Haulotte Star 10, Star 26J TRAINING MANUAL
T
E
C
H
T
E
C
DII
D
H
A
A
NII
N
G
G
C
C
N
OSSTTII
N
O
A
A
L
L
T
R
R
AII
A
T
C LLEEVVEELL IIII
C
NII
N
N
N
G
G
Stt
S
arr
a
1
1
0
0
–
–
Stt
S
arr
a
2
2
6
6
J
J
HHooww ttoo uussee tthhiiss ddooccuummeenntt??
YYoouu hhaavvee bbeettwweeeenn tthhee hhaannddss tthhee ssuummmmaarryy ggiivveenn dduurriinngg tthhee tteecchhnniiccaall ttrraaiinniinngg HHAAUULLOOTTTTEE .
wwiillll eennaabbllee yyoouu ttoo ffiinndd iinnffoorrmmaattiioonn nneecceessssaarryy ffoorr tthhee mmaaiinntteennaannccee aanndd tthhee rreeppaaiirr ooff yyoouurr
mmaacchhiinnee HHAAUULLOOTTTTEE ..
TThhaannkkss ttoo tthhee gguuiiddee bbeellooww yyoouu wwiillll rreeaacchh tthhee rreeqquuiirreedd cchhaapptteerr qquuiicckkllyy..
CChhaapptteerr 11:: MMaaiinn ffeeaattuurreess aanndd ffuunnccttiioonnss
IItt iiss aabboouutt aa rreeccaallll ooff tthhee iinnffoorrmmaattiioonn ccoonnttaaiinneedd iinn tthhee mmaannuuaall uusseerr ddeelliivveerreedd wwiitthh tthhee mmaacchhiinnee:
ccoommppoonneennttss,, oovveerraallll ddiimmeennssiioonnss,, wwoorrkkiinngg zzoonneess ,, ccoommmmaannddss,, eettcc……
CChhaapptteerr 22:: SSttuuddyy ooff tthhee wwiirriinngg ddiiaaggrraamm
YYoouu wwiillll ffiinndd tthheerree tthhee eelleemmeennttss ffoolllloowwiinngg::
-- AA ssuummmmaarryy ooff tthhee ssttaannddaarrddiizzeedd ssyymmbboollss uusseedd bbyy HHAAUULLOOTTTTEE GGrroouupp
-- TThhee ccoommpplleettee wwiirriinngg ddiiaaggrraamm ooff tthhee ssttuuddiieedd mmooddeell
-- TThhee nnoonn eexxhhaauussttiivvee lliisstt ooff tthhee eelleeccttrriicc lloooommss aanndd eelleeccttrroonniicc bbooaarrddss
-- LLooccaalliizzaattiioonn ooff tthhee pprriinncciippaall ssaaffeettyy uunniittss ((ttiilltt ,, lliimmiitt sswwiittcchheess,, sseennssoorrss,, ttrraannssdduucceerrss……))
-- LLooggiiccaall eeqquuaattiioonnss ooff ooppeerraattiioonn:: bbyy ffuunnccttiioonn,, ttoo ddiiaaggnnoossee tthhee mmaaiinn ddyyssffuunnccttiioonnss
CChhaapptteerr 33:: SSttuuddyy ooff tthhee hhyyddrraauulliicc ddiiaaggrraamm
YYoouu wwiillll ffiinndd tthheerree tthhee eelleemmeennttss ffoolllloowwiinngg::
-- aa ssuummmmaarryy ooff tthhee ssttaannddaarrddiizzeedd ssyymmbboollss uusseedd bbyy HHAAUULLOOTTTTEE GGrroouupp
-- tthhee ccoommpplleettee hhyyddrraauulliicc ddiiaaggrraamm ooff tthhee ssttuuddiieedd mmooddeell
-- tthhee nnoonn eexxhhaauussttiivvee lliisstt ooff tthhee hhoosseess ttrraacckk
-- aa llooccaalliizzaattiioonn ooff tthhee pprriinncciippaall hhyyddrraauulliiccss mmaanniiffoolldd ((pprrooppoorrttiioonnaall bblloocckk ,, oonn//ooffff mmoovveemmeennttss
bblloocckk,,……))
-- LLooggiiccaall eeqquuaattiioonnss ooff ooppeerraattiioonn:: bbyy ffuunnccttiioonn,, ttoo ddiiaaggnnoossee tthhee mmaaiinn ddyyssffuunnccttiioonnss
CChhaapptteerr 44:: AAddjjuussttmmeennttss
TThhiiss iiss tthhee aaddjjuussttmmeennttss aanndd ccaalliibbrraattiioonnss,, hhyyddrraauulliiccss aanndd eelleeccttrriicc,, nneecceessssaarryy ttoo tthhee ggoooodd mmaaiinntteennaannccee
ooff tthhee mmaatteerriiaall.. YYoouu wwiillll ffiinndd aass wweellll tthhee mmeetthhooddss ooff aaddjjuussttmmeenntt wwiitthh ttaabbllee vvaalluueess..
CChhaapptteerr 55:: GGuuiiddee ooff bbrreeaakkddoowwnn
QQuuiicckk ssuummmmaarryy ooff tthhee sstteepp ttoo bbee ffoolllloowweedd ffoorr ppoossssiibbllee ssoouurrcceess ooff bbrreeaakkddoowwnn..
IInn ccaassee ooff aannyy ddeeffeecctt oorr aannyy ddyyssffuunnccttiioonn yyoouu wwiillll bbee aabbllee ttoo iiddeennttiiffyy tthhee eelleemmeennttss iinn qquueessttiioonn,,
wwhhaatteevveerr tthheeyy aarree eelleeccttrriicc oorr hhyyddrraauulliicc..
CChhaapptteerr 66:: SSuummmmaarryy ooff tthhee vveerrssiioonnss
TThhiiss mmaannuuaall ttrreeaattss ooff tthhee llaatteesstt vveerrssiioonn ,, hhoowweevveerr tthhiiss ssuummmmaarryy ttaabbllee eennaabblleess yyoouu ttoo ffiinndd tthhee ffoorrmmeerr
vveerrssiioonnss ooff tthhee mmaatteerriiaall ((eelleeccttrriicc aanndd hhyyddrraauulliiccss))..
CChhaapptteerr 77:: SSppeecciiaall ffuunnccttiioonnss
TThhiiss cchhaapptteerr ggaatthheerrss aallll tthhee ffuunnccttiioonnss aanndd aaddjjuussttmmeenntt ssppeecciiffiicc ttoo ccaarrrryy oouutt oonn tthhee mmaacchhiinnee.. TThheerree
ddooeess nnoott eexxiisstt ffoorr aallll tthhee mmaatteerriiaallss aanndd ddeeppeennddss oonn tthhee ssttuuddiieedd mmooddeell..
IItt mmuusstt bbee tthhee ssuubbjjeecctt ooff aa ssppeecciiaall aatttteennttiioonn ooff yyoouurr sshhaarree bbeeccaauussee aann iinntteerrvveennttiioonn bbaaddllyy ccaarrrriieedd oouutt
ccaann ddeetteerriioorraattee tthhee ggoooodd ppeerrffoorrmmaannccee ooff tthhee mmaacchhiinnee aanndd tthhuuss ccoonnsseeqquueennttllyy tthhee ssaaffeettyy ooff tthhee uusseerrss..
OOnnllyy aa tteecchhnniicciiaann HHAAUULLOOTTTTEE oorr aapppprroovveedd bbyy HHAAUULLOOTTTTEE SSeerrvviicceess iiss aabbllee ttoo ccaarrrryy oouutt tthhiiss kkiinndd ooff
iinntteerrvveennttiioonn..
OOnn tthhiiss cchhaapptteerr,, ssoommee ssppeecciiaall aaddjjuussttmmeenntt ((sseennssoorrss)) aarree aallssoo eexxppllaaiinneedd pprriioorr ttoo ccaalliibbrraattiioonn ((ddeeppeennddss
oonn tthhee mmooddeell))
MMAAIINNTTEENNAANNCCEE AANNDD RREEPPÄÄIIRR OOPPEERRAATTIIOONNSS OONN YYOOUURR HHAAUULLOOTTTTEE MMAACCHHIINNEE
MMUUSSTT BBEE DDOONNEE OONNLLYY BBYY TTRRAAIINNEEDD ,,EEXXPPEERRIIEENNCCEEDD AANNDD AAUUTTHHOORRIIZZEEDD TTEECCHHNNIICCIIAANNSS
. IItt
:
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SUMMARY
1. MAIN FEATURES AND FUNCTIONS....................................................................................................................5
1.1. C
1.2. COMMANDS S
2. STUDY OF THE WIRING SCHEMATICS ........................................................................................................... 14
2.1. S
2.2. M
2.3. T
2.4.
2.5. L
2.6.
2.7. L
2.8. O
2.9. L
2.10.
2.11.
HARACTERISTICS
1.1.1.
Main components.......................................................................................................................................... 5
1.1.2.
Overall dimensions – Star10 ........................................................................................................................ 7
1.1.3.
working zone Star 8...................................................................................................................................... 8
1.1.4.
working zone Star10..................................................................................................................................... 9
1.1.5.
main characteristics ................................................................................................................................... 10
1.2.1.
Upper controls............................................................................................................................................ 12
1.2.2.
Lower controls............................................................................................................................................ 13
YMBOLS USED
ETHODOLOGY OF CONTROL
2.2.1.
electric continuity control........................................................................................................................... 19
2.2.2.
Control of an on/off valve........................................................................................................................... 20
2.2.3.
Control of components ...............................................................................................................................21
HE WIRING DIAGRAM
LOOMS
(155P258150).......................................................................................................................................... 24
2.4.1.
The weighing board (bpe)........................................................................................................................... 28
2.4.2.
Cables on bpe board...................................................................................................................................29
OCALIZATION OF THE MAIN SAFETY COMPONENTS
PRINTED CIRCUIT LOWER PANEL
IST COMPONENTS
2.7.1.
Fuses........................................................................................................................................................... 33
2.7.2.
inputs.......................................................................................................................................................... 33
2.7.3.
Outputs ....................................................................................................................................................... 34
2.7.4.
Others......................................................................................................................................................... 35
PTIONS
USA...................................................................................................................................................... 35
OGICAL EQUATIONS OF OPERATION
2.9.1.
Powering .................................................................................................................................................... 36
2.9.2.
Steering....................................................................................................................................................... 36
2.9.3.
Drive........................................................................................................................................................... 36
2.9.4.
mast lifting.................................................................................................................................................. 37
2.9.5.
Jib lifting.....................................................................................................................................................37
2.9.6.
Turret slewing.............................................................................................................................................38
ALARMS
BATTERIES CHARGE
CODES..................................................................................................................................................39
................................................................................................................................................. 5
TAR
(UP AND DOWN) ............................................................................................................. 12
.................................................................................................................................................... 14
............................................................................................................................... 19
(E621E)........................................................................................................................... 23
........................................................................................................................... 31
............................................................................................................................................... 33
INDICATOR.......................................................................................................................42
............................................................................................30
.................................................................................................................... 36
3. STUDY OF THE HYDRAULIC SCHEMATICS...................................................................................................43
3.1. S
3.2. H
3.3. D
3.4.
4. ADJUSTMENTS........................................................................................................................................................ 51
4.1.
4.2. S
4.3. S
YMBOLS USED
YDRAULIC DIAGRAM STAR10
ETAILS OF HYDRAULIC BLOCK
HYDRAULIC LOGICAL EQUATIONS
DESCRIPTION CALIBRATOR
TEERING
•
adjustment...........................................................................................................................................................56
YSTEM OF LOAD CONTROL
4.3.1.
Operation....................................................................................................................................................58
principle of the load control.........................................................................................................................................58
4.3.2.
The angle sensor A1 ................................................................................................................................... 58
4.3.3.
Electric stop................................................................................................................................................ 58
4.3.4.
State of the outputs of the relays................................................................................................................. 58
4.3.5.
Management of the overlap of nominal load..............................................................................................59
4.3.6.
connection of the calibrator tool ................................................................................................................59
4.3.7.
Procedure of overload calibration .............................................................................................................60
4.3.8.
alarms codes on weighing board bpe......................................................................................................... 61
4.3.9.
values of the sensors...................................................................................................................................61
.................................................................................................................................................... 43
(P23343NG)....................................................................................................... 47
........................................................................................................................... 48
........................................................................................................................ 49
...................................................................................................................................51
.............................................................................................................................................................55
................................................................................................................................. 58
4.4. P
4.5. ZAPI P
4.6.
5. BREAKDOWN SERVICE GUIDE..........................................................................................................................74
5.1. NO START.......................................................................................................................................................... 74
5.2. N
5.3. N
5.4. N
5.5. N
5.6. N
5.7. N
5.8. N
5.9. N
5.10. N
5.11. N
5.12.
5.13. N
6. SUMMARY OF THE STAR VERSIONS ...............................................................................................................77
7. SENSORS MOUNTING INSTRUCTIONS ............................................................................................................ 78
7.1. ANGLE SENSOR............................................................................................................................................... 78
7.2. PRESSURE SENSOR.........................................................................................................................................78
7.3.
7.4.
ARAMETER SETTINGS
ARAMETER
PRESS
URES......................................................................................................................................................... 71
4.6.1.
Table of the pressures.................................................................................................................................73
O MOVEMENT (BOTH CONTROLS
O MOVEMENT FROM UP
O MOVEMENT FROM
O JIB FROM UP
O JIB FROM LOWER CONTROLS
O MAST FROM UPPER CONTROLS
O MAST FROM LOWER CONTROLS
O TURRET ROTATION FROM UPPER CONTROLS
O TURRET ROTATION FROM LOWER CONTROLS
O DRIVE
MICROSPEED ONLY
O STEERING
BRAKE RELEASE FUNCTION
VARIATOR TRIPLAT IMPEDANCE CHECK
.............................................................................................................................................................76
....................................................................................................................................................... 76
......................................................................................................................................... 62
............................................................................................................................................... 63
PER
CONTROLS
LOWER
PER
CONTROLS
............................................................................................................................................... 76
..................................................................................................................................79
).......................................................................................................................74
.............................................................................................................74
CONTROLS
........................................................................................................................... 74
........................................................................................................................... 75
........................................................................................................................ 75
.......................................................................................................... 74
...................................................................................................................... 75
................................................................................................... 75
.................................................................................................. 76
...............................................................................................................81
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11.. MMAAIINN FFEEAATTUURREESS AANNDD FFUUNNCCTTIIOONNSS
11..11..
11..11..11.. M
M
CCHHAARRAACCTTEERRIISSTTIICCS
AAIINN CCOOMMPPOONNEENNTTSS
S
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11..11..22.. O
O
VVEERRAALLLL DDIIMMEENNSSIIOONNSS
–
S
R
TTAAR
–
S
1100
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11..11..33..
WWOORRKKIINNGG ZZOONNEE
S
S
TTAARR
88
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11..11..44..
WWOORRKKIINNGG ZZOONNEE
S
R
S
TTAAR
1100
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11..11..55..
STAR 8
MMAAIINN CCHHAARRAACCTTEERRIISSTTIICCS
S
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STAR 10
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11..22..
11..22..11..
CCOOMMMMAANNDDSS SSTTAARR ((UUPP AANNDD DDOOWWNN))
U
PPPPEERR CCOONNTTRROOLLS
U
S
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11..22..22..
L
OOWWEERR CCOONNTTRROOLLS
L
S
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22.. SSTTUUDDYY OOFF TTHHEE WWIIRRIINNGG SSCCHHEEMMAATTIICCSS
22..11..
SSYYMMBBOOLLSS UUSSEEDD
Battery with one element
Alternator
Fuse (Here 10 amps)
Coil winding roll
Electric motor
light
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Diode
Hourmeter
Standard push-button of safety “mushroom-headed
button”
Rotary knob
Push-button
Limit switch
Pressure switch
Key selector with 3 positions (T turret, O neutral, N
platform)
Toggle switch with 2 positions
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Electrovalve
relay
horn
Proportional electrovalve
Controller/joysticks
Pedals “dead man” or “foot dead man” switch
buzzer
“light”
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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%)
Sensor length (reach limitation)
Pressure sensor (weighing)
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Angle sensor (weighing)
Standard light “Led”
Strain gauge
Interruptor Lame Switch (ILS) detection of the magnets
on the telescopic boom/arm extension
Level detector (diesel tank)
Proximity detector with impulses (detection teeth slew
ring)
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22..22.. MMEETTHHOODDOOLLOOGGYY OOFF CCOONNTTRROOLL
Note: during an intervention on a component or a loom, it is important to remember to switch
OFF the power supply of the machine in order to avoid any risk.
22..22..11..
The continuity check of a loom or an electric component determines the resistor of this
device, in order to detect a possible interruption of continuity (open circuit, short-circuit…).
This control is carried out with a multimeter commutated in position Ohmmeter (Ω).
First of all, it is necessary to determine the terminals of the component or the cable to control
and insulate them.
Then, connect the multimeter in order to record the value.
It must indicate a value of resistor close to 0 Ω if continuity is good.
In the contrary case (resistor which tends towards the infinite one : ∞), continuity presents a
defect.
Control of insulation
EELLEECCTTRRIICC CCOONNTTIINNUUIITTYY CCOONNTTRROOL
L
At the contrary of continuity, insulation represents a non electric connection between the
ground and the component
The test of insulation consists in obtaining the opposite result of that described for continuity,
i.e. a value of the Ohmmeter which must tend towards the infinite one :
∞
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C
22..22..22..
Note: These tests are to be carried out when power is ON .
Also control the state of the terminals or any another connectors (oxidation…)
Control supply of the coil
disconnect the plug socket of supply of the valve in order to connect in derivation the
multimeter on the terminals of the connector (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
OONNTTRROOLL OOFF AANN OON
C
N
/
OOFFFF VVAALLVVE
/
E
Control intensity of the coil
disconnect the plug socket of supply of the valve in order to connect in series the multimeter
on the terminals of the connector (example below).
select the position Ammeter (A), then activate the command to the valve which must be
tested.
The intensity indicated by the voltmeter must be of approximately 2A (to be checked
according to the data manufacturer)
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Control resistance of the coil
disconnect the plug socket of supply of the valve in order to connect the multimeter on the
terminals of the connector industry.
select the position Ohmmeter (Ω), then compare the value measured with that of the data
manufacturer.
In the event of nonconformity of the coil, carry out its replacement
C
22..22..33..
• Control of an electric relay
Disconnect the relay, then locate its various terminals.
Control the resistor of the solenoid terminals 85 and 86 (see manufacturer data’s) using
a multimeter in Ohmmeter position.
If the resistor is null, change the relay.
If this test is OK, check continuity between terminals 30 and 87a and insulation between
terminals 30 and 87
In the event of dysfunction, replace the relay.
• supply control of the relay
locate the relay without disconnecting it and locating it its various terminals.
control the continuity of terminal 86 with the ground
.(In the event of defect of continuity, check the concerned loom)
connect the multimeter in position Voltmeter (V) between terminal 30 and the ground and thus
control the power supply of the component (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.
OONNTTRROOLL OOFF CCOOMMPPOONNEENNTTS
C
S
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• Control of a fuse
Color code
Fuse check
Multimeter in Ω position, it must indicate a value near 0
OK
NOK
• Control of a diode
locate the diode and disconnect it from the loom.
Control must be done with a multimeter in “diode” position .
connect the multimeter on each terminal of the diode, in one direction then on the other.
In a direction, the diode should have no continuity,
in the other it must be beep
If the diode is beeping in both ways, replace it.
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22..33..
See at the end of this manual
TTHHEE WWIIRRIINNGG DDIIAAGGRRAAMM ((EE662211EE))
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22..44..
Old version
LLOOOOMMSS ((115555PP225588115500))
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Turntable box (P20593)
See at the end of this manual
Battery main switch SB1 (155P258130)
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upper box (155P258800)
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Connector J11 (pressure sensor)
Connector J15 (angle sensor)
22..44..11..
T
HHEE WWEEIIGGHHIINNGG BBOOAARRDD
T
(
(
E
BBPPE
))
terminal Description Notes
1 Positive Red
2 - 3 Signal 4-20mA white
Terminal Description Notes
1 Positive red
2 Négative black
3 Signal white
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Supply on BPE board :
Connector J4 :
J4.1 : + ALIM
J4.2 : - ALIM
J4.3 : input VAR 38
J4.4 :
J4.5 : input VAR 26
J4.6 :
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