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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 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 ……………………..
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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.
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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…
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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.
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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, •…
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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.
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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…
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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…
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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…
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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…
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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…
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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…
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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:…
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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»).
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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.
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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.
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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. •…
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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.
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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…
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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…
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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.
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Page 44: Maintenance Plan
Operation and servicing — STAR 8 — 10 5.2.2 — Maintenance plan…
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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 •…
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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…
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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.
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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. •…
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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…
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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…
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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;…
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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…
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Manuals and User Guides for Haulotte STAR 10. We have 3 Haulotte STAR 10 manuals available for free PDF download: Maintenance Book, Operator’s Manual
Haulotte STAR 10 Maintenance Book (166 pages)
Aerial Work Platform
Brand: Haulotte
|
Category: Boom Lifts
|
Size: 16.14 MB
Table of Contents
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Table of Contents
3
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Preface — Foreword
7
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Symbols and Colors
8
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Safety
11
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General Safety Rules
11
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Maintenance Implementation
11
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Uncontrolled Movement Hazard
11
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Electrocution Hazards
12
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Explosion / Fire Hazards
13
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Maintenance and Repair Training
14
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Owner’s Responsability
14
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Technician’s Responsability
14
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HAULOTTE Services
14
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Training
14
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Product Modification
15
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After Sales Service
15
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Product Information
15
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Manufacturer’s Warranty
16
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Warranty Acceptance
16
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Warranty Period
16
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Conditions of Warranty
16
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Warranty Conditions
17
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Primary Machine Components
20
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Layout
20
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Ground Control Box
22
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Layout
22
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Activ’screen
23
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Platform Control Box
24
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Layout
24
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Device Layout
26
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Sensors and Actuators
26
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Consumables
27
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Ingredient
28
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Hydraulic Oil
28
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Lubrication Diagram
29
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Greasing Points Localization
30
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Machine Specifications
31
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Movement Speed
31
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Inspection and Maintenance Schedule
33
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Maintenance Schedule
33
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Inspection Program
37
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Daily Inspection
38
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Periodic Inspection
42
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Reinforced Inspection
44
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Major Inspection
46
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Structural Part Inspection
49
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Pins and Bearing Inspection
53
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Cylinder Inspection
57
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Breaking Test Procedure
61
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Torque Values
63
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Slew Ring Inspection
67
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Condition of the Cables Inspection — Criteria of Replacement
73
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Hoses Inspection — Replacement
77
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Electrical Wiring
79
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Inspection of the Condition of the Chains — Criteria of Replacement
81
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Tires (Tyres) and Pressures — Wheel Replacement
85
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Lubrication — Jib Cylinder — Steering Cylinder — Lift Cylinder
89
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Dismantling / Reassembling Wheels Reducer
93
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Replacing the Wheel Pivot
99
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Steering Cylinder Replacement
109
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Hydraulic Oil — Level Replacement
113
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Hydraulic Filter Cartridge Replacement
115
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Battery (Ies)
117
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Battery (Ies)
125
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Return Cables
129
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Specific Adjustment Procedure STAR 8 — STAR 20J — STAR 10 — STAR 26J
131
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Tube Wedging Procedure
137
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Inspection of the Slack Chain Sensors
139
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Overriding Function Reset
145
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Haulotte STAR 10 Operator’s Manual (100 pages)
Telescopic Masts
Brand: Haulotte
|
Category: Lifting Systems
|
Size: 15.7 MB
Table of Contents
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Table of Contents
3
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Operator’s Manual
7
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After Sales Service
7
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Compliance
8
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HAULOTTE Services® Contact Details
9
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Safety Precautions
11
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Recommendations
11
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Operator’s Manual
11
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Symbols Used
11
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Label Colors
12
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Pre-Operation Instructions
13
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General Instructions
13
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Specific Instructions
14
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Operation Instructions
15
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Prohibitions
15
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Potential Risks
16
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Risk of Command System Disturbance
16
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Risk of Falling
16
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Risk of Electrocution
17
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Risk of Uncontrolled Movement and Overturning
18
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Risk of Burns and Explosion
20
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Risk of Crushing and Collision
20
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Intervenor’s Responsibility
21
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Owner’s (or Hirer’s) Responsibility
21
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Employer’s Responsibility
21
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Trainer’s Responsibility
21
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Operator’s Responsibility
21
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Inspection and Maintenance
22
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Machine Layout
23
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Identification
23
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Main Components
23
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Safety Devices
27
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Sliding (or Swinging) Intermediate Guardrail
27
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Swing Doors
27
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Anchorage Point (Please See Machine Configuration)
28
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Labels
29
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Classification Plan
29
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Red Labels
29
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Orange Labels
31
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Yellow Labels
32
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Other Labels
33
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Green Labels
35
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Identification
36
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Control Boxes
45
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Ground Control Box — Emergency Control Panel
45
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Platform Control Box
49
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Operating Principle
55
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Description
55
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Safety Devices
55
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Activation of Controls
55
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Drive Speed
55
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Electronic Variable Speed Drive
55
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Multi-Function Indicator : Battery Charge Status Calculator-Indicator Hour
56
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Load Limiting in the Platform (if Fitted)
56
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Chassis Tilt
57
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Machine Braking
57
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Wheel Motor Brake Release
57
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Anti-Pothole Safety System
57
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On-Board Charger
58
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Order Picker Specific
58
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Driving
59
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Recommendations
59
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Checks and Inspection before Use
59
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Visual Inspections
59
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General Mechanical Functions
59
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Environment
61
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Functional Tests
62
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Safety Features
62
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Ground Control Box Controls (Emergency Station)
62
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Platform Control Box Controls (Driving Station)
63
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Periodical Checks
63
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Repairs and Adjustments
64
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Inspection / Testing Requirements
64
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Operation
65
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Test Procedure
65
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Emergency Stop Button Operation
65
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Tilt Sensor Switch Operation
66
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Visual and Sound Alarms
67
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Weighing System
67
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Operation from Ground Position
67
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Machine Start-Up
67
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Machine Shutdown
67
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Movement Control
68
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Other Controls
68
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Operations from the Platform
69
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Machine Start-Up
69
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Machine Shutdown
69
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Movement Control
69
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Other Controls
71
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Special Procedure
73
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Emergency Lowering
73
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Principle
73
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Procedure
73
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Lowering for Repairs
74
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Principle
74
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Procedure
74
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Towing
76
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Brake Release
76
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Loading and Unloading
77
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Principle
77
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Loading by Ramp
77
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Loading by Power Lift Truck
77
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Unloading by Power Lift Truck
78
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Loading by Lifting
78
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Unloading by Lifting
78
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Putting in Transport Position
79
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Unloading
80
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Warning
80
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Detection of Internal Fault
80
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Principle
80
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Procedure
80
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Technical Characteristics
81
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Main Characteristics
81
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Overall Dimensions
86
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Working Area
89
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Machine STAR 6
89
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Machine STAR 6 P
90
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Machine STAR
91
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Machine STAR
92
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AS — CE Standard Specifics
93
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Overload Test
93
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Functional Test
93
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Stability Test
94
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Declaration of Conformity
98
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Intervention Register
99
Haulotte STAR 10 Maintenance Book (132 pages)
Brand: Haulotte
|
Category: Boom Lifts
|
Size: 13.95 MB
Table of Contents
-
Table of Contents
3
-
Preface — Foreword
7
-
Symbols and Colors
8
-
Safety
11
-
General Safety Rules
11
-
Maintenance Implementation
11
-
Uncontrolled Movement Hazard
12
-
Electrocution Hazards
12
-
Explosion / Fire Hazards
13
-
Maintenance and Repair Training
14
-
Owner’s Responsability
14
-
Technician’s Responsability
14
-
HAULOTTE Services
14
-
Training
14
-
Product Modification
15
-
After Sales Service
15
-
Product Information
15
-
Manufacturer’s Warranty
16
-
Warranty Acceptance
16
-
Warranty Period
16
-
Conditions of Warranty
16
-
Warranty Conditions
17
-
Primary Machine Components
20
-
Layout
20
-
Ground Control Box
22
-
Layout
22
-
Platform Control Box
24
-
Layout
24
-
List of Actuators and Sensors
26
-
Sensors and Actuators
26
-
Power Source — Engine Specifications
27
-
General Safety and Specific Interventions on Motor
27
-
General Specifications
27
-
Consumables
28
-
Ingredient
28
-
Lubrication Diagram
30
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Consumables (Oils — Fuels — Engine Oil — Coolant Level
32
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Fuel
32
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Other Fuels
33
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Engine Oil
34
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Hydraulic Oil
35
-
Machine Specifications
36
-
Movement Speed
36
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Inspection and Maintenance Schedule
37
-
Inspection Program
37
-
Daily Inspection
38
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Preventive Maintenance
38
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Periodic Inspection
43
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Major Inspection
45
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Structural Part Inspection
47
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Wheel Reducer
51
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Pins and Bearing Inspection
53
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Cylinder Inspection
57
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Fuel Tank
61
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Braking Test Procedure
63
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Slew Ring
65
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Torque Values
69
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Wheel
71
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Screws, Bolts and Nuts
75
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Pulleys and Wear Pads
77
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Battery
79
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Hydraulic Filter Cartridge Replacement
83
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Glow Plugs
87
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Universal Plug
89
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Trouble Shooting
91
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Recommendations
91
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Description
91
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Troubleshooting
92
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Legend
94
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Electric Circuit
94
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Main Components
94
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Fuses
98
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Relays and Terminals
100
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Connectors
102
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Diagnosis Assistance Indicators
104
-
Buzzers
105
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Indicators
105
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Hydraulic Circuit
106
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Solenoid Valves
106
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Drive Unit
107
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Steering Unit
109
-
Unit TOR
110
-
Proportional Unit
111
-
Electric Diagram
114
-
Hydraulic Diagram
124
-
Intervention Register
127
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