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STAR 6 - STAR 13 - 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.
STAR 6 - STAR 13 - 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.
STAR 6 - STAR 13 - 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..
STAR 6 - STAR 13 - Foreword 2 - Safety 2.1 - SAFETY INSTRUCTIONS 2.1.1 - Misuse Hazards • Do not use the machine for any other purpose than to position people, their tools and material to the overhead/elevated temporary work places.
STAR 6 - STAR 13 - Foreword 2.1.2 - Falling Hazards To enter or exit from the platform : • The machine must be completely stowed. • Face the machine to access the entry opening to the platform. • Keep 3 points of contact (both hands and a foot) on the steps and the guardrail.
STAR 6 - STAR 13 - Foreword 2.1.3 - Overturning / Tip-over Hazards Before positioning and operating the machine : • Ensure that the surface is capable of supporting the machine weight including the rated capacity. Check the load bearing capacity of the supporting ground.
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STAR 6 - STAR 13 - Foreword Using a machine on a slope Do not exceed the slope limit for each operation. Section B 4.1Technical specifications. While machine is on a slope, take extra precautions : • to make sure that the machine does not over steer.
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STAR 6 - STAR 13 - Foreword N.B.-:-The Beaufort scale of wind force is accepted internationally and is used when communicating weather conditions. A wind speed range at 10 m (32 ft 9 in) above flat, clear land is associated with each degree.
STAR 6 - STAR 13 - Foreword 2.1.4 - Electrocution Hazards The machine is not electrically insulated and does not provide protection from contact or proximity to electrically charged conductors. Always position the lift at a safe distance from electrically charged conductors to ensure that no part of the machine is within an unsafe area.
STAR 6 - STAR 13 - Foreword 2.1.5 - Explosion / Fire Hazards Always wear protective clothing and eye wear when working with batteries and power sources/systems. N.B.-:-Acid is neutralized with sodium bicarbonate and water. • Do not work on or operate a machine in an explosive or flammable atmosphere / environment.
STAR 6 - STAR 13 - Foreword • When driving, position the platform so as to provide the best possible visibility and to avoid any blind spots. • Hold on securely to the guardrails. • Occupants must wear a fall arrest harness, with lanyard and energy absorber in accordance with governmental regulations.
STAR 6 - STAR 13 - Foreword 3 - Safety inquiries Inquiries relating to design criteria/specifications of a product, standards compliance, or overall machine safety should be sent to the HAULOTTE® PRODUCT SAFETY department. Each inquiry or request should include all relevant information; including contact name, telephone number, mailing address, email address, plus the machine model and serial number.
STAR 6 - STAR 13 - Foreword 5 - Compliance 5.1 - PRODUCT INFORMATION Without the written permission from Haulotte, modifying a HAULOTTE® product is a Safety concern. Any modification may violate Haulotte design parameters, government regulations and industry standards.
Company stamp is mandatory : Tick here if the machine has been permanently removed from service (scrapped). The manufacturer's nameplate must be removed and returned to HAULOTTE Group when the unit is removed from service. Reason for removal : 4000426500 E 02.16...
STAR 6 - STAR 13 - Foreword 5.2 - PRODUCT SPECIFICATIONS HAULOTTE® cannot be held liable for any changes to the technical characteristics/ specifications contained in this manual. HAULOTTE® has a continuous improvement policy in place for its product range; given this policy, the Company reserves the right to modify their products technical characteristics / specifications without notice.
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STAR 6 - STAR 13 - Foreword Notes 4000426500 E 02.16 USA / GB...
STAR 6 - STAR 13 - Familiarization Familiarization 1 - General safety 1.1 - INTENDED USE To ensure the safe use of an Aerial Work Platform, support personnel must always be available on the ground. If necessary, support personnel will be required to operate the emergency functions of the machine and in rescuing the operator.
STAR 6 - STAR 13 - Familiarization 1.2 - DECAL CONTENT Decals are provided to alert the user of hazards inherent with the Aerial Work Platforms. Decals provide the following information : • The level of severity. • The specific hazard.
STAR 6 - STAR 13 - Familiarization 1.3 - SYMBOLS AND COLORS Symbols and colors are used to alert the operator of safety precautions and/or to highlight important safety information. The following safety symbols are used throughout this manual to indicate specific hazards and the hazard severity level when operating or maintaining the Aerial Work Platform.
STAR 6 - STAR 13 - Familiarization 1.5 - SYMBOLS LEGEND AND DEFINITIONS Symbols are used throughout this manual to depict hazards, avoidance measures and indicate when information is required. Refer to the following table to familiarize yourself with these symbols.
STAR 6 - STAR 13 - Familiarization 2 - Models description Regulation Models ANSI and CSA standards STAR 13 CE and AS standards STAR 6 4000426500 E 02.16 USA / GB...
STAR 6 - STAR 13 - Familiarization 3.2 - MAINTENANCE SUPPORT The maintenance stand must be in place before any maintenance operation is begun. Placing the machine in maintenance configuration : • Raise the telescoping mast upto 1,20 m (3 ft 11in).
STAR 6 - STAR 13 - Familiarization 3.3 - EXTENSION DECK (IF FITTED) N.B.-:-Do not load the extension deck, for ease of manoeuvring. Ensure that gate or sliding bar is in it’s proper closed position. Perform these operations on flat, horizontal ground.
STAR 6 - STAR 13 - Familiarization 3.4 - GROUND CONTROL BOX 3.4.1 - Layout General view Controls and indicators Marking Description Function Pulled out : Ground control box energized E-stop button Pushed in : De-energizes control system Horn Horn button...
STAR 6 - STAR 13 - Familiarization 3.4.2 - HAULOTTE Activ'Screen Upon starting and during operation of the machine, the LCD screen "Activ'Screen" located on the ground control box displays in real time the machine operating status. HAULOTTE Activ'Screen Controls and indicators...
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STAR 6 - STAR 13 - Familiarization 3.4.2.1 - LCD screen At startup At startup with the ground or platform controls selected; system initiates a self check : • Bar gets filled up. • Home screen comes on with status icon of the machine - okay to proceed functioning the controls.
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STAR 6 - STAR 13 - Familiarization • Pressing either one of the buttons , the following screen shot will be displayed : Symbol Description Software part number Software version + Screen software version + Screen version Screen identification + Screen software version Machine serial number displayed •...
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STAR 6 - STAR 13 - Familiarization Alarm status Alarm status displayed as applicable - samples shown below • Tilt • Low battery 4000426500 E 02.16 USA / GB...
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STAR 6 - STAR 13 - Familiarization • Present fault • Platform control box E-stop button pressed in (de-energized) 4000426500 E 02.16 USA / GB...
STAR 6 - STAR 13 - Familiarization 3.5 - PLATFORM CONTROL BOX 3.5.1 - Layout General view 100% 4000311500c 4000426500 E 02.16 USA / GB...
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STAR 6 - STAR 13 - Familiarization Controls and indicators Marking Description Function Tilt indicator Machine on excessive slope Overload indicator Not used Horn button Move upwards and hold to activate horn Pulled out : Platform control box power supply energized...
STAR 6 - STAR 13 - Familiarization 4 - Performance Specifications 4.1 - TECHNICAL CHARACTERISTICS Use the table to select the right Haulotte machine for the job. CE and AS standards Machine STAR 6 Characteristics - Dimensions Imp. Maximum working height...
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STAR 6 - STAR 13 - Familiarization Machine STAR 6 with platform extension Characteristics - Dimensions Imp. Maximum working height 5,80 m 19 ft 0 in Maximum platform height 3,80 m 12 ft 6 in Total weight 890 kg 1962 lbs...
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STAR 6 - STAR 13 - Familiarization ANSI and CSA standards Machine STAR 13 Characteristics - Dimensions Imp. Maximum working height 5,80 m 19 ft 0 in Maximum platform height 3,80 m 12 ft 6 in Total weight 835 kg...
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STAR 6 - STAR 13 - Familiarization Machine STAR 13 with platform extension Characteristics - Dimensions Imp. Maximum working height 5,80 m 19 ft 0 in Maximum platform height 3,80 m 12 ft 6 in Total weight 890 kg 1962 lbs...
STAR 6 - STAR 13 - Familiarization 4.2 - WORKING AREA / RANGE OF MOTION STAR 6 - STAR 13 ft in -6ft 6in -3ft 3in 3ft 3in 6ft 6in 19ft 8in 16ft 5in 13ft 10in 9ft 10in 6ft 6in...
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STAR 6 - STAR 13 - Familiarization STAR 6 - STAR 13 with platform extension ft in -6ft 6in -3ft 3in 3ft 3in 6ft 6in 19ft 8in 16ft 5in 13ft 10in 9ft 10in 6ft 6in 3ft 3in -2 m -1 m 4000426500 E 02.16...
STAR 6 - STAR 13 - Familiarization 5 - Decals and markings locations CE standard 4000426500 E 02.16 USA / GB...
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STAR 6 - STAR 13 - Familiarization CE standard Marking Color Description Quantity STAR 6 Height of the floor and load 4000414150 Blue Maximum Pressure per Tire - Floor Loading 4000425950 Other Commercial name - Bright machine 4000425510 Other Commercial name - Dark machine...
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Position of the lift truck forks 3078143830 Blue Transport height 4000426370 Other Electric traction 4000425350 Other "Made in Europe" 4000137690 (1.) For STAR 6 with extension only (2.) For STAR 6 with extension only 4000426500 E 02.16 USA / GB...
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STAR 6 - STAR 13 - Familiarization Notes 4000426500 E 02.16 USA / GB...
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STAR 6 - STAR 13 - Familiarization AS standard 4000426500 E 02.16 USA / GB...
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Transport height 4000426370 Other Electric traction 4000425350 Wearing a harness 4000275670 Do not travel down slopes in high speed 4000275680 (1.) For STAR 6 with extension only (2.) For STAR 6 with extension only 4000426500 E 02.16 USA / GB...
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STAR 6 - STAR 13 - Familiarization Russia and the Ukraine version 4000426500 E 02.16 USA / GB...
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STAR 6 - STAR 13 - Familiarization Russia and the Ukraine version Marking Color Description Quantity STAR 6 Height of the floor and load 4000425130 Blue Maximum Pressure per Tire - Floor Loading 4000425950 Other Commercial name - Bright machine...
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STAR 6 - STAR 13 - Familiarization Marking Color Description Quantity STAR 6 Yellow Vertical crushing of the body 4000014270 Blue Caution glasses 307P226670 (1.) For STAR 6 with extension only (2.) For STAR 6 with extension only 4000426500 E 02.16 USA / GB...
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STAR 6 - STAR 13 - Familiarization Notes 4000426500 E 02.16 USA / GB...
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STAR 6 - STAR 13 - Familiarization ANSI and CSA standards 4000426500 E 02.16 USA / GB...
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STAR 6 - STAR 13 - Familiarization ANSI and CSA standards Marking Color Description Quantity STAR 13 In english : 4000425160 Height of the floor and load - Single load In french : 4000425170 machine In spanish : 4000425180 Blue...
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STAR 6 - STAR 13 - Familiarization Marking Color Description Quantity STAR 13 Blue Transport height 4000426370 Other Electric traction 4000425350 (1.) For STAR 13 with extension only (2.) For STAR 13 with extension only (3.) For STAR 13 with extension only 4000426500 E 02.16...
STAR 6 - STAR 13 - Pre-operation inspection Pre-operation inspection 1 - Recommendations The owner, the site manager, the supervisor and the operator are all responsible to ensure the machine is fit for the work it is to perform; i.e. that the machine is suitable to carry out the work in complete safety and in compliance with this Operator's Manual.
STAR 6 - STAR 13 - Pre-operation inspection 2 - Working area assessment To ensure safety during operation, the following should be considered : • Segregate other site traffic (delivery vehicles, dumpers, etc) from the work area. • Check the work area for localised features, e.g. manholes, service ducts, potholes, etc.
STAR 6 - STAR 13 - Pre-operation inspection 3 - Inspection and Functional test 3.1 - DAILY INSPECTION Each day before the beginning of a new work session and with each change of operator, the machine must be subjected to a visual inspection and a complete functional test.
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STAR 6 - STAR 13 - Pre-operation inspection Daily inspection Visual inspection without Check level disassembly To check by test Corrected applicable Manuals and displays. Clean or replace if necessary. Presence, cleanliness and legibility of the manufacturer's plate Presence, cleanliness and legibility of operator's...
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STAR 6 - STAR 13 - Pre-operation inspection Entry bar/gate closes automatically and is not prevented from closing. The locking system of the deck extension functions properly Folding guard-rail (if fitted) is fixed securely in position Extending structure (jib, mast)
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STAR 6 - STAR 13 - Pre-operation inspection Energy storage and motorisation: tanks, batteries and engine Battery electrolyte level No screws missing / loose parts Presence and good condition of hydraulic hose Presence and good condition of engine components Presence and good condition of the batteries: terminations and clamps, electrolyte level ...
STAR 6 - STAR 13 - Pre-operation inspection 4 - Safety functional checks To protect the user and the machine, safety systems prevent the movement of the machine beyond its operating limits. These safety systems when activated immobilize the machine and prevent further movement.
STAR 6 - STAR 13 - Pre-operation inspection 4.2 - ACTIVATION OF CONTROLS The enable switch must be active to allow all movements. The "Enable Switch" system depends on the machine configuration and will consist of one of the following : •...
STAR 6 - STAR 13 - Pre-operation inspection 4.4 - SLOPE WARNING DEVICE From each control box, a buzzer alerts the operator that the machine is not folded/stowed and is positioned on a slope exceeding the slope allowed. N.B.-:-The slope sensor is only active when the platform is not in the stowed position.
STAR 6 - STAR 13 - Pre-operation inspection 4.6 - ELECTRONIC VARIABLE SPEED DRIVE The machine is equipped with 2 electronic variable speed regulators configured for each function that manages the amount of power sent to each motor. Do not interchange the speed controllers/regulators between machines even if they are the same model..
STAR 6 - STAR 13 - Pre-operation inspection 4.9 - WHEEL MOTOR BRAKE RELEASE Each time a drive command is activated, electric power releases the brakes. 4.10 - POTHOLE PROTECTION SYSTEM To reduce the risk of overturning, the machine is equipped with a pothole mechanism under the chassis that is deployed automatically when the platform is out of the stowed position .
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STAR 6 - STAR 13 - Pre-operation inspection Notes 4000426500 E 02.16 USA / GB...
STAR 6 - STAR 13 - Operation instructions Operation instructions 1 - Operation 1.1 - INTRODUCTION Aerial Work platforms are equipped with two control boxes which allow operators to safely use the machine. An auxiliary device is available on the chassis to assist with the emergency rescue of people.
STAR 6 - STAR 13 - Operation instructions A buzzer beeps in the following conditions : • Overload (if fitted). • Machine out of stowed position and on a slope greater than allowable slope. • Hydraulic oil overheating. • Movements option.
STAR 6 - STAR 13 - Operation instructions 2 - Ground control box 2.1 - TO START AND STOP THE MACHINE • Pull the E-Stop button at the ground control box. • Turn the control box activation selector key ( 92 ) downwards to activate the ground control box.
STAR 6 - STAR 13 - Operation instructions 3 - Platform control box 3.1 - TO START AND STOP THE MACHINE To start the machine : At the ground control box : • The E-stop button on the ground control box must be in ON position (pulled out / activated).
STAR 6 - STAR 13 - Operation instructions 4 - Emergency procedure 4.1 - IN CASE OF POWER LOSS If an operating problem prevents the user on the platform from descending, a competent operator can do this from the chassis.
STAR 6 - STAR 13 - Operation instructions 5 - Transportation 5.1 - PUTTING IN TRANSPORT POSITION To avoid any risk of machine movement during loading, ensure that : • The loading ramp can support the machine weight. • The loading ramp is correctly attached to transport vehicle.
STAR 6 - STAR 13 - Operation instructions 5.3 - UNLOADING Before unloading, check that the machine is in good condition. • Remove the tie downs. • Switch the machine on. • Move progressively the drive joystick (108). Warning : Upon starting a machine that has been secured and transported, the safety system may detect a false overload preventing all movement from the platform control box.
STAR 6 - STAR 13 - Operation instructions 5.4.1 - Electric brake release To tow a broken-down machine, the brakes can be released using the electric system. Perform these operations on flat, horizontal ground. Failing that, block the wheels to immobilize the machine.
STAR 6 - STAR 13 - Operation instructions 5.5 - STORAGE When the machine is in elevated position, it is necessary to regularly switch the power ON to ensure that the security systems are active. Machine must be parked in a protected/designated area with the mast fully retracted. Make sure there is no load in the platform.
STAR 6 - STAR 13 - Operation instructions 5.8 - LIFTING OPERATION 5.8.1 - Loading and unloading Before any lifting operation, it is necessary to take into account the following points : ONLY trained and authorized personnel should attempt to lift the machine.
STAR 6 - STAR 13 - Operation instructions 5.8.1.4 - Procedure for the use of slings The machine must be completely stowed (Extension retracted). Designated lifting points are marked/labeled with the following symbol Position the spreader line up with the chassis.
STAR 6 - STAR 13 - Operation instructions 5.9 - LOADING AND UNLOADING WITH FORKLIFT • Completely lower the mast. • Ensure that the potholes are retracted. The machine must be in the fully stowed transport position. • Ensure that the machine controls are in the OFF position.
STAR 6 - STAR 13 - Operation instructions 6 - Cold Weather Recommendations In extreme cold conditions, machines should be equipped with optional cold start kits. N.B.-:-Initial starting should always be performed from the ground control box. 6.1 - HYDRAULIC OIL External environmental conditions can reduce performance of the machine if the hydraulic oil temperature does not reach its optimum range.
STAR 6 - STAR 13 - Operation instructions 7 - Battery care and maintenance 7.1 - BATTERY CHARGING Recharge aerial work platform batteries after each work shift or as needed. When the aerial work platform is not in use, batteries should be recharged at least once per week. Under normal circumstances, battery recharge should take approximately 8-10 hours.
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STAR 6 - STAR 13 - Operation instructions When should the batteries be charged? : • Never discharge the batteries to more than 80 % of their capacity in 5 h (hours). • When the batteries are discharged to between 35 % and 80 % of their nominal capacity.
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STAR 6 - STAR 13 - Operation instructions To recharge the aerial work platform batteries : Attach a 12 AWG multi-strand, grounded extension cord with a maximum length of 15 m (50 ft) to the receptacle located on the charger.
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STAR 6 - STAR 13 - Operation instructions Notes 4000426500 E 02.16 USA / GB...
STAR 6 - STAR 13 - General Specifications General Specifications 1 - Machine dimensions Stowed / Transport position : Configuration that takes the minimum floor space necessary for storage and / or delivery of the machine - Access position. CE and AS standards...
STAR 6 - STAR 13 - General Specifications 2 - Major component masses N.B.-:-Masses measured with empty tanks. Component STAR 6 STAR 13 Frame assembly mass 328 kg 723 lbs Counterweight mass 118 kg 260 lbs Battery mass 60 kg...
STAR 6 - STAR 13 - General Specifications 4 - Wheel/Tire assembly 4.1 - TECHNICAL SPECIFICATIONS Component Standard wheel Reference number Solideal Type Solid tires/tyres Size 318 mm / 108 mm (12,52 in/ 4,25 in) Torque 80 Nm (59 ft lbs) 4.2 -...
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STAR 6 - STAR 13 - General Specifications Procedure of replacement : • Loosen the wheel nuts on the wheel to be removed. • Raise the machine using a jack or a hoist. • Remove the wheel nuts. • Remove the wheel.
STAR 6 - STAR 13 - Maintenance Maintenance 1 - General As an owner and/or operator of Haulotte equipment, your Safety is of utmost importance to HAULOTTE® , which is why HAULOTTE® places such a high priority on product safety.
STAR 6 - STAR 13 - Maintenance 2 - Maintenance Schedule This section provides the necessary information needed to place the machine in safe operation. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed.
STAR 6 - STAR 13 - Maintenance 3 - Inspection program 3.1 - GENERAL PROGRAM The machine must be inspected on a regular basis at intervals of no less than once 1 per year. The purpose of the inspection is to detect any defect which could lead to an accident during routine use of the machine.
STAR 6 - STAR 13 - Maintenance 3.3 - PERIODIC INSPECTION The Periodic inspection is a thorough evaluation of the operation and safety features of the machine. It must be conducted before the sale / resale of the machine and/or at least once 1every year.
STAR 6 - STAR 13 - Maintenance 4 - Repairs and adjustments Extensive repairs, interventions or adjustments on the safety systems or components must be performed by a HAULOTTE Services® technician. Use original spare parts and components only. N.B.-:-HAULOTTE Services® technicians are trained professionals to perform extensive repairs, interventions and adjustments on the safety systems or components of HAULOTTE®...
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STAR 6 - STAR 13 - Maintenance Notes 4000426500 E 02.16 USA / GB...
STAR 6 - STAR 13 - Other information Other information 1 - Warranty disclosure 1.1 - AFTER SALES SERVICE Our HAULOTTE Services® After Sales Service is at your disposal throughout your machine's service life to ensure the optimum use of your HAULOTTE product : •...
STAR 6 - STAR 13 - Other information 1.2.4 - Conditions of warranty HAULOTTE® guarantees its products against defects, faults or manufacturing defects when the owner or rental company has informed HAULOTTE® of the defect. The warranty does not cover the consequences of normal wear, nor any defects, failure or...
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STAR 6 - STAR 13 - Other information The present warranty does not cover damage that may result directly or indirectly from any flaws or defects covered by the latter : • Consumables : No claims will be accepted for objects or parts replaced in the context of normal machine usage.
STAR 6 - STAR 13 - Other information 2 - Subsidiary contact information HAULOTTE FRANCE HAULOTTE INDIA PARC DES LUMIERES HAULOTTE ITALIA Unit No. 1205, 12th foor,Bhumiraj Costarica, 601 RUE NICEPHORE NIEPCE VIA LOMBARDIA 15 Plot No. 1&2, Sector 18,...
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STAR 6 - STAR 13 - Other information For electric (battery operated) machines CALIFORNIA PROPOSITION 65 BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.
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STAR 6 - STAR 13 - Other information Notes 4000426500 E 02.16 USA / GB...
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