Pinguely-Haulotte STAR Series Operating manual

L'ACCES A L'ESPACE
CISEAUXARTICULEES TELESCOPIQUESMATS TRACTEES
ISO 9001
PINGUELY HAULOTTE • LA PERONNIERE - BP 9 - 42152 L'HORME • Tél. [phone] • Fax SAV [phone]
email [email protected] • Web www.haulotte.com
OPERATING AND MAINTENANCE
INSTRUCTION
Self-propelled platform
STAR 8 - STAR 10
242 031 7880 - E 04.02 GB

Operating and maintenance instructions
i
Caution !
Caution !
GENERAL
You have just taken delivery of your mobile elevating work platform
It will give you complete satisfaction if you follow the operating and maintenance
instructions exactly.
The purpose of this instruction manual is to help you in this.
We stress the importance:
• of complying with the safety instructions relating to the machine itself, its use
and its environment,
• of using it within the limits of its performances,
• of proper maintenance upon which its service life depends.
During and beyond the warranty period, our After-Sales Department is at your
disposal for any service you might need.
Contact in this case our Local Agent or our Factory After-Sales Department,
specifying the exact type of machine and its serial number.
When ordering consumables orspares, use this documentation, together with the
«Spares» catalogue so as to receive original parts, the only guarantee of
interchangeability and perfect operation.
This manual is supplied with
the machine and is included
on the delivery note.
REMINDER:You are reminded that our machines comply with the provisions of
the «Machines Directive» 89/392/EEC of June 14th 1989 as
amended by the directives 91/368/EEC of June 21st 1991, 93/44/
EEC of June 14th 1993, 93/68/EEC of July 22nd 1993 and 89/336/
EEC of May 3rd 1989, directive 2000/14/CE and directive EMC/89/
336/CE.
The technical data contained
in this manual cannot involve
our responsibility and we
reserve the right to proceed
with improvements or
modifications without
amending this manual.

Operating and maintenance instructions
ii

Operating and maintenance instructions - STAR 8 - 10
iii
CONTENTS
1 - GENERAL RECOMMENDATIONS - SAFETY............................................................ 1
1.1 - GENERAL WARNING................................................................................................. 1
1.1.1 - Manual..................................................................................................................................... 1
1.1.2 - Labels ...................................................................................................................................... 1
1.1.3 - Safety....................................................................................................................................... 1
1.2 - GENERAL SAFETY INSTRUCTIONS......................................................................... 2
1.2.1 - Operators................................................................................................................................. 2
1.2.2 - Environment............................................................................................................................. 2
1.2.3 - Using the machine................................................................................................................... 2
1.3 - RESIDUAL RISKS....................................................................................................... 4
1.3.1 - Risks of jerky movements and tipping over ............................................................................. 4
1.3.2 - Electrical risk............................................................................................................................ 4
1.3.3 - Risk of explosion or burning..................................................................................................... 4
1.3.4 - Risks of collision ...................................................................................................................... 4
1.4 - INSPECTIONS............................................................................................................ 4
1.4.1 - Periodic inspections................................................................................................................. 4
1.4.2 - Examination of machine suitability........................................................................................... 5
1.4.3 - State of conservation............................................................................................................... 5
1.5 - REPAIRS AND ADJUSTMENTS................................................................................. 5
1.6 - VERIFICATIONS WHEN RETURNING TO SERVICE................................................ 5
2 - PRESENTATION ......................................................................................................... 7
2.1 - IDENTIFICATION........................................................................................................ 7
2.2 - MAIN COMPONENTS................................................................................................. 8
2.3 - WORKING AREA ........................................................................................................ 9
2.3.1 - Working area for the STAR 8 mast.......................................................................................... 9
2.3.2 - Working area for the STAR 10 mast...................................................................................... 10
2.4 - TECHNICAL DATA.................................................................................................... 11
2.4.1 - STAR 8 / 10 technical data:.................................................................................................. 11

Operating and maintenance instructions - STAR 8 - 10
iv
2.4.2 - Dimensions of the STAR 8 and STAR 10 masts.................................................................... 11
2.5 - LABELS......................................................................................................................13
2.5.1 - Label positioning.................................................................................................................... 13
2.5.2 - Yellow labels: .........................................................................................................................16
2.5.3 - Red labels: .............................................................................................................................16
2.5.4 - Miscellaneous labels:............................................................................................................. 17
2.5.5 - Specific labels for Holland:..................................................................................................... 17
2.5.6 - Specific labels for Australia:...................................................................................................17
3 - OPERATING PRINCIPLE...........................................................................................19
3.1 - HYDRAULIC CIRCUIT...............................................................................................19
3.1.1 - Turntable orientation, mast telescoping, jib lifting movements............................................... 19
3.1.2 - Steering movement................................................................................................................ 19
3.1.3 - Mast telescoping and jib lifting cylinders................................................................................ 19
3.1.4 - Turntable rotation................................................................................................................... 19
3.1.5 - Manual emergency movement...............................................................................................19
3.2 - ELECTRIC CIRCUIT..................................................................................................20
3.2.1 - Electronic speed chopper.......................................................................................................20
3.2.2 - Contactor plate....................................................................................................................... 20
3.2.3 - Direct electric travel................................................................................................................ 20
3.2.4 - Tilt control up to 3°.................................................................................................................20
3.2.5 - High travel speed ................................................................................................................... 21
3.2.6 - Wheel motor brake release....................................................................................................21
4 - USE.............................................................................................................................23
4.1 - SAFETY SYSTEMS...................................................................................................23
4.1.1 - Movement (control from the "paltform" station)......................................................................23
4.1.2 - Battery discharge................................................................................................................... 23
4.2 - UNLOADING - LOADING - MOVING.........................................................................23
4.2.1 - Unloading by lifting................................................................................................................. 23
4.2.2 - Unloading by trunk .................................................................................................................24
4.2.3 - Unloading with ramps............................................................................................................. 24
4.2.4 - Loading .................................................................................................................................. 25
4.2.5 - Moving....................................................................................................................................25

Operating and maintenance instructions - STAR 8 - 10
v
4.3 - OPERATIONS BEFORE THE FIRST OPERATION.................................................. 26
4.3.1 - "Turntable" control station...................................................................................................... 26
4.3.2 - "Platform" control station........................................................................................................ 26
4.3.3 - Checks before operation........................................................................................................ 27
4.4 - BEFORE EACH USE................................................................................................. 28
4.4.1 - Switching power on................................................................................................................ 28
4.4.1.1 - Movement tests .................................................................................................................................... 28
4.4.1.2 - Switching to the "platform" control........................................................................................................ 28
4.4.2 - Operations from the platform................................................................................................. 28
4.4.3 - Testing the platform control station........................................................................................ 29
4.5 - STANDBY AND EMERGENCY OPERATIONS: .......................................................29
4.5.1 - Standby or emergency procedure.......................................................................................... 29
4.5.2 - Manual pump emergency operation. ..................................................................................... 29
4.5.3 - Wheel brake release.............................................................................................................. 30
4.5.4 - Emergency operation............................................................................................................. 30
4.6 - BATTERY CHARGE STATE CHECK / TIMER ........................................................30
4.7 - USING THE BUILT-IN CHARGER............................................................................ 30
4.7.1 - Characteristics....................................................................................................................... 30
4.7.2 - Light indicators (photo 6) ....................................................................................................... 31
4.7.3 - Starting the charge................................................................................................................. 31
4.7.4 - Maintenance charge .............................................................................................................. 31
4.7.5 - Charge interruption................................................................................................................ 31
4.7.6 - Precautions for use................................................................................................................ 31
4.8 - BATTERY USE AND SERVICING ............................................................................ 32
4.8.1 - Starting up.............................................................................................................................. 32
4.8.2 - Discharge............................................................................................................................... 32
4.8.3 - Charge................................................................................................................................... 32
4.8.4 - Servicing................................................................................................................................ 32
5 - MAINTENANCE......................................................................................................... 35
5.1 - GENERAL RECOMMENDATIONS........................................................................... 35
5.2 - MAINTENANCE PLAN.............................................................................................. 35
5.2.1 - Consumable........................................................................................................................... 35
5.2.2 - Maintenance plan................................................................................................................... 36

Operating and maintenance instructions - STAR 8 - 10
vi
5.2.3 - OPERATIONS........................................................................................................................ 37
5.3 - OPERATIONS............................................................................................................37
5.3.1 - Hydraulic oil filter.................................................................................................................... 37
5.3.2 - Hydraulic oil tank.................................................................................................................... 37
5.3.3 - Electric batteries.....................................................................................................................38
6 - OPERATING INCIDENTS ..........................................................................................39
6.1 - TROUBLE-SHOOTING..............................................................................................40
7 - HYDRAULIC DIAGRAMS ..........................................................................................43
8 - WIRING DIAGRAMS..................................................................................................45
9 - SAFETY SYSTEMS....................................................................................................47
9.1 - MACHINE ELEMENTS..............................................................................................47
9.1.1 - Power supplies and fuses:..................................................................................................... 47
9.1.2 - Command inputs:................................................................................................................... 47
9.1.3 - Safety inputs:.......................................................................................................................... 47
9.1.4 - Relays:................................................................................................................................... 47
9.1.5 - Electrovalve logic outputs:......................................................................................................47
9.1.6 - Management elements:..........................................................................................................48
9.1.7 - LEDs:...................................................................................................................................... 48

Operating and maintenance instructions
1
Caution !
1 - GENERAL RECOMMENDATIONS - SAFETY
1.1 - GENERAL WARNING
1.1.1 - Manual
This manual is designed to familiarise the operator with HAULOTTE self-
propelled platforms in order to ensure efficient and safe use. However, it
cannot replace the basic training required by any user of site equipment.
The site manager is bound to inform the operators of the instructions
contained in the manual. He is also responsible for applying the «user
regulations» in force in the country of use.
Before using the machine, it is essential to understand all these instructions
in order to ensure safe and efficient operation.
This manual must be kept available for all operators. Additional copies can
be supplied by the manufacturer on request
1.1.2 - Labels
Potential dangers and machine instructions are indicated on labels and
plates. All instructions on such plates must be read.
All labels conform to the following colour code:
• Red indicates a potentially fatal danger.
• Orange indicates a danger of causing serious injury.
• Yellow indicates a danger that may cause material damage or slight
injury.
The site manager must ensure that these labels are in good condition and
remain legible. Additional copies can be supplied by the manufacturer on
request.
1.1.3 - Safety
Ensure that any persons entrusted with the machine are fit to meet the
safety requirements that its use imposes.
Avoid any working method that may jeopardise safety. Any use not
compliant with the instructions may cause risk and damage to persons and
property.
To attract the reader's attention
instructions are signalled by this
sign.
This manual must be kept by the user throughout the machine’s service
life, including in the case of loan, lease and resale.
Ensure that all plates or labels relative to safety and hazards are complete
and legible.

Operating and maintenance instructions
2
Caution !
1.2 - GENERAL SAFETY INSTRUCTIONS
1.2.1 - Operators
Operators must be aged over 18, and hold an operating permit issued by
their employer after undergoing a medical check and a practical test that
prove they are apt to operate the machine.
Only trained operators can use
Haulotte self-propelled platforms. There must always be at least two operators present, so that one can always:
• Take fast action if necessary.
• Take over the controls in case of accident or malfunction.
• Monitor and prevent movement of vehicles and people near the plat-
form.
• Guide the platform operator if required.
1.2.2 - Environment
Never use the machine:
• On ground that is soft, unstable, congested.
• On a ground that has a slope greater than permissible limit.
• In winds greater than the permissible limit. If used outside, use an an-
emometer to ensure that the wind speed does not exceed the permis-
sible limit.
• Near power lines (check minimum safe approach distances according
to voltage carried).
• In temperatures less than -15°C (especially in refrigerated chambers).
Consult us if it is necessary to work below -15°C.
• In explosive atmospheres.
• In poorly-ventilated areas, since the exhaust fumes are toxic.
• During storms (risk of lightning).
• In the dark, unless the optional floodlight is fitted.
• In the presence of intense electromagnetic fields (radar, moving and
high currents).
DRIVING ON PUBLIC ROADS IS PROHIBITED.
1.2.3 - Using the machine
In normal service (i.e. operating from the platform), the platform/turntable
control select key must be removed and kept at ground level by a person
who is present and trained in rescue/emergency assistance manoeuvres.
Do not use the machine:
• with a load greater than allowed load,
• if wind speed exceeds the maximum
• with more than maximum authorised number of occupants in platform,
• with a side load in the platform greater than permissible limit.
X km/h
Y km/h Y>X
-15 0
˚C