BERG BENOMIC STAR 300 Release Note

Technical Handbook
BENOMIC STAR 300 & 350
Berg Hortimotive
Burg. Crezeelaan 42a
2678 KZ De Lier
The Netherlands
Tel: [phone]
Fax: [phone]
Email: [e-mail]
Internet: www.berghortimotive.com

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Machine type plate
The BENOMIC STAR is fitted with a machine type plate which contains the following
information: address details for Berg Hortimotive, CE mark, serial and type reference, serial
number, year of construction.
If you would like to contact Berg Hortimotive, or one of their dealers with respect to this
BENOMIC STAR, please ensure that this information is always readily available.
Version 6, January 2019
The machine is manufactured by:
Berg Hortimotive
Burg. Crezeelaan 42a
2678 KZ De Lier
The Netherlands
Tel: [phone]
Fax: [phone]
Email: [e-mail]
Internet: www.berghortimotive.com

Translated user manual BENOMIC STAR 3/ 39
1. Declaration
1.1 Copyright
Berg Hortimotive
De Lier, 2019
No part of this publication may be reproduced and/or published by way of print, photocopy,
film or by any other means without the prior written consent of Berg Hortimotive, registered at
De Lier, the Netherlands.
Exceptions to this include parts of the documentation which are intended for reproduction,
such as abridged instructions and specifications on the machine itself.
1.2 Liability
Berg Hortimotive does not accept liability for dangerous situations, accidents and damage
that occur as a result of ignoring warnings or instructions, such as those shown on the
BENOMIC STAR, or contained in this documentation - for example:
- inexperienced or incorrect usage or maintenance
- being used for applications other than those for which it was designed, or in
circumstances other than those given in this documentation
- the use of components or spare parts which are not prescribed
- repairs carried without the consent of Berg Hortimotive and/or a certified dealer
- changes to the BENOMIC STAR include the following:
- alterations to the controls
- welding, mechanical works, etc
- extensions to the BENOMIC STAR or its controls
Berg Hortimotive does not accept liability when:
- customers do not meet their obligations with respect to Berg Hortimotive (financial or
otherwise)
- consequential damage is caused by defects on the BENOMIC STAR - e.g. interruption
of business, delays, etc.

Translated user manual BENOMIC STAR 4/ 39
1.3 Guarantee
For a period of 6 months after delivery, Berg Hortimotive gives the client a warranty on
material and manufacturing defects that occur during normal use. This warranty does not
apply if the defects are caused by improper use or causes other than by material and
manufacture, if Berg Hortimotive - following consultation with the client - delivers used
material or used goods or if the cause of the defects cannot be demonstrated clearly.
The warranty provisions are set out in the METAALUNIE CONDITIONS as they read
according to the most recent relevant text. The terms and conditions of delivery are available
on request.
The warranty given by Berg Hortimotive for all goods and materials not manufactured by
Berg Hortimotive will never be more than that given by its supplier. The warranty is ex works.
Faulty machines and/or parts must be sent postage paid.
When it is not possible to send out machines or systems, any travel and subsistence
expenses will be payable by the client.
Sold and delivered goods with manufacturer's, importer's or wholesaler's warranties are
subject only to the warranty provisions set by the suppliers.
Hydraulic pumps are subject only to the manufacturer's warranty, provided the pump comes
with an undamaged safety seal from the supplier.
Berg Hortimotive accepts responsibility for the availability of replacement parts, provided they
are available from its suppliers at reasonable conditions.
2. Foreword
This handbook describes the BENOMIC STAR.
This handbook provides you with information including the safety aspects, a description of
the BENOMIC STAR together with the working principles, as well as the operating
instructions and maintenance of the machine.
Potentially dangerous situations are indicated together with recommendations for avoiding
them.
It is important that this handbook is carefully read in order to learn how the BENOMIC STAR
should be operated and maintained. By reading this handbook and then using the BENOMIC
STAR, you, or anyone else, will be assisted in using the BENOMIC STAR in the correct
manner thereby helping to avoid personal injury as well as damage to the machine.
Berg Hortimotive produces safe machines. The machines are designed to meet the latest
standards and are manufactured in accordance with the latest CE approval markings. The
user remains responsible for the proper operation and for carrying out maintenance on the
machine.

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Table of contents
1. DECLARATION ................................................................................................................................................................ 3
1.1 COPYRIGHT............................................................................................................................................................... 3
1.2 LIABILITY................................................................................................................................................................... 3
1.3 GUARANTEE.............................................................................................................................................................. 4
2. FOREWORD..................................................................................................................................................................... 4
3. INTRODUCTION............................................................................................................................................................... 6
3.1 GENERAL.................................................................................................................................................................. 6
3.2 SUPPLIERS INFORMATION........................................................................................................................................... 6
4. SAFETY............................................................................................................................................................................ 7
4.1 EXPLANATION OF THE SAFETY TERMINOLOGY............................................................................................................... 7
4.2 SAFETY INSTRUCTIONS .............................................................................................................................................. 7
4.3 SAFETY PICTOGRAMS............................................................................................................................................... 10
4.4 RESIDUAL RISKS...................................................................................................................................................... 10
5. INTENDED APPLICATION............................................................................................................................................. 11
5.1 AREA OF APPLICATION.............................................................................................................................................. 11
5.2 MAIN COMPONENTS OF THE BENOMIC STAR.......................................................................................................... 11
6. TRANSPORTATION....................................................................................................................................................... 13
6.1 EXTERNAL TRANSPORT ............................................................................................................................................ 13
6.2 INTERNAL TRANSPORT ............................................................................................................................................. 13
7. PUTTING INTO OPERATION ......................................................................................................................................... 14
7.1 INSPECTION BEFORE STARTING OPERATIONS ............................................................................................................. 14
7.2 HORTICULTURE SECTOR GUIDELINES FOR PIPE RAIL SYSTEMS..................................................................................... 14
7.3 MINIMUM REQUIREMENTS FOR THE PIPE RAIL SYSTEM................................................................................................. 15
7.4 TILT ALARM ............................................................................................................................................................. 16
8. USE................................................................................................................................................................................. 17
8.1 CONTROLS.............................................................................................................................................................. 18
8.1.1 Controls on the chassis................................................................................................................................ 18
8.1.2 Controls on the platform............................................................................................................................... 19
8.2 EMERGENCY LOWERING VALVE................................................................................................................................. 21
8.3 MOVING THE BENOMIC STAR ON THE MAIN PATH .................................................................................................... 21
8.4 OUT OF USE ............................................................................................................................................................ 21
8.5 CLEANING............................................................................................................................................................... 22
8.6 PROBLEMS,CAUSES &SOLUTIONS............................................................................................................................ 22
8.7 DISMANTLING .......................................................................................................................................................... 23
9. REPAIRS & MAINTENANCE.......................................................................................................................................... 24
9.1 SPECIALIST MAINTENANCE........................................................................................................................................ 24
9.2 MAINTENANCE AND INSPECTION BY THE OPERATOR.................................................................................................... 25
9.3 BERG SERVICE ALERT ............................................................................................................................................. 25
9.4 MAINTENANCE IN AND AROUND THE SCISSOR MECHANISM........................................................................................... 26
9.5 INSPECTING THE CARBON BRUSHES .......................................................................................................................... 26
9.6 CHAIN TENSIONING .................................................................................................................................................. 27
9.7 ADJUSTING FALL VELOCITY OF SCISSORS PLATFORM .................................................................................................. 27
9.8 CHARGING THE BATTERIES....................................................................................................................................... 28
9.9 PIPE RAIL SYSTEM MAINTENANCE.............................................................................................................................. 28
10. TECHNICAL SPECIFICATIONS ................................................................................................................................ 29
11. EG DECLARATION OF CONFORMITY..................................................................................................................... 30
APPENDIX 1: MAINTENANCE LOGBOOK................................................................................................................... 31
APPENDIX 2: TECHNICAL DRAWINGS STAR 300...................................................................................................... 32
APPENDIX 3: BATTERY SAFETY SHEET.................................................................................................................... 34
APPENDIX 4: CLEANING THE POWDER COATING ................................................................................................... 39

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3. Introduction
3.1 General
You have made a good choice by purchasing the Berg Hortimotive BENOMIC STAR. You
are the owner of an first class piece of equipment that has been manufactured with great
care. You will gain the most advantage from the equipment provided that you carefully follow
the instructions given in this handbook with regard to safety, operating and maintenance.
Please study this user's handbook carefully before starting to use the BENOMIC STAR.
Always follow the safety instructions and recommendations given in this handbook.
Berg Hortimotive does not accept liability for damage or indirect damage resulting from not
following the operating and safety instructions contained in this handbook.
Neither does Berg Hortimotive accept liability whenever you or a third party make
modifications to the pipe rail wagon or its accessories, without receiving prior written
permission from the manufacturer.
The BENOMIC STAR is supplied in accordance with the conditions of sale of the Dutch
METAALUNIE, as determined by the registrar of the law court of Rotterdam and in
accordance with the most recent text contained therein. A copy of the terms and conditions
of supply can be provided on request. You can also contact the Koninklijke Metaalunie, PO
Box 2600, 3430 GA Nieuwegein, the Netherlands.
3.2 Suppliers information
In the event of breakdowns or defects occurring on the BENOMIC STAR please contact your
Berg Hortimotive dealer.

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4. Safety
4.1 Explanation of the safety terminology
Safety terminology
Danger : Indicates serious or even fatal injury may occur if the instructions in
the handbook are ignored.
Warning : Indicates injury if the instructions described in this handbook
are ignored.
Caution : Indicates damage may occur to the equipment if the instructions
described in this handbook are ignored.
Warning : Indicates possible problems if the instructions described in this
handbook are ignored.
4.2 Safety instructions
Read the following safety instructions carefully.
After reading the safety instructions they should be strictly observed at all times.
If the Pipe rail wagon safety instructions are not observed while it is being operated, it will
become substantially more dangerous and may lead to serious physical injury.
DANGER!
-Carefully read all of the user's handbook. Observe the operating and safety instructions
at all times.
-De BENOMIC STAR is only suitable for operating on pipe rail systems that comply with
the horticulture sector guidelines, the health and safety catalog in force in the
Netherlands (see 7.2).
-The BENOMIC STAR should only be used on the correct type of pipe rail system. Check
that the centre-to-centre measurement of the rails and the pipe rail wagon correspond -
see the pictogram on the platform.
-Never exceed the maximum load of 250 kg.
- 1 person including load (e.g. tools); see pictogram on the platform.
-Never exceed lateral (sideways) manual force of 110N (11 kg traction).
- The BENOMIC STAR should not be used for carrying out general maintenance activities.
-The BENOMIC STAR may only be used for maintaining crops in greenhouses.
-Using the BENOMIC STAR when it is tilting more than 2from the vertical (lengthwise
and/or crosswise) is strictly forbidden.
-All loads should be secured and placed at the centre of the work platform.
-Only one person is permitted to stand on the platform at any time.
-It is prohibited to carry/lift passengers.
-It is prohibited to remove the safety rail.

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Increasing the lifting height in any way whatsoever is strictly forbidden.
-Always remain standing on the work platform
-Keep a safe distance from fixed and/or moving parts within the greenhouse as well as
cables and ropes.
-It is prohibited to pull steel cables or lay screens using the BENOMIC STAR.
-It is forbidden to use the BENOMIC STAR as a crane.
-It is forbidden for either people or animals to enter the path on which the BENOMIC
STAR is being operated. Never operate more than one pipe rail wagon on the same
path!
-When using the BENOMIC STAR all the protective screens and covers and caps must
be fitted and secured.
-Additional options, accessories and spares must be ordered and supplied exclusively
by the manufacturer, Berg Hortimotive.
Warning!
- Operating the BENOMIC STAR may only take place when there are no other persons in
the vicinity (apart from the operator) of the machine.
-The BENOMIC STAR may only be operated by persons of 18 years or older who have
received thorough instruction about the BENOMIC STAR, who are fully familiar with this
instruction handbook and are completely aware of the dangers associated with
operating the machine.
-The BENOMIC STAR may only be operated once it has been correctly installed on the
pipe rail system.
-All personnel working in the area of the BENOMIC STAR should be made familiar with
relevant safety rules and precautions that apply to the pipe rail system.
- Instructions from the employer.
-Repairs to the BENOMIC STAR may only be carried out by personnel who have
received specific training from Berg Hortimotive.
-When carrying out maintenance on the scissor mechanism, the scissor blocks must
always be put in place before starting (see 9.4).
-Never carry out repairs to the BENOMIC STAR if it is already being operated by
someone else. Always switch it off via the main switch before carrying maintenance
activities and remove the charging plug from the wagon.
-Check the BENOMIC STAR daily for defects and carry out maintenance frequently - see
chapter 9: maintenance.
-Keep the operating controls and safety pictograms clean.
- operating controls and safety pictograms should always be clearly visible.
-Once you have finished working with the BENOMIC STAR always turn off the
main switch.
-Never leave the BENOMIC STAR unattended.
- Only when you have removed the key from the main switch.

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-It is forbidden to carry out modifications or make alterations to the BENOMIC STAR
without prior written permission from Berg Hortimotive.
-When leaving a path, you must first stop and check whether anybody is standing in the
direct vicinity before continuing on the main path.
-It is forbidden to transport loose cargo with the BENOMIC STAR.
-When stacking loads ensure that they do not protrude more than 40 cm above the
working platform. All loads should be properly secured.
-Before entering a path, ensure that there are no obstacles such as plant remains, etc
lying on it.
-Never clean the BENOMIC STAR with a water hose or steam cleaner.
-When moving the BENOMIC STAR when not on the rails, the scissor mechanism should
be fully collapsed.
-Never use the BENOMIC STAR on the public highway.
-It is forbidden to step off the equipment before it has reached the lowest position.
-Observe the safety instructions for batteries - see Appendix 3.
-Always watch out for feet and toes when operating the lift on the BENOMIC STAR! The
wagon is moved a few centimetres forward when put into position!
-It is mandatory to wear shoes with protective toe caps (S1).
-Remove the charging plug before using the BENOMIC STAR.
-After use, the direction switch must always be set at the neutral position.
Please note!
- Always keep the workplace tidy.
- An untidy working area can lead to dangerous situations.
-Always concentrate on the task in hand.
- Always keep your wits about you when operating the Pipe rail wagon. Never operate the
BENOMIC STAR when you are unable to concentrate properly or when taking medicine
whereby it is not advisable to operate machines or drive in traffic.

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4.3 Safety pictograms
On the BENOMIC STAR a number of safety pictograms have been applied. These pictograms warn
the operator about possible dangers or dangerous situations. Always observe the warnings and
contact your suppliers whenever the actual danger illustrated by the pictogram is not clear.
Always make sure that the pictograms are visible and undamaged!
The BENOMIC STAR operator must have read and fully understood this handbook. When the
operator does not understand the warnings given in either this handbook or on the machine (e.g. they
speak another language), all the instructions, potential dangers, warnings and functions must be fully
explained to them by a responsible person so that they can fully understand them.
4.4 Residual risks
Despite the best possible design and the use of risk-reducing devices and the warnings about the
dangers given in the handbook and applied to the machine itself, it is still possible that dangerous
situations can arise. Beware of the following:
-Danger of hands, fingers, arms and head becoming trapped in the scissor mechanism!
-The danger of becoming trapped while standing under the wagon when depositing or picking up
items with lifting system!
-The wagon falling over because of an incorrect pipe rail system!
-The wagon falling over because the maximum weight or manual force has been exceeded!
Only to be used indoors (in greenhouse)
Suitable for the pipe diameter stated with minimum thickness
Suitable for the centre-to-centre pipe rail system measurement
Maximum tilted position 2°
Maximum sideways manual force in Newtons (kg x10)
Maximum support distance 1250 mm
Maximum total load in kg (maximum 1x person + moveable load)
The values depend on the type of BENOMIC STAR!
Beware! Read the handbook before using!
Beware! Disconnect the power supply and consult the handbook when
carrying out maintenance
Upwards = scissor up, downwards = scissor down
Main power switch: key vertical = ON, key horizontal = OFF
Key can be removed by rotating further in the off position.
Beware: Dangerous chemical
battery - corrosive battery acid
and explosive gasses
Beware of the platform lowering!
Always use the scissor blocks
when working under or on the
scissor mechanism!
Beware: Danger of becoming trapped!
Keep hands away from the scissor
parts!

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5. Intended application
5.1 Area of application
The BENOMIC STAR has been designed for use in the greenhouse horticulture sector.
The machine may only be operated by one person with a minimum age of 18 years who has
received thorough instruction in the operation of the BENOMIC STAR and who is already
familiar with the safety instructions and this handbook, both of which they have fully
understood.
The BENOMIC STAR runs on pipe rails which have been installed according to the
horticultural sector guidelines and is intended to be used as an aid for harvesting and/or
maintaining the plants in a greenhouse. Use of the De BENOMIC STAR for any other
purposes is strictly forbidden. The maximum loading may consist of one person plus a
secured load which together should not exceed 250 kg in weight. The wagon may only be
operated once it has been correctly installed on the pipe rail system. Pay extra attention
when the scissor mechanism is descending ensuring that no people or objects can become
trapped under or between the scissor mechanism. The platform may not be entered while the
machine is on the concrete path. Always walk alongside the machine, therefore not on the
chassis when transporting it over the main path.
5.2 Main components of the BENOMIC STAR
Rail safety railing
Control panel
Foot pedal (5)
Platform
Lifting wheels
Scissor
mechanism
Gate
Drive roller
Trailing reel
Cylinder
Chassis
controls
Figure 5.1; Names of the components on the upper part of the BENOMIC STAR

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Hydraulic pump
Main box
Lift system limit
switch
Lift swivelling wheels
0.37 kW motor
Chain
Drive flanged
roller
Hydraulic
motor
Figure 5.2; Names of the components on the lower part of the BENOMIC STAR
Emergency
lowering valve
Scissor blocks
Chain tensioning
bolt

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6. Transportation
6.1 External transport
When the BENOMIC STAR has to be transported, please do as follows:
1. Close the scissor mechanism fully.
2. Retract the lift wheels so that the wagon stands on the flanged rollers.
3. Set the direction switch to neutral (0) and the speed regulator to speed 0.
4. Switch off the BENOMIC STAR via the main switch (rotate the top of the red key to
the horizontal position).
5. Secure the BENOMIC STAR properly so that it cannot move about, roll forward or tilt
over.
6. Ensure that the BENOMIC STAR remains dry and frost-free during transportation.
7. When arriving at its destination, the BENOMIC STAR should be set up in accordance
with the points described at chapter 7.1.
6.2 Internal transport
It is also possible to transport the BENOMIC STAR internally (in the greenhouse). It is
preferred that the wagon is moved on the flange rollers and lift wheels, but it can also be
moved by forklift truck for example. Moving with a forklift truck is done as follows:
1. Close the scissor mechanism fully.
2. Retract the lift wheels so that the wagon stands on the flanged rollers.
3. Switch off the BENOMIC STAR via the main switch (rotate the red key to a horizontal
position).
4. Put the forklift truck forks as far apart as possible then push them under the wagon as
far as possible.
5. Check the other side to see whether the forks stick out and are positioned at the
centre of the BENOMIC STAR
6. Secure the BENOMIC STAR to the elongation of the forks on the forklift truck so that
wagon cannot move or slide off.
7. Lift the BENOMIC STAR carefully from the ground and no higher than is necessary.
Please note!
- Never lift higher than necessary!
- Ensure that the forklift truck can lift at least 500 kg weight!
- Remove anything lying loosely on the platform before lifting!
- Drive slowly and carefully!

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7. Putting into operation
The BENOMIC STAR has been specially designed to run on a pipe rail system. When
leaving the Berg Hortimotive factory, the pipe rail wagon is checked for proper functioning
and safety. Before starting up the BENOMIC STAR, the items described at section 7.1
should be inspected.
The pipe rail system must comply with the requirements as laid down in the horticulture
sector guidelines. The minimum specifications are given at Article 7.3 for the track width,
pipe diameter and supports. These minimum requirements are also displayed on a pictogram
(see 2.3) on the BENOMIC STAR.
These pipe rail specifications have been taken from the horticulture sector guidelines for pipe
rail systems from the health and safety catalog in force in the Netherlands. For the complete
contents of the policy regulation please contact the Ministry of Social Affairs & Employment.
7.1 Inspection before starting operations
The following points should be checked before starting up the BENOMIC STAR
-There are no loose electrical connections (all the functions and buttons work
properly).
-No damaged cables and/or hydraulic hoses leaks.
-The drive roller, trailing reel and lift wheels are not damaged and run freely.
-The batteries are charged (see battery indicator 8.1, no 4).
-There is no general damage (specifically the scissor mechanism).
-There is no impairment to the visibility of the control components, pictograms and
symbols.
-All the screens and protective caps and covers are firmly in place.
-The scissor mechanism is secured on the chassis and the safety railing to the
scissor.
-The lifting system working properly.
7.2 Horticulture sector guidelines for pipe rail systems
The BENOMIC STAR has been designed to run on a pipe rail system. This means that there
are rails on the paths between the plants which consists of two pipes of the same diameter
and having a fixed width between them (centre-to-centre measurement). The pipes are often
used as heating pipes and are supported along fixed distances. The pipe rail system must
satisfy the most recent requirements of the horticultural sector guidelines for pipe rail
systems. In Article 7.3, the minimum requirements are also given for the pipe rail systems
which are taken from the sector guidelines for pipe rail systems. The pipe rail system on
which the BENOMIC STAR is intended to be used, must also comply with these
requirements. All the above-mentioned items should also be checked periodically according
to the health and safety catalog in force in the Netherlands. It is absolutely prohibited to use
a pipe rail system that does not comply with the sector guidelines or policy regulations. A
number of tests are described in the policy regulations for determining whether it is possible
to operate safely with the wagons on the pipe rail system. These tests should be
implemented prior to working with the combination of the pipe rail wagon and the available
pipe rail system.

Translated user manual BENOMIC STAR 15 / 39
7.3 Minimum requirements for the pipe rail system
The rails (normally heating pipes) must have an external diameter of either 51 mm or 45 mm
and a wall thickness of at least 2 mm. The minimum material specifications for the pipes is as
follows: Steel 37 (S235JR). The distance between the pipe rail system supports may not
exceed 1.25 metres (centre-to-centre). When combining pipes with a diameter of 45 mm to a
track width of 42 cm, the distance between the rail supports should not exceed 1 metre. The
pipe rail supports used should be in accordance with, or equivalent to the following
specifications: 1.5 mm thick steel base plate with reinforcing profile - base plate width of at
least 115 mm - the length should be such that the base plate protrudes at least 70 mm from
the two vertical supports which carry the load of the pipes. The centre-to-centre distance
between the pipes should be at least 42 cm. The pipes must be properly secured, precisely
installed and with a maximum tilt of no more than 2in both length or in width. The pipes
must also be properly attached to the supports and the concrete track. Loose fitting pipes
must not be used! A soil test bore should be carried out using probing equipment (see policy
regulation). It should have a so-called cone value on the top layer of more than 0.4 Mpa (62
psi).
Employing a pipe rail system that is not described in the policy regulation according to the
health and safety catalog in force in the Netherlands is permitted provided that a stability test
is carried out in accordance with the pipe rail system policy regulation according to the health
and safety catalog in force in the Netherlands and where it appears that the combination of
pipe rail trolley and pipe rail system in question is in fact stable. Furthermore, the supports
for this exceptional pipe rail system must have a maximum spacing of one metre and the
alignment variation in both length and breadth must not exceed 2 degrees.
The tubes are similar or at least equal to the specifications given in the table below.
The conditions for the axle load stand in the table below.
Cat.
Track-
width
Tube-
diameter /
thickness
Support-
distance
Permissible axle load at
center to center size
Cat.
[mm]
[mm]
[mm]
420mm
[kg]
500mm
[kg]
550mm
[kg]
600mm
[kg]
1
420 t/m
600
51 / 2,25
max. 1000
507
548
573
593
2
420 t/m
600
51 / 2,25
max. 1250
406
438
458
475
3
420 t/m
600
45 / 2
max. 1000
345
372
372
403
4
420 t/m
600
45 / 2
max. 1250
276
298
276
323
Quality steel 37 (St37)
Wheelbase between 62.5% and 125% of the support distance.
All values for other pipe and tube rail supports should be calculated separately.
Source: The Dutch health and safety catalog in force in the Netherlands
https://agroarbo.nl/catalogus/buisrailsysteem/

Translated user manual BENOMIC STAR 16 / 39
7.4 Tilt alarm
The BENOMIC STAR is fitted with a tilt indicator alarm with an acoustic warning signal. The
tilt indicator provides an acoustic signal when the machine is tilting over in excess of 2.
When this occurs all work being carried out must stop immediately, the scissor
mechanism should be lowered as far as possible, and the operator should step off the
BENOMIC STAR then take it back while walking beside it. Thereafter the pipe rail system
should be adjusted before any activities can be restarted. First test the prepared section of
rails with the scissor mechanism in the lowest position and at low speed. If there are no
problems with this, test again with the scissor mechanism in the highest position at minimum
speed. Normal activities can be restarted if no problems arise.
Always try to find a permanent solution to prevent the machine tilting on the rails!

Translated user manual BENOMIC STAR 17 / 39
8. Use
Ensure that you are familiar with the BENOMIC STAR and its control devices. Ensure that
those using the BENOMIC STAR have received instruction for Pipe rail wagons and have
read and thoroughly understand the safety instructions and have read this handbook.
- The BENOMIC STAR should only be used when the operator is certain that there is nobody
in the nearby vicinity of the Pipe rail system.
- Always remove plant remains etc, and any other obstacles from the pipe rail system.
- Keep the wagon clean and regularly remove any waste materials. Before cleaning the
wagon, switch it off by removing the keys from the contact.
- After using the BENOMIC STAR always remove the key from the contact.
- Service the BENOMIC STAR regularly and store it in a dry and frost-free environment if it is
out of use over long periods.
Charge the batteries when the battery indicator remains in the red zone. If this occurs
while working, there is normally enough power to last until the end of the day. When
the acoustic signal repeatedly gives off 2 beeping noises, then the batteries on the
BENOMIC STAR should be charged immediately. During charging, the charger must
remain connected for approximately 12 hours until the charger indicates the battery is
charged. (see the battery handbook for further information). Short battery charging
periods during breaks, etc, must be avoided as they can cause serious damage to the
batteries. Charging a battery before it is flat (battery condition meter still in the green
zone) can shorten the life of the battery because each charging cycle wears out the
battery - so avoid unnecessary charging!
BEWARE! Danger of injury with batteries:
Avoid the battery fluid (electrolyte) coming into contact with skin, wear safety goggles and
gloves as this battery acid is highly corrosive. Wash with soap and water if it comes into
contact. If it comes into contact with the eyes, immediately rinse in running water for a period
of at least five minutes and call for medical assistance. Always ensure there is sufficient soap
and water in the vicinity and that assistance is within calling distance when people have to
work around batteries. Avoid short circuits (sparks), and ensure that there is no electrical
connection between the battery poles. The battery cover should be in good condition. Bare
patches or dents can cause short circuits!
Explosive gas is released while batteries are being charged. Always stay well clear with
sparks, naked flames or cigarettes. Ensure that the place where batteries are charged and/or
stored is well ventilated. Ensure that no metal objects can fall on top of the batteries as this
could cause short circuits or sparks which could lead to an explosion.
Remove all personal objects including rings, bracelets, neck chains and wrist watches when
working within the vicinity of batteries. For example, a short circuit could melt a ring resulting
in serious burn injuries.

Translated user manual BENOMIC STAR 18 / 39
8.1 Controls
8.1.1 Controls on the chassis
1. MAIN SWITCH / EMERGENCY STOP
The BENOMIC STAR can be switched off and on using the main switch. When the key is in
the vertical position (drive) the wagon is ON, and in the horizontal position (opposite of drive)
the wagon is OFF. Whenever the BENOMIC STAR is switched on the battery condition
meter also operates (see no 4). When the BENOMIC STAR is not being used or is being
charged, the red key should be removed from the contact. The main switch also acts as an
emergency stop. The wagon is completely switched off whenever the key is in the horizontal
position.
Only switch on the BENOMIC STAR when the direction switch (6) is set to neutral and
the speed regulator button (7) is at 0. If this is not done then the battery condition meter
will display a start-up error by way of the flashing LEDs, so you must now put the direction
switch and/or potentiometer to the neutral and/or RESET position in order to remove this
start-up error.
2. SERVICE BUTTON SCISSOR CONTROLS
You can raise or lower the scissor with the scissor control selector switch without having to
stand on the platform. Rotate the button clockwise (white strip at the top) and the scissor will
rise for as long as the button is pressed. Rotate the button anticlockwise (white strip at the
bottom) and the scissor will lower for as long as the button is pressed.
Please note!
-Make sure that no people or objects can fall under or between the scissor
mechanism when it is being lowered!
-Make sure there is sufficient space above the BENOMIC STAR when being
raised!
-Never operate the button when somebody is on the platform!
3. SOCKET FOR THE CHARGING PLUG
The batteries are charged using this plug. Always ensure that the plug is disconnected
before starting to use the BENOMIC STAR! Always remove the charging plug when carrying
out maintenance. Only a suitable charger should be used - see the specifications on the
charger.
When the BENOMIC STAR is fitted with an internal battery charger (stated on
the contact see figure 8.2) then only a 230 volt mains cable needs to be
connected.
Figure 8.1; Controls on
the chassis of the
BENOMIC STAR
Figure 8.2; Internal battery charger!
1
2
3
4

Translated user manual BENOMIC STAR 19 / 39
4. BATTERY CONDITION METER
The battery condition meter gives information about the status of the battery. The battery is
full when all the LEDs are lit - the fewer the LEDs lit up, the lower the battery charge. The
LEDs are coloured green, orange and red. When the red, orange and green LEDs are all lit
up the battery is 80% to 100% full –with only the red and orange LEDs it is 40% to 70% -
and only the red LEDs means that the batteries have only 20% to 30% of the charge
remaining. Charge the batteries when the battery indicator is in the red zone. If this occurs
while working, there is normally enough power to last until the end of the day. When the
acoustic signal repeatedly gives off 2 beeping noises, then the batteries on the BENOMIC
STAR should be charged immediately. Switch off the BENOMIC STAR with the key switch
and then charge the battery for at least 12 hours without interruption or until the battery
charger indicates that the battery is full. (consult the battery charger handbook!)
Avoid charging the battery when the battery condition meter is still showing at least 50%
charge remaining. Always try to go down to approximately 20% state of charge before
charging. This has the following advantages:
Fewer charging cycles, increased battery life
Lower water consumption
Less energy consumed
When the battery condition meter LEDs all flash in turn, it means that the BENOMIC STAR
has been started up wrongly. Make sure that the emergency stop is pulled out, then switch
the main switch (1) OFF and then ON again. With the above, always put the direction
selector switch (6) in neutral.
5. FOOT PEDAL
The foot pedal (5) is mounted in the platform (page 11), the BENOMIC STAR will drive in the
desired direction as long as the foot pedal is actuated.
8.1.2 Controls on the platform
Fig. 8.3; Control panel
6
7
8
9
10
10

Translated user manual BENOMIC STAR 20 / 39
6. SWITCHING THE DIRECTION OF TRAVEL TO REVERSE
The direction of travel selected is determined by setting the selector to the desired direction.
The switch has a central neutral position (0). When leaving the BENOMIC STAR unattended,
always put the switch to the central position.
7. SPEED REGULATION BUTTON
0 = standstill 10= maximum speed
Put this button to 0/RESET for switching on the BENOMIC STAR!
8. EMERGENCY STOP
Only to be used in emergencies! Use only the main switch (1) for switching off.
- Press = stopping and switching off
- Turn and pull = releasing
Only release the emergency stop when the direction switch (6) is set to neutral and the
speed regulation button (7) is at 0.
9. WORK PLATFORM LOWERING/RAISING, ROTATING SWITCH
The work platform can be raised and lowered using the rotating switch. The platform lowers
for as long as the button is turned downwards in an anticlockwise direction.
Beware of people or objects in the vicinity of the scissor mechanism when lowering!
The scissor mechanism rises to a maximum platform height by pushing the button clockwise
and upwards.
10. RAISING THE WAGON HYDRAULICALLY
Pressing (1x) of these buttons completely, lowers or raises
the BENOMIC STAR after which it can be manually turned and moved.
The press-button on the right hand side is for extending the lift. (wagon up)
The press-button on the left hand side is for retracting the lift. (wagon down)
Please note!
- Only raise the platform on flat ground (concrete path or main path) and never do this
on the pipe rails or on a sloping surface.
-Allow the platform to completely lower before raising the BENOMIC STAR!
-Beware of toes and fingers when lowering the BENOMIC STAR!