Pinguely-Haulotte STAR Series Operating And Maintenance Instruction Manual
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Pinguely-Haulotte STAR Series Operating And Maintenance Instruction Manual

Self-propelled platform
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O PE RA TI NG AN D M AI NT EN AN C E
I NS TR UC TIO N
Self-propelled platform
STAR 8 - STAR 10
242 031 7880 - E 04.02
GB
I S O 9 0 0 1
ARTICULEES
MATS
TELESCOPIQUES
CISEAUX
TRACTEES
L ' A C C E S
A
L ' E S P A C E
PINGUELY HAULOTTE • LA PERONNIERE - BP 9 - 42152 L'HORME • Tél. +33 (0) 4 77 29 24 24 • Fax SAV +33 (0) 4 77 31 28 11
email haulotte@haulotte.com • Web www.haulotte.com

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  • Page 1 O PE RA TI NG AN D M AI NT EN AN C E I NS TR UC TIO N Self-propelled platform STAR 8 - STAR 10 242 031 7880 - E 04.02 I S O 9 0 0 1 ARTICULEES MATS TELESCOPIQUES...
  • Page 3 Operating and maintenance instructions 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: •...
  • Page 4 Operating and maintenance instructions...

  • Page 5: Table Of Contents

    Operating and maintenance instructions - STAR 8 - 10 CONTENTS 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 ..........................
  • Page 6 Operating and maintenance instructions - STAR 8 - 10 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: ......................
  • Page 7 Operating and maintenance instructions - STAR 8 - 10 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........................
  • Page 8 Operating and maintenance instructions - STAR 8 - 10 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 OPERATING INCIDENTS ..................39 6.1 - TROUBLE-SHOOTING ....................40 HYDRAULIC DIAGRAMS ..................43 WIRING DIAGRAMS ....................

  • Page 9: General Recommendations - Safety

    Operating and maintenance instructions 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.

  • Page 10: General Safety Instructions

    Operating and maintenance instructions 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. Caution ! Only trained operators can use There must always be at least two operators present, so that one can...
  • Page 11 Operating and maintenance instructions 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.

  • Page 12: Residual Risks

    Operating and maintenance instructions 1.3 - RESIDUAL RISKS 1.3.1 - Risks of jerky movements and tipping over Caution ! The direction of travel can be Risks of jerky movement and tipping over are high in the following reversed after a 180° turntable situations: rotation.

  • Page 13: Examination Of Machine Suitability

    PINGUELY-HAULOTTE 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, •...
  • Page 14 Operating and maintenance instructions...

  • Page 15: Presentation

    Operation and servicing - STAR 8 - 10 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.

  • Page 16: Main Components

    Operation and servicing - STAR 8 - 10 2.2 - MAIN COMPONENTS Fig. 2 - Main components 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...

  • Page 17: Working Area

    Operation and servicing - STAR 8 - 10 2.3 - WORKING AREA 2.3.1 - Working area for the STAR 8 mast Fig. 3 - STAR 8 working area...

  • Page 18: Working Area For The Star 10 Mast

    Operation and servicing - STAR 8 - 10 2.3.2 - Working area for the STAR 10 mast Fig. 4 - STAR10 working area...

  • Page 19: Technical Data

    Operation and servicing - STAR 8 - 10 2.4 - TECHNICAL DATA 2.4.1 - STAR 8 / 10 technical data: 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...

  • Page 20: Dimensions Of The Star 8 And Star 10 Masts

    Operation and servicing - STAR 8 - 10 2.4.2 - Dimensions of the STAR 8 and STAR 10 masts Fig. 5 - Dimensions...

  • Page 21: Labels

    Operation and servicing - STAR 8 - 10 2.5 - LABELS 2.5.1 - Label positioning Code Description 3078146180 Manufacturer’s plate (French) 3078146190 Manufacturer’s plate (Spanish) 3078146200 Manufacturer’s plate (German) 3078146210 Manufacturer’s plate (English) 3078146220 Manufacturer’s plate (Italian) 3078146230 Manufacturer’s plate (Dutch) 3078146240 Manufacturer’s plate (Danish) 3078146250...
  • Page 22 Operation and servicing - STAR 8 - 10 Code Description 3078144490 a Sling load for Australia only 3078144390a Charger connection label for Australia only 3078145200 Pressurised fluid for Australia only 3078144520 Harness must be worn for Australia only 3078144360 Do not go down slopes at HS for Australia only...
  • Page 23 Operation and servicing - STAR 8 - 10...

  • Page 24: Yellow Labels

    Operation and servicing - STAR 8 - 10 2.5.2 - Yellow labels: 2.5.3 - Red labels:...

  • Page 25: Miscellaneous Labels

    Operation and servicing - STAR 8 - 10 2.5.4 - Miscellaneous labels: 2.5.5 - Specific labels for Holland: 7814 573 a 2.5.6 - Specific labels for Australia: WARNING This accumulator contains pressurissed oil. Care must be taken whilst carrying out maintenance on this component.
  • Page 26 Operation and servicing - STAR 8 - 10...

  • Page 27: Operating Principle

    Operation and servicing - STAR 8 - 10 OPERATING PRINCIPLE 3.1 - HYDRAULIC CIRCUIT All machine movements, apart from travel, are powered by the hydraulic energy supplied by an electropump whose operating speed is controlled by an electronic chopper. A pressure filter fitted on the pump output protects the installation from contamination.

  • Page 28: Electric Circuit

    Operation and servicing - STAR 8 - 10 3.2 - ELECTRIC CIRCUIT The electric power used to drive the motors and supply the controls is supplied by a set of two 24 V - 250 Ah traction battery units. A built-in charger enables these batteries to be recharged overnight by connecting it to a domestic 16A socket.

  • Page 29: High Travel Speed

    Operation and servicing - STAR 8 - 10 Caution! DO NOT GO DOWN STEEP SLOPES 3.2.6 - Wheel motor brake release AT HIGH SPEED For each travel movement control, there is an electric supply for the brakes. When towing the machine, it is possible to force wheel motor brake release.
  • Page 30 Operation and servicing - STAR 8 - 10...

  • Page 31: Use

    Operation and servicing - STAR 8 - 10 4.1 - SAFETY SYSTEMS If an attempt is made to use the machine beyond its capabilities, safety systems are installed to protect personnel and the machine and avoid all risk of accidents. These systems immobilise the machine or disable movements.

  • Page 32: Unloading By Trunk

    Operation and servicing - STAR 8 - 10 - the personnel controlling movement is authorised to use lifting equipment. • Unloading: - attach the 4 slings to the 4 slinging lugs. - slowly lift, making sure that the load is evenly distributed and slowly set the machine down.

  • Page 33: Loading

    Operation and servicing - STAR 8 - 10 Caution! DO NOT GO DOWN THE RAMPS AT 4.2.4 - Loading HIGH SPEED. The precautions are the same as for unloading. The machine should be wedged according to the diagram below. To climb the ramps of a lorry, select high speed. Fig.

  • Page 34: Operations Before The First Operation

    Operation and servicing - STAR 8 - 10 4.3 - OPERATIONS BEFORE THE FIRST OPERATION REMINDER: Before operation, familiarise yourself with the machine and check it, by reading this manual, the instructions marked on the various plates and consult the maintenance plan (see line: "before each operation").

  • Page 35: Checks Before Operation

    Operation and servicing - STAR 8 - 10 Caution! DURING HIGH PRESSURE 4.3.3 - Checks before operation CLEANING, DO NOT DIRECT THE • Ensure that the machine is on flat, stable ground that can bear the JET DIRECTLY ONTO THE weight of the machine (pressure on the ground, Chap.

  • Page 36: Before Each Use

    Operation and servicing - STAR 8 - 10 Photo 4: Photo 5: 4.4 - BEFORE EACH USE IMPORTANT: do not start operation before completing all the checks described in the previous chapter. To familiarise yourself with the machine, the first movements should be made on the ground with the machine in the transport position: mast retracted, and for STAR 10 type machines, jib lowered.

  • Page 37: Testing The Platform Control Station

    Operation and servicing - STAR 8 - 10 PLATFORM MODEL STAR 8; STAR 10: 230 kg. - 2 people (indoor); 120 kg. - 1 pers. (outdoor). 4.4.3 - Testing the platform control station • Ensure that the emergency stop button (ref.2) is armed. •...

  • Page 38: Wheel Brake Release

    Operation and servicing - STAR 8 - 10 4.5.3 - Wheel brake release Photo 8: Wheel brake release If the machine is towed, the drive wheels can be braked using the switch in the turntable electric box (Photo 8 : Wheel brake release ). This requires machine power to be switched off by activating the emergency stop and free of load.

  • Page 39: Light Indicators (Photo 6)

    Operation and servicing - STAR 8 - 10 4.7.2 - Light indicators (photo 6) Photo 9: Light indicator The charger is equipped with a light indicator (led) (ref. 1); See table below: State Description RED on Machine charging YELLON on 50% charged GREEN on Machine charging complete...

  • Page 40: Battery Use And Servicing

    Operation and servicing - STAR 8 - 10 4.8 - BATTERY USE AND SERVICING The batteries are the power source for your platform. Here is some advice to enable you to use them to their capacity, without risk of premature damage. Caution! It is absolutely forbidden to change 4.8.1 - Starting up...
  • Page 41 Operation and servicing - STAR 8 - 10 • Take safety precautions when servicing the batteries (wear protective gloves and goggles). To make a rapid diagnosis of the condition of your batteries, once a month, note the density of each element, using a hydrometer, and the graphs below according to the temperature (do not measure directly after filling).
  • Page 42 Operation and servicing - STAR 8 - 10 STATE OF BATTERY CHARGE ACCORDING TO DENSITY AND TEMPERATURE STOP ! RECHARGE DO NOT RECHARGE RECHARGE 1.30 1.29 1.28 1.27 1.26 1.25 1.24 1.23 1.22 1.21 1.20 1.19 1.18 1.17 1.16 15∞C 1.15 30∞C 1.14...

  • Page 43: Maintenance

    Operation and servicing - STAR 8 - 10 MAINTENANCE 5.1 - GENERAL RECOMMENDATIONS The servicing operations indicated in this manual are given for normal operating conditions. In difficult conditions: extreme temperature, high hygrometry, polluted atmosphere, high altitude, etc. certain operations must be performed more often and specific precautions should be taken: contact HAULOTTE PINGUELY After-sales service for information.

  • Page 44: Maintenance Plan

    Operation and servicing - STAR 8 - 10 5.2.2 - Maintenance plan...

  • Page 45: Operations

    Operation and servicing - STAR 8 - 10 5.2.3 - OPERATIONS FREQUENCY OPERATION REFERENCE • Check Every day or before plan ref.1 hydraulic tank level. See chap. 4.3.3. each start of opera- electrolyte level in the batteries. See tion chap. 4.3.3. plan ref.2 •...

  • Page 46: Electric Batteries

    Operation and servicing - STAR 8 - 10 5.3.3 - Electric batteries To have access to the lower tray (ref.3 photo 7), pivot the upper tray (ref.2 photo 7). Photo 10: Electric batteries...

  • Page 47: Operating Incidents

    Operation and servicing - STAR 8 - 10 OPERATING INCIDENTS REMINDER:Respecting machine’s operating servicing instructions will enable you to avoid most incidents. However, certain incidents may arise and before any intervention, it is essential to consult table 6.1. If the incident is listed, simply follow the instructions.

  • Page 48: Trouble-Shooting

    Operation and servicing - STAR 8 - 10 6.1 - TROUBLE-SHOOTING CODE ALARM PROBABLE CAUSES REMEDIES • The battery is discharged. • The alarm is only indicated if the "BATTERY CHECK" option has been selected. LOW BATTERY • Recharge the batteries. •...
  • Page 49 Operation and servicing - STAR 8 - 10 CODE ALARM PROBABLE CAUSES REMEDIES • Incorrect start sequence. The machines only INCORRECT • Humidity upper starts if the sequence is respected: key-bar (or START station: blow the card. seat) - operation •...
  • Page 50 Operation and servicing - STAR 8 - 10 CODE ALARM PROBABLE CAUSES REMEDIES • Alarm informing that machine maintenance is CHECK UP due. Time >300 hours. Does not disable the • NEEDED machine but continues to show the fault until the message is eliminated (CHECK UP DONE on ON) •...

  • Page 51: Hydraulic Diagrams

    Operation and servicing - STAR 8 - 10 HYDRAULIC DIAGRAMS...
  • Page 52 Operation and servicing - STAR 8 - 10...

  • Page 53: Wiring Diagrams

    Operation and servicing - STAR 8 - 10 WIRING DIAGRAMS Emergency stop Arret urgence Signal Signal Traction Traction Potentiometre Potentiometre direction direction Down Mast Descente Mat Freins Brake Down pendular or Descente Pend ou up pendular Montee Pend Up mast MontÈe m‚t Up mast MontÈe m‚t...
  • Page 54 Operation and servicing - STAR 8 - 10...

  • Page 55: Safety Systems

    Operation and servicing - STAR 8 - 10 SAFETY SYSTEMS 9.1 - MACHINE ELEMENTS 9.1.1 - Power supplies and fuses: FU1 1A Overload protection FU2 5A Command protection FU3 10A Electrovalve protection FU4 250A Power fuse 9.1.2 - Command inputs: Station selector (turntable panel) Movement selector switch (platform panel) Emergency stop;...

  • Page 56: Management Elements

    Operation and servicing - STAR 8 - 10 9.1.6 - Management elements: Charger Chopper Turntable serial card Platform serial card 9.1.7 - LEDs: Timer; battery indicator...

This manual is also suitable for:

Star 8Star 10

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