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

Operating and maintenance instructions
3
Caution !
To reduce the risks of serious falls, operators must respect the
following instructions:
• Hold the guardrail firmly when lifting or driving the platform.
• Remove any traces of oil or grease from the platform steps, floor or
guardrails.
• Wear personal protective equipment suited to working conditions and
conform to local regulations, particularly when working in hazardous
areas.
• Never disable the limit switches of the safety devices.
• Avoid contact with stationary or moving obstacles.
• Do not increase the platform operating height by means of ladders or
other accessories.
• Never use the guardrails to climb into or out of the platform (use the
steps provided).
• Never climb on the guardrails when the platform is up.
• Avoid driving the machine at high speed in narrow or congested are-
as.
• Never use the machine without putting in place the platform safety bar
or closing the safety gate.
• Never climb on the covers.
Never use the platform as a crane,
hoist or lift.
Never use the machine to pull or
tow.
Never use the boom as a ram or
thruster or to lift the wheels.
To reduce the risks of tipping over, operators must follow these
instructions:
• Never disable the limit switches of the safety devices.
• Never move the control handles from one direction to the other with-
out stopping in the «O» position. (To stop when travelling, gradually
move the handle to «O», keeping your foot down on the pedal.).
• Do not exceed the maximum load or the number of occupants allowed
in the platform.
• Spread the load and if possible place in the centre of the platform.
• Check that the ground resists the pressure and load per wheel.
• Avoid contact with stationary or moving obstacles.
• Do not drive the platform at high speed in narrow or congested areas.
• Do not drive the platform in reverse gear (poor visibility).
• Do not use the machine with a congested platform.
• Do not use the machine with equipment or objects hanging from the
guardrails or boom.
• Do not use the machine with items liable to increase the wind load
(e.g. panels).
• Never carry out maintenance on the machine with the platform raised,
without first installing the required safety provisions (overhead crane,
crane).
• Perform the daily checks and monitor the machine’s good working or-
der during periods of use.
• Preserve the machine from any uncontrolled intervention when it is
not in operation.
NOTE : Do not tow the platform. (It has not been designed for towing
and must be transported on a trailer).

Operating and maintenance instructions
4
Caution !
Caution !
1.3 - RESIDUAL RISKS
1.3.1 - Risks of jerky movements and tipping over
The direction of travel can be
reversed after a 180° turntable
rotation. Take account of the colour
of the arrows on the chassis
compared with the direction of
travel (green = forward, red =
reverse)
Risks of jerky movement and tipping over are high in the following
situations:
- Sudden action on the controls.
- Overloading of the platform.
- Uneven ground (Be careful during thaw periods in winter).
- Gusts of wind.
- Contact with an obstacle on the ground or at a height.
- Working on platforms, pavements, etc.
Allow sufficient stopping distances:
- 3 meters at high speed,
- 1 meter at low speed.
1.3.2 - Electrical risk
If the machine has a 220 V 16A max.
plug, the extension must be
connected to a mains socket
protected by a 30 mA differential
circuit breaker.
Electrical risks are high in the following situations:
- Contact with a live line (check safety distances before operation
near electricity lines).
- Use during storms.
1.3.3 - Risk of explosion or burning
The risks of explosion or burning are high in the following situations:
- Working in explosive or inflammable atmosphere.
- Filling the fuel tank near naked flames.
- Contact with the hot parts of the motor.
- Use of a machine generating hydraulic leakage.
1.3.4 - Risks of collision
- Risk of crushing people in the machine operation zone (when
travelling or manoeuvring equipment).
- The operator must assess the risks above him before using the
machine.
1.4 - INSPECTIONS Comply with the national regulations in force in the country of machine use.
For FRANCE: Order dated 9 June 1993 + circular DRT 93 dated 22
September 1993 which specify:
1.4.1 - Periodic inspections
The machine must be inspected every 6 months in order to detect any
defects liable to cause an accident.
These inspections are performed by an organisation or personnel specially
designated by the site manager and under his responsibility (whether or not
they belong to the company) Articles R 233-5 and R 233-11 of the French
Labour Code.
The results of these inspections are recorded in a safety register kept by
the site manager and constantly available to the labour inspector and the
site safety committee (if one exists) and the list of specially designated
personnel (Article R 233-5 of the French Labour Code).

Operating and maintenance instructions
5
Caution !
NOTE : This register can be obtained from trade organisations, and in
some cases from the OPPBTP or private prevention agen-
cies.
The designated persons must be experienced in risk prevention (Articles R
233-11 or order n° 93-41).
No member of personnel is allowed to perform any check whatsoever
during machine operation (Article R 233-11 of the French Labour Code).
1.4.2 - Examination of machine suitability
The manager of the site where the machine is operated must ensure the
machine is suitable, i.e. capable of performing the work in complete safety,
and in compliance with the operating manual. Furthermore, the French
order of 9 June 1993 addresses problems relative to leasing, examination
of the state of conservation, checking upon operation after repairs, and test
conditions (static test coefficient 1.25; dynamic test coefficient 1.1). All
users must consult this order’s requirements and comply with them.
1.4.3 - State of conservation
Detect any deterioration liable to cause hazardous situations (concerning
safety devices, load limiters, tilt sensor, cylinder leaks, deformation, welds,
bolt tightness, hoses, electrical connections, tyre state, excessive
mechanical gaps).
NOTE : If the machine is rented/leased, the user responsible for the
machine must examine its state of conservation and suitabili-
ty. He must obtain assurance from the leaser that general pe-
riodic inspections and pre-operation inspections have been
performed.
1.5 - REPAIRS AND ADJUSTMENTS
These cover major repairs, and work on or adjustments to safety systems
or devices (of a mechanical, hydraulic or electrical nature).
These must be performed by personnel from or working for PINGUELY-
HAULOTTE who will use only original parts.
Any modification not controlled by PINGUELY-HAULOTTE is
unauthorised.
The manufacturer cannot be held responsible if non-original parts are used
or if the work specified above is not performed by PINGUELY-HAULOTTE-
approved personnel.
1.6 - VERIFICATIONS WHEN RETURNING TO SERVICE
To be performed after:
• extensive disassembly-reassembly operation,
• repair affecting the essential components of the machine,
• any accident caused by the failure of an essential component.
It is necessary to perform a suitability examination, a state of conservation
examination, a static test, a dynamic test (see coefficient in paragraph (see
Chap 1.4.2, page 5).
These test must be performed by a
competent person.

Operating and maintenance instructions
6

Operation and servicing - STAR 8 - 10
7
2 - PRESENTATION
Self-propelled platforms, STAR 8 and STAR 10 MAST models, are
designed for all elevated work within the limits of their characteristics
(Chap. 2.4, page 11) and conform to all the safety recommendations
specific to the equipment and places of use.
The main control station is in the plaform.
The turntable control station is a standby or emergency control station.
2.1 - IDENTIFICATION A plate (Figure: Manufacturer’s plate, page 7, ), fixed on the right rear of
the chassis, bears all the information (engraved) necessary to identify the
machine.
REMINDER:When requesting information, intervention or spare parts,
please specify the type and serial number.
Fig. 1 - Manufacturer’s plate

Operation and servicing - STAR 8 - 10
8
2.2 - MAIN COMPONENTS
Fig. 2 - Main components
1
7
8
910
11
5
6
2
3
4
12
1 - steering wheels 7 - jib
2 - battery box 8 - winder
3 - bottom control panel 9 - top control panel
4 - counterweight 10 - document holder
5 - drive wheels 11 - platform
6 - anchoring lugs 12 - turntable

Operation and servicing - STAR 8 - 10
9
2.3 - WORKING AREA
2.3.1 - Working area for the STAR 8 mast
Fig. 3 - STAR 8 working area
9
8
7
6
5
4
3
2
1
0-4-3-2-101234

Operation and servicing - STAR 8 - 10
10
2.3.2 - Working area for the STAR 10 mast
Fig. 4 - STAR10 working area
11
10
9
8
7
6
5
4
3
2
1
0-4-3-2-101234

Operation and servicing - STAR 8 - 10
11
2.4 - TECHNICAL DATA
2.4.1 - STAR 8 / 10 technical data:
• All pressures can be checked by means of a tap.
- 2 drive wheels with braked reducing gears and electric motors
controlled by choppers.
- Jib movement, lifting, telescoping, orientation: hydraulic
electropump and speed control by chopper.
- Steering by electro-distributing valve.
-
-
-
STAR 8 STAR 10
Useful load (outdoor / indoor) 230 kg -2 people. / 120 kg - 1 pers.
Maximum side force (outdoor / indoor) 40 kg / 20kg
Working height 8.73 10 m
Floor height 6.73 8 m
Maximum reach 2.6 2.6 m
Turntable rotation 360° not continuous
Maximum slope and tilt during operation 3° (approx. 5.2%)
Platform floor dimensions 670 x 920 mm
Maximum slope during travel 25%
Low travel speed 0.7 km/h
High travel speed 4.5 km/h
Traction batteries 24V - in 2 trays
Floor clearance (under pothole device) 100 mm max. - (40 mm)
Tyres Solid tyres
Turning radius:
* Internal
* External 440 mm
1875 mm
Mast telescoping stroke 3700 mm 4900 mm
Max. wind speed in operation (outdoor / indoor) 45 km/h / 0 km/h
Max. pressure on the ground with load of 230 kg:
concrete 13.5 kg/cm² 17.5 kg/cm²
Max. force on one wheel 860 kgs 1050 kg
Movement time with one person:
* Turntable orientation (approx. 360°)
* Mast telescoping: extend / retract (approx.)
* Jib lifting: up / down (approx.)
60 s
31 s / 33 s
21 s / 29 s
50 s
50 s / 33 s
20 s / 39 s
Motor
* Voltage
* Power
* Consumption
separate energising
24V
1.2 kW
63A
Hydraulic pump in operation: volume 1 + 5.5 cm3/rev
Hydraulic oil tank capacity 25 litres
Hydraulic operating pressure*:
* max steering pressure
* max orientation pressure
* max mast extension telescoping pressure
* max jib lifting pressure
160 bars
50 bars
45 bars
160 bars
160 bars
50 bars
45 bars
160 bars
Tightening torque of steering wheel nuts 29 daNm
Tightening torque of drive wheel nuts 29 daNm
Tightening torque of slew ring nuts 13.5 daNm
Weight 2380 kg 2440 kg
Size (Figure: Dimensions, page 11, )

Operation and servicing - STAR 8 - 10
12
2.4.2 - Dimensions of the STAR 8 and STAR 10 masts
Fig. 5 - Dimensions
2610
1200
2000
990