the key connected to B+ve
• The wiring
C
MOFSET is short circuited
MOFSET S/C FET S/C No 3 flash(es) Recycle FS1 or the
inverter
SYSTEM FAULT
CAN
FAULT
F05005 12 flash(es)
Faulty CAN bus
Communication fault
between nodes
Check cables, connections
and modules
D
Recycle the main switch
Check the line contactor

P. UP. TRAC. P. UP. Contacts soldered onto line
No OFF Check the control and power
WELD WELD contactor
cable bundles
VARIOUS
INTERNAL
E
CONTROLLER
Faulty variable speed drive Contact HAULOTTE
POWER UP FAIL No OFF
power internal self-tests Services®
MESSAGES
(HIGHEST
PRIORITY)
No No OFF Slack chain Check chain tension

F
Lower the platform
ALARME Perform a drive movement to
BUZZER No No OFF Permissable tilt exceeded bring the machine back
within the authorised
threshold G
Validation off for over 5 s
Begin the validation
'Dead man's' selector and
No F04003 OFF operation again (action on
validation are off for over 5
the joystick)
s
AUCUN
No F0001 OFF Validation activated
Joystick and 'Dead man's'

No action is requested
H
No F04005 OFF selector are not validated Release the joystick
for over 5 s
24203 3352 0 E 10 07 EN 157

Telescopic masts
D i a g n o s i s S TA R 8 ( S TA R 2 2 J ) - S TA R 1 0 ( S TA R 2 6 J )
Code Incident Probable cause Solution
Incorrectly set battery adjustment. Adjust the battery voltage setting.
Incorrect adjustment of the variable Check the variable speed drive

1 BATTERY LOW
speed drive parameters. settings.
Battery voltage below 19 V . Recharge the battery or batteries.
• Check the drive and pump motors

• Check the internal resistance of the
• Power cable cut-off variable speed drive between B-
2 CAPACITOR CHARGE • Cut-off or short circuit in the engine and T1/T2 and P : If it is below
• Broken variable speed drive. • 65000O
, replace the variable speed drive
• Check the cable carrier chain.
Probable fault on the weighing card :

3 WEIGHING CARD KO Short circuit on the weighing inputs. • Check variable speed drive
inputs 26 and 38.
• Overload on the weighing card

4 PRESSURE NOT OK Pressure sensor alarm. (Wire 28 to 0 V )
• Change the weighing card.
Steering potentiometer power supply Check the steering potentiometer

cut off. connections.
Check the steering potentiometer

5 STEER SENSOR KO Broken potentiometer.
and change it if necessary.
Incorrect Steer mini or Steer maxi or Check the variable speed drive
Steer 0 settings adjustment. settings (Adjust if necessary).
Problem on the MDI and/or on the link Check the MDI and the connection
6 NO COMMUNICATION between the MDI and the variable wire between the MDI and the
speed drive. variable speed drive.
• Short-circuited or badly connected

The general contactor driver does not
7 CONTACTOR DRIVER contactor coil
close.
• Faulty speed variator
Contacts jammed on the general

8 CONTACTOR CLOSED Change the general contactor (SB1).
contactor.
Short-circuited general contactor driver. Check the main relay of the coil.
Wire 19 on terminal 9 is disconnected

9 DRIVER SHORTED and forward engaged on hydraulic
Check the YV2 and the 19 wire.
unit(Variable speed drive out of order if
the relay is continuously powered).
10 SERIAL ERROR #1 Problem on the serial card. Check the serial card.
158 24203 3352 0 E 10 07 EN

Telescopic masts
A
Check the cables in the cable carrying Replace the cables in the cable
chain. carrying chain.
Check the electro-magnetic brakes.

• Replace the electro-magnetic
brakes
B
11 EB DRIVER KO • Replace the brakes.
Check the SW1 output from the main

Replace the main card.
card.
12 MICRO CONTROL KO
Check the variable speed drive.
Variable speed drive out of order.

Replace the variable speed drive.
Replace the variable speed drive.

C
Forward and reverse drive joystick • Check the joystick
13 FORW + BACK contact receives current • Check the serial card
simultaneously. • Check the variable speed drive.
• Check the validation switches

• Check the joystick contacts
D
14 INCORRECT START Erroneous start-up sequence. • Check and try out the 'Clear
Eprom'- Replace the variable speed
drive.
Check the solenoid valve cables and

Short circuit on the solenoid valves.
15 POWER FAILURE #1
Short circuit on the general contactor.
coils.
Check the main relay of the coil.

E
Short circuit on the buzzer. Check the buzzer.
Current is always zero in the right-hand • Replace the variable speed drive
16 RIGHT I=0 EVER
motor. • Check the motor pump and wiring.
17 LEFT I=0 EVER

Current is always zero in the left-hand
motor.
• Replace the variable speed drive
• Check the motor pump and wiring.
F
VMN low in idle mode or incoherent
18 RIGHT VMN NOT OK with the PWM applied (Variable speed Replace the variable speed drive.
drive out of order).
19 LEFT VMN NOT OK

VMN low in idle mode or incoherent
with the PWM applied (Variable speed Replace the variable speed drive.
G
drive out of order).
Current high in idle mode in the drive

20 LEFT STBY I HIGH motor Left (Variable speed drive out of
order).
21 RIGHT STBY I HIGH

motor Right (Variable speed drive out of
H
order).

• Change the controller
22 HIGH FIELD CUR. motor field(Variable speed drive out of
order).
I
24203 3352 0 E 10 07 EN 159

Telescopic masts
• Check the drive motor field

• Check the cable between the motor
and the variable speed drive
23 VFIELD NOT OK Voltage low in the drive motor field. • Check the internal resistance of the
variable speed drive between F1
and F2- F1 and B-- F2 and B-- F1
and B+- F2 and B+.
24 NO FIELD CURRENT
25 EEPROM KO Eprom out of order. Replace the variable speed drive.
26 CHOPPER NOT CONFIG
Variable speed drive temperature

27 TH. PROTECTION Replace the variable speed drive.
exceeds 75 °C (167 °F) .
The variable speed drive is looking for a Incorrect adjustment of the variable
28 EVP NOT OK
proportional valve. speed drive parameters.
Incorrect adjustment of the variable

29 CHECK UP NEEDED Contact HAULOTTE Services®
speed drive parameters.
General contactor opened by the

30 CONTACTOR OPEN Replace the variable speed drive.
module.
• Check the potentiometer powered

Voltage is too high on the joystick off
31 CONTACTOR OPEN in 51 and 52 (Output in 39)
neutral.
• Check the serial card or joystick.
Difference of at least 10 h between the

• Check the MDI
39 time clocks of the variable speed drive
• Replace the variable speed drive.
and the MDI.
D i a g n o s i s S TA R 9 - S TA R 1 1 - S TA R 1 2
Code Incident Probable cause Solution
Short-circuit on :
• Valve ON / OFF
1 POWER FAILURE • Proportional solenoid valve Contact HAULOTTE Services®
• Line contactor coil
• Electro-magnetic brake
Fault in the configured settings memory

zone :
• If the fault persists when the key is
turned on and then off again, replace
2 EEPROM KO the EEPROM memory and the Replace the variable speed drive
microprocessor
• If the alarm disappears, the memory
settings have been erased or replaced
by the default settings
160 24203 3352 0 E 10 07 EN

Telescopic masts
A
Forward/reverse drive, arm lifting/
lowering, platform lifting/lowering, left/
3 INCORRECT START
right steering, traction authorisation
which are active when the key is turned
off or a traction control activated before
Contact HAULOTTE Services®
B
traction authorisation
Test carried out during intitial diagnosis.

The alarm is triggered if the capacitors
4 CAPACITOR CHARGE do not charge 500 mn after the key is
turned off
• Faulty in the power unit
Replace the variable speed drive
C
5 R VMN NOT OK Test performed in idle mode with the
general contactor closed and runningIn
idle mode, if the VMN is lower than the
battery voltage, the variable speed drive
will trigger the alarm
When running, the alarm is triggered if
Check the right-hand drive motor
and the wiring (sleeve)
Replace the variable speed drive if
D
6 L VMN NOT OK the VMN does not follow the variable
the above check is ok
speed drive 'duty cycle'progression
• Incorrect motor connections
• Leakage from the motor to the earth
Check the potentiometer voltage value

in idle mode
E
The alarm alerts the user to a voltage
(on the traction accelerator received
from the serial card) above 1 V when
7 VACC NOT OK the key is turned off Check the serial card or joystick
Problem on the serial card :
• Broken potentiometer wire
• Incorrectly wired potentiometer
F
• Faulty potentiometer
• Incorrect programming
Test performed in idle mode

Voltage on the 2 field connections is
approximately half the battery voltage
The alarm is triggered when the voltage Check the drive motor field
G
is different from this value systemsCheck the F1 and F2
8 VFIELD NOT OK
• Voltage drain from the motor to the output resistances in relation to
earth positive and negative
• Motor field is not connected to the
variable speed drive
• Faulty in the power unit H
The microprocessor module checks
that the steering potentiometer signal is Check the steering potentiometer,
9 STEER SENSOR KO not outside the programmed range wiring and variable speed drive data
• Incorrect programming (steer sensor adjustment)
• Steering potentiometer maladjusted
I
24203 3352 0 E 10 07 EN 161

Telescopic masts
Test carried out during intial diagnosis

and in idle mode
This test checks that the current signal
is zero. If not, the variable speed drive
RIGHT STBY I HIGH,
10 alerts the user by disabling the machine Replace the variable speed drive
LEFT STBY I HIGH
functions
• Faulty sensor
• Fault in the measuring circuit (logic or
power)
Test carried out while in operation

The variable speed drive checks that
RIGHT I=0 EVER, LEFT the current is above the minimum
11 Replace the variable speed drive
I=0 EVER thresholdIf not, the variable speed drive
alerts the user by disabling the machine
functions
Field current anomaly. Field current is

not zero in idle mode
12 HIGH FIELD CURRENT Replace the variable speed drive
• Current sensor anomaly
Field current anomaly. Field current is

not zero in idle mode
13 NO FIELD CURRENT Replace the variable speed drive
• Current sensor anomaly
Test carried out with the line contactor

open
• Driver short-circuited
Check the general contactor driver
14 DRIVER SHORTED • Voltage measurement circuit anomaly
Contact HAULOTTE Services®
on the contactor coil
• Wiring error
• Fault in the protection hardware circuit
Test carried out with the general

contactor closed
15 CONTACTOR DRIVER • Driver short-circuited Replace the variable speed drive
• Voltage measurement circuit anomaly
on the contactor coil
Test carried out each time the general

Replace the power contactor or the
contactor is closed
variable speed drive
16 CONTACTOR CLOSED • Contacts jammed on the general
Check F1 and F2 on the variable
contactor
speed drive
Test running continuously

The alarm is triggered when 2
movement controls are activated at the
17 FORW + BACK same time Check the serial card or joystick
• Faulty wiring
• Jammed movement microswitch
• Incorrect user operation
162 24203 3352 0 E 10 07 EN

Telescopic masts
A
If the alarm is triggered when the
• Reduced traction current and pump battery is still charged, check the
18 BATTERY LOW
functions disabled
• Low battery alarm (triggered wit 10 %
residual charge)
battery value read in the TESTER
menu on the consoleIf the value is
incorrect, adjust this in the menu
B
CONFIG MENU - ADJUSTEMENT
The alarm is triggered when a problem

occurs on the electro-magnetic brake
19 BRAKE DRIVER KO
driver
• Driver short-circuited
• Faulty driver cannot control the
Replace the variable speed drive C
electro-magnetic brake
• Faulty voltage measurement circuit on
the electro-magnetic brake coil
• Faulty control module

20 CONTACTOR OPEN
• The module identifies a dangerous
situation which has not been picked up
Replace the variable speed drive D
by the main controller
• Faulty logic controller

21 MICRO CONTROL KO • Damaged microprocessor Replace the variable speed drive
connections
Request for programmed maintenance

Period since the last maintenance
Cancel the maintenance
E
22 CHECK UP NEEDED greater than 300 h Message is
programming or reset
cancelled by ON on option CHECK UP
DONE
Check the insulation on the circuit

23 NO ISOLATION
Chassis is short-circuited with the+
BATT or to the earth
and the variable speed drive
outputs
F
Repair the damaged circuit
Overload pressure switch is damaged

or disconnected Check the shunt on the card and
24 PRESSURE NOT OK Emergency stop is disabled (positive is the presence of positive voltage on
cut off at the pressure switchand not at
the logic)
the variable speed drive input
G
Invalid model configuration for the
CHOPPER NOT Check programming (shunt on the
25 variable speed drive (see the model
CONFIGURATED serial card on the lower console)
selection table)
26 EVP NOT OK
Proportional solenoid valve open in idle
mode
Check the variable speed drive
programming and absence EVP H
No messages are received from the
Check the serial card selected by
27 SERIAL ERROR 1 serial card selectedIncorrect messages
SA1
received from the serial card selected
Alert to temperature in excess of 75 °C
28
THERMAL
PROTECTION
(167 °F) Maximum current on the
armature reduced linearly to 0 at 90 °C
Check the variable speed drive
temperature (console) or replace
I
(194 °F) Alarm suppression if T is the variable speed drive
below 70 °C (158 °F)
24203 3352 0 E 10 07 EN 163

Telescopic masts
164 24203 3352 0 E 10 07 EN

Telescopic masts
E - Electric circuit
A
Electric circuit
1 - Wiring diagram-Main components B
N.B.-:- SEE END OF MANUAL.
N o m e n c l a t u r e C
Marking Description
A1 Angle sensor
ED / EG Right- and left-hand drive motor field systems
EFD / EFG Right- and left-hand electo-magnetic brakes
FU1
1A
Overload protection fuse
D
10 A
FU2
Break release protection fuse
10 A
FU3
Solenoid valve protection fuse
FU4
FU5
250 A
Power protection fuse
U5 weighing card and U4 5A serial card fuse (Option)
E
GB1 Battery group 1
GB2 Battery group 2
HA Tilt LED
HA1 Tilt warning
KM1
KM2 / KA2
Variable speed drive insulation control
Releasing of the brakes F
KM3 Main contactor
KM4 Solenoid valve power supply circuit
M1 Motor pump unit 24V 3000W
MD / MG Right- and left-hand drive motor
PV
RCH
RL1
Engine hour meter-Battery indicator (MDI)
Battery charger relay
Power relay
G
RL2 Insulation relay (inactive)
SA1 Key selector console selection (Lower console)
SA2 Movement selector (Upper console)
SB1 Lower console emergency stop push button-Line circuit-breaker
SB3
SB5
Upper console emergency stop push button
Jib control validation (Lower console)
H
SB6 Mast control validation (Lower console)
SB7 Turntable rotation validation (Lower console)
SB8 Movement validation selector (Upper console)
SB9 Horn switch
SM1
SM2
Turntable rotation joystick-Mast elevation/lowering
Platform joystick-Orientation/steering
I
SM3 Platform joystick-Driving
SQ1 Tilt sensor
24203 3352 0 E 10 07 EN 165

Telescopic masts
Marking Description
SQ4 Lower end of drive sensor (Mast)-Tilt reset contactor
SQ10 Upper end of drive sensor (Mast)
SQ12 Jib end of drive-Tilt reset contactor
U1 Battery charger socket
U2 Variable speed drive socket
U3 Turntable SERIEL card
U4 Platform SERIEL card
U5 Weighing card
YV1A Right-hand steering control solenoid valve
YV1B Left-hand steering control solenoid valve
YV2A Solenoid valve for left-hand turntable orientation control
YV2B Solenoid valve for right-hand turntable orientation control
YV3A Jib lifting or mast lowering control solenoid valve
YV3B Mast lifting control solenoid valve
YV4 Mast lifting control solenoid valve1
YV5 Jib lowering control solenoid valve2
YV6 Mast lowering control solenoid valve3
1. For Star 8NG (Star 22J) and Star 10NG (Star 26J) only
2 - Fuses
D e s c r i p t i o n o f t h e c o m p o n e n t s S TA R 6 ( S TA R 1 3 )
Marking Description
1A
FU1
10 A
FU2
10 A
FU3
Option
D e s c r i p t i o n o f t h e c o m p o n e n t s S TA R 8 ( S TA R 2 2 J ) -
S TA R 1 0 ( S TA R 2 6 J )
Marking Description
1A
FU1
10 A
FU2
10 A
FU3
166 24203 3352 0 E 10 07 EN

Telescopic masts
A
Marking Description
250 A
FU4
FU5
U5 weighing card and U4 5A serial card fuse (Option)
B
D e s c r i p t i o n o f t h e c o m p o n e n t s S TA R 9 - S TA R 1 1 -
S TA R 1 2
Marking Description C
1A
FU1
10 A
FU2
FU3
10 A
200 A
D
FU4
3 - Relays and terminals E

D e s c r i p t i o n o f t h e c o m p o n e n t s S TA R 6 ( S TA R 1 3 ) -
S TA R 8 ( S TA R 2 2 J )
Marking
KM1 Line circuit-breaker
Description
F
KM2 / KA2 Pump contactor
RCH Battery charger relay
RL1 Overload relay
RL2 Insulation relay
24203 3352 0 E 10 07 EN 167

Telescopic masts
4 - Locations and functions of the main safety features

L o c a l i z a t i o n S T A R 8 ( S T A R 2 2 J ) - S T A R 1 0 ( S T A R
2 6 J )
SQ12
A1
SQ10
SQ4 G1
P1
SQ1
168 24203 3352 0 E 10 07 EN

Telescopic masts
A
D e s c r i p t i o n o f t h e c o m p o n e n t s
Marking
A1 Jib angle sensor
Description
B
G1 Angle sensor (weighing)
P1 Steering potentiometer
SQ1 Tilt sensor
SQ4 Lower end of drive sensor (Mast)-Tilt reset contactor
SQ10
SQ12
Upper end of drive sensor (Mast)
Jib end of drive-Tilt reset contactor C
5 - Buzzers
D e s c r i p t i o n o f t h e c o m p o n e n t s S TA R 6 ( S TA R 1 3 ) -
D
S TA R 8 ( S TA R 2 2 J )
Marking Description
HA1 Warning signal
E
6 - LEDs
F
Marking Description
BDI Engine hour meter- Battery indicator
HL3 Flashing lights option
HL4 Work light option
G
S TA R 1 0 ( S TA R 2 6 J )
Marking Description
HA
HPh
MDI
Overload light- Tilt LED
Work light option
Engine hour meter- Battery indicator
H
S TA R 1 2
Marking
HL2 Flashing lights option
Description I
MDI Engine hour meter- Battery indicator
24203 3352 0 E 10 07 EN 169

Telescopic masts
170 24203 3352 0 E 10 07 EN

Telescopic masts
F - Hydraulic circuit
A
Hydraulic circuit
1 - Hydraulic diagram-Main components B
N.B.-:- SEE END OF MANUAL.
2 - Solenoid valves C
L o c a l i z a t i o n S T A R 6 ( S T A R 1 3 )
YV3 YV1 - YV2

F
Photos of the components
YV3
YV2
G
YV1a
YV1b H
24203 3352 0 E 10 07 EN 171

Telescopic masts
Marking Description
YV1A Left-hand steering control solenoid valve
YV1B Right-hand steering control solenoid valve
YV2 Mast lifting control solenoid valve
YV3 Mast lowering control solenoid valve-Safety valve
L o c a l i z a t i o n S T A R 8 ( S T A R 2 2 J ) - S T A R 1 0 ( S T A R
2 6 J )
YV5
YV4 YV1 - YV2 - YV3

P h o t o s o f t h e c o m p o n e n t s
YV3a YV3b
YV2a YV2b
YV1a YV1b
172 24203 3352 0 E 10 07 EN

Telescopic masts
A
S TA R 1 0 ( S TA R 2 6 J )
Marking Description B
YV1A Right-hand steering control solenoid valve
YV1B Left-hand steering control solenoid valve
YV2A Solenoid valve for left-hand turntable orientation control
YV2B Solenoid valve for right-hand turntable orientation control
YV3A
YV3B
YV4
Mast lifting control solenoid valve
Jib lifting control solenoid valve
Mast lowering control solenoid valve
C
YV5 Jib lowering control solenoid valve
L o c a l i z a t i o n S T A R 9 - S T A R 1 1 - S T A R 1 2
EV1 - EV4 EV10 EV10

D
Seulement pour Star 11-12 Seulement pour Star 9
EV5 - EV6 Only for Star 11-12 Only for Star 9
EV7 - EV8
F
YVx
S TA R 1 2 G
Marking Description
EV1 Mast lifting control solenoid valve
EV4 Platform elevation control solenoid valve- Jib lifting control solenoid valve
EV5
EV6
EV7
Solenoid valve for left-hand turntable orientation control
Solenoid valve for right-hand turntable orientation control
Left-hand steering control solenoid valve
H
EV8 Right-hand steering control solenoid valve
EV10 Platform lowering control solenoid valve- Jib lowering control solenoid valve
YVx Mast lowering control solenoid valve
24203 3352 0 E 10 07 EN 173

Telescopic masts
174 24203 3352 0 E 10 07 EN

Telescopic masts
G - Intervention log
A
Intervention log
1 - Intervention log B
The intervention log keeps a record of maintenance and repair work carried out during or outside the
maintenance programme.
N.B.-:-I F A HAULOTTE S ERVICES ® INTERVENTION , THE QUALIFIED TECHNICIAN MUST FILL IN
THEHAULOTTE SERVICES® INTERVENTION NUMBER. C
HAULOTTE
Number Services®
Date Type of intervention Intervenor
of hours intervention
number D
24203 3352 0 E 10 07 EN 175

Telescopic masts
HAULOTTE
Number Services®
number
176 24203 3352 0 E 10 07 EN

Telescopic masts
A
HAULOTTE
Number Services®
Date Type of intervention
of hours
Intervenor
intervention
number
B
24203 3352 0 E 10 07 EN 177

Telescopic masts
HAULOTTE
Number Services®
number
178 24203 3352 0 E 10 07 EN

Telescopic masts
A
HAULOTTE
Number Services®
Date Type of intervention
of hours
Intervenor
intervention
number
B
24203 3352 0 E 10 07 EN 179

Telescopic masts
HAULOTTE
Number Services®
number
180 24203 3352 0 E 10 07 EN

Electrical diagram
Telescopic masts
1 - STAR 6 (STAR 13)

1.1 - FOLIO 1/2
/ BDI / HOUR METRE

/ CHARGER
119
(2 - 14)
(1 - 16) (2 - 14)
/ black
/ red
133
(2 - 1)
149
(1 - 16) (2 - 1)
(2 - 1)
118
(1 - 14)
VARIATEUR / VARIABLE SPEED UNIT

(1 - 05)
145
(2 - 1)
112 (2 - 1)
(2 - 1)
109
LOW POSITION SWITCH (1 - 06)

(1 - 04)
MAIN SWITCH - battery cut-off LINE CONTACTOR SLOPE SWITCHES
FLASHING LIGHT
WORK HEADLIGHT
E609 1/2
1
Electrical diagram
Telescopic masts
1.2 - FOLIO 2/2
LS ar e on
ge AN n as iti
HS e ar M io le n
g rs ge T T at re or p os lack
s
tin eed ve GH F AD lid e H ut p
Lif Sp Re FW RI LE DE Va ak ha To hain
Br c
109
( 1 -13)
( 1 -13) Emergency
stop n°2
111
/ Dead man
( 1 -21) 133 112
( 1 -21) 149
( 1 -21) 118 / power supply

/ traction selection
118
149
150
147
126
144
143
142
141
( 1 -21) 145
( 1 -21) 112
( 1 -21) 109
Horn
bas Steering sensor Top position switch Right steering Left steer Alarms
Lifting
Low position Steering or lifting (up) ing (buzzer)
Up / down
chain slack
E609 2/2
2
100
Telescopic masts
100 L2
2.1 - FOLIO 1/3
GB2
GB1
Electrical diagram
220V
100
L6 L5
E621e - 1/3
B- P
M1
100
1
SB1
L4
(1-9)
FU4
L4 L4 L3
B+
U2
10A
L9 L7
T1
250A
F1
Variateur
F3
MD
D2
D1
EG
A1
A2
RCH
201
L4
100
L3
L10 L8
F2 T2
3
MG
2
D2
D1
ED
A1
A2
SB1a
(1-15)
FU2
20A 20A 103 L3

série
107
TRAVAIL
fusible en
installer le
PHARE DE
Si OPTION
5A
1
2
RL1
(1-11)
L3
RCH
100
D1
5A
107A
U1
FU5
2 - STAR 8/10NG (STAR 22/26J)
42A
(3-2)
107A
100
42A
SQ1
13A
107
25 A
(2-4)
SA1
20A
42A
107
1A4
42A
4
SQ4
SQ12
36A 106 42A

36
SB7
SB6
SB5
Pendulaire > 0° / Fcb

25
42A 2B6/2A6
42
105
FU1
jib
1B4
A
42A
SQ10
5A Contacteur 24A
1A
Mat
5
24
Fch (2-2)
SB1
main contactor 2B7/2A8

1A5
Pendulaire
Orientation
13A
3A18
YV1a
102 Direction droite 25 A

présence pesage
20
Shunté
steering right
BN
presence weighing
D3
Pressostat
3B17
3A17
1
2
100
détecteurs
à monter en
3B18
YV1b
SQ13
6A Direction gauche BU
BK
série si option
6
mou de chaîne
steering left
BN
27A
PNP NO
100
3B19
3A19
25
Devers 25A 100

CNB/T
RL1
CNB/S
CNB/R
CNB/Q
3A15
YV2a
SQ14
17A Orientation Gauche tilt detector 2B5 BU

BK
17
orientation left PNP NO

Q
3B14
3A14
13A 13A
13
3B12
YV2b
16A Orientation Droite 2A1 / CNA1
16
orientation right 22A
1
R S T
22
Signal U3
3B13
3A13
1B9 / 1B8
2 3
3A24
Montee
YV3a
9A 27 100 100
9
27
Pendulaire
3B20
3B23
3A23
up jib Dialogue pesage
CNC/2 CNC/3 CNC/1
U3
8A
8
weighing com
3B27
YV3b
100
100
12A 3A22
12
Montee mat
8A
3B28
3A28
up mast (1-5)
(3-2)
100
(2-2)
3B15
(3-2)
YV4
18A 86A
BUZZER
18
Descente mat
down mast
3B16
3A16
Pesage descente
Carte seriel Tourelle
26
26
6 7 8 9 10
(3-11)
Weighing down
YV5
19A Montée / descente 1A6 / 1B6 86A
2A17
19
pendulaire
3B18
3A18
up / down jib Pesage montée 38
38
76
86
CNA/6
CNA/8
CNA/9
CNA/7
(3-10)
Weighing up
CNA/10
2B14 / 2A14 Défreinage
U2
67
68
3A6 / 3B6 15A
15
Freins
Option feu à éclat
X2
X1
brakes 3A7 / 3B7 1A
7
flashing light
3A21
3B20
3A20
Montée ou Droite
100
Potentiometre 34A
34
3B4 / 3A4
86A
Descente ou Gauche
Voyant pesage de direction EFG
40
steering 28A
1A
weighing light
28
3B11
3A11
P1
potentiometer 3B5 / 3A5
R1
2,5KOhm
35A EFD
11
35
libre / free 3B3 / 3A3
1A
(2-2)
29
Traction
3A2 / CNB4 NCLTXD
2A16
2B16
4
30
SM1
21
Signal U4
1A
100
15A
2B8 / CNB5 GND
2
5
2A12
2B12
par
fil 100
37
1
2
3
4
29A
3B2 / CNB6 +12V
3
6
2B15
2A15
32
21A
connecteur MDI
Arret d'Urgence
D2
MDI indicator
37A
Indicateur MDI
Emergency stop
3A1 / CNB2 NCLRXD connecteur
3B1 / CNB3 PCLTXD défreinage
MDI
31 23
(2-2) (2-2) (2-2)
DEFREINAGE
POUR OPTION
TELECOMMANDE
3
Electrical diagram
Telescopic masts
2.2 - FOLIO 2/3
(1-9) 105 105
ORIENTATION / DIRECTION TRANSLATION / ELEVATION

(1-18) 40A ORIENTATION / STEERING TRAVEL / LIFTING
105
105
SM2 SM3
voyant de pesage
Weighing light
Australie pas de voyant HA SB9
SB3 SA2 R2 R3
not light for Australia SB8
37A
(1-21) 37A 37A
29A
(1-21) 29A
(1-21) 21A
(1-14) 100
29A
Droite Right
Gauche Left
21A
37A
traction
validation
Signal
pendulaire(jib)
Arrêt d'urgence
Marche arrière ou Descente
Marche avant ou Montée
Reverse gear or Down
Forward or Up
100
Emergency stop
CNB6
CNB3
CNB4
CNB7
CNC2
CNC4
CNC1
CN2 3
CN1/2
CN1/4
CN1/5
CN1/3
CN1/1
CN1/7
CN1/9
CN1/8
CN1/6
CN1/10
Translation / Direction
200
1 0
Travel / Steering 1 2 3 4 5
Mât / Orientation 6 7 8 9 10
0 0
Mast / Orientation
Pendulaire U4
0 1
Jib
Carte sériel Nacelle
Platform serial card
(1-7) 107A 216

100
(3-16)
X1
SA4 Option Phare de travail
HPh HA1
Work headlight Option
X2
100 100
E621e - 2/3
4
Electrical diagram
Telescopic masts
2.3 - FOLIO 3/3
CAPTEUR DE
PRESSION
382
PESAGE
(1-16) (1-15)
WEIGHING
381
PRESSURE
1 2 SENSOR
G1
(1-14) 100 +A1
Weighting up
384
Weighting down
CAPTEUR D'ANGLE
pesage en montée
pesage en descente
PESAGE
(1-6) L3 (Potentiometre)
382
38
26
381
WEIGHING
ANGLE SENSOR
2
+A1
3 1 A1
384 100
(2-13)
J4.1 J4.2 J4.3 J4.5 J11.3 J11.1 J15.1 J15.3
U5
J4 J10 J11 J15
(1-14) 8A
6 5 4 6 5 4 3 2 1 3 2 1
J10.2
3 2 1 3 2 1
CARTE PESAGE
WEIGHING CARD
E621e - 3/3
5
6
Telescopic masts
E597 1/2
220V
3.1 - FOLIO 1/2
Electrical diagram
RL2
B-
P
3 - STAR 9/11/12
SB1
(1-9)
FU4
102
B+
D2
D1
ED
T1
250A
F1
5A
FU2
F2 T2
D2
D1
EG
RCH
FU3
SB1a
RL1
10A
(1-13)
RCH
HL2
(1-16)
U1
SQ1
Battery Charger
Chargeur Batteries
SA1
2B5 25
1A4
4
Devers
SB7
SB6
SB5
Tilt detector
Contacteur
5
SB1
1A5
SQ4
SQ12
Contactor Pend > 0° / Fcb 2A6

36
1A
FU1
2B6
Jib >0˚ / Fcb
SQ10
42
1B4 2A8
24
Fch
Mat Mast
2B7
Pendulaire
Orientation
3A17 Dir gauche

20
3A18
Jib
3B17
(2-6)
Steering left
RL2
1A3
(1-2)
Isolement
27
EV7
Isolating
3A19 Dir droite
6
3B18
3B19 Steering right 2A14
38
EV8 2B14
CNB8
CNB6
CNB7
CNB1
3A20 Orientation D
7
3A21
3B20 Orientation right 1B6
26
EV6
2
1 4
E.S.
CNC
CND
3A22 Orientation G
8
3B21
3B22 Orientation left Pressostat shunté
RL1
EV5
Pressure switch shunted
CNC1
Descente nacelle
3A16
3B15 ou pendulaire
18
3B16
Down platform 1B8
22
Signal
or down jib 1B9
EV10
CNC4
CNA
MAN
3A28 Montee mat

3B27
12
3B28
13
6 7 8 9 10
Up mast 2A1
EV1
CNA1
CNC2
Montée nacelle
3A23 ou pendulaire
9
3A24
3B23 Up platform
CN2
W X
U V
COD
EV4
or up jib
(2-1)
3A18 Descente mat
19
2A17 CNB8
3B18
1
Down mast
CNB7
U3
YVx
3
+12V
32
3B2 - - - CNB6
PV
SEL
CNB
GND
2
(1-6)
2A4 - - - CNB5
6 7 8
NCLTXD
Carte seriel Tourelle
Turntable Serial card
30
3A2 - - - CNB4
MDI
5
PCLTXD
23
3B1 - - - CNB3
Tourelle
BUZZER
6
NCLRXD
MDI Indicator
Indicateur MDI
31
3A1 - - - CNB2
1
PCLRXD
CNB1
Arret d'Urgence
CNA6
CNA8
CNA7
37
2A15
2B15
Emergency
Stop 3A4 Défreinage
34
3B4
2A16 Potentiometre Brake Release
29
2B16
Traction de direction 3A5
CNA10 Up or right
28
CNA9 Down or left
P1
3B5
(2-4)
2A12 Steering
21
Signal potentiometer
2,5KOhm
2B12
Montée ou Droite
3A3
35
3B3
Descente ou Gauche
(2-2)
EFG
R1
3A7
(2-3)
3B7
3A11 EFD
40
3B11 Freins
U2
Brakes
3A6
Variateur
15
3B6
SM1
Variable speed unit
(2-5)
Electrical diagram
Telescopic masts
3.2 - FOLIO 2/2
(1-10)
ORIENTATION / DIRECTION TRANSLATION / ELEVATION

HA ORIENTATION / STEERING TRAVEL / LIFTING
(1-21) SM2 SM3

SB3
(1-18)
SB9
R2 R3
(1-20)
SA2
(1-19)
Right
(1-15) SB8
Droite
Gauche Left
Marche arrière ou Descente
Forward or Up
Marche avant ou Montée
Reverse gear or Down
CNC4
CNC1
CNB6
CNB3
CNB4
CNB7
CN2 3
CNC2
CNA/2
CNA/4
CNA/5
CNA/1
CNA/6
CNA/7
CNA/9
CNA/8
CNA/3
CNA/10
CND CNA CN2 CNB

1 2 3 4 5 3 4
Translation / Direction
1 0 Travel / Steering 6 7 8 9 10 3 6 7
CNC
Mât / Orientation MAN COD SEL
0 0
Mast / Orientation
2 U4
0 1 Pendulaire
Jib 1 4
Carte sériel Nacelle
E.S.
Platform Serial card
HA1
E597 2/2
7
Electrical diagram
Telescopic masts
8
Hydraulic diagram
Telescopic masts
1 - STAR 6 (STAR 13)

1.1 - FOLIO 1/1
MAT DIRECTION
STEERING
MAST
GAUCHE DROITE
4 LEFT 1/4" 1/4" RIGHT
PORT 2 PORT 3
2 1/4" 1/4"
0.6 mm
3 5
A B
YV1a P T YV1b
YV3
0.5 bar 0.5 bar
PORT 1 YV2
1/4" 1/4" 1/4" 1/4"
1 mm
2.3 bar 8 bar
TEST
1/4"
140 b
2030 PSI
1
2000W
1.6 cm3 24V
0.097 in3 (KM2)
C17596a
1
Hydraulic diagram
Telescopic masts
2 - STAR 8/10NG (STAR 22/26J)

2.1 - FOLIO 1/1
12
ÉCHELLE TÉLESCOPIQUE
OU PENDULAIRE LEVAGE MÂT
hydraulic ladder or jib up mast
11
7
P Commentaire:
U Version USA et AUSTRALIE pas de repère 7
2
1,
Ø
YV5
ENROULEUR
HYDRAULIQUE
5 6,9b 1 - GROUPE ÉLECTROPOMPE

I (A)
2,3b 9 140
Ø 1,4 120
YV4 100
80
YV3b
60
A
PENDULAIRE
P
I P Q
40
B
LEVAGE MÂT
Jib up mast 20
T YV3a
0 50 100 150 200 P (bar)
3 KW 3,2
Q (l/mn)
YV2a
24 V 8
P
7
T
ORIENTATION
6
YV2b
5
8 4
3
YV1a
2
P
B
T
1
DIRECTION 10 50b 50b
0 50 100 150 200 P (bar)
YV1b
STEERING
315
cm3
DIRECTION
STEERING
4
2
3
moteur hydraulique
5 cm3 ORIENTATION TOURELLE
hydraulic motor
1 turett orientation
130 b
3000 W - 24 VDC M 3,2
(KM1) =
Débit pompe 5.7L/mn à 130b
7,2 L utile
P23343d
2
Hydraulic diagram
Telescopic masts
3 - STAR 9/11/12
3.1 - FOLIO 1/1
STAR 9 nacelle / platformSTAR 11&12 pendulaire/ jib

STAR 9 60/50 C1250
MÂT/MAST
STAR 11 60/50 C1450
STAR 12 60/50 C1650
STAR 9 C1200
NACELLE/PLATFORM
PENDULAIRE/JIB ORIENTATION DIRECTION/STEERING MAT/MAS T
TENSION BOBINES / COILS VOLTAGE 24V DC
ORIENTATION DIRECTION/STEERING
B16367
3
Hydraulic diagram
Telescopic masts

CE MATS ANG E10.07

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Maintenance book

E010 - Steering wheel pivots . . . . . . . . . . . . . . . . 141

You have just bought a HAULOTTE® telescopic

handler and we would like to thank you for your

2 - After Sales Service

The maintenance book is intended for the on-site maintenance technician.

If regular maintenance work is not carried out this may :

1.2 - SYMBOLS USED

Danger : Risk of injury or death (work safety)

Caution : Risk of material damage (work quality)

Prohibition relating to work safety and quality

Reminder : No identified risk but a reminder of common sense, good

Cross-reference to another part of the manual (see section or sheet)

Cross-reference to another manual (see manual)

Cross-reference to repairs (contact HAULOTTE Services®)

Time required for intervention

N.B. : Additional technical information

Red Potentially fatal danger

Orange Risk of serious injury

Other Additional technical information E

Labels Color Meaning

Orange Risk of serious injury

Yellow Risk of material damage and/or minor injury G

Green CSA maintenance operation or information

2.2 - WARRANTY PERIOD

Spare parts are covered by a 6 month warranty.

2.3 - CONDITIONS OF WARRANTY

N.B.-:-ACID IS NEUTRALISED WITH SODIUM BICARBONATE AND WATER. C

4 Biological hydraulic oil - Barrel 209 l (55,2 gal US) 2820304310

5 Lithium exteme pressure grease 2820304320

Lead-free grease - Aerosol 0,4 l (0.1 gal US) 2820304330

9 High pressure lubricant

The red labels indicate a potentially fatal danger.

3.1.2 - Orange labels

The orange labels indicate a risk of serious injury.

J4 J13 J14 J15

3.1.4 - Other labels

The other labels provide additional technical information.

7813 744 a 7813 743 a

R16 R22 R15 R19

A23 A29 A32 F

3.1.5 - Green labels

Green labels provide maintenance operation or information( CSA standard).

R31 A1 A12 A11 A11 A12 R1 J10 J4 O1

R22 R15 Only for Australia

Only for Star9 A54

Height of the floor and load

Color Marking Description Quantity STAR 11 STAR 12

R31 A1 A12 A11 A11 A12 R1 J10 J4 O1

Height of the floor and load

R31 A1 A12 A11 A11 A12 R1 J10 J4 O1

R32 A34 A32 R31 R1

Color Marking Description Quantity STAR 6 (STAR 13)

Symbol Meaning Symbol Meaning

Check level Tightening (bolt, etc.)

Lubrication-Lubrication Tightening (oil clearance) E

1 - Increase in regular inspections

Harness anchorage points

Cables and tank bands

Rotation crown gear (3)

Tyres and rims

Wheel nuts and bolts