Haulotte STAR 6, STAR 13, STAR 10, STAR 6P, STAR 8 Operator's Manual

Operator's manual

T

ELESCOPIC

MASTS

2420343790 e10.11 AUS

Operator's manual

TELESCOPIC MASTS

STAR 6 (STAR 13) - STAR 6P - STAR 8 (STAR 22J) -

STAR 10 (STAR 26J)

2420343790

e10.11

AUS

2 2420343790 e10.11 AUS

Telescopic masts

3

CONTENTS

Operator's manual

CONTENTS

1 - Operator's manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

2 - After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

3 - Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

4 - HAULOTTE Services® contact details. . . . . . . . . . . . . . .

9

A

SAFETY PRECAUTIONS

1 - Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

1.1 - Operator's manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.2 - Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.3 - Label colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2 - Pre-operation instructions. . . . . . . . . . . . . . . . . . . . . . . .

13

2.1 - General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.2 - Specific instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3 - Operation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

3.1 - Prohibitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.2 - Potential risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.2.1 - Risk of command system disturbance . . . . . . . . . . . . . . . . . . . . 16

3.2.2 - Risk of falling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.2.3 - Risk of electrocution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.2.4 - Risk of uncontrolled movement and overturning . . . . . . . . . . . . 18

3.2.5 - Risk of burns and explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.2.6 - Risk of crushing and collision . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

B

INTERVENOR'S RESPONSIBILITY

1 - Owner's (or hirer's) responsibility. . . . . . . . . . . . . . . . . .

21

2 - Employer's responsibility . . . . . . . . . . . . . . . . . . . . . . . .

21

3 - Trainer's responsibility . . . . . . . . . . . . . . . . . . . . . . . . . .

21

4 - Operator's responsibility . . . . . . . . . . . . . . . . . . . . . . . . .

21

5 - Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . .

22

C

MACHINE LAYOUT

1 - Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

2 - Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

3 - Safety devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

3.1 - Sliding (or swinging) intermediate guardrail. . . . . . . . . . . . . . . . . . . . . . . 27

3.2 - Swing doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.3 - Anchorage point (Please see machine configuration) . . . . . . . . . . . . . 28

4 - Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

4.1 - Classification plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.1.1 - Red labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.1.2 - Orange labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.1.3 - Yellow labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.1.4 - Other labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4.1.5 - Green labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.2 - Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5 - Control boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

5.1 - Ground control box - Emergency control panel. . . . . . . . . . . . . . . . . . . 45

5.2 - Platform control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4

Operator's manual

D

OPERATING PRINCIPLE

1 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55

2 - Safety devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55

2.1 - Activation of controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.2 - Drive speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.3 - Electronic variable speed drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.4 - Multi-function indicator : Battery charge status calculator-Indicator hour56

2.5 - Load limiting in the platform (if fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

2.6 - Chassis tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

2.7 - Machine braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

2.8 - Wheel motor brake release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

2.9 - Anti-pothole safety system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

2.10 - On-board charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

2.11 - Order Picker Specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

E

DRIVING

1 - Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59

2 - Checks and inspection before use . . . . . . . . . . . . . . . . .

59

2.1 - Visual inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

2.1.1 - General mechanical functions . . . . . . . . . . . . . . . . . . . . . . . . . . 59

2.1.2 - Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2.2 - Functional tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

2.2.1 - Safety features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

2.2.2 - Ground control box controls (emergency station) . . . . . . . . . . . 62

2.2.3 - Platform control box controls (driving station) . . . . . . . . . . . . . . 63

2.3 - Periodical checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2.4 - Repairs and adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

2.5 - Inspection / Testing requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

3 - Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65

3.1 - Test procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

3.1.1 - Emergency stop button operation . . . . . . . . . . . . . . . . . . . . . . . 65

3.1.2 - Tilt sensor switch operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.1.3 - Visual and sound alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

3.1.4 - Weighing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

3.2 - Operation from ground position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

3.2.1 - Machine start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

3.2.2 - Machine shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

3.2.3 - Movement control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3.2.4 - Other controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3.3 - Operations from the platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

3.3.1 - Machine start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

3.3.2 - Machine shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

3.3.3 - Movement control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

3.3.4 - Other controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

5

CONTENTS

Operator's manual

F

SPECIAL PROCEDURE

1 - Emergency lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73

1.1 - Principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

1.2 - Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

2 - Lowering for repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74

2.1 - Principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

2.2 - Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

3 - Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76

3.1 - Brake release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4 - Loading and unloading . . . . . . . . . . . . . . . . . . . . . . . . . .

77

4.1 - Principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

4.1.1 - Loading by ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

4.1.2 - Loading by power lift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

4.1.3 - Unloading by power lift truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4.1.4 - Loading by lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4.1.5 - Unloading by lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4.2 - Putting in transport position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4.3 - Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

4.4 - Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

5 - Detection of internal fault. . . . . . . . . . . . . . . . . . . . . . . . .

80

5.1 - Principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

5.2 - Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

G

TECHNICAL CHARACTERISTICS

1 - Main characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81

2 - Overall dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86

3 - Working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89

3.1 - Machine STAR 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

3.2 - Machine STAR 6 P. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

3.3 - Machine STAR 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

3.4 - Machine STAR 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

4 - AS - CE standard specifics . . . . . . . . . . . . . . . . . . . . . .

93

4.1 - Overload test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

4.2 - Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

4.3 - Stability test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

5 - Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . .

98

H

INTERVENTION REGISTER

1 - Intervention register . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99

6

Operator's manual

7

2420343790 e10.11 AUS

Telescopic masts

You have just purchased a HAULOTTE® product

and we would like to thank you for your business.

1 - Operator's manual

As stated on the delivery slip, this manual is one of the documents in the on-board document holder
provided upon delivery of your HAULOTTE® machine.

The operator manual is a translation of the original instructions.

Safe operation of this product can only be assured if you follow the operating instructions contained in
this manual.

We would particularly like to draw your attention to 2 essential points :

• Compliance with safety instruction (machine, use, environment)

• Use of the equipment within the performance limits set down in this manual.

2 - After Sales Service

Our HAULOTTE Services® After Sales Service is at your disposal throughout your machine's service
life to ensure optimal use of your HAULOTTE product..

• When contacting our After Sales Service, ensure that you provide the machine model and serial
number.

• When ordering any consumables or spare parts, please use this manual and the Haulotte Essential
catalogue to receive your genuine HAULOTTE spare parts, your only guarantee of parts
interchangeability and correct machine operation.

• If there is an equipment malfunction involving a HAULOTTE® product, then contact HAULOTTE
Services® immediately even if the malfunction does not involve material and/or bodily damage..

• In the event of malfunctions or incidents involving a HAULOTTE® machine, contact HAULOTTE
Services® immediately even if no material or bodily damage is observed and we will intervene as
soon as possible (See : HAULOTTE Services® contact details)

With regard to the designation of our equipment, we stress that this is purely for commercial purposes and
not to be confused with the technical characteristics. Only the tables of technical characteristics should
be used to study the suitability of the equipment for the intended use.

8 2420343790 e10.11 AUS

Telescopic masts

3 - Compliance

We would like to remind you that HAULOTTE® complies with the provisions of any applicable
directives applicable to this type of machine.

HAULOTTE advises you that NO modifications carried out without the written permission
of HAULOTTE® will void the HAULOTTE warranty..

HAULOTTE® cannot be held liable for any changes to the technical specifications contained in this

manual.

HAULOTTE® reserves the right to alter technical specifications and to make improvements or
modifications to the machine without modifying this manual.

Certain options can modify the machine's operating characteristics and its associated safety. If your
machine was originally delivered with options fitted, replacing a safety component associated with a
particular options not require any particular precautions other than those associated with the installation
itself (static test).

If you intend to add options to your product after original delivery, it is essential to follow the

manufacturer's recommendations below :

• Installation by authorised HAULOTTE® personnel only.

• Update the manufacturer's identification plate.

• Have stability tests carried out by a certified agency/competent person.

• Ensure that any additional labels that relate to the option installed, are affixed to the machine in the
appropriate location/s.

9

2420343790 e10.11 AUS

Telescopic masts

4 - HAULOTTE Services® contact details

HAULOTTE Services® contact details

HAULOTTE FRANCE

PARC DES LUMIERES

601 RUE NICEPHORE NIEPCE

69800 SAINT-PRIEST

TECHNICAL Department:

[phone]

SPARE PARTS : [phone]

FAX : [phone]

E

-mail : [e-mail]

www.haulotte.fr

HAULOTTE ITALIA

VIA LOMBARDIA 15

20098 SAN GIULIANO MILANESE

(MI)

TEL: [phone]

FAX: [phone]

E-mail : [e-mail]

www.haulotte.it

HAULOTTE HUBARBEITSBÜHNEN GmbH

AN DER MÖHLINHALLE 1

D-79189 BAD KROZINGEN-HAUSEN

TEL : [phone]

FAX : [phone]

E.mail : [e-mail]

www.haulotte.de

HAULOTTE VOSTOK, OOO

3, ZHUKOVSKOGO STREET

DOLGOPRUDNY

141700 MOSCOW REGION

RUSSIAN FEDERATION

TEL/FAX : [phone]

E.mail : [e-mail]

www.haulotte-international.com

HAULOTTE DO BRASIL

AV. CECI, 608 – B 13

CEP: 06460-120 – TAMBORE

BARUERI – SAO PAULO – BRASIL

TEL : [phone]

FAX : [phone]

E.mail : [e-mail]

www.haulotte.com.br

HAULOTTE IBERICA

C/ARGENTINA N° 13 - P.I. LA GARENA

28806 ALCALA DE HENARES

MADRID

TEL : [phone]

TEL SAT : [phone]

FAX : [phone]

E.mail : [e-mail]

www.haulotte.es

HAULOTTE POLSKA Sp. Z.o.o.

UL. GRANICZNA 22

05-090 RASZYN - JANKI-

TEL : [phone]

FAX : [phone]

E-mail :

[e-mail]

www.haulotte.pl

HAULOTTE MÉXICO, Sa de Cv

Calle 9 Este, Lote 18, Civac, Jiutepec,

Morelos

CP 62500 Cuernavaca

México

TEL : [phone]

FAX : [phone]

E-mail : [e-mail]

www.haulotte-international.com

HAULOTTE PORTUGAL

ESTRADA NACIONAL NUM. 10

KM. 140 - LETRA K

2695 - 066 BOBADELA LRS

TEL : + 351 21 995 98 10

FAX : + 351 21 995 98 19

E.mail : [e-mail]

www.haulotte.es

HAULOTTE SINGAPORE Pte Ltd.

No.26 CHANGI NORTH WAY,

SINGAPORE 498812

Parts and service Hot line: +65

6546 6179

FAX : [phone]

E-mail: [e-mail]

www.haulotte.sg

HAULOTTE MIDDLE EAST FZE

PO BOX 293881

Dubaï Airport Free Zone

DUBAÏ

United Arab Emirates

TEL : [phone]

FAX : [phone]

E-mail : haulottemiddle-

[e-mail]

www.haulotte-international.com

HAULOTTE SCANDINAVIA AB

Taljegårdsgatan 12

431 53 Mölndal

SWEDEN

TEL : [phone]

FAX : [phone]

E-mail : [e-mail]

[e-mail]

www.haulotte.se

HAULOTTE TRADING (SHANGHAI)

Co. Ltd.

#7 WORKSHOP No 191 HUA

JIN ROAD

MIN HANG DISTRICT

SHANGHAI CHINA 201108

TEL : [phone]

FAX : [phone]

E-mail :

[e-mail]

www.haulotte.cn

HAULOTTE ARGENTINA

Ruta Panamericana Km. 34,300 (Ramal A

Escobar)

1615 Gran Bourg (Provincia de Buenos

Aires)

Argentina

TEL.: [phone]

FAX. [phone]

E-mail : [e-mail]

www.haulotte-international.com

HAULOTTE UK Ltd

STAFFORD PARK 6

TELFORD - SHROPSHIRE TF3 3AT

TEL : [phone]

FAX : + 44 (0)1952 292758

E.mail : [e-mail]

www.haulotte.co.uk

HAULOTTE GROUP / BILJAX

125 TAYLOR PARKWAY

ARCHBOLD, OH 43502 – USA

TEL : [phone]

FAX :[phone]

Toll free : [phone]

E.mail : [e-mail]

www.haulotte-usa.com

HAULOTTE DO BRASIL

AV. CECI, 608 – B 13

CEP: 06460-120 – TAMBORE

BARUERI – SAO PAULO – BRASIL

TEL : [phone] / +55 11

4208 4206

FAX : [phone]

E.mail : [e-mail]

www.haulotte-international.com

HAULOTTE NETHERLANDS BV

Koopvaardijweg 26

4906 CV OOSTERHOUT - Nederland

TEL : [phone]

FAX : [phone]

E.mail :

[e-mail]

HAULOTTE AUSTRALIA PTY Ltd

46 GREENS ROAD

DANDENONG – VIC – 3175

TEL : [phone]

FAX : [phone]

E.mail : [e-mail]

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- Safety precautions

Safety precautions

1 - Recommendations

1.1 - OPERATOR'S MANUAL

This operators manual is specific to the HAULOTTE® products listed on the cover page of this
manual..

1.2 - SYMBOLS USED

Symbols are used to alert the operator to safety precautions or to highlight practical
information.

Legend

The operator manual does not replace the basic training required for all worksite equipment operators.

HAULOTTE® has compiled this manual to assist in safe and efficient operation of the products covered
by the manual.

This manual must be kept on the machine (or in the cab in its storage case. The manual must be available
to all operators and must be kept in good condition. Additional copies can be ordered from HAULOTTE
Services®.

Symbol Meaning

Danger : Risk of injury or death (work safety)

Caution : Risk of material damage (work quality)

Prohibition relating to work safety and quality

Reminder : No identified risk, but a reminder of the need for common
sense, good practice or pre-action prerequisites

Cross-reference to another part of the manual (see section or sheet)

Cross-reference to another manual (see manual)

Cross-reference to repairs (contact HAULOTTE Services®)

N.B. : Additional technical information

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1.3 - LABEL COLORS

The potential dangers and any specific regulations are indicated around the product by labels
and identification plates.

Familiarize yourself with the labels and their respective color codes.

Label color code

The labels must be kept in good condition. Additional labels can be obtained from HAULOTTE Services®.

Labels Color Meaning

Red Potentially fatal danger

Orange Risk of serious injury

Yellow Risk of material damage and/or minor injury

Other Additional technical information

Green Maintenance operation or information

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2 - Pre-operation instructions

2.1 - GENERAL INSTRUCTIONS

• On soft, unstable or cluttered ground.

• With wind blowing faster than the permissible limit. Check the maximum value in the technical
characteristics ( Section G 1-Main characteristics). Consult the Beaufort scale
( Section A 3.2.4-Risk of uncontrolled movement and overturning).

• Close to power lines. Respect the safety distance ( Section A 3.2.3-Risk of electrocution).

• At ambient temperatures higher than 45 °C(113 °F) and lower than -15 °C(5 °F) .
Consult HAULOTTE® if it is necessary to work outside this range.

• In an explosive atmosphere.

• During storms (risk of lightning).

• In the presence of strong electromagnetic fields (radar, etc ...).

N.B.-:-You are advised to use the machine under "NORMAL" climatic conditions.. If you need to use
the machine in climatic conditions likely to cause deterioration (humidity, temperatures outside the
recommended ranges, salinity, corrosiveness, atmospheric pressure), contact HAULOTTE Services®.
Reduce intervals between servicing.

N.B.-:-Whilst the machine is not in use, care must be taken to ensure that if the machine is not locked
in a secure location, that the unit key switch is removed to prevent unauthorised use of the machine.

• The employer has the obligation to issue a driving permit to the operator.

• The employer is obliged to inform the operator of the local regulations.

Do not operate the product in the following situations :

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2.2 - SPECIFIC INSTRUCTIONS

• If the load in the platform exceeds the maximum load authorized. Check the maximum value in the
technical characteristics ( Section G 1-Main characteristics).

• If the ground slope is greater than the permissible limit. Check the maximum value in the technical
characteristics ( Section G 1-Main characteristics).

• At night unless the machine is equipped with the optional light.

• If the number of persons exceeds the permissible limit. Check the maximum value in the technical
characteristics ( Section G 1-Main characteristics)

• If the side force is greater than the permissible force. Check the maximum value in the technical
characteristics ( Section G 1-Main characteristics)

Do not operate the product in the following situations :

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3 - Operation instructions

3.1 - PROHIBITIONS

It is preferable to operate the machine on flat, consolidated ground (tarmac, concrete, etc.).

• Never use a faulty machine (hydraulic leaks, worn tires, malfunction).

• Never operate the machine controls suddenly.

• Never place the machine against a structure to hold that structure in place.

• Never use the machine to tow other machines or to drag materials.

• Never expose the batteries or electrical components to water (pressure cleaner, rain).

• Never disable the safety devices.

• Do not make contact with a fixed or mobile obstacle. The contact can cause premature deterioration of
the structure and lead to the corruption of certain safety elements.

• Do not climb onto the covers.

• Never use the machine with only an operator in the platform. It must be used by 2 operators.

• Never use the machine when the platform is cluttered.

• Never increase the surface area of the platform by using floor extensions or accessories not authorized
by HAULOTTE®.

• Never leave the hydraulic cylinders fully extended or retracted before switching off the machine, or
during an extended stop period.

• Never use the machine with material or objects suspended from the guard-rail.

• Never use the machine with elements that can increase the wind force (panels).

• Never increase the working height by using attachments (ladder).

• Never use the guardrail as a means of access for climbing in or out of the platform. The basket can be
easily accessed in its low position. For machines fitted with : Steps have been provided for this purpose
where required.

• Never climb on the guardrail.

• Never use the adjustable tray as step.

• Never climb onto the adjustable tray.

• Never use the machine without fitting the sliding (or rotating) middle rail, closing the safety gate or the
swing gates beforehand.

• Never use the machine as a crane, material lift or elevator.

• Never use the machine for any other purpose than to transport people, their tools and material to the
desired place.

• Never drive fast in narrow or cluttered areas. Keep speed under control in bends.

• Never tow the machine over extended distances (it must be transported on a trailer).

For STAR 6 P only :

When the machine is used in the picking mode, the area in which it is to be used must be clearly marked
with a barrier to prevent access to other equipment or individuals. The area protected by the barrier must
be sufficient in all direction to cater for the length of the machine. There should be a person at ground
level at all times to act as an observer to ensure that no one enters the area protected by the barrier. The
observer must also remain outside the barrier unless an emergency occurs and the platform needs to
lowered using the ground level controls.

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3.2 - POTENTIAL RISKS

3.2.1 - Risk of command system disturbance

Risk of disrupted movement. Maintain clearance from high voltage lines or magnetic fields.

3.2.2 - Risk of falling

When in the platform, respect the following instructions :

• Carry individual protection equipment adapted to the work conditions and local
rules.

• Avoid contact with fixed or mobile obstacles (other machines).

• Ensure that the adjustable midrail is closed (low position and against the guardrails).

• Ensure that the gate is closed and locked (For machines fitted with).

• Hold on securely to the guardrails during elevation and driving.

• Do not sit, stand, or climb on the platform guard rails.

• Ensure that guard rails are correctly installed and locked.

• Always keep your feet firmly on the floor of the platform.

• Remove any trace of oil or grease from the steps, floor, handrail and the guardrails.

• Keep the floor of the platform free of debris.

• Do not leave the platform until it is fully in its stowed position.

• Do not climb on to the platform if the machine is not in the stowed position.

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For STAR 6 P only :

• Check that the swing gates are locked.

• The boxes must be securely strapped onto the tray if stacking several boxes or if the boxes are
unstable (ie. the height is greater than the width or length). Use the 6 anchorage points provided for
this purpose.

• Only parcels not exceeding the surface of the adjustable tray can be handled.

• The adjustable tray must be set at the same the same height as the load to be transferred onto it.

3.2.3 - Risk of electrocution

The machine is not electrically insulated and does not offer any insulation
protection.

The risks of electrocution are high in the following situations :

• Close to live power lines, consider the movement of the machine and the sway of the electric power
lines particularly in windy conditions.

• In the event that you were to make accidental contact with a high voltage line, wait for the power to
the line to be switched off before operating the machine.

• During storms.

Never use the machine as a welding earth.

Maintain a minimum safe distance with regard to power lines and electrical devices.

Respect the local rules and the minimum safety distance from power lines..

Minimum safety distance

N.B.-:-This table is applicable, except when the local regulations are more strict.

To climb up or climb down from the platform :

• The machine must be completely stowed.

• Face the machine to access the entry opening to the
platform

• Keep 3 support points between the steps and the guardrail

Electric voltage Minimum safety distance

Mètre Feet

0 - 300 V Avoid contact

300 V - 50 kV 3 10

50 - 200 kV 5 15
200 - 350 kV 6 20
350 - 500 kV 8 25
500 - 750 kV 11 35

750 - 1000 kV 14 45

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3.2.4 - Risk of uncontrolled movement and overturning

When in the platform, respect the following instructions :

• Before operating the machine on any indoor or outdoor surface (premises, bridge,
truck, etc.), check that the surface is capable of supporting the combined machine
weight and platform capacity. Check the maximum value in the technical characteristics

( Section G 1-Main characteristics).

• Remain vigilant of driving direction reversal at the platform. Check the driving direction with the help
of the red or green arrow on the chassis relative to the red and green arrows on the platform control
box.

• Always ensure that the chassis is never driven any closer than 1 m(3 ft3 in) m to holes, bumps, tilts,
obstructions, debris and ground coverings that may hide holes and other dangers.

• During motion direction reversal from the platform or ground control box, the joysticks or switches
must be stopped in neutral position before reversing the direction of motion.

• Taking note of the overall load dimensions and weight, place the loads in the centre of the platform or
distribute them it a uniform manner.

• If the tilt alarm sounds when the platform is raised, lower platform completely, then reposition machine
onto level ground before raising platform.

N.B.-:-The Beaufort scale measures the wind force with a graduation system. A wind speed range at 10
m(32 ft9 in) above flat, clear land is associated with each degree.

• Do not drive the machine on slopes or tilts beyond the design limits. Check the maximum value in the
technical characteristics( Section G 1-Main characteristics).

• Do not travel down slopes at high speed.

• Do not use the machine (elevation and travel) on an incline greater than that permitted by the slope
sensor.

• Do not drive in reverse (direction opposite the field of vision).

• Never use the machine in winds exceeding the permissible limit.

• Do not increase the surface area exposed to wind. The greater the surface area exposed, the more
unstable the machine becomes.

For STAR 6 P only :

Only drive the machine when the goods to be transported on the tray are securely positioned. The
operator must have full visibility of the ground on which the machine is operating.

Some models have a zero wind rating and must not be exposed to wind forces. It should also be noted
that winds can occur inside buildings if external windows or doors are left open. Refer to the machine
identification plate to confirm the allowable wind load on the product being used.

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Beaufort scale

Force

Meteorological

description

Observed effects m/s km/h mph

0 Calm Smoke rises vertically. 0 - 0,2 0 - 1 0 - 0,62

1 Very light breeze

Smoke indicates the wind
direction.

0,3 - 1,5 1 - 5 0,62 - 3,11

2 Light breeze

Wind felt on the face. Leaves
rustle. Weather vanes turn.

1,6 - 3,3 6 - 11 3,72 - 6,84

3 Slight breeze

Leaves and small branches in
constant movement. Flags move
slightly.

3,4 - 5,4 12 - 19 7,46 - 11,8

4 Nice breeze

Dust and loose papers fly. Small
branches bend.

5,5 - 7,9 20 - 28 12,43 - 17,4

5 Nice breeze

Small trees sway. Crested
wavelets form on inland waters.

8,0 - 10,7 29 - 38 18,02 - 23,6

6 Cool wind

Large branches shake. Power
lines and chimneys 'sing'. It is
difficult to use an umbrella.

10,8 - 13,8 39 - 49 24,23 - 30,45

7 Strong cool wind

All trees shake. Walking against
the wind becomes difficult.

13,9 - 17,1 50 - 61 31 - 37,9

8 Squall

Some branches break.
Generally we cannot walk
against the wind.

17,2 - 20,7 62 - 74 38,53 - 45,98

9 Strong squall

The wind causes slight damage
to buildings. Tiles and chimney
stacks are blown off.

20,8 - 24,4 75 - 88 46,60 - 54,68

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3.2.5 - Risk of burns and explosion

N.B.-:-Acid is neutralised with sodium bicarbonate and water.

3.2.6 - Risk of crushing and collision

When in the platform, respect the following instructions :

• During operation, keep all the parts of the body inside the platform.

• To position the machine close to obstacles, use the raise controls (arm, boom, etc.) instead of the
drive controls.

• Ensure there are no obstacles (structure) in the work area.

• When driving, position the platform so as to provide the best visibility possible.

• Always obtain assistance from a guide on the ground when manoeuvring.

• All the personnel in the platform or on the within the vicinity of the machine must wear Personal
Protection Equipment (safety helmet, etc.).

• When lifting or lowering the basket and during driving, the operator must check that the area above,
below and to each side of the machine are clear.

• When moving the machine, ensure that the machine operating areas is free of persons and obstacles.

• Adjust the movement speed to the ground conditions (traffic, slope, etc.).

• Respect stopping distances after the controls are released :

• 3 m(9 ft10 in) at high speed.

• 1 m(3 ft3 in) at low speed.

For any intervention on the power sources, wear glasses and protective clothes (acid spray).

• Do not work in an explosive or flammable atmosphere (spark, flame, etc.).

• Do not touch the hot parts of the hydraulic power source (engine, filters, etc.).

• Do not bridge the battery terminals with metallic objects.

• Do not service the battery close to a spark, naked flame, glowing tobacco (emissions of gas).

Do not operate other machines (crane, platform, etc.) in the work area.

Take account of the distance, reduced visibility and blind spots during use of the machine.

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- Intervenor's responsibility

Intervenor's responsibility

1 - Owner's (or hirer's) responsibility

The owner (or hirer) has the obligation to inform operators of the instructions contained in the Operator
Manual.

The owner (or hirer) has the obligation to renew all manuals or labels that are either missing or in bad
condition. Additional copies can be ordered from HAULOTTE Services®.

The owner (or hirer) is responsible for applying the local regulations regarding operation of the
machine.

2 - Employer's responsibility

. The employer has the obligation to issue a driving permit to the operator.

N.B.-:-In accordance with the regulation in the country where the machine is operating, the user must
be authorized to drive by the doctor of Labour Ministry.

3 - Trainer's responsibility

The trainer must be qualified to provide training to operators in accordance with applicable local
regulations. The training must be given in an obstacle-free area until the trainee is considered
competent as defined by the training program undertaken.

4 - Operator's responsibility

The operator must read and understand the contents of this manual and the labels affixed on the
machine.

The operator must inform the owner (or hirer) if the manual or any labels are missing or in poor
condition, and of any malfunction of the machine.

The operator may only operate the machine for the purpose intended by the manufacturer.

All operators must become familiar with and fully understand the emergency controls and how to
operate the machine in an emergency as a component of their formal operator training.

The operator has the obligation to stop using the machine in the event of malfunction or safety
problems on the machine or in the work area and report the problem to his/her supervisor.

Forbid anyone from operating the machine who is :

• Under the influence of drugs, alcohol, etc..

• subject to fits, loss of motor skills, dizziness, etc..

Only authorized and qualified operators may operate HAULOTTE® machines.

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5 - Inspection and maintenance

The inspection and maintenance table below, identifies the role and the responsibilities of each party
in periodical machine maintenance..

Inspections and maintenance

If the machine is operated in a hostile environment or intensively, increase the frequency of maintenance.

Type of

intervention

Frequency Person-in-charge Intervenor Reference document

Pre-delivery
inspection

Before each delivery
of sold, hired or
resold equipment

Owner (or hirer)

Qualified HAULOTTE
Services® technician

Operator's manual

Pre-operation
inspection

Before operation or
when the operator
changes

Operator Operator Operator's manual

Periodical
preventive
maintenance

At the specified
intervals (250 hours
or 1 year)

Owner (or hirer)

On-site technician or
qualified HAULOTTE
Services® technician

Maintenance book

Periodical visit

2 times a year or at
the latest 6 months
after the last
periodic visit, and
according to the
local regulations

Owner (or hirer)

Organization or
technician approved
by the employer or by
the intermediary
of HAULOTTE
Services® in
accordance with
the HAULOTTE
Services® contract

Maintenance book

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- Machine layout

Machine layout

1 - Identification

The manufacturers identification plate fixed on the chassis bears all pertinent information to identify the
machine (Please see machine configuration).

The manufacturers identification plate fixed on the chassis bears all pertinent information to identify the
machine (Please see machine configuration).

2 - Main components

STAR 6 - Major Component Location Diagram

STAR 6 - Description of the components

For any request for information, intervention or spare parts, specify the type and serial number of the
machine.

Marking Description

C1 Chassis
C6 Platform

C7 Platform control box
C20 Tie-down (and/or lifting) points
C27 Ground control box
C34 Drive wheels
C35 Document holder
C44 Slack chain limit switch
C45 Mast raised/mast lowered contactor
C50 Battery charger socket
C52 Emergency lowering
C53 Connection control box/chassis
C54 Telescopic mast

C54

C53

C20 C20

C45

C55

C7

C56C56

C35

C6

C59

C76

C27

C64

C136C50C1

C44

C34C58 C58 C52

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C55 Platform control box connection
C56 Battery box
C58 Pothole protection
C59 Hinged midrail
C64 Tilt sensor switch
C76 Guardrail

C136 Steer wheels

Marking Description

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STAR 6 P - Major Component Location Diagram

STAR 6 P - Description of the components

Marking Description

C1 Chassis

C6 Platform

C7 Platform control box
C20 Tie-down (and/or lifting) points
C27 Ground control box
C34 Drive wheels
C35 Document holder
C44 Slack chain limit switch
C45 Mast raised/mast lowered contactor
C50 Battery charger socket
C52 Emergency lowering
C54 Telescopic mast
C55 Platform control box connection
C56 Battery box
C58 Pothole protection
C64 Tilt sensor switch
C76 Guardrail

C136 Steer wheels
C154 Adjustable tray ( Picking type)
C155 Weighing limit switch for the tray
C156 Swing doors

C54

C20

C64

C45

C7

C56

C76

C27

C136

C50

C1

C44

C34

C58

C58

C52

C35

C6

C20

C155

C154

C156

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STAR 8 - STAR 10 - Major Component Location Diagram

STAR 8 - STAR 10 - Description of the components

Marking Description

C1 Chassis

C4 Pendulum jib

C6 Platform

C7 Platform control box
C10 Slew ring
C11 Turntable assembly
C20 Tie-down (and/or lifting) points
C27 Ground control box
C33 Counterweight
C34 Drive wheels
C35 Document holder
C47 Battery isolation switch
C50 Battery charger socket
C54 Telescopic mast
C57 Cable reel (Option)
C58 Pothole protection
C59 Hinged midrail
C64 Tilt sensor switch
C76 Guardrail
C90 Battery bay (hydraulic block, hydraulic filter and winder)

C136 Steer wheels

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3 - Safety devices

3.1 - SLIDING (OR SWINGING) INTERMEDIATE GUARDRAIL

The platform is comprised of guardrails and a sliding mid-rail facilitating platform access.

3.2 - SWING DOORS

The illustrations in this paragraph do not necessarily correspond to the range of products designated in
the manual.

Do not restrain the sliding midrail to the guard rail.

For STAR 6 P only :

The platform is comprised of 2 swing doors facilitating
platform access. The function is assured by spring
hinges returning the door to its closed position as soon
as the operator has passed.

The doors close automatically once the operator has
entered the platform and stepped clear of the swinging
doors.

Do not restrain the swinging doors in their open position.

Do not open the swing doors until the machine is in the
stowed position.

307P228060 a

Star 6P

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3.3 - ANCHORAGE POINT (PLEASE SEE MACHINE CONFIGURATION)

The machine is equipped with harness anchorage points points which accept a single harness
per anchorage point. The anchorage points are identified by the presence of the Anchorage
point label.

The illustrations in this paragraph do not necessarily correspond to the range of products designated in
the manual.

If the local regulation imposes the wearing of a harness, use the approved anchorage points.

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4 - Labels

4.1 - CLASSIFICATION PLAN

4.1.1 - Red labels

Common labels

Specific labels STAR 6

The red labels indicate a potentially fatal danger.

R7

R21

R8

R31

R3 R5

307P228390 a

R57

R1

R9

R2

R39

R55

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Specific labels STAR 6 P

Specific labels STAR 8

307P229050

F

max = 464 daN

P

max = 17,6 daN/cm²

Star 6 P

Star 6P

307P228050

90

307P228060 a

Star 6P

R1

R9

R2

R56

R55

R1 R9 R30

R32

R4