Haulotte Group star 6 User manual

Operator's manual
STAR 6 - STAR 13
4000426500 E 02.16 USA / GB
Operator's manual
STAR 6 - STAR 13
24203 0
E 02.16
USA

2 4000426500 E 02.16 USA / GB
STAR 6 - STAR 13

3
CONTENTS
Operator's manual
CONTENTS
A
FOREWORD
1 - User responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 - Owner's responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 - Employer's responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 - Trainer's responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 - Operator's responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 - Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 - Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1.1 - Misuse Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1.2 - Falling Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1.3 - Overturning / Tip-over Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1.4 - Electrocution Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.5 - Explosion / Fire Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.6 - Crushing / Collision Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.7 - Uncontrolled movement Hazards . . . . . . . . . . . . . . . . . . . . . . . . 17
3 - Safety inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 - Incident notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 - Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 - Product information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1.1 - Change of Ownership Notification . . . . . . . . . . . . . . . . . . . . . . . 19
5.1.2 - Owner information update form . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2 - Product specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
B
FAMILIARIZATION
1 - General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.1 - Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2 - Decal content. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3 - Symbols and colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.4 - Level of severity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.5 - Symbols legend and definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2 - Models description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3 - Primary machine components. . . . . . . . . . . . . . . . . . . . . 28
3.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2 - Maintenance support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3 - Extension deck (If fitted). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4 - Ground control box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4.2 - HAULOTTE Activ'Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.5 - Platform control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.5.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4 - Performance Specifications. . . . . . . . . . . . . . . . . . . . . . . 40
4.1 - Technical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2 - Working area / Range of motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5 - Decals and markings locations . . . . . . . . . . . . . . . . . . . . 46

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Operator's manual
C
PRE-OPERATION INSPECTION
1 - Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2 - Working area assessment . . . . . . . . . . . . . . . . . . . . . . . . 60
3 - Inspection and Functional test . . . . . . . . . . . . . . . . . . . . 61
3.1 - Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4 - Safety functional checks . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.1 - E-Stop button check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.2 - Activation of controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.3 - Fault detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.3.1 - Buzzers test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.4 - Slope warning device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.5 - Travel speed limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.6 - Electronic variable speed drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.7 - Operating temperature (For Russia and the Ukraine only) . . . . . . . . . 68
4.8 - Machine braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.9 - Wheel motor brake release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.10 - Pothole protection system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.11 - On-board charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.11.1 - Battery charge level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
D
OPERATION INSTRUCTIONS
1 - Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.2 - Operation from the ground control box. . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.3 - Operation from the platform control box. . . . . . . . . . . . . . . . . . . . . . . . . . 72
2 - Ground control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.1 - To start and stop the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.2 - Movement control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.3 - Additional controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3 - Platform control box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.1 - To start and stop the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.2 - Drive and steer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.3 - Movement control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.4 - Additional controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4 - Emergency procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.1 - In case of power loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.2 - Exit from platform when elevated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5 - Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.1 - Putting in transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.2 - Machine layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.3 - Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.4 - Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.4.1 - Electric brake release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.5 - Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.6 - Loading by ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.7 - Unloading by ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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CONTENTS
Operator's manual
5.8 - Lifting operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.8.1 - Loading and unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.8.1.1 - Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.8.1.2 - Necessary equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.8.1.3 - Preliminary procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.8.1.4 - Procedure for the use of slings . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.9 - Loading and unloading with forklift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6 - Cold Weather Recommendations . . . . . . . . . . . . . . . . . . 84
6.1 - Hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7 - Battery care and maintenance. . . . . . . . . . . . . . . . . . . . . 85
7.1 - Battery charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
E
GENERAL SPECIFICATIONS
1 - Machine dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2 - Major component masses . . . . . . . . . . . . . . . . . . . . . . . . 90
3 - Acoustics and vibrations . . . . . . . . . . . . . . . . . . . . . . . . . 90
4 - Wheel/Tire assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.1 - Technical specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2 - Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
F
MAINTENANCE
1 - General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2 - Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3 - Inspection program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.1 - General program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.2 - Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.3 - Periodic inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.4 - Reinforced inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.5 - Major inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4 - Repairs and adjustments . . . . . . . . . . . . . . . . . . . . . . . . . 97
G
OTHER INFORMATION
1 - Warranty disclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.1 - After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.2 - Manufacturer's warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.2.1 - Warranty acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.2.2 - Warranty period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.2.3 - Procedure conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.2.4 - Conditions of warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2 - Subsidiary contact information. . . . . . . . . . . . . . . . . . . 102

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Operator's manual

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A - Foreword
Foreword
You have just purchased a HAULOTTE® product and we would like to thank you for your business.
The Aerial Work Platform is a mechanical device primarily designed and manufactured with the intent to position people
with the necessary tools and material to overhead elevated temporary workplaces. All other uses or alterations/modifi-
cations to the aerial work platform must be approved by HAULOTTE®.
This manual shall be considered a permanent component of the machine and shall be kept with the aerial work platform
in the designated Manual Holder, at all times.
Safe operation of this product can only be assured if you follow the operating instructions contained in this manual. To
ensure proper and safe use of this equipment, it is strongly recommended that only trained and authorized personnel
operate and maintain the aerial work platform.
We would particularly like to draw your attention to 2 essential points :
• Comply with safety instructions.
• Use the equipment within the specified/published performance limits.
With regard to the designation of our equipment, we stress that this is purely for commercial purposes and not to be con-
fused with the technical specifications. Only the specifications in this manual should be used to study the suitability of
the equipment for the intended use.
This operator's manual is specific to the HAULOTTE® products listed on the cover page of this manual.
The operator's manual does not replace the basic training required for equipment operators. HAULOTTE® has compiled
this manual to assist in safe and efficient operation of the products covered in the manual.
The manual must be available to all operators and must be kept in a legible condition. Additional copies can be ordered
from HAULOTTE Services®.
Stay Safe and keep working with HAULOTTE® !
Original language and version :
Manuals in English and French are the original instructions. Manuals in other languages are translations
of the original instructions.

8 4000426500 E 02.16 USA / GB
STAR 6 - STAR 13
A - Foreword
1 - User responsibility
1.1 - OWNER'S RESPONSIBILITY
The owner (or hirer) has the obligation :
• To inform operators of the instructions contained in the Operator's Manual.
• For applying the local regulations regarding operation of the machine.
• To replace all manuals or decals that are either missing or not legible. Additional copies can be
ordered from HAULOTTE Services®.
• To establish a preventive maintenance program in accordance with the manufacturer's
recommendations, taking into account the environment and severity of use of the machine.
• To perform periodic inspections in accordance with HAULOTTE® recommendations and local
regulations.
All malfunctions and problems identified during the inspection shall be corrected before the
aerial work platform is returned to service.
1.2 - EMPLOYER'S RESPONSIBILITY
The employer has the obligation :
• To authorize the operator to use the machine.
• To inform and familiarize the operator with the local regulations.
Forbid anyone from operating the machine if :
• Under the influence of drugs, alcohol, etc.
• Subject to fits, loss of motor skills, dizziness, etc.
1.3 - TRAINER'S RESPONSIBILITY
The trainer must be qualified to provide training to operators in accordance with applicable
local regulations. The training must be given in an obstacle-free area until the trainee is
considered competent as defined by the training program undertaken.

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A - Foreword
1.4 - OPERATOR'S RESPONSIBILITY
The operator has the obligation to :
• Read and understand the contents of this manual and familiarize himself with the decals affixed on
the machine.
• To inspect the machine before use according to HAULOTTE®'s recommendations..
• To inform the owner (or hirer) if the manual or any decals are missing or are not legible.
• To inform of any malfunctioning of the machine.
The operator shall ensure that frequent inspections were conducted by the owners and the
operator may only operate the machine for the purpose intended by the manufacturer.
Only authorized and qualified operators may operate HAULOTTE® machines.
All operators must become familiar with and fully understand the emergency controls and be
able to operate the machine in an emergency.
The operator has the obligation to stop using the machine in the event of malfunction or safety
problems on the machine or in the work area and report the problem immediately to his/her
supervisor.

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A - Foreword
2 - Safety
2.1 - SAFETY INSTRUCTIONS
2.1.1 - Misuse Hazards
• Do not attach overhanging loads when raising or lowering the platform.
• Do not tie the platform to an adjacent fixed or mobile structure.
• Do not use/operate the machine when alone. A survey person or immediate Supervisor must be
present on the ground in case of emergency.
• Do not use a faulty or poorly maintained machine. Remove defective/damaged machine from service.
• Do not climb onto the compartment covers of the machine.
• Do not replace items critical to machine stability with items of different weight or specification.
• Do not replace factory-installed tires with tires of different specifications or ply rating.
• Do not alter or disable machine components that in any way affect safety and stability.
• Do not disable the safety devices.
• Do not use the machine for any other purpose than to position people,
their tools and material to the overhead/elevated temporary work places.
• Do not use the machine as a crane, material lift or elevator. Only use
the machine as it was intended.