Haulotte Star 6 Technical Training Manual
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Haulotte Star 6 Technical Training Manual

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Summary of Contents for Haulotte Star 6

  • Page 1 – –...
  • Page 2 … … … … … … 2/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 3 Revision Edition Subject Created Validated Modified Translated Language 03-11 Creation Star 6/6P FR/EN/SP 07-13 Add newest schematics +overload / mast adjustments 02-14 Add chapter schematics 04-15 Ad coloured PUS-MM schematics in A3 format 3/82 TRAINING MANUAL Star 6/13J range 2420344370...

  • Page 4: Table Of Contents

    Features Star 6 ............................13     1.2................................14 COMMANDS     1.2.1. Single control unit (up/down) for star 6 ..................... 14     1.2.2. Single control unit for star 6P ........................15     THE ELECTRICAL PART ............................16  ...
  • Page 5 ............................. 72 VERLOAD ADJUSTMENT     7.5..........................72 VARIATOR IMPEDANCE CHECK     LIST OF SCHEMATICS ............................73     8.1............................75 HYDRAULIC FUNCTION     8.2.............................. 77 ELECTRIC FUNCTION 5/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 6: Main Features

    6/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 7 7/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 8: Overall Dimensions

    8/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 9 9/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 10: Working Zone Star 6

    10/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 11: Features Star 6

    11/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 12: Working Zone Star 6P

    12/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 13: Features Star 6

    13/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 14: Commands

    14/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 15: Single Control Unit For Star 6P

    15/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 16: The Electrical Part

    Battery with one element Alternator Fuse (Here 10 amps) Coil winding roll Electric motor light Diode Hourmeter Standard push-button of safety “mushroom-headed button” 16/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 17 Rotary knob Push-button Limit switch Pressure switch Key selector with 3 positions (T turret, O neutral, N platform) Toggle switch with 2 positions Electrovalve relay horn Proportional electrovalve 17/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 18 “light” Electrovalve “ON/OFF » ( bang-bang) Tilt sensor ( ramp detection) Angle sensor (reach limitation) Contact « mercury » (angle detection) Resistor (here value 100 ohms, 3 Watts, tolerance of 5%) 18/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 19 Standard light “Led” Strain gauge (ILS : Flexible Blade Switch) ILS detection of the magnets on the telescopic boom/arm extension Level detector (diesel tank) Proximity detector with impulses (detection teeth slew ring) 19/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 20: Methodology Of Control

    (see below). select the position to voltmeter (V), then activate the command to the valve which must be tested. The voltage indicated by the voltmeter must be close to the tension of battery 20/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 21 Ohmmeter (Ω), then compare the value measured with that of the data manufacturer. In the event of nonconformity of the coil, replace it 21/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 22: Control Of Components

    (It must be close to the battery voltage Vbat) select the function of this relay and check the output voltage between terminal 87 and ground. In the event of dysfunction, replace the relay. 22/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 23: The Wiring Diagram

    In one direction, the diode should have no continuity, in the other it must beep If the diode is beeping in both ways , replace it. See at the end of this manual 23/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 24: The Looms ( Star 6P)

    24/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 25 25/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 26: Localization Of The Safety Components

    SQ12 SQ11 (inside mast) SQ13 SQ10 26/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 27 US version 1 with foot switch US version 2 (with trigger on joystick ) 27/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 28: Limit Switchs Star 6

    Slackness of chain (mast foot) SQ10 Slackness of chain (high position of mast) SQ11 Inclination switch front (for overspeed prevention) SQ12 Inclination switch rear (for overspeed prevention) SQ13 Line contactor Pump contactor Brakes release 28/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 29: Contactors

    29/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 30 B + 2 D OUT D Neg C Neg B Neg A IN D IN 30/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 31: Variable Speed Unit

    Connector A Connector B 31/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 32: List Components ( Star 6 P )

    Option remote control for brakes release system (111B) 02 - 13 Validation movements (131) 02 - 8 Joystick drive/ movements: Trigger HM (132) Right/left steering (130/129) REV/FWD (112) Signal from 0.5 V to 4.5 V (137) 32/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 33: Outputs

    BUZZER AND LIGHTS 02 - 27 Buzzer alarms (141) 01 - 26 Option working light (106) 02 - 19 horn (147) 02 -17 Light for alarms (146) 01 -28 Option flashing light (107) 33/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 34: Others

    01 - 8 Hour recorder + alarms (113) No movement cut if in slope (sound alarm only) The battery charge needs to be adjusted as follow (select at 2 used for HAULOTTE machine equipped with lead batteries) 34/82 TRAINING MANUAL...

  • Page 35: Logical Equations ( Star 6P)

    Steering proximity KM =1 + KM2 = 1 + YV2 = switch SQ6 Left steering YV1b=1 SA1 + SB7 =1 + SM1 GD (validation dead man line 132 =1 +line 129 =1) 35/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 36: Drive

    SQ9 = 0 Rise YV 3=1 KM2 = 1 + YV2 = 1 (overload) SQ1=0 SQ10 = 0 SQ11 = 0 YV2 =1 Descent YV3 =1 KM2 = 0 SQ3 = 1 Star 6P 36/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 37 If voltage tension, lower than the charge batteries parameter of adjustment low battery F04010 Battery high Voltage battery If voltage correct above than the check if B+ is parameter connected to the 37/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 38 Drive 0 off Defect desactivation check KM1 contactor n°0 F05014 Drive 1 off Defect desactivation check KM2 contactor number 1 F05019 Stack corrupted None Defect of the internal change the variable battery of variable 38/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 39 Visualisation of none Normal function the hours None 2 DIR. Fault The 2 ways of check joystick SM1 steering (L/R) are selected at the same time 39/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 40: Battery Charger Indicator

    U, I2 and stop before equalisation Green led at the end of this phase Blinking green led in equalisation phase no power When batteries are fully charged , the led is green fixed 40/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 41 41/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 42: The Hydraulic Part

    (here maximum 38 cc /rpm) Pump with fixed cubic capacity flow (here 23 cc/rpm) Pump with variable flow (used for the hydrostatic transmission in closed circuits on HAULOTTE big booms like HA32PX, HA41PX, H28TJ+, H43TPX) Hydraulic motor with 2 directions of drive (ex FWD/REV)
  • Page 43 Position hydraulic valve (used for the HA32PX/HA41PX) Adjustable pressure relief valve (here set at 145 bars/2104 psi) Fixed flow restrictor or spray nozzle (here diameter of 0.75 mm) Adjustable flow restrictor + check valve 43/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 44 Counter balance valve with piloting line of the opposite line (here set at 210bars) Position valve proportional 5/3 with piloting manual by lever Rotary cylinder /jack (here range at 180°) Piloted valve 44/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 45: Hydraulic Diagram Star 6/6P

    HA32PX/HA41PX) Position valve proportional 4 ways/3 positions Pressure balance/flow control valve Flow regulator See all versions at the end of this manual Pump motor unit Cylinder steering Block emergency lowering Mast Cylinder 45/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 46: Valves Location

    YV1A YV1B YV1A Left steering valve YV1B Right steering valve Lift /steering Safety valve for mast 46/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 47: Adjustments

    Connection on logic connector B 47/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 48: Drive Menu

    Initialising… 1 Traction 1.3Traction 1.1Traction 1.2Traction Test Personal… Status Parameters state Test 1.4Traction 1.5Traction 1.6Traction FaultLog Setup Battery set Error report Configuration 1.7Traction 1.8Traction MotorSetup Display Configuration display 48/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 49: Pump/ Movements Menu

    Initialising… 1 Traction 2 Pump 2.2Pump 2.1Pump Status Personal… 1.5Traction 1.6Traction 1.4Traction Fault Log Setup Parameters Test upper controls Parameters 2.6Pump LowerBoxTest Test lower controls 49/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 50: List Of Parameters

    Note: the following parameters are accessible only by the technician having followed the SEVCON console training All the other parameters are specific for the Star 6 (6P) and must not be modified without the authorization of HAULOTTE Services  Star 6...
  • Page 51 Armature Resistance (mOhm) 1.7.8 Field Resistance (Ohm) 0,25 0,01 0,75 1.7.9 Drive Proportional Gain 1.7.10 Drive Integral Gain 1.7.11 Brake Proportional Gain 1.7.12 Brake Integral Gain 1.7.13 Speed Estimate Gain 0,01 0,96 51/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 52 Y-Axis Forward Voltage (V) 0.00 5.00 0.02 4.70 2.3.18 Y-Axis Reverse Voltage (V) 0.00 5.00 0.02 0.58 2.3.19 X-Axis Zero Voltage (V) 0.00 5.00 0.02 0.58 2.3.20 X-Axis Full Voltage (V) 0.00 5.00 0.02 4.06 52/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 53 Slew Right Speed (%) 2.5.13 Cage Level Forward Speed (%) 2.5.14 Cage Level Reverse Speed (%) 2.5.15 Cage Rotate Left Speed (%) 2.5.16 Cage Rotate Right Speed (%) 2.5.17 Overload Cutback Speed (%) 53/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 54  Star6P Note : These parameters are valid with EPROM version FR001610 54/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 55 SA1 (LS /HS selection) 55/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 56 56/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 57 57/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 58 58/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 59 SA1 (selection LS /HS) 59/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 60 Specific datas depending the country For US/CDN , the validation button SB7 is not used if the machine is equipped with a footswitch on platform For EUR : activation of overload detection by SQ9 60/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 61: List Of Alarms

    61/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 62: Parameter Settings

    Braking distance (High Speed drive with no load on tray) 0.78 m Braking distance (no load on tray) 0.17 m The adjustments are carried out on a flat surface without any obstacle 62/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 63: Console Diag Pad

    This diagnostic console could be used in WIFI using a VCI adapter (Vehicle Computer Interface) The full description of how to use that console and their menus is explained in an other technical note (refer to your nearest HAULOTTE SERVICES of your area) 63/82...

  • Page 64: Pressures

    New failure code Original failure code F01.06 AL62 F01.13 AL06 F01.14 AL13 F01.15 AL94 F01.16 AL01 AL10 AL32 AL37 AL38 AL49 AL53 AL60 AL74 AL75 AL78 AL79 AL80 AL90 AL91 AL95 AL96 AL97 AL99 64/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 65 Star 6P DESIGNATION Star 6 100 (+/-5) b General 125 (+/-5) b 100 (+/-5) b Lifting mast ( no lift if load > 190kg) 125 (+/-5)b 100 (+/-5) b Steering 125 (+/-5) b 65/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 66: Breakdown Service Guide

    Defective variable speed unit  Contactors KM1 - KM2  Validation movements SB7  Defective joystick SM1  Defective variable speed unit  Electrovalve YV1a and/or YV1b  Steering cylinder (pressure or defective) 66/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 67: Summary Of Versions

    Star 6 Electric Hydraulic All versions E 609 C17596 Single version Star 6 P (Picking) Electric Hydraulic All versions 113P339260 C17596 C Single version 67/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 68: Special Functions

    In case of major problems (variator not working) , it’s possible to release the brake on the electric motor in order to move the machine by holding the draw bar BR1 Remote control for brake release (in option) : 68/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 69: Hourmeter Connection

     Raise the mast to see the base of the lifting cylinder by the inspection hole  With flashlight verify the good condition and the position cable N°1 (between mast foot and 69/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 70 With flashlight verify the condition and the position cable N°2 (between box 1 and box 3) + pulley (the mirror must be used to see the pulley fixed approximately 25/35cm below the inspection hole)  If the cables are in good condition, proceed to adjustments 70/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 71 Cable N°1 _ unscrew CHC M6 screw half turn while applying a pressure towards up in order to maintain the state of cable tension (see below) Apply a tension on the cable always up 71/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 72: Overload Adjustment

    Adjust the position of the limit switch, when load (40kg) is located on the tray, the spring is compressed and will activate the roller of the limit switch Before any control, disconnect all wires from the variable speed unit 72/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 73: List Of Schematics

    See below all schematics (electric/hydraulic) all versions of the studied model 73/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 74 74/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 76 76/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

  • Page 77: Electric Function

    77/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 78 78/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 79 79/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 80 80/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 81 81/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...
  • Page 82 82/82 TRAINING MANUAL Star 6/13J range 2420344370 E04-15...

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