Haulotte STAR 6 Installation guide

T
TE EC CH HN NI IC CA AL L T TR RA AI IN NI IN NG G
S
St ta ar r 6 6/ /6 6P P – – S St ta ar r 1 13 3J J

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H
Ho ow w t to o u us se e t th hi is s d do oc cu um me en nt t? ?
Y
Yo ou u h ha av ve e b be et tw we ee en n t th he e h ha an nd ds s t th he e s su um mm ma ar ry y g gi iv ve en n d du ur ri in ng
g t th he e H HA AU UL LO OT TT TE E t te ec ch hn ni ic ca al l t tr ra ai in ni in ng g
I
It t w wi il ll l e en na ab bl le e y yo
ou u t to o f fi in nd d i in nf fo or rm ma at ti io on n n ne ec ce es ss sa ar ry y f fo or r t th he e m ma ai in nt te en na an nc
ce e a an nd d t th he e r re ep pa ai ir r o of f y yo ou ur r
H
HA AU UL LO OT TT TE E m ma ac ch hi in ne e . .
T
Th ha an nk ks s
t to o t th he e g gu ui id de e b be el lo ow w y yo ou u w wi il ll l r re ea ac ch h t th he e r re eq qu ui ir re ed d c ch ha
ap pt te er r q qu ui ic ck kl ly y. .
C
Ch ha ap pt te er r 1 1:
:M Ma ai in n f fe ea at tu ur re es s a an nd d f fu un nc ct ti io on ns s
I
It t i is s a ab bo ou ut t a a r re es su um me e o
of f t th he e i in nf fo or rm ma at ti io on n c co on nt ta ai in ne ed d i in n t th he e u us se er r m ma an nu ua al l d de el
li iv ve er re ed d w wi it th h t th he e m ma ac ch hi in ne e: :
c
co om mp po on ne en nt ts s, , o ov ve er ra al ll l d di im me en ns si
io on ns s, , w wo or rk ki in ng g z zo on ne es s , , c co om mm ma an nd ds s, , e et tc c… …
C
Ch ha ap pt te er r 2 2:
:S St tu ud dy y o of f t th he e e el le ec ct tr ri ic c s sc ch he em ma at ti ic cs s
Y
Yo ou u w wi il ll l f fi in nd d t th he
er re e t th he e e el le em me en nt ts s a as s f fo ol ll lo ow wi in ng g: :
-
- A A s su um mm ma ar ry y o of f t th he e s
st ta an nd da ar rd di iz ze ed d s sy ym mb bo ol ls s u us se ed d b by y H HA AU UL LO OT TT TE E G Gr ro ou up p
-
- T Th he e c co
om mp pl le et te e w wi ir ri in ng g d di ia ag gr ra am m o of f t th he e s st tu ud di ie ed d m mo od de el l
-
- T Th he e
n no on n e ex xh ha au us st ti iv ve e l li is st t o of f t th he e e el le ec ct tr ri ic c l lo oo om ms s a an nd d e el le ec ct
tr ro on ni ic c b bo oa ar rd ds s
-
- L Lo oc ca al li iz za at ti io on n o of f t th he e p pr ri in nc ci ip pa al l s sa af fe et
ty y u un ni it ts s ( (t ti il lt t , , l li im mi it t s sw wi it tc ch he es s, , s se en ns so or rs s, , t tr ra an ns sd du uc ce er
rs s… …) )
-
- L Lo og gi ic ca al l e eq qu ua at ti io on ns s o of f o op pe er ra at ti io on n: : b by y f fu un nc ct ti io on n, ,
t to o d di ia ag gn no os se e t th he e m ma ai in n d dy ys sf fu un nc ct ti io on ns s
C
Ch ha ap pt te er r 3 3:
:S St tu ud dy y o of f t th he e h hy yd dr ra au ul li ic c s sc ch he em ma at ti ic cs s
Y
Yo ou u w wi il ll l f fi in nd d t th
he er re e t th he e e el le em me en nt ts s f fo ol ll lo ow wi in ng g: :
-
- a a s su um mm ma ar ry y o of f t th he e s st ta
an nd da ar rd di iz ze ed d s sy ym mb bo ol ls s u us se ed d b by y H HA AU UL LO OT TT TE E G Gr ro ou up p
-
- t th he e c co om mp
pl le et te e h hy yd dr ra au ul li ic c d di ia ag gr ra am m o of f t th he e s st tu ud di ie ed d m mo od de el l
-
- a a l lo
oc ca al li iz za at ti io on n o of f t th he e p pr ri in nc ci ip pa al l h hy yd dr ra au ul li ic cs s m ma an ni if fo ol ld d ( (p pr
ro op po or rt ti io on na al l b bl lo oc ck k , , o on n/ /o of ff f m mo ov ve em me en nt ts s
b
bl lo oc ck k, ,… …) )
-
- L Lo og
gi ic ca al l e eq qu ua at ti io on ns s o of f o op pe er ra at ti io on n: : b by y f fu un nc ct ti io on n, , t to o d di ia ag gn no os
se e t th he e m ma ai in n d dy ys sf fu un nc ct ti io on ns s
C
Ch ha ap pt te er r 4 4:
:A Ad dj ju us st tm me en nt ts s
T
Th hi is s i is s t th he e a ad dj ju us st tm me en nt ts s a an nd d c ca al li ib br ra at ti io
on ns s, , h hy yd dr ra au ul li ic cs s a an nd d e el le ec ct tr ri ic c, , n ne ec ce es ss sa ar ry y t to o t th he e g go oo od
d m ma ai in nt te en na an nc ce e
o
of f t th he e m ma at te er ri ia al l. . Y Yo ou u w wi il ll l f fi in nd d a as s w we el ll l
t th he e m me et th ho od ds s o of f a ad dj ju us st tm me en nt t w wi it th h t ta ab bl le e v va al lu ue es s. .
C
Ch ha ap
pt te er r 5 5:
:G Gu ui id de e o of f b br re ea ak kd do ow wn n
Q
Qu ui ic ck k s su um mm ma ar ry y o of f t th he e s st te ep p t to o b
be e f fo ol ll lo ow we ed d f fo or r p po os ss si ib bl le e s so ou ur rc ce es s o of f b br re ea ak kd do ow wn n. .
I
In n c
ca as se e o of f a an ny y d de ef fe ec ct t o or r a an ny y d dy ys sf fu un nc ct ti io on n y yo ou u w wi il ll l b be e a
ab bl le e t to o i id de en nt ti if fy y t th he e e el le em me en nt ts s i in n q qu ue es st ti io on n, ,
w
wh ha at te ev ve er
r t th he ey y a ar re e e el le ec ct tr ri ic c o or r h hy yd dr ra au ul li ic c. .
C
Ch ha ap pt te er r 6 6:
:S Su um mm ma ar ry y o of f t th he e v ve er rs si io on ns s
T
Th hi is s m ma an nu ua al l t tr re ea at ts s o of f t th he e
l la at te es st t v ve er rs si io on n , , h ho ow we ev ve er r t th hi is s s su um mm ma ar ry y t ta ab bl le e e en na ab bl le
es s y yo ou u t to o f fi in nd d t th he e f fo or rm me er r
v
ve er rs si io on ns s o of f t th he e m ma at te er ri ia al l (
(e el le ec ct tr ri ic c a an nd d h hy yd dr ra au ul li ic cs s) ). .
C
Ch ha ap pt te er r 7 7:
:S Sp pe ec ci ia al l f fu un nc ct ti io on ns s
T
Th hi is s c ch ha ap pt te er r g ga at th he er rs s a al ll l t th he e f fu un
nc ct ti io on ns s a an nd d a ad dj ju us st tm me en nt t s sp pe ec ci if fi ic c t to o c ca ar rr ry y o ou ut t o on n t th he
e m ma ac ch hi in ne e. . T Th he er re e
d
do oe es s n no ot t e ex xi is st t f fo or r a al ll l t th he e m ma at te er ri ia al ls
s a an nd d d de ep pe en nd ds s o on n t th he e s st tu ud di ie ed d m mo od de el l. .
I
It t m mu us st t b be e t th he e
s su ub bj je ec ct t o of f a a s sp pe ec ci ia al l a at tt te en nt ti io on n a as s a an n i in nt te er rv ve en nt ti io on n b
ba ad dl ly y c ca ar rr ri ie ed d o ou ut t c ca an n d de et te er ri io or ra at te e t th he e
g
go oo od d p pe er rf fo or rm ma
an nc ce e o of f t th he e m ma ac ch hi in ne e a an nd d t th hu us s c co on ns se eq qu ue en nt tl ly y t th he e s sa af fe et ty
y o of f t th he e u us se er rs s. .
O
On nl ly y a a H HA AU UL LO OT TT TE E t te ec ch hn ni ic ci ia an n o or r a ap pp pr ro
ov ve ed d b by y H HA AU UL LO OT TT TE E S Se er rv vi ic ce es s i is s a ab bl le e t to o c ca ar rr ry y o ou ut t t th hi is s
k ki in nd d o of f
i
in nt te er rv ve en nt ti io on n. .
O
On n t th hi is s c ch ha ap pt te er r, , s so om me e s sp pe ec ci ia
al l a ad dj ju us st tm me en nt t ( (s se en ns so or rs s) ) a ar re e a al ls so o e ex xp pl la ai in ne ed d p pr ri io or r t to o
c ca al li ib br ra at ti io on n ( (d de ep pe en nd ds s
o
on n t th he e m mo od de el l) )
C
Ch ha ap pt te er r 8 8
: : l li is st t o of f s sc ch he em ma at ti ic cs s
T
Th hi is s c ch ha ap pt te er r l li is st ts s a al ll l s sc ch he em ma
at ti ic cs s ( (e el le ec ct tr ri ic c/ /h hy yd dr ra au ul li ic c) ) i in n A A3 3 s si iz ze e o of f a al ll l v ve er rs si io on
ns s a an nd d s so om me e l la ay yo ou ut t i if f
r
re eq qu ui ir re ed d
M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R O OP PE ER RA AT TI IO ON NS S O ON N Y YO OU UR R H HA AU UL LO OT TT TE
E M MA AC CH HI IN NE E
M MU US ST T B BE E D DO ON NE E O ON NL LY Y B BY Y T TR RA AI IN NE ED D , ,E EX XP PE ER RI IE EN NC CE
ED D A AN ND D A AU UT TH HO OR RI IZ ZE ED D T TE EC CH HN NI IC CI IA AN NS S

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R
RE EV VI IS SI IO ON N
Revision Edition Subject Created
by Validated by Modified by Translated by Language
00 03-11 Creation Star 6/6P MGD FRE MGD FR/EN/SP
01 07-13 Add newest
schematics
+overload / mast
adjustments
MGD MGD EN
02 02-14 Add chapter
schematics
MGD EN
03 04-15 Ad coloured
schematics in A3
format
MGD PUS-MM

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SUMMARY
1.MAIN FEATURES......................................................................................................................................................6
1.1.CHARACTERISTICS .................................................................................................................................................6
1.1.1.main components star 6p..............................................................................................................................6
1.1.2.Overall dimensions.......................................................................................................................................8
1.1.3.working zone Star 6....................................................................................................................................10
1.1.4.Features Star 6...........................................................................................................................................11
1.1.5.working zone star 6p ..................................................................................................................................12
1.1.6.Features Star 6...........................................................................................................................................13
1.2.COMMANDS.......................................................................................................................................................... 14
1.2.1.Single control unit (up/down) for star 6..................................................................................................... 14
1.2.2.Single control unit for star 6P....................................................................................................................15
2.THE ELECTRICAL PART......................................................................................................................................16
2.1.SYMBOLS USED.................................................................................................................................................... 16
2.2.METHODOLOGY OF CONTROL...............................................................................................................................20
2.2.1.electric continuity control...........................................................................................................................20
2.2.2.Control of an on/off valve........................................................................................................................... 20
2.2.3.Control of components ...............................................................................................................................22
2.3.THE WIRING DIAGRAM (113P339260) .................................................................................................................. 23
2.4.THE LOOMS (STAR 6P)..........................................................................................................................................24
2.5.LOCALIZATION OF THE SAFETY COMPONENTS......................................................................................................26
2.5.1.limit switchs star 6......................................................................................................................................26
2.5.2.limit switchs star 6P ................................................................................................................................... 28
2.5.3.contactors................................................................................................................................................... 29
2.6.CONNECTORS (VARIABLE SPEED UNIT)...........................................................................................................29
2.6.1.logical board ..............................................................................................................................................29
2.6.2.variable speed unit .....................................................................................................................................31
2.7.LIST COMPONENTS (STAR6P)................................................................................................................................32
2.7.1.Fuses...........................................................................................................................................................32
2.7.2.inputs.......................................................................................................................................................... 32
2.7.3.Outputs.......................................................................................................................................................33
2.7.4.Others.........................................................................................................................................................34
2.8.OPTIONS USA......................................................................................................................................................34
2.9.LOGICAL EQUATIONS (STAR6P) ........................................................................................................................... 35
2.9.1.powering.....................................................................................................................................................35
2.9.2.steering....................................................................................................................................................... 35
2.9.3.drive............................................................................................................................................................36
2.9.4.lifting mast..................................................................................................................................................36
2.10.ALARMS CODES....................................................................................................................................................36
2.11.BATTERY CHARGER INDICATOR ...........................................................................................................................40
3.THE HYDRAULIC PART........................................................................................................................................42
3.1.SYMBOLS USED.................................................................................................................................................... 42
3.2.HYDRAULIC DIAGRAM STAR 6/6P ......................................................................................................................45
3.3.VALVES LOCATION............................................................................................................................................... 46
4.ADJUSTMENTS........................................................................................................................................................47
4.1.DESCRIPTION OF CONSOLE.................................................................................................................................... 47
4.1.1.drive menu.................................................................................................................................................. 48
4.1.2.pump/ movements menu..............................................................................................................................49
4.2.LIST OF PARAMETERS ...........................................................................................................................................50
4.3.LIST OF ALARMS...................................................................................................................................................61
4.4.PARAMETER SETTINGS .........................................................................................................................................62
4.1.CONSOLE DIAG PAD ..............................................................................................................................................63
4.2.PRESSURES ...........................................................................................................................................................64
5.BREAKDOWN SERVICE GUIDE..........................................................................................................................66
5.1.NO START.............................................................................................................................................................66

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5.2.NO MAST LIFT ....................................................................................................................................................66
5.3.NO DRIVE............................................................................................................................................................. 66
5.4.DRIVE IN MICROSPEED ONLY ................................................................................................................................ 66
5.5.NO STEERING .......................................................................................................................................................66
6.SUMMARY OF VERSIONS ....................................................................................................................................67
7.SPECIAL FUNCTIONS............................................................................................................................................68
7.1.BRAKE RELEASE SYSTEM...................................................................................................................................... 68
7.2.HOURMETER CONNECTION ...................................................................................................................................69
7.3.MAST CHECKINGS.................................................................................................................................................69
7.4.OVERLOAD ADJUSTMENT.....................................................................................................................................72
7.5.VARIATOR IMPEDANCE CHECK .............................................................................................................................72
8.LIST OF SCHEMATICS..........................................................................................................................................73
8.1.HYDRAULIC FUNCTION......................................................................................................................................... 75
8.2.ELECTRIC FUNCTION.............................................................................................................................................77

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1
1. . M MA AI IN N F FE EA AT TU UR RE ES S
1
1. .1 1. . C
CH HA AR RA AC CT TE ER RI IS ST TI IC CS S
1
1. .1 1. .1 1. . M
MA AI IN N C CO OM MP PO ON NE EN NT TS S S ST TA AR R 6
6P
P

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1. .1 1. .2 2. . O OV
VE ER RA AL LL L D DI IM ME EN NS SI IO ON NS S

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1. .1 1. .3 3. .
W
WO OR RK KI IN NG G Z ZO ON NE E S
ST
TA AR R 6
6

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1. .1 1. .4 4. .
F
FE
EA AT TU UR RE ES S S
ST
TA AR R 6
6

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1. .1 1. .5 5. .
W
WO OR RK KI IN NG G Z ZO ON NE E S ST TA AR R 6
6P
P

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1. .1 1. .6 6. .
F
FE
EA AT TU UR RE ES S S
ST
TA AR R 6
6

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1. .2 2. . C CO OM MM MA AN ND DS S
1
1. .2 2. .1 1. .
S
SI
IN NG GL LE E C CO ON NT TR RO OL L U UN NI IT T (
(U
UP P/
/D
DO OW WN N)
)
F FO OR R S ST TA AR R 6
6

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1. .2 2. .2 2. .
S
SI
IN NG GL LE E C CO ON NT TR RO OL L U UN NI IT T F FO OR R S ST TA AR R 6
6P P

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2. . T TH HE E E EL LE EC CT TR RI IC CA AL L P PA AR RT T
2
2. .1 1. . S SY YM MB BO OL LS S U US SE ED D
Battery with one element
Alternator
Fuse (Here 10 amps)
Coil winding roll
Electric motor
light
Diode
Hourmeter
Standard push-button of safety “mushroom-headed
button”

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Rotary knob
Push-button
Limit switch
Pressure switch
Key selector with 3 positions (T turret, O neutral, N
platform)
Toggle switch with 2 positions
Electrovalve
relay
horn
Proportional electrovalve

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Controller/joysticks
Foot pedal switch
buzzer
“light”
Electrovalve “ON/OFF » ( bang-bang)
Tilt sensor ( ramp detection)
Angle sensor (reach limitation)
Contact « mercury » (angle detection)
Resistor (here value 100 ohms, 3 Watts, tolerance of 5%)

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Sensor length (reach limitation)
Pressure sensor (weighing)
Angle sensor (weighing)
Standard light “Led”
Strain gauge
(ILS : Flexible Blade Switch)
ILS detection of the magnets on the telescopic boom/arm
extension
Level detector (diesel tank)
Proximity detector with impulses (detection teeth slew
ring)

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2. .2 2. . M ME ET TH HO OD DO OL LO OG GY Y O OF F C CO ON NT TR RO OL L
Note: during an intervention on a component or a loom, it is important to remember to switch OFF
the power supply of the machine in order to avoid any risk.
2
2. .2 2. .1 1. . E
EL LE EC CT TR RI IC C C CO ON NT TI IN NU UI IT TY Y C CO ON NT TR RO OL L
The continuity check of a loom or an electric component determines the resistor of this device, in
order to detect a possible interruption of continuity (open circuit, short-circuit…).
This control is carried out with a multimeter commutated in position Ohmmeter (Ω).
First of all, it is necessary to determine the terminals of the component or the cable to control and
insulate them.
Then, connect the multimeter in order to record the value.
It must indicate a value of resistor close to 0 Ωif continuity is good.
In the contrary case if the continuity presents a defect (resistor which tends towards the infinite one :
∞),
Control of insulation
At the contrary of continuity, insulation represents a non electric connection between the ground and
the component
The test of insulation consists in obtaining the opposite result of that described for continuity, i.e. a
value of the Ohmmeter which must tend towards the infinite one : ∞
2
2. .2 2. .2 2. .
C
CO
ON NT TR RO OL L O OF F A AN N O ON N/
/O
OF FF F V VA AL LV VE E
Note: These tests are to be carried out when power is ON .
Also control the state of the terminals or any other connectors (oxidation…)
Control supply of the coil
disconnect the plug socket from the valve in order to connect in derivation the multimeter on the
terminals of the connector (see below).
select the position to voltmeter (V), then activate the command to the valve which must be tested.
The voltage indicated by the voltmeter must be close to the tension of battery