Haulotte Group STAR 8 Operating And Maintenance Instructions Manual
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Haulotte Group STAR 8 Operating And Maintenance Instructions Manual

Haulotte Group STAR 8 Operating And Maintenance Instructions Manual

Self-propelled platform
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OPERATING AND MAINTENANCE
INSTRUCTION
Self-propelled platform
STAR 8 & 10
242 032 7160 - E 02.06 Ind. A AUST

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Summary of Contents for Haulotte Group STAR 8

  • Page 1 OPERATING AND MAINTENANCE INSTRUCTION Self-propelled platform STAR 8 & 10 242 032 7160 - E 02.06 Ind. A AUST...
  • Page 3 Distribué par / Distributed by/ Distribuito da Haulotte France Centre Mondial Pièces de Rechange Tél / Phone +33 (0)4 72 88 05 70 Spare Parts International Centre Fax / Fax +33 (0)4 72 88 01 43 Tél / Phone +33 (0)4 77 29 24 51 Fax / Fax +33 (0)4 77 29 98 88 Haulotte Portugal...
  • Page 5 REVIEW JOURNAL Issue Date Subject 01.06 10/01/2006 Created (Index a) - STAR 10 02.06 01/02/2006 STAR 8 & 10 (Index b) 03.06 08/03/2006 STAR 8 & 10 (Index A)
  • Page 7 Operating and maintenance instructions FOREWORD You have just taken delivery of your mobile elevating work platform. The purpose of this manual is to help the owners, the operators, the lessors to get to know HAULOTTE self-propelled lifts so as to use them efficiently and SAFELY. It cannot, however, replace the basic training necessary for any user of site plant.
  • Page 8 Operating and maintenance instructions...

  • Page 9: Table Of Contents

    Operation and Servicing CONTENTS SAFETY INSTRUCTIONS ................... 1 1.1 - GENERAL WARNING ....................1 1.2 - BEFORE USE......................2 1.2.1 - Training and operator knowledge .................... 2 1.2.2 - Environment..........................3 1.3 - USING THE MACHINE....................4 1.4 - DANGER OF ELECTROCUTION................5 1.5 - MINIMUM SAFETY DISTANCES ................
  • Page 10 Operation and Servicing 2.4 - DESCRIPTION OF CONTROL STATIONS ...............12 2.4.1 - "Turntable" control station ...................... 13 2.4.2 - "Platform" control station ......................13 CHECKS PRIOR TO MACHINE OPERATION ............15 3.1 - GENERAL INSTRUCTIONS ..................15 3.2 - VISUAL CHECKS ......................15 3.2.1 - General mechanical appearance of the machine..............
  • Page 11 Operation and Servicing 5.1.2 - Movement (control from the "platform" station)..............27 5.1.3 - Battery discharge ........................27 5.2 - OPERATION......................28 5.2.1 - Operation from the ground..................... 28 5.2.2 - Operations from the platform ....................29 5.3 - USING THE BUILT-IN CHARGER ................31 5.3.1 - Characteristics ........................
  • Page 12 Operation and Servicing 9.2 - MAINTENANCE PLAN....................43 9.2.1 - Consumable ........................... 43 9.2.2 - Maintenance plan ........................44 9.3 - OPERATIONS......................45 9.3.1 - Hydraulic oil filter ........................46 9.3.2 - Electric batteries........................46 9.3.3 - Checking 'wear and tear' of chains..................46 9.3.4 - Checking the tension of the bracing ropes ................

  • Page 13: Safety Instructions

    Operating and maintenance instructions SAFETY INSTRUCTIONS 1.1 - GENERAL WARNING The owner, lessor, user or operator of the machine must not use this machine before having read and understood this manual under any circumstances. Prohibit any working mode liable to jeopardise safety. Any use not compliant with the instructions could lead to risks and injury to people and damage to property, and even a mortal danger.

  • Page 14: Before Use

    Operating and maintenance instructions 1.2 - BEFORE USE IT IS THE USER'S RESPONSIBILITY TO STOP USING THE MACHINE IN THE CASE OF OPERATING FAULTS OR SAFETY PROBLEMS OF THE MACHINE ITSELF OR IN THE AREA AROUND THE MACHINE. 1.2.1 - Training and operator knowledge Only authorised and qualified operators can use Haulotte self-propelled platforms.

  • Page 15: Environment

    Operating and maintenance instructions 1.2.2 - Environment IT IS STRICTLY FORBIDDEN TO USE THE MACHINE: • neither on lorries, trailers, trains, sea vessels, nor any other vehicles or equi- pment unless this is authorized by HAULOTTE in writing. • On ground that is soft, unstable, congested. •...

  • Page 16: Using The Machine

    Operating and maintenance instructions 1.3 - USING THE MACHINE • Never operate a faulty machine. It must be serviced and repaired in accor- dance with the instructions contained in the maintenance and repair ma- nuals. • Never use the machine for any purpose other than taking people together with their tools and materials to a particular place.

  • Page 17: Danger Of Electrocution

    Operating and maintenance instructions 1.4 - DANGER OF ELECTROCUTION Caution ! If the machine has a 220 V 16A Our machines are not insulated, the electrical risks are considerable in the max. plug, the extension must following situations: be connected to a mains - hitting a power line, also consider the movements performed by the socket protected by a 30 mA machine and the oscillation of electrical lines.

  • Page 18: Danger Of Falls

    Operating and maintenance instructions 1.6 - DANGER OF FALLS When the operators are on board the machine, they must observe the following rules: • Wear personal protective equipment suited to working conditions and con- form to local regulations, particularly when working in hazardous areas. •...

  • Page 19: Risks Of Jerky Movements And Tipping Over

    Operating and maintenance instructions 1.7 - RISKS OF JERKY MOVEMENTS AND TIPPING OVER Caution ! Never use the platform as a When the operators are on board the machine, they must observe the crane, hoist or lift. following rules: Never use the machine to pull •...

  • Page 20: Danger Of Squashing And Collision

    Operating and maintenance instructions 1.8 - DANGER OF SQUASHING AND COLLISION Caution ! Wearing a safety helmet is When the operators are on board the machine, they must observe the compulsory for any operator following rules: working on the platform or in •...

  • Page 21: Examination Of Machine Suitability

    Operating and maintenance instructions NOTE : This register can be obtained from trade organisations, and in some cases from the OPPBTP or private prevention agencies. 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).

  • Page 22: Beaufort Scale

    Operating and maintenance instructions 1.13 - BEAUFORT SCALE The Beaufort Scale of wind force is accepted internationally and is used when communicating weather conditions. It consists of number 0 - 17, each representing a certain strength or velocity of wind at 10m (33 ft) above ground level in the open.

  • Page 23: Presentation

    Operating and maintenance instructions PRESENTATION Self-propelled platforms, STAR 8 & STAR 10 models, are designed for all elevated work within the limits of their characteristics (Chap. 8, page 39) and conform to all the safety recommendations specific to the equipment and places of use.

  • Page 24: Safety Equipment

    Operating and maintenance instructions 2.3 - SAFETY EQUIPMENT Caution ! Do not put your feet towards 2.3.1 - Pothole safety system the pothole safety systems, The machine has fixed potholes situated underneath the base-frame, which helps so as to avoid risks of to prevent it from swaying.

  • Page 25: Turntable" Control Station

    Operating and maintenance instructions 2.4.1 - "Turntable" control station Fig. 2 - : "Turntable" control station 1 - Timer with charge level 5 - Turntable orientation control 2 - Control panel selection switch: turntable / platform 6 - Jib raising control 3 - Movement control manipulator 7 - Charge indicator 4 - Mast telescoping control...
  • Page 26 Operating and maintenance instructions...

  • Page 27: Checks Prior To Machine Operation

    Operating and maintenance instructions CHECKS PRIOR TO MACHINE OPERATION 3.1 - GENERAL INSTRUCTIONS During its manufacture, each lift is the subject of continuous quality controls. Transport can cause damage. You must report any damage to the carrier before the machine is put into service for the first time. See Chapter 7, page 37. Each day and at the beginning of a new work period, the machine will undergo a visual inspection and an operating test.

  • Page 28: The Machine's Environment

    Operating and maintenance instructions 3.2.4 - The machine's environment Caution ! Do not use the machine if the 3.2.4.1 -Outdoors wind speed exceeds 28 mph / For use outdoors, it is important to comply with the operating instructions as well 45 km/h.

  • Page 29: Movement Tests

    Operating and maintenance instructions Fig. 4 - Safety systems 1- Bottom panel 2 - Top panel 3 - Overload light 4 - Validation 5 - Tilt detector emergency stop emergency stop indicator 3.3.1.4 -Validating movements • When testing the movements of the machine, Chap. 3.3.2, page 17, check the correct functioning of the validation button of the control station at the platform: - Control a movement, press validation button (Figure: 4 - Validation,...
  • Page 30 Operating and maintenance instructions...

  • Page 31: Operating Principle

    Operating and maintenance instructions OPERATING PRINCIPLE 4.1 - 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 filter mounted on the hydraulic return line protects the machine from pollution. In the case of a fault, manual rescue measures allow the emergency operator to obtain the movements of the mast, the movements of the jib as well as the movements of the turntable.

  • Page 32: Electric Circuit

    Operating and maintenance instructions 4.2 - ELECTRIC CIRCUIT Caution ! These machines are not The electrical power used for the controls and the starting of the machine is insulated and must not be put supplied by a unit of two traction battery blocks of 24 V - 250 Ah. A built-in charger into service near power lines enables these batteries to be recharged overnight by connecting it to a domestic 16A socket.

  • Page 33: Battery Charge Monitor / Hour Counter

    Operating and maintenance instructions 4.2.4 - Battery charge monitor / Hour counter This combines in a single unit the following functions : • State of charge of the batteries • Hour counter • Resetting. 4.2.4.1 -State of charge of the batteries The state of charge of the battery is indicated by 5 LEDs: •...
  • Page 34 Operating and maintenance instructions ALARM MESSAGE ON CODE PROBABLE CAUSES REMEDIES CONSOLE (MDI) • The test is executed during the initial diagnosis. The alarm switches on if, 500 m after the ignition CAPACITOR key has been turned off, condensers have not •...
  • Page 35 Operating and maintenance instructions ALARM MESSAGE ON CODE PROBABLE CAUSES REMEDIES CONSOLE (MDI) • The test is executed during the initial diagnosis, at rest. It maintains that the current is superior to a minimum threshold. In the opposite case, the •...
  • Page 36 Operating and maintenance instructions ALARM MESSAGE ON CODE PROBABLE CAUSES REMEDIES CONSOLE (MDI) • The test is performed non stop. The alarm is on if requests different operations simultaneously activated. • Replace the serial card FORW + BACK • Possible reasons: or joystick.

  • Page 37: Safety Systems

    Operating and maintenance instructions ALARM MESSAGE ON CODE PROBABLE CAUSES REMEDIES CONSOLE (MDI) • Check the chopper’s • Heat alarm > 75°C/167°F ; the maximum current THERMAL temperature using the on inductors is linearly stepped down to 0 at 90°C/ PROTECTION console or replace the 194°F.

  • Page 38: Contact Switches' Function

    Operating and maintenance instructions 4.3.5 - Contact switches’ function 4.3.5.1 - SQ1 - Tilt control See “Tilt control up to 3°”, page 25 4.3.5.2 -SQ4 - Low position limit switch • When being raised: - micro - gear activated - tilt activated •...

  • Page 39: Use

    Operating and maintenance instructions 5.1 - RECOMMENDATIONS 5.1.1 - Reminders Do not use the machine : • without reading the recommendations dealing with machine operation, - See “Before use”, page 2. - See “Using the machine”, page 4. • with various hazards, - See “Danger of electrocution”, page 5.

  • Page 40: Operation

    Operating and maintenance instructions 5.2 - OPERATION Fig. 6 - : Bottom panel The main control panel is in the platform. emergency stop • In normal operation, the "turntable" operation station is an emergency sta- tion only used if necessary. •...

  • Page 41: Operations From The Platform

    PLATFORM MODEL STAR 8: 200 kg. (2 persons) (indoor); 200 kg.(1 pers.) (outdoor). STAR 10: 200 kg. (2 persons) (indoor); 200 kg.(1 pers.) (outdoor). • Pull the emergency stop (Figure: Platform control station, page 30) ref.1 5.2.2 - Operations from the platform...
  • Page 42 Operating and maintenance instructions Fig. 8 - Platform control station 7814 828 e 5.2.2.1 - Mast or jib lifting • Place the selector switch on the pictogram (ref.2). • Press the validation button (ref. 3). • Operate the master controller (rep.5) from bottom to top . •...

  • Page 43: Using The Built-In Charger

    Operating and maintenance instructions 5.3 - USING THE BUILT-IN CHARGER CHARIS HF 24V - 30A STD type. Caution ! Set the chassis emergency 5.3.1 - Characteristics stop on the ’OFF’ position • Power supply: 220V single phase 50 Hz before recharging. •...
  • Page 44 Operating and maintenance instructions...

  • Page 45: Rescue And Repair Operations

    Operating and maintenance instructions RESCUE AND REPAIR OPERATIONS Caution ! Only a skilled and authorised operator may perform standby or emergency movements. 6.1 - RESCUE LOWERING This is the case in which the operator on the platform is no longer able to control the movements, even though the machine is functioning as normal.

  • Page 46: Manual Repair

    Operating and maintenance instructions 6.2 - MANUAL REPAIR Caution ! It is prohibited to lower If an operating fault prevents the operator on the platform from coming back overloads using emergency down, a competent operator may bring the platform back down from the control lowering at the risk of station at the base-frame.

  • Page 47: Manual Pump Emergency Operation

    Operating and maintenance instructions 6.3 - MANUAL PUMP EMERGENCY OPERATION Movements may be controlled from the ground if the main power source fails. There is a hand pump (ref.1) next to the hydraulic distirbuting valves on the turntable. In association with manual control of the electrodistributing valves, this pump enables mast lifting, turntable orientation and steering orientation (if the machine is towed).
  • Page 48 Operating and maintenance instructions...

  • Page 49: Unloading - Loading - Moving

    Operating and maintenance instructions UNLOADING - LOADING - MOVING MPORTANT: Before any unloading operation, check the machine’s overall condition to make sure that it has not been damaged during transport. Otherwise, please file the necessary reservations with the carrier within 48 hours in writing.

  • Page 50: Loading / Unloading With Ramps

    Operating and maintenance instructions 7.3 - LOADING / UNLOADING WITH RAMPS IMPORTANT: When going on a ramp, whether ascending or descending, we recommend that the axle at the back engine should be oriented towards the lower end of the slope. Caution ! DO NOT GO DOWN THE •...

  • Page 51: Technical Data

    Operating and maintenance instructions TECHNICAL DATA 8.1 - STAR 8 &10 TECHNICAL DATA STAR 8 STAR 10 Useful load (outdoor / indoor) 200 kg (2 persons) / 200 kg (1 person) Maximum side force (outdoor / indoor) 40 kg / 20 Kg Working height 8.8 m...

  • Page 52: Dimensions Of Star 10 Mast

    Operating and maintenance instructions 8.2 - DIMENSIONS OF STAR 8 AND STAR 10 MASTS Fig. 12 - Dimensions 1000 mm / 3 ft 3 1200 mm / 3 ft 11 1636 mm / 5 ft 6 2655 mm / 8 ft 8...

  • Page 53: Working Area For The Star 10 Mast

    Operating and maintenance instructions 8.3 - WORKING AREA 8.3.1 - Working area for the STAR 8 mast Fig. 13 - STAR 8 working area Feet METRES...
  • Page 54 Operating and maintenance instructions 8.3.2 - Working area for the STAR 10 mast Fig. 14 - STAR10 working area Feet METRES...

  • Page 55: Maintenance

    Operating and maintenance instructions MAINTENANCE 9.1 - 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 After-sales service for information.

  • Page 56: Maintenance Plan

    Operating and maintenance instructions 9.2.1.1 -’Intense cold’ hydraulic oil conditions of use This oil is meant for working at low temperature. Caution ! The ambient temperature must not exceed 15°C. In the opposite case, use a standard or organic hydraulic oil. 9.2.2 - Maintenance plan K K...

  • Page 57: Operations

    Operating and maintenance instructions IMPORTANT: If "ORGANIC" OR "EXTREME COLD" OIL IS USED, FREQUENCIES IN THE TABLE BELOW ARE REDUCED BY HALF FREQUENCY OPERATION REFERENCE • Check: - hydraulic tank level. - electrolyte level in the batteries. See Chap. 9.3.2, page 46. Every day or •...

  • Page 58: Hydraulic Oil Filter

    Operating and maintenance instructions 9.3.1 - Hydraulic oil filter • Filter without clogging indicator. • Unscrew the cap (ref.1) • Remove the cartridge (ref.2). • Fit a new cartridge. • Screw up the cap. 9.3.2 - Electric batteries To have access to the lower tray (ref.3), pivot the upper tray (ref.4). Photo 7: Electric batteries 9.3.3 - Checking 'wear and tear' of chains Fig.

  • Page 59: Load Testing

    • Overturning moment in transversal position Overturning moment Machine Side slope (°) W (kg) L (m) (mN) STAR 8 6,831 754,96 HM10P (STAR 10) 8,003 890,66 See § 1.12.2 of AS 1418.10-1996 for additional testing details. The elevating work platform must come to a stationary conditions without overturning.
  • Page 60 Operating and maintenance instructions 9.4.3.1 -STAR8 9.4.3.2 -HM10P - STAR10...

  • Page 61: Labels

    Operating and maintenance instructions 10 - LABELS 10.1 - YELLOW LABELS 7814 573 a 10.2 - RED LABELS WARNING This accumulator contains pressurissed oil. Care must be taken whilst carrying out maintenance on this component. 7814 520...

  • Page 62: Miscellaneous Labels

    Operating and maintenance instructions 10.3 - MISCELLANEOUS LABELS 10.4 - LABELS SPECIFIC TO MODELS STAR 8 STAR 10...

  • Page 63: Label Positioning

    Operating and maintenance instructions 10.5 - LABEL POSITIONING...

  • Page 64: References Of The Machine's Labels

    Hand crush risk 3078148800 ON / OFF 3078144490 Anchoring hooks’ minimum load capacity 307P219210 Floor height and load STAR 8 307P216420 Floor height and load STAR 10 3078148300 Turntable control panel 3078143600 Caution, do not use as a welding ground...

  • Page 65: Hydraulic Diagram

    Operating and maintenance instructions 11 - HYDRAULIC DIAGRAM 11.1 - HYDRAULIC COMPONENT’S LIST (DIAGRAM P23343D) • Reference Component • 1 Motorpump group • 2 Hydraulic filter • 3 Emergency pump • 4 One way valve 0.5 bar • 5 ON / OFF movements block •...
  • Page 66 Operating and maintenance instructions...

  • Page 67: Wiring Diagrams

    Operating and maintenance instructions 12 - WIRING DIAGRAMS...

  • Page 68: Electric Components' List (E621C Diagrams)

    Operating and maintenance instructions 12.1 - ELECTRIC COMPONENTS’ LIST (E621C DIAGRAMS) • Component • Description • A1 • Angle sensor • FU1 1A • Overload protection • FU2 5A • Electrovalve protection • FU3 10A • Command protection • FU4 250A •...

  • Page 69: Folio 1

    Operating and maintenance instructions 12.2 - FOLIO 1...

  • Page 70: Folio 2

    Operating and maintenance instructions 12.3 - FOLIO 2...

  • Page 71: Folio 3

    Operating and maintenance instructions 12.4 - FOLIO 3...
  • Page 72 Operating and maintenance instructions...

This manual is also suitable for:

Star 10

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