Star6 6p Training Manual

Training manual
STAR 6 - STAR 6 PICKING
Training manual
STAR 6 - STAR 6
PICKING
USA
4000598840 E 11.16 USA / GB

2 4000598840 E 11.16 USA / GB

Training manual
CONTENTS
A
FOREWORD
1 - Revision. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
B
MAIN FEATURES AND FUNCTIONS
1 - Models description . . . . . . . . . . . . . . . . . . . . . . . 9
2 - Primary machine components . . . . . . . . . . . . 10
2.1 - Working area / Range of motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 - Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.1 - Machine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 - Ground control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3.1 - 14
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.2 - HAULOTTE Activ'Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3.2.1 - LCD screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3.2.2 - 16
At startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.2.3 - Alarm status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.4 - Platform control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5 - Auxiliary control box for STAR 6 PICKING. . . . . . . . . . . . . . . . . . . . . . . 23
2.5.1 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
C
CONTENTS
STUDY OF THE ELECTRIC SCHEMATICS

1 - System architecture . . . . . . . . . . . . . . . . . . . . . 25
1.1 - Power circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2 - Logic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.3 - Drive circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3.1 - Function of the variators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.3.1.1 - Control of the traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.3.1.2 - Control of the pump (other movements). . . . . . . . . . . . . . . . . . . 32
1.3.1.3 - Details of sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3.1.4 - System of unbraking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3.1.5 - Detail of the connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3
Training manual
2 - List of actuators and sensors . . . . . . . . . . . . . 36

2.1 - Sensors and actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.2 - Sensors detail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2.1 - 39
Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.2 - 40
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.3 - List of sensors Picking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.2.4 - 42
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 - Actuators and their location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.3.1 - List of actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.3.2 - Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.3.3 - Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.3.4 - Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.3.5 - Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.4 - Cut out conditions of every function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.4.1 - Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.4.2 - Power supply/commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.4.3 - Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.4.3.1 - Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.4.4 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.4.4.1 - Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.4.4.2 - Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.4.5 - Mast lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.4.5.1 - Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.4.5.2 - Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.4.6 - Plate lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.4.6.1 - Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.4.6.2 - Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.4.7 - Potholes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.4.7.1 - Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.4.7.2 - Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4
Training manual
D
STUDY OF THE HYDRAULIC SCHEMA
1 - Hydraulic units . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.1 - General overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.1.1 - Detail pump unit block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.1.2 - Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E
ADJUSTMENTS
1 - Adjustments with diag pad console . . . . . . . . 69
2 - List of menus . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.1 - Machine settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.1.1 - Speeds and ramps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.1.2 - Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.1.3 - Countries and models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.2 - Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.2.1 - Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.2.2 - Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3 - Failures list . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.1 - List of failures per category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.1 - Steering calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5 - Load management system . . . . . . . . . . . . . . . 82
5.1 - Picking calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
CONTENTS
6 - Adjustment of pressures . . . . . . . . . . . . . . . . . 83
5
Training manual
F
SIMPLIFIED BREAKDOWN GUIDE
1 - No start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2 - No mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3 - No tray lift (picking models) . . . . . . . . . . . . . . 86
4 - No drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5 - No steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
G
VERSION SUMMARY
1 - Version summary . . . . . . . . . . . . . . . . . . . . . . . 87
2 - List of schematics . . . . . . . . . . . . . . . . . . . . . . 87
3 - List of wiring harnesses . . . . . . . . . . . . . . . . . 87
6
A - Foreword
Foreword
How to use this document ?
A
MAINTENANCE AND REPAIR OPERATIONS ON YOUR HAULOTTE® MACHINE MAY ONLY BE PERFORMED BY
TRAINED AND EXPERIENCED TECHNICIANS
B
You are in possession of the summary document provided during the HAULOTTE® technical training
programme. It will allow you to find the information necessary for performing maintenance and repairs on
your HAULOTTE® machine.
The following guide will help you to rapidly access the required chapter.
C
Section A : Foreword
You will find there the elements as following :

• A resume of any update made since the creation of the manual.
D
Section B : Main characteristics and functions
You will find there the elements as following : E

• The list of the models.
• Their main datas.
• Their overall dimensions.
• Their working envelop.
• Controls boxes.
• Some maintenance topics on specific components (charger, engine ..).
F
Section C : Study of the wiring diagram
It will include the following elements: : G

• Structure of the system.
• Localization/photo of each safety components.
• The location/function of each component in schematics.
• Cut out conditions of every function.
H
Section D : Study of the hydraulic diagram
It will include the following elements: :

• The localization of every manifolds.
• The location/function of each component on block. I
4000598840 E 11.16 USA / GB 7

A - Foreword
Section E : The adjustments

• The way to use/connect the console of diagnostic.
• The list of main menus and its architecture.
• The list of alarms with their explanation.
• Any calibration/settings required for the model of the machine.
• The way to check/adjust the pressures for the model.
Section F : Repair guide

• A summary of every function and items to be checked in case of breakdowns.
Section G : Summary of the versions

• A summary of the different versions made per model.
• Any schematics (electric /hydraulic) linked to the models studied.
• Coloured schematics (electric/hydraulic) per function.
• List of main harnesses in the models studied.
1 - Revision
CREATED VALIDATED MODIFIED TRANSLATED
REVISION EDITION SUBJECT LANGUAGE
BY BY BY BY
00 11.16 Creation ASA MGD ASA ITC USA / GB
8 4000598840 E 11.16 USA / GB

B - Main features and functions
Main features and functions A

1 - Models description
REGULATION MODELS
ANSI and CSA standards
CE, AS and EAC standards

STAR 13
STAR 6
B
REGULATION MODELS
ANSI and CSA standards
CE, AS and EAC standards

STAR 13 P
STAR 6 P
C
4000598840 E 11.16 USA / GB 9

2 - Primary machine components

2.1 - WORKING AREA / RANGE OF MOTION
STAR 6 - STAR 13
ft in
-6ft 6in -3ft 3in 0 3ft 3in 6ft 6in
6m 19ft 8in
5m 16ft 5in
4m 13ft 10in
3m 9ft 10in
2m 6ft 6in
1m 3ft 3in
0 0
-2 m -1 m 0m 1m 2m
m
10 4000598840 E 11.16 USA / GB


STAR 6 - STAR 13 with platform extension
ft in
A
6m 19ft 8in
B
5m 16ft 5in
C
4m 13ft 10in
D
3m 9ft 10in
2m 6ft 6in E
1m 3ft 3in
F
0 0
m
-2 m -1 m 0m 1m 2m
G
4000598840 E 11.16 USA / GB 11


STAR 6 P - STAR 13 P
ft in
6m 19ft 8in
5m 16ft 5in
4m 13ft 10in
10
0
3m 9ft 10in
2m 6ft 6in
1m 3ft 3in
0 0
-2 m -1 m 0m 1m 2m
m
12 4000598840 E 11.16 USA / GB


2.2 - TRANSPORTATION
2.2.1 - Machine layout
A
STAR 6 - STAR 13
D
STAR 6 P - STAR 13 P
4000598840 E 11.16 USA / GB 13


2.3 - GROUND CONTROL BOX
2.3.1 - Layout
General view
Controls and indicators
MARKING DESCRIPTION FUNCTION

Pulled out : Ground control box energized
15 E-stop button
Pushed in : De-energizes control system
43 1 Horn
Horn button
90 Battery charging indicator Battery charger status
Move upwards : Platform control box energized
92 Control box activation key selector Center : De-energizes control system
Move downwards : Ground control box energized
Move to the right : Activated
105 Beacon light 2
Move to the left : Off
253 Diagnostic tool socket Connection to the diagnostic tool (HaulotteDiag)
1. For machines fitted with
2. For machines fitted with
14 4000598840 E 11.16 USA / GB


2.3.2 - HAULOTTE Activ'Screen
A
Upon starting and during operation of the machine, the LCD screen "Activ'Screen" located on the
ground control box displays in real time the machine operating status.
HAULOTTE Activ'Screen
MARKING DESCRIPTION FUNCTION

F
1 Mast control Mast extension
2 LCD screen Display status of operation of the machine
3 Navigation button Navigation of menu to select function - Scroll up
4
5
Confirmation button
Cancellation button
Confirmation of the selected function
Go back
G
6 Platform overload indicator Not used
7 Machine fault indicator light Constantly lit in the event of an operation malfunction
8 Navigation button Navigation of menu to select function - Scroll down
9
10
'Enable Switch' selector
Mast control
Press in and hold : Enable switch
Mast retraction
H
4000598840 E 11.16 USA / GB 15


2.3.2.1 - LCD screen
At startup
At startup with the ground or platform controls selected; system initiates a self check :
• Bar gets filled up.
• Home screen comes on with status icon of the machine - okay to proceed functioning the controls.
SYMBOL DESCRIPTION
1 Information icons
2 Information text
3 Status icon of the machine
SYMBOL DESCRIPTION
Battery status
Maintenance use
Fault / alarms
Hour meter
16 4000598840 E 11.16 USA / GB

• Pressing either one of the buttons , the following screen shot will be displayed : A
C
SYMBOL DESCRIPTION
1 Software part number
3
Software version + Screen software version + Screen version
Screen identification + Screen software version

D
4 Machine serial number displayed
• After again pressing either one of the buttons , the following screen shot will be displayed
E
• Access code screen comes on - refer to maintenance manual for entering the access code
G
• Validation by pressing on is active only if access code is known and entered - refer to maintenance manual for
the procedure for the different level code useage
4000598840 E 11.16 USA / GB 17


2.3.2.2 - Alarm status
Alarm status displayed as applicable - samples shown below
• Tilt
• Low battery
18 4000598840 E 11.16 USA / GB


• Present fault
A
• Platform control box E-stop button pressed in (de-energized) C
4000598840 E 11.16 USA / GB 19


2.4 - PLATFORM CONTROL BOX
2.4.1 - Layout
General view STAR 6 - STAR 13
123
108
135
43
20% 40% 100%
85
30
110 27
111
112
46
4000311500c
20 4000598840 E 11.16 USA / GB


General view STAR 6 P - STAR 13 P
A
123
B
108
C
135
43
20% 40% 100%
85
D
30
110 27
E
111
112
46
F
4000311500c
245
H
4000598840 E 11.16 USA / GB 21


MARKING NAME DESCRIPTION FUNCTION

27 HL800 Tilt indicator Machine on excessive slope
30 HL802 Overload indicator Not used
43 SA907 Horn button Move upwards and hold to activate horn
Pulled out : Platform control box power supply

46 SB802 E-stop button energized
85 HL903 Fault indicator Faulty or tilting machine
Move forward : Forward drive or mast extension

Movement joystick
Move backwards : Reverse drive or mast retraction
108 SM901
Front axle steering Press right side of thumb button : Right-hand steering
selector Press left side of thumb button : Left-hand steering
Mast Extension / On : Mast extension / retraction selection activated

110 HL4203 Retraction selection Off : Mast extension / retraction movement is not
indicator selected
Driving selection On : Driving function activated

111 HL100
indicator Off : Driving movement is not selected
Move to the left : Mast Extension / Retraction

112 SA908 2-position selector
Move to the right : Drive and steer movements
Press in : Associated command is validated

123 SA905 'Enable Switch' selector
Release : Associated command movement is halted
100%
Battery charged
Battery charging
135 HL904
indicator
40%
Flashing : Batteries have 40 % charge left
20%
Constantly on : Batteries have only 20 % charge left
Foot pedal switch (For
245 SB800 Press in and hold : Enable switch
Japan only)
22 4000598840 E 11.16 USA / GB


2.5 - AUXILIARY CONTROL BOX FOR STAR 6 PICKING
2.5.1 - Layout
A
General view
F
MARKING
247
NAME
SB806
DESCRIPTION
'Enable Switch' selector
FUNCTION
Press in and hold : Enable switch
G
Move upwards and hold : Raising
253 SA723 Picking tray control
Move downwards and hold : Lowering
Move upwards and hold : Raising

254 SA520 Mast control
Move downwards and hold : Lowering H
Pulled out : Platform control box power supply
255 SB805 E-stop button energized
4000598840 E 11.16 USA / GB 23

Notes
24 4000598840 E 11.16 USA / GB

C - Study of the electric schematics
Study of the electric schematics A

1 - System architecture
4000598840 E 11.16 USA / GB 25

26 4000598840 E 11.16 USA / GB


1.1 - POWER CIRCUIT
A
4000598840 E 11.16 USA / GB 27


1.2 - LOGIC CIRCUIT
28 4000598840 E 11.16 USA / GB


1.3 - DRIVE CIRCUIT
A
The traction is controlled by 2 asynchronous 3 phases motors (24VAC - 1KW).
Each motor is piloted by one variator ( COMBIACX master for RR motor and ACEX slave for RL
motor) through CAN - BUS network.
B
Each variator consists of :

E
• One thermistor for temperature control (ST302/ST303).
• One encoder for speed control (SV300/SV301).
• One electromagnetic brake at negative excitation (YB100/YB101).

F
4000598840 E 11.16 USA / GB 29


The whole unit is located in the chassis (rear side as shown below)
30 4000598840 E 11.16 USA / GB


1.3.1 - Function of the variators
A
• The COMBIACX variator is the master and controls the traction of the RR motor and a chopper for the DC pump
motor and some I/O too.
• The software upload process is done by connecting the DIAG PAD console or HAULOTTE DIAG application.
• The ACEX variator (slave) controls the traction of RL motor (no need to upload software on it).
B
• The 2 variators has the regenerative braking function (deceleration).
• Each variator is protected with a speed and temperature sensor and electromagnetic brake disc.
• In case of low battery charge, the maximum current is reduced to the half of the maximum current programmed
C
(an alarm message is displayed).
• The 2 variators are protected against reverse battery polarity.
Overview
D
4000598840 E 11.16 USA / GB 31


1.3.1.1 - Control of the traction
1.3.1.2 - Control of the pump (other movements)
32 4000598840 E 11.16 USA / GB


1.3.1.3 - Details of sensors
A
• The speed rotation of each motor is controlled through an encoder with 2 signals shifted at 90° each and 48
impulses per round.
• The temperature of each motor is controlled through a thermistor located inside the winding (from 85°C the
current is reduced in proportion the temperature increases until reaching 105°C where the current is null and
traction stopped).
B
E
1.3.1.4 - System of unbraking
The electro magnetic brakes are at negative excitation (remains stuck if not or lack of current).
In case of necessity, it’s possible to release the brakes using the toggle switch SA103 located behind
the variator’s support (see below). F
4000598840 E 11.16 USA / GB 33


1.3.1.5 - Detail of the connections
34 4000598840 E 11.16 USA / GB


Detail of the connectors on variators.
For any connector, the pin 1 always start at the lower right corner as shown below.
A
Connector are labelled as follow :
• CXA/B/C/D for COMBIACX.
• AXA/B/C/D for ACEX.

B
(See below and refer to electric schematic)
E
Connectors (power side) :
• U/V/W are the 3 motors phases. F

• B+ : positive of the battery.
• BF+: positive of the battery protected by a fuse of 300 A for COMBIACX and 125 A for ACEX.
• B- : negative of the battery. G

• P+ : output of the pump motor ( COMBIACX only).
4000598840 E 11.16 USA / GB 35


2 - List of actuators and sensors
2.1 - SENSORS AND ACTUATORS
Sensors and actuators (STAR 6)
SQ800 YV903
SQ721
YV520
YV145 YV150R
YV144 YV150L
SR150
SQ144 SQ145
YB101 YB100
36 4000598840 E 11.16 USA / GB


Sensors and actuators (STAR 6 PICKING)
A
SQ700 SQ725 SQ701 SQ724
SQ800 YV903
B
YV520 D
SQ721
YV145 YV150R
YV144 YV150L
E
SR150
F
SQ144 SQ145 G
H
YB101 YB100
4000598840 E 11.16 USA / GB 37

NAME DESCRIPTION
SQ144 Pothole limit sensor
SQ145 Pothole limit sensor
SQ721 Position sensor mast folded
SQ700 Door sensor - Door 1 - Right
SQ701 Door sensor - Door 2 - Left
SQ724 Limit switch tray up
SQ725 Limit switch tray down
SQ800 Sensor - Tilt 3°
SR150 Steering potentiometer
YB100 Right rear brake-release solenoid valve
YB101 Left rear brake-release solenoid valve
YV144 Pothole extraction solenoid valve
YV145 Pothole retraction solenoid valve
YV150L Left steering electro-distributor
YV150R Right steering electro-distributor
YV520 Mast lifting/lowering solenoid valve
YV903 Discharge valve
38 4000598840 E 11.16 USA / GB


2.2 - SENSORS DETAIL
A
2.2.1 - Chassis
MARKING
1
FUNCTION
SQ144
DESCRIPTION
G
Potholes position ( = 1 if retracted; out in lift mode)
2 SQ145
Tilt Y = 1.5° / X =3° (wire 12 = Vbat if machine on flat surface)

3 SQ800
1=red=+Batt / 2=white=signal / 3=black=GND
4 YV903 Discharge valve (by-pass: pump is in pressure) H

5 KAH Relay for main modules power supply
6 KA1 Relay for horn
7 FU4 Protection accessories circuit (10A)
8 FU3 Protection main circuit (10A) I

9 FU2 Protection electrovalve circuit (10A)
4000598840 E 11.16 USA / GB 39


2.2.2 - Steering
MARKING FUNCTION DESCRIPTION

1 SR150 Potentiometer for steering wheels angle (value 2.5 kΏ)
40 4000598840 E 11.16 USA / GB


2.2.3 - List of sensors Picking
A

F
The function of this sensor is to check the current in loop when picking tray is
moving.
1 SI900 If motor current is out of range ( < 12 A or > 25 A ). An alarm F07.41 is
generated.
White wire 30 + 5 VDC / brown wire = 0 VDC / green wire 28 = signal
G
4000598840 E 11.16 USA / GB 41


2.2.4 - Motors

1 ACEX Slave variator
2 COMBIACX Variator master
Tilt Y = 1.5° / X =3° (wire 12 = Vbat if machine on flat surface)

3 SQ800
4 SA103 Manual brake release switch
5 M371 AC drive motor (RL)
6 M370 AC drive motor (RR)
7 YB101 Electromagnetic brake at negative excitation for RL motor
8 YB100 Electromagnetic brake at negative excitation for RR motor
Controls the motor speed through an encoder with 2 signals shifted at 90° each
9 SV301
and 48 pulses per revolution
Controls the motor speed through an encoder with 2 signals shifted at 90° each
10 SV300
and 48 pulses per revolution
Temperature probe inside AC RL drive motor (if at 105° C: current null and no
11 ST303
drive)
Temperature probe inside AC RR drive motor (if at 105° C: current null and no
12 ST302
drive)
42 4000598840 E 11.16 USA / GB


2.3 - ACTUATORS AND THEIR LOCATION
A
2.3.1 - List of actuators
In the following tables :
• The column n°2 indicates the position on the connector on modules (if required).
B
• The state noted "0" corresponds to 0 V, opened contact or not activated.
• The state noted "1" corresponds to the tension of the circuit, closed or activated contact.
Glossary
C
MARKING DESCRIPTION
FWD Forward drive
REV Reverse drive
FL
FR
Front left
Front right D
RL Rear left
RR Rear right
PF Platform
LS Low speed drive
LS valve/adj
MS
Load sensing valve/adjustment
Medium speed drive
E
HS High speed drive
ILS Magnet reed sensor
UCB Upper control box
LCB
ECU
Lower control box
Electronic Control Unit
F
PWM Pulse Width Modulation
PCB Printed circuit board
2.3.2 - Modules
G
MODULES
NAME LOCATION FUNCTION

01 Multi function CAN display (Activ screen)
02 COMBIACX Variator (Master) H

02 ACEX Variator
U4 03 CAN tiller board (UCB)
4000598840 E 11.16 USA / GB 43


2.3.3 - Fuses
FUSES
NAME LOCATION CONNECTOR FUNCTION

FU1A 01 - 03 Protection ACEX variator (125 A)
FU1C 01 - 07 Protection COMBIACX variator (300 A)
FU2 01 - 08 Protection electrovalve circuit (10 A)
FU3 01 - 05 Protection main circuit (10 A)
FU4 01 - 12 Protection accessories circuit (10 A)
FU5 01- 08 Protection circuit for STAR 6 picking (10 A)
2.3.4 - Inputs
INPUTS

SA103 02 - 17 AXC.2 Manual brake release switch (21)
SA110 03 - 15 B.3 Option for STAR 8 S
SA520 03 - 08 B.8/B.9 Enable switch for picking models (203)
SA723 03 - 07 A.1 Switch for tray lift/descent for picking models
SA901 01 - 12 Key selection (upper/lower controls) (133/135)
SA903 01 - 15 Flashing light (Option) (32)
SA904 03 - 05 Option working light (134)
SA907 03 - 17 B.4 Horn switch (Upper controls) (34)
SA907B 02 - 18 AXB.4 Horn switch in lower controls ( RUS/UKR option) (41)
SA908 03 - 18 B.12/B.13 Selection function (movements/drive) (76/85)
Foot pedal switch ( US/JPN option = 1 for any movement)
SB800 03 - 13 B.1
(37)
SB801 01 - 13 Emergency stop button (Lower controls) (84)
SB802 01 - 15 Emergency stop button (Upper controls) (109)
SB805 01 - 15 Emergency stop button (picking)
SM901 03 - 12 A.10 Joystick ( 73: value 0.5 / 2.5 / 4.5 VDC)
44 4000598840 E 11.16 USA / GB

SENSORS A
SI900 02 - 03 CXC.9 Measure the current inside picking motor M1 (28)
SQ144 / SQ145 02 - 20 AXA.4 Potholes position ( = 1 if retracted; out in lift mode) (15)
SQ700 / SQ701
SQ721
03 - 07
02 - 19
A.4
AXA.13
ILS sensors for platform gate (700)
Mast position ( = 1 if stowed) (20)
B
SQ724 03 - 07 E3 Position of tray for picking models ( = 1 if full up) (705)
SQ725 03 - 06 E3 Position of tray for picking models ( = 1 if stowed) (704)
Tilt Y = 1.5° / X = 3° (wire 12 = Vbat if machine on flat
SQ800
SR150
02 - 02
02 - 14
CXA.12
AXC.4
surface)
Potentiometer for steering wheels angle (value 2.5 kΏ) (47)
C
Temperature probe inside AC RR drive motor (if at 105° C:
ST302 02 - 08 CXD.3/6
current null and no drive)
Temperature probe inside AC RL drive motor (if at 105° C:
ST303 02 - 17 AXD.3/6
ST903 02 - 17 AXC.7
current null and no drive)
Temperature sensor (Option RUS/UKR)
D
Controls the motor speed through an encoder with 2
SV300 02 - 09 CXD.1/2/4/5
signals shifted at 90° each and 48 pulses per revolution
Controls the motor speed through an encoder with 2
SV301 02 - 13 AXD.1/2/4/5
signals shifted at 90° each and 48 pulses per revolution
2.3.5 - Outputs E
RELAYS-MOTORS

KAH
KA1
01 - 07
02 - 17 AXB.7
Main relay for commands (115)
Horn command (70) F
KA2 02 - 20 AXA.8 Flashing light command (89)
KA3 02 - 10 CXB.1/5 Brake release command (remote control)
KA4 04 - 04 Option
KM900 01 - 06
Battery charger relay (If activated, no function on machine)
(98) G
KAS1 03 - 06 E3 Command for tray lift mode (picking models) (200)
KAS2 03 - 07 E3 Command for tray descent mode (picking models) (200)
M1 03 - 02 Motor for picking models
M370 02 - 06 U/V/W AC drive motor (RR)
M371
SB801
02 - 13 U/V/W AC drive motor (RL)
Main line contactor for ECU modules (84)
H
4000598840 E 11.16 USA / GB 45


VALVES

YB100 02 - 11 CXB.1/5 Electromagnetic brake at negative excitation for RR motor
YB101 02 - 12 AXB.1/5 Electromagnetic brake at negative excitation for RL motor
YV144 02 - 04 CXB.3 Potholes descent (56)
YV145 02 - 05 CXA.2 Potholes retraction (57)
YV150R 02 - 05 CXA.1 Right steering (54)
YV150L 02 - 05 CXA.8 Left steering (53)
YB700 03 - 03 Electromagnetic brake with negative excitation (706/707)
YV903 02 - 19 AXA.2 Discharge valve (by-pass: pump is in pressure) (55)
BUZZER AND LIGHTS

HA901 02 - 06 CXA.9 Buzzer (04)
HA907 01 - 10 Horn (184)
EL901 01 - 13 Option flashing light
EL904 03 - 04 Option working light (134)
HL100 03 - 12 E.7 Drive selection indicator (94)
HL420 03 - 12 E.6 Movement selection indicator (46)
HL800 03 - 11 F.3 Slope (tilt) indicator (45)
HL802 03 - 10 F.1 Overload indicator (44)
HL903 03 - 09 F.5 Other alarms indicator (43)
HL904 03 - 13 F.2 Battery level indicator (42)
46 4000598840 E 11.16 USA / GB


2.4 - CUT OUT CONDITIONS OF EVERY FUNCTION
A
2.4.1 - Glossary
MARKING DESIGNATION
U
D
Up
Down B
L Left
R Right
F/FWD Forward
REV/B Reverse/backward
SETP
A IN
Setpoint
Analogic input
C
D IN Digital input
D OUT Digital output
A OUT Analogic output
PWM
VAR
Pulse Width Modulation (Proportionnal valve in current square modulated signal)
Internal variable in the module (not accessible with the console)
D
I/O Inputs/Outputs
I Input
O Output
µS
MS
Micro speed drive
Medium speed drive
E
HS High speed drive
2WS 2 wheels steering
4WS 4 wheels steering
4000598840 E 11.16 USA / GB 47


EC standards
1 2 3 4 5 6 7 8 9
Platform rotation
Turret rotation
Platform level
Standard
Steering
Telescope
Simultaneous movements Drive
( 2WS or 4WS)
VAR[AuthorizedMvt]=1
Boom
Arm
Jib
µS LS MS-HS µS LS MS-HS
µS 0 0 0 0 0 0 0
1 Drive LS 1 1 1 1 1 1 1 0
MS-HS 1 0 0 0 1 1 0
µS 0 0 0 0
Steering
2 LS 1 1 1 1 0
( 2WS or 4WS)
MS-HS 1 0 0 0
3 Turret rotation 1 1 1 1 1 0
4 Arm 1 1 1 0 0
5 Boom 1 1 0 0
6 Telescope 1 0 0
7 Jib 0 0
8 Platform rotation 0
9 Platform level
48 4000598840 E 11.16 USA / GB


Australia standards
A
1 2 3 4 5 6 7 8 9
Platform rotation
Turret rotation
Platform level
Australia
Steering
B
Telescope
( 2WS or 4WS)
Boom
Arm
Jib
µS 1 1 1 1 1 1 0
1 Drive LS
MS-HS
1 1
1
1
0
1
0
1
0
1
1
1
1
0
0 C
µS 1 1 1 1 1
Steering
2 LS 1 1 1 1 1 0
( 2WS or 4WS)
MS-HS 1 0 0 0 1
3
4
Turret rotation
Arm
1 1
1
1
1
1
1
1
0
0
0 D
5 Boom 1 1 0 0
6 Telescope 1 0 0
7 Jib 0 0
9 Platform level E
N.B.-:-THE MACHINE GETS A DEDICATED HYDRAULIC BLOCK TO ALLOW THE COMBINATION OF JIB AND
STEERING MOVEMENTS.
4000598840 E 11.16 USA / GB 49


USA standards
1 2 3 4 5 6 7 8 9
Platform rotation
Turret rotation
Platform level
USA
Steering
Telescope
( 2WS or 4WS)
Boom
Arm
Jib
µS 1 1 1 1 1 1 0
1 Drive LS 1 1 1 1 1 1 1 0
MS-HS 1 0 0 0 1 1 0
µS 1 1 1 1
Steering
2 LS 1 1 1 1 0
( 2WS or 4WS)
MS-HS 1 0 0 0
3 Turret rotation 1 1 1 1 1 0
4 Arm 1 1 1 0 0
5 Boom 1 1 0 0
6 Telescope 1 0 0
7 Jib 0 0
9 Platform level
50 4000598840 E 11.16 USA / GB


2.4.2 - Power supply/commands
A
N.B.-:-
• The diagnostic menu is very important on this model as it will permit to the technician to focuse only on the
dysfunction encountered and then save time to repair the machine.
• The explanation done below is built on the same basis for all movements.
B
COMMANDS ALL COMMANDS COMING FROM LOWER/UPPER CONTROLS
Inputs Digitals or analogic inputs (ETOR-EANA)
Setpoint (0-100%)
In Diagnostic menu, it's the parameter Internal setpoint for the function described Neutral to Fwd/
up/left or Rev/down/Right (0-1000pts) C
This setpoint is null when no movement is performed or there is a failure on the josytick
Conditions for cutting the movements :
Cuttings • Null movement is authorized
• 1 movement is inhibited
Validation and formatting the
command
Conditions for validation of the movement D
Slow down Condtions for slowing down the movement (from 0 to 100%)
In Diagnostic menu, it’s the parameter Internal control for the internal command of the function (0-
Control (0-100%)
1000pts)
Outputs Digitals or Analogic outputs (STOR-SPWM-SANA)
Actuator Any device like valves/cylinders/motors/relays
E
Explanation of the cinematic
Explanation of the Cuttings function
This is valid for every movement including drive mode.

G
BIT CUT-OFF CONDITIONS DESCRIPTION
0 Enable General movement deactivation
1 General General Inhibition H

2 Simultaneous movements Inhibition due to numerous movements activated at the same time
3 Overload Inhibition due to machine is in overload mode
4 Tilt Inhibition due to machine is in tilt/slope
6
Reach limit
Failure
Inhibition due to machine is in outreach limitation mode
Inhibition due to Faliures

I
7 Specific Inhibition due to specific conditions /options
4000598840 E 11.16 USA / GB 51

REQUIREMENTS DEFINITION
Machine is powered ON with key SA901 of lower control box if no emergency stop is pushed (ES=1 and
PO=1). At power on, the relays close : SB801=1 and KAH=1
PS01 • Supply 24 V of power part (motor, pump and electro valves).
• Supply 24 V of lower signal part (switches and sensors).
• Supply the upper part.
At power ON, Star compares soft ID stored into EEPROM with the one of the loaded soft. If identifiers
are different (blank ECU or new soft type loaded), then :
• All failures are reinitialized (reset of counters and log).
PS02
• Default speed, ramps, options and configurations vales are reloaded.
• Hour-meter stored into EEPROM is set to 0.
• Failure F12.04 is triggered.
If one of the emergency stop is pushed ( ES = 0) until end of saves in EEPROM (and at least during 800
ms); machine is on power hold mode :
• SB801=0 : Power part and upper part are not supply.
PS03
• All failures are inhibited.
• KAH doesn’t change : Supply of the inverters only.
• Start of EEPROM saves before stop.
On power hold mode; when all EEPROM saves are done, a counter is triggered to le end the last
PS04 EEPROM save: KAH = 0 800 ms after the last EEPROM save.
• All the machine is switch off.
Machine counters (hours and service) are stored into ECU EEPROM in order to detect when the inverter
is changed and then to reload automatically the old values stored into the new cluster. For that, at machine
power ON :
PS05
• If Hourmeter(EEPROM) > Hourmeter(SCREEN) => Counters (hours and service) are reloaded from
values stored into ECU EEPROM.
• Otherwise current counters values are stored into ECU EEPROM.
52 4000598840 E 11.16 USA / GB


2.4.3 - Drive
2.4.3.1 - Validation
A
Drive movements in the chosen direction are driven by the SETP coming from the platform control
DSV01
boxSETP[Drive] = N|F|R : [0..1000]
B
Forward (F) or reverse (R) drive is allowed if all validation conditions are satisfied and none of cut-offs
condition is true
DSV02
VALIDATION
1
F
1
R
1
ENABLE CONDITIONS
Power on timer finished
C
0 Enable 2 1 1 Machine configured
3 1 1 User is identified
1: The condition allows the movement
D
Each of the followings cut-offs conditions prohibits the forward (F) or reverse (R) drive
CUT-OFF F R GENERAL CUT-OFF CONDITIONS
DSV03.2
1 General
1
2
1
1
1
1
Low battery and machine unfolded
Steering cut except if it's reach limit cut or failure on
SM901 rocker
E
DSV03.2
CUT-OFF F R
SIMULTANEOUS MOVEMENTS CUT-OFF
CONDITIONS F
Simultaneous
2 N/A N/A N/A Mast or brake release is running
movements
REQUIREMENTS
DSV03.2
CUT-OFF F
DEFINITION
R OVERLOAD CUT-OFF CONDITIONS

G
3 Overload N/A N/A N/A N/A
DSV03.2
CUT-OFF F R TILT CUT-OFF CONDITIONS H
4 Tilt 1 1 1 Machine tilt and tilt cut and machine unfolded
4000598840 E 11.16 USA / GB 53


CUT-OFF F R REACH LIMIT CUT-OFF CONDITIONS

DSV03.2
5 Reach limit 1 1 1 Potholes not out and machine unfolded
CUT-OFF F R FAILURE CUT-OFF CONDITIONS

1 1 1 Detected power supply failure
DSV03.2
6 Failure 2 1 1 Detected main contactor failure
3 1 1 Detected joystick failure
CUT-OFF F R SPECIFIC CUT-OFF CONDITIONS

Extreme temperature activated and machine
1 1 1
unfolded
DSV03.2 Doors open on picking machine
7 Specific
2 1 1 Movement authorised again when neutral set point is
detected for drive and steering and mast
3 1 1 Drive restriction while unfolded
1: The condition prohibits the movement
Following limits are applied on the set point (SETP[Drive]):
PLATFORM BOX
MOVEMENT SET POINT LIMIT CONDITIONS
FORWARD BACKWARD
DSV04
Param[Fwd uS] Param[Bwd uS] 1 Machine unfolded
Param[Fwd uS] Param[Bwd uS] 2 Failure on steering sensor
F(VAR[SteerAngle]) F(VAR[SteerAngle]) 3 Depending on steer angle value
Lower value is applied if several limits are active ( 100% = max speed)
Except at micro-speed or if the steering angle is in [-15; 15]°; the driving speed is reduced of a value
DSV05
proportional to the steering angle ( max: 21%)
In a turn, except if the steer angle is in failure ( F07.33), if the steer angle is not calibrated ( F10.14) or if the
DSV06
steering angle is in [-5; 5]°. The speed of the interior wheel is reduced proportionally to the steering angle.
54 4000598840 E 11.16 USA / GB


2.4.4 - Steering
A
Steering movements of the front axle wheels in the chosen direction are driven by the SETP coming from
STV01
the platform control box : SETP[SteeringFront] = N|LEFT|RIGHT : [0|1000]
B
Left (L) or right (R) steering of the front axle wheels is allowed if all validation conditions are satisfied
STV02
VALIDATION
1
L
1
R
1
ENABLE CONDITIONS
Power on timer finished C
0 Enable 2 1 1 Machine configured
REQUIREMENTS DEFINITION D
Each of the followings cut-offs conditions prohibits the forward (F) or reverse (R) drive
CUT-OFF L R GENERAL CUT-OFF CONDITIONS
STV03.2
1 1 1 Pump not ready
1 General
2 1 1 Low battery and machine unfolded
E

CUT-OFF L R
CONDITIONS
STV03.2
2
Simultaneous
movements
N/A N/A N/A Mast or brake release is running F
CUT-OFF L R OVERLOAD CUT-OFF CONDITIONS

STV03.2
3 Overload N/A N/A N/A N/A G
CUT-OFF L R TILT CUT-OFF CONDITIONS

STV03.2
4 Tilt 1 1 1 Machine tilt and tilt cut and machine unfolded H
4000598840 E 11.16 USA / GB 55


CUT-OFF F R REACH LIMIT CUT-OFF CONDITIONS

1 1 1 Left limit position and calibration of steering OK
STV03.2
5 Reach limit 2 1 1 Right limit position and calibration of steering OK
3 1 1 Potholes not out and machine unfolded
CUT-OFF L R FAILURE CUT-OFF CONDITIONS

1 1 1 Steer valve failure
2 1 1 Unload valve failure
STV03.2
6 Failure 3 1 1 Pump failure
4 1 1 Main contactor failure
5 1 1 Rocker failure
CUT-OFF L R SPECIFIC CUT-OFF CONDITIONS

1 1 1
unfolded
STV03.2 7 Specific Doors open on picking machine
2 1 1 Movement authorised again when neutral set point is
2.4.4.2 - Actuators
The formatted control (CTRL[SteeringFront]) is applied on the actuators driving the movement
CTRL YV150R YV150R YV903
LEFT 0 1 1
STA01
NEUTRAL 0 0 0*
RIGHT 1 0 1
*At the end of a movement, when the control is seen neutral, YV903 stays at 1 during 200 ms
56 4000598840 E 11.16 USA / GB


2.4.5 - Mast lifting
A
In UCB; lifting mast movements in the chosen direction are driven by the SETP coming from the joystick
MLV01
SM901 :
SETP[Mast] = N|UP|DOWN : [0-1000] or from switch SA520 if Var[Picking]=1 & SB806=1 -> SETP[Mast]
B
= 1000
In LCB; lifting mast movements are driven by the SETP coming from switch Screen_button 1: if
Screen_button2=1 -> SETP[Mast] = 1000
Raise (R) or descent (D) of the mast is allowed if all the validation conditions are satisfied
C
VALIDATION R D ENABLE CONDITIONS
1 1 1 Power on timer finished
MLV02.1
0 Enable 2
3
1
1
1
1
Machine configured
User is identified D
MLV03.2
Each of the followings cut-offs conditions prohibits the raise (R) or descent (D) of the mast
CUT-OFF R D GENERAL CUT-OFF CONDITIONS E
1 1 0 Pump not ready
1 General
2 1 0 Low Battery

F
CUT-OFF R D
CONDITIONS
MLV03.2
Simultaneous
2 NA 1 1 Drive, steering or brake release is running
movements
G
CUT-OFF R D OVERLOAD CUT-OFF CONDITIONS
MLV03.2
REQUIREMENTS DEFINITION H
CUT-OFF R D TILT CUT-OFF CONDITIONS
MLV03.2
Machine tilt and tilt cut activated and machine
4 Tilt 1 1 0
unfolded
4000598840 E 11.16 USA / GB 57


CUT-OFF R D REACH LIMIT CUT-OFF CONDITIONS

MLV03.2
5 Reach limit N/A N/A N/A N/A
CUT-OFF R D FAILURE CUT-OFF CONDITIONS

1 1 1 Pump failure
2 1 1 Unload valve failure detected
MLV03.2
6 Failure 3 1 1 Mast lift valve failure
5 1 1 Joystick failure
CUT-OFF R D SPECIFIC CUT-OFF CONDITIONS

1 1 0
unfolded
Doors open on picking machine
MLV03.2 7 Specific 2 1 1 Movement authorised again when neutral set point is
On Picking machine, the overload calibration is
3 1 1
running
Following limits are applied on the SETP (SETP[Mast])
RAISE DESCENT (*) MOVEMENT SET POINT LIMIT CONDITIONS
MLV04.1 50% 50% 1 Machine tilt and unfolded

85% 85% 2 Chassis control box selected
Lower value is applied if several limits are active ( 100% = max speed)
(*): valid if machine setting for type of descent electro valve is proportional
58 4000598840 E 11.16 USA / GB


2.4.5.2 - Actuators
A
The formatted control (CTRL[Mast]) is applied on the actuators driving the movement :
• Mast descent electro valve is "digital".
CTRL
Max
YV520
1
YV903
1
B
RAISE
Min 1 1
NEUTRAL 0 0*
Min 1 0
MLA01.1
DESCENT
Max 1 0
At the end of a raise movement, when the control is seen neutral, YV903 stays at 1 during 200 ms :
C
• Mast descent electro valve is "proportional".
CTRL YV520 YV903
Max 100% 1
RAISE
NEUTRAL
Min 100%
0
1
0*
D
Min SPEED[Mast Descent Min] 0
DESCENT
Max SPEED[Mast Descent Max] 0
4000598840 E 11.16 USA / GB 59


2.4.6 - Plate lifting
For picking control box, the plate movements in the chosen direction are driven electrically by SA723
MLV01 switch. The SA723 switch is supplied if the control of lift plate is active :
SETP[LiftingPlate] = OFF|ON
Control of the plate is allowed if all the validation conditions are satisfied
VALIDATION I O ENABLE CONDITIONS
1 1 1 Power on timer finished
MLV02.1 2 1 1 Machine configured
0 Enable
3 1 1 Picking machine
Each of the followings cut-offs conditions prohibits the control of the plate
MLV03.1 CUT-OFF C GENERAL CUT-OFF CONDITIONS
1 General N/A N/A N/A N/A

CUT-OFF C
CONDITIONS
MLV03.1
Simultaneous
2 N/A N/A N/A N/A
movements
CUT-OFF C OVERLOAD CUT-OFF CONDITIONS

MLV03.1
Overload of the Picking tray if the picking calibration
3 Overload N/A 1 1
is not running
CUT-OFF C TILT CUT-OFF CONDITIONS

MLV03.1
4 Tilt N/A N/A N/A N/A
60 4000598840 E 11.16 USA / GB

REQUIREMENTS DEFINITION A
CUT-OFF C REACH LIMIT CUT-OFF CONDITIONS
MLV03.1
5 Reach limit N/A N/A N/A N/A
REQUIREMENTS DEFINITION B
CUT-OFF C FAILURE CUT-OFF CONDITIONS
MLV03.1
6 Failure N/A 1 1 Picking overload sensor failure
REQUIREMENTS
CUT-OFF
DEFINITION
C SPECIFIC CUT-OFF CONDITIONS

C
MLV03.1 200 ms Delay between two activations of plate
7 Specific N/A 1 1
movement
2.4.6.2 - Actuators D
The formatted control (CTRL[PlateLifting]) is applied on the actuators driving the movement
MLA01
CTRL
ON
SA723
1
E
OFF 0
4000598840 E 11.16 USA / GB 61


2.4.7 - Potholes
If the machine is folded and CTRL[Driving] is not null ; SETP[Potholes] = IN: 1000
POV01 If CTRL[LiftMast] is not null ; SETP[Poholes] = OUT: 1000
Otherwise ; SETP[Potholes] = N
In (I) or out (R) of the potholes is allowed if all the validation conditions are satisfied
VALIDATION I O ENABLE CONDITIONS
POV02 1 1 1 Power on timer finished
0 Enable
2 1 1 Machine configured
Each of the followings cut-offs conditions prohibits the in (I) or out (O) of the potholes
POV03 CUT-OFF I O GENERAL CUT-OFF CONDITIONS
1 General 1 1 1 Pump not ready

CUT-OFF I O
CONDITIONS
POV03
Simultaneous
2 N/A 1 1 Steering or brake release is running
movements
CUT-OFF I O OVERLOAD CUT-OFF CONDITIONS

POV03
CUT-OFF I O TILT CUT-OFF CONDITIONS

POV03
4 Tilt N/A N/A N/A N/A
62 4000598840 E 11.16 USA / GB

REQUIREMENTS DEFINITION A
CUT-OFF I O REACH LIMIT CUT-OFF CONDITIONS
POV03 1 1 0 In timer finished

5 Reach limit Out timer finished (this 1 s timer starts when
2 0 1
potholes are seen out ( SQ144|SQ145) = 0)
B
CUT-OFF I O FAILURE CUT-OFF CONDITIONS

1 1 1 Unload valve failure
POV03
6 Failure
2
3
1
N/A
1
N/A
Potholes valve failure
N/A
C
4 1 1 Pump failure
REQUIREMENTS DEFINITION D
CUT-OFF I O SPECIFIC CUT-OFF CONDITIONS
POV03 7 Specific N/A N/A N/A N/A
2.4.7.2 - Actuators E
The formatted control (CTRL[Potholes]) is applied on the actuators driving the movement
CTRL YV903 YV144 YV145
POA01
IN
NEUTRAL
1
0*
1
0
0
0
F
OUT 1 0 1
*At the end of a movement, when the control is seen neutral, YV903 stays at 1 during 200 ms
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Notes
64 4000598840 E 11.16 USA / GB

D - Study of the hydraulic schema
Study of the hydraulic schema A

1 - Hydraulic units
1.1 - GENERAL OVERVIEW
4000598840 E 11.16 USA / GB 65


1.1.1 - Detail pump unit block

1 YV145
Activation potholes (descent/retract)
2 YV144
3 YV150R
Steering (Left/Right)
4 YV150L
5 YV903 Discharge valve
6 ACEX Slave variator
7 AXD (CXD)
8 AXC (CXC)
Connectors ACEX variator (Connectors COMBIACX)
9 AXB (CXB)
10 AXA (CXA)
11 COMBIACX Variator master
66 4000598840 E 11.16 USA / GB


1.1.2 - Mast
A
E
Above view
H
1
1
YV520
SQ721
Mast U/D
Mast folded
I
4000598840 E 11.16 USA / GB 67

Notes
68 4000598840 E 11.16 USA / GB

E - Adjustments
Adjustments A
1 - Adjustments with diag pad console
The adjustments/parameters settings /list of alarms, calibration of the machine are accessible on on-board activ
screen console, as well as this console below or Haulotte Diag application installed in laptop.
The VCI (Vehicle Computer Interface) adapter could be connected from any controls (turret or in platform) using
B
wireless or cable connection.
The full description of how to use that console and its menus is explained in a technical note PI144 (for more
information refer to your nearest HAULOTTE Services® of your area)
G
VCI
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E - Adjustments
2 - List of menus
See end of manual
2.1 - MACHINE SETTINGS

2.1.1 - Speeds and ramps
See end of manual : Annex 1
2.1.2 - Options
2.1.3 - Countries and models
2.2 - DIAGNOSTIC
2.2.1 - Inputs/Outputs
2.2.2 - Variables
70 4000598840 E 11.16 USA / GB

E - Adjustments
3 - Failures list A
• For any type A (ACTIVE) failure code, it will appear on display in lower control and the warning light will flicker
on upper controls (see below).
E
• For any type D (DETECTED) failure code, it will also appear on display in lower control and the warning light
will flicker on upper controls.
• For any type N failure code, it means that this alarm will never appear on display.
• An internal code (column C) with 5 digits, visible only on the console, allows specifying the trigger conditions of
the failure.
Each trigger condition is associated with a single code number (16 possible single codes in decimal format
F
corresponding to a single bit in binary format) :
• If several conditions are active at the same time, single codes are added to form the resulting code displayed.
For example, il conditions 1 and 4 of single code are active, then the resulting code displayed will be 5 (1+4=5).
All alarms codes are gathered per category (ex F02xxx contactors)
G
4000598840 E 11.16 USA / GB 71

E - Adjustments
3.1 - LIST OF FAILURES PER CATEGORY
FAILURES N C DESCRIPTION
INVERTER
1 Zapi failure code 17 on COMBIACX
F01.01 4 Zapi failure code 31 on COMBIACX
A
Inverter Master 8 Zapi failure code 40 on COMBIACX
F01.05
A 4 Zapi failure code 55 on COMBIACX
Pump failure
A
Overheating 2 Zapi failure code 32 on ACEX
F01.08
A 1 Zapi failure code 33 on COMBIACX (Battery level <10%)
Low Battery
Electrical park A
brake 1
32 Zapi failure code 38 on COMBIACX and no Zapi failure code 38 on ACEX
1 Zapi failure code 16 on ACEX
F01.10 4 Zapi failure code 29 on ACEX
Electrical park A
brake 2
32 Zapi failure code 38 on ACEX and no Zapi failure code 38 on COMBIACX
F01.11
A 4 Zapi failure code 31 on ACEX
Inverter Slave
F01.12 1 COMBIACX is a power version
Wrong controller D
2 ACEX is a power version
hardware
72 4000598840 E 11.16 USA / GB

E - Adjustments
FAILURES N C DESCRIPTION A
CONTACTOR
Power Contactor D
SB801 4
8
Zapi failure code 46 on COMBIACX
Supervisor status: alarm or wait reset and main contactor is not forced open by a Zapi failure
B
ELECTROVALVES
F04.01 1
Steering front left valve YV150R failure (short circuit) and steering setpoint active :
--> YV150R = FAIL & STP(Steering)
C
Steering D
Steering front right valve YV150L failure (short circuit) and steering setpoint active :
YV150R/YV150L 2
--> YV150L = FAIL & STP(Steering)
F04.11
Principal
movement valve
YV903
D 1
Unload valve YV903 failure (short circuit) and setpoint which need its activation active :
--> YV903 = FAIL & (STP(Steering)|| STP(MastUp)|| STP(Potholes)) D
F04.39 Mast descent valve YV520 open circuit failure or Mast descent valve YV520 short circuit failure
Mast D 1 and mast setpoint active :
YV520 --> YV520 = OPEN-CIRCUIT || (YV520 = SHORT-CIRCUIT & STP(Mast))
F04.40
1
Potholes in valve YV145 failure (short circuit) and potholes setpoint active :
--> YV145 = FAIL & STP(Potholes) E
Potholes D Potholes Out valve YV144 open circuit failure or Potholes Out valve YV144 short circuit failure
YV144/YV145 2 and potholes setpoint active :
--> YV144 = OPEN-CIRCUIT || (YV144 = SHORT-CIRCUIT & STP(Potholes))
FAILURES N C DESCRIPTION F
JOYSTICKS
Analog signal SM901Y of main joystick SM901 out of range :
1
F05.01 --> SM901Y < 0.2V | SM901Y > 4.8V
Drive joystick D Incoherence between analog and out of neutral signals of main joystick SM901 :
SM901 2 --> SM901N = 1 & (2.45V < SM901Y < 2.55V)
--> or SM901N = 0 & (SM901Y < 2V | SM901Y > 3V)
G
F05.11
Neutral position of main joystick SM901 not detected after power on :
Joystick neutral A
--> SM901 < 2.35V | SM901 > 2.65V
SM901
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E - Adjustments
OVERLOAD
F06.01
Overload not D 1 Picking overload not calibrated
calibrated
SENSORS

Motor D
Temperature
F07.33 Analog signal calibrated SR150 of steer angle sensor calibrated and out of range [-44.1° to
Steer Angle D 1 75.0°] :
SR150 --> (SR150 < -54.1° | SR150 > +85°) & calibrated

D
Motor encoder 2 Zapi failure code 47 on ACEX

ECU D
temperature
F07.38
D 1 Potholes are seen out but the IN timer is finished
Potholes not in
No movement is asked and a current is present (short circuit of the sensor or stuck relay) :
F07.41 1
CTRL[Plate]=0 && VAR[MotorCurrent]>32.5A
Overload D
The neutral current is less than the expected value (sensor in open circuit or stuck relay) :
Picking 2
CTRL[Plate]=0 && VAR[MotorCurrent]<42.5A
74 4000598840 E 11.16 USA / GB

E - Adjustments
ELECTRIC CIRCUIT
F08.04
A
4
8
B
Supply 16 Zapi failure code 18 on ACEX
F08.07
1 SA901B=0 & SA901C=0 C
Control Box A
2 SA901B=1 & SA901C=1
incoherence

Common D
outputs supply 2
1
Zapi failure code 50 on ACEX
Zapi failure code 38 on ACEX and Zapi failure code 38 on COMBIACX

D
F08.10
D 2 Zapi failure code 24 on COMBIACX
Power supply
FAILURES N C DESCRIPTION E
FUNCTIONS
F10.14
Steering angle D 1 Steer angle not calibrated
not calibrated
F
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E - Adjustments
INTERNAL FAULTS
1 Cantiller RX failure
F12.01 2 Screen RX failure

CAN Fault A 4 Zapi failure code 39 on COMBIACX
Check wires 8 Zapi failure code 39 on ACEX
16 No time (date/hour) update (problem with screen communication)
1 EEPROM failure status error
2 EEPROM failure stack full
E2P Read/Write
D 8 Zapi failure code 69 on COMBIACX
Error
Change calc. 16 Zapi failure code 25 on ACEX
64 Read EEPROM during init failed
F12.04
ID of software loaded into machine is different from the ID stored into EEPROM: all machine
E2P Param
D 1 parameters have been reset and must then be set again (speeds, ramps, options, configs,
Reset access code level 2, failure counters and calibration data)
Check settings
1 Model not set
2 Country not set
F12.05 4 Serial number = 0
E2P Param Not A
8 At least one of the parameter used and not set
Set
16 At least one option used and not set
32 At least one config not set
F12.07
ECU software
A 1 Zapi software version different on COMBIACX and on ACEX
version
incoherence
ECU fault A
(master)
F12.09 8 Zapi failure code 43 on ACEX
A
ECU fault (slave) 16 Zapi failure code 54 on ACEX
76 4000598840 E 11.16 USA / GB

E - Adjustments
FAILURES N C
1
DESCRIPTION
Incoherence of Battery Parameters ; new value forced, restart mandatory
A
2 Incoherence of Motor Accessories Parameters ; new value forced, restart mandatory
4 Incoherence of Motor Parameters ; new value forced, restart mandatory
F12.10 8 Incoherence of Option Parameters ; new value forced, restart mandatory
Wrong default
parameters
A
16
32
Incoherence of Input Output Parameters ; new value forced, restart mandatory
Incoherence of Machine Parameters ; new value forced, restart mandatory
B
64 A parameter has changed and a restart is mandatory
128 No parameters verification
1 Wrong parameter : out of expected range
F12.11
Parameters
reload
A
2
4
Wrong parameter : EEPROM problem or RAM problem
Wrong parameter : parameter current value is different from parameter initialized value
C
Restart machine
8 Wrong parameter : incoherence between master and slave parameter source
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E - Adjustments
SWITCHES
F13.02
Platform Incoherence between the 2 signals of front steering switch of platform box (both active) :
D 1
switches --> SM901L = 1 & SM901R = 1
Check switches
Neutral position of mast lifting switch of chassis box not detected after power on :
1
--> Screen_button1=1 | Screen_button2=1
F13.10 Neutral position of deadman of chassis box not detected after power on :
2
Neutral switch --> Screen_button3= 1
A
Check chassis Neutral position of unbraking of chassis box not detected after power on :
4
switches --> SB100 = 1
Neutral position of horn option switch of chassis box not detected after power on :
8
--> SA907C = 1
Neutral position of front steering switch of platform box not detected after power on :
1
--> SM901L = 1 | SM901R = 1
Neutral position of deadman of platform box not detected after power on :
2
--> SM901DM = 1
Neutral position of horn switch of platform box not detected after power on :
4
--> SA907 = 1
F13.11 Neutral position of drive selection switch of platform box not detected after power on :
8
Switches neutral --> SA908D= 1
A
2 Neutral position of mast selection switch of platform box not detected after power on :
16
Check plat. switches --> SA908M= 1
Neutral position of deadman of picking box not detected after power on :
32
--> SA806 = 1
Neutral position of lift mast of picking box not detected after power on :
64
--> SA520U = 1 | SA520D = 1
Neutral position of lift plate of picking box not detected after power on :
128
--> SA723 = 1
CAN J1939
F15.06
D 1 Error on CAN BUS
J1939
78 4000598840 E 11.16 USA / GB

E - Adjustments
ENGINE

A
Overheating 2 Zapi failure code 35 on ACEX
F16.02
Speed problem
A
1
2
Zapi failure code 52 on ACEX
B
F16.03
8
16
C
A
Motor supply 32 Zapi failure code 19 on ACEX
D
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E - Adjustments
4 - Steering
The function of this transducer SR150 is to check the wheels angles during steering.
Depends of the signal sent to the variators, it will permit de decrease the current/voltage of the motor in internal
curve.
It needs to be preset prior to calibration.

SR150 steering transducer
80 4000598840 E 11.16 USA / GB

E - Adjustments
4.1 - STEERING CALIBRATION
A
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E - Adjustments
5 - Load management system

5.1 - PICKING CALIBRATION
82 4000598840 E 11.16 USA / GB

E - Adjustments
6 - Adjustment of pressures A
The pressure adjustment depends of the model.
Test port (M)
C
Relief valve
F
VALUE
MARKING MODELS
1 STAR 6
(bars - psi)
85 (0/+5) - 1232 (0/+ 72.5)
G
2 STAR 6 PICKING 100 (0/+3) - 1450 (0/+ 43.5)
3 STAR 8S 103 (0/+2) - 1493.5 (0/+ 29)
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E - Adjustments
Notes
84 4000598840 E 11.16 USA / GB

F - Simplified breakdown guide
Simplified breakdown guide

This guide does not replace the cut out conditions described previously in this manual. It allows the technician to
have a logical step of breakdown service, detailing the successive steps to be followed starting from general tips
A
until the details. The checking of the electric part is carried out in priority because less sensitive to the external
parameters than the hydraulics part (Temperature, pollution, viscosity). The denomination of the movements
describes below implies the 2 phases (Example not lifting, neither raise, nor descent from both controls, up and
down).
For a quicker diagnostic : B

Do check the failures code on Activ’screen display and refer to the alarms list before scrolling this breakdown
guide.
Do check all fuses.
Beware as some options once activated might prohibit some movements (the option ASB, Active Shield Bar
device). C
1 - No start
• Battery set.
• Emergency stops(SB801/SB802/SB805 ). D
• Key selector SA901.
• Relay battery charge KM900.
• Main relay KAH.
• Variators COMBIACX/ACEX.
• Main pump.
• Temperature sensor ST903 ( RUS only).
E
2 - No mast
• Battery set.
• Activ’screen touch pad.
F
• Toggle switch SA908 (Upper controls).
• Joystick SM901 out of range.
• Foot pedal switch SB800 (Upper controls) US option.
• CAN Tiller card.
• Valves YV903/YV520.
G
• Potholes system SQ144/SQ145/YV144/YV145.
• Machine in slope/tilt mode (SQ800), not for US mode.
• No lifting pressure.
H
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F - Simplified breakdown guide
3 - No tray lift (picking models)

• Toggle switches SA520/SA723.
• Enable switch SB806.
• Relays KAS1/KAS2.
• Sensors SQ700/SQ701/SQ724/SI900.
• Motor M1.
• Brake YB700.
• Picking calibration not done or erased.
4 - No drive
• Toggle switch SA908.
• Joystick SM901.
• Foot pedal switch SB800( US only).
• AC motor M370 - M371.
• Brakes YB100 - YB101.
• Temperature probes ST301 - ST302.
• Speed sensors SV300 - SV301.
• Machine in tilt (not for US).
5 - No steering
• Toggle switch SA908.
• Joystick SM901 (Rocker).
• Steering calibration.
• Angle sensor SR150.
• Brakes YB100 - YB101.
• Valves YV105L/YV150R/YV903.
86 4000598840 E 11.16 USA / GB

G - Version summary
Version summary A
1 - Version summary
STAR 6 Standards Wiring diagram Hydraulic diagram
Single version All countries E 609 C17596 B

STAR 6 P (PICKING) Standards Wiring diagram Hydraulic diagram
Single version All countries 113P339260 C17596 C
2 - List of schematics C
See end of manual
3 - List of wiring harnesses D

See end of manual
4000598840 E 11.16 USA / GB 87

G - Version summary
Notes
88 4000598840 E 11.16 USA / GB

ANNEX 1
Movement Parameter [Target] Factory tolerance Configuration
Drive forward Min speed [‐100 ; +10]
Drive forward Max speed [8.000000 ; 10.000000] [‐100 ; +0] High speed selected, drive on 10m/33ft length
Drive forward Max speed micro [23.000000 ; 26.000000] [‐100 ; +0] Machine unfolded, drive on 5m/16ft
Drive forward Acceleration [‐5 ; +5]
Drive forward Deceleration [‐5 ; +5] 1 m/3.3 ft ± 0,2 m/0.66 ft in high speed
Drive forward Max speed micro [23.000000 ; 26.000000] [‐100 ; +0] Machine unfolded, drive on 5m/16ft
Drive reverse Min speed [‐100 ; +10]
Drive reverse Max speed [8.000000 ; 10.000000] [‐100 ; +0] High speed selected, drive on 10m/33ft length
Drive reverse Max speed micro [23.000000 ; 26.000000] [‐100 ; +0] Machine unfolded, drive on 5m/16ft
Drive reverse Acceleration [‐5 ; +5]
Drive reverse Deceleration [‐5 ; +5] 1 m/3.3 ft ± 0.2 m/0.66 ft in high speed
Drive reverse Max speed micro [23.000000 ; 26.000000] [‐100 ; +0] Machine unfolded, drive on 5m/16ft
Steering left Max speed [1.000000 ; 3.000000] [‐100 ; +0]
Steering right Max speed [1.000000 ; 3.000000] [‐100 ; +0]
Potholes extend Max speed [‐100 ; +10]
Potholes retract Max speed [‐100 ; +10]
Mast Raise Min speed [‐100 ; +10]
Mast Raise Max speed raise [16.000000 ; 20.000000] [‐100 ; +0] Platform controls, from lower to upper stop
Mast Raise Max speed raise [12.000000 ; 16.000000] [‐100 ; +0] Platform controls, from lower to upper stop
Mast Raise Acceleration raise [‐5 ; +5]
Mast Raise Deceleration raise [‐5 ; +5]
Mast Raise Min speed [‐100 ; +100]
Mast Descent Min speed [‐100 ; +10]
Mast Descent Max speed descent [18.000000 ; 24.000000] [‐100 ; +0] Platform controls, from upper to lower stop
Mast Descent Acceleration descent [‐100 ; +100]
Mast Descent Deceleration descent [‐100 ; +100]
Mast Descent Max speed descent [18.000000 ; 24.000000] [‐100 ; +0] Platform controls, from upper to lower stop
ANNEX 2
Name Description & Values [Level_min]
Buzzer Choose for which movements the buzzer must be activated 1
OFF
Descent / Retract Movements
All Movements
Drive
Drive + All Movements
Flashing light 1
OFF
All Movements
Drive
Drive + All Movements
ON
Tracking system 1
OFF
ON
Drive restriction when lifted 1
OFF
ON
User Identiﬁcation inhibited Allows to inhibit user identiﬁcation in case screen is not usable 3
OFF
ON
ANNEX 3
Country Model 1 Model 2 Model 3
Standard STAR6 STAR6P STAR8
USA STAR19 STAR19P STAR22
Australia STAR6 STAR6P STAR8
Russia/Ukraine STAR6 STAR6P STAR8
ANNEX 4A
Type: Name Diagnostic instructions: ECU: [Ref] [Pin] [Wire] Type:2
If all emergency stops are pulled, input must be ON (+VBAT). If not:
‐ check frame emergency stop function (SB801)
Digital input
DIGITAL INPUTS SB801 ‐ Emergency stop (turntable/frame) ‐ check platform emergency stop function (SB802) CombiACX ‐ Frame m_I3 B.4 109
(HS)
‐ check picking emergency stop function (SB805)
‐ check input wire continuity
If tilt < 3° (longitudinal) / 1.5° (lateral), input must be ON (+VBAT). If not:
‐ check sensor adjustment
Digital input
SQ800 ‐ Tilt sensor ‐ check sensor supply fuse (FU3‐10A) CombiACX ‐ Frame m_I8 A.12 12
(HS)
‐ check sensor supply (wires 0=0V and 109=+VBAT)
If turret control box is selected, input must be ON (+VBAT). If not:
‐ check switch function
Digital input
SA901TU ‐ Control box selector ‐ Turret ‐ check switch supply fuse (FU3‐10A) CombiACX ‐ Frame m_I2 C.7 135
(HS)
‐ check switch supply (wire 98=+VBAT)
If platform control box is selected, input must be ON (+VBAT). If not:
Digital input
SA901PF ‐ Control box selector ‐ Platform ‐ check switch supply fuse (FU3‐10A) CombiACX ‐ Frame m_I1 C.2 133
(HS)
If horn function is activated from turret control box, input must be ON (+VBAT). If not:
41 Digital input
SA907TU ‐ Horn switch ‐ Turret ‐ check switch supply fuse (FU3‐10A) ACEX ‐ Frame s_I3 B.4
(CN0.8) (HS)
If platform is not in high position, input must be ON (+VBAT). If not:
‐ check sensor adjustment
Digital input
SQ721 ‐ Platform low position switch ‐ check supply fuse (FU3‐10A) ACEX ‐ Frame s_I10 A.13 20
(HS)
‐ check power supply (wire 109=+VBAT)
If ambient temperature is inside normal working conditions [‐20;+40]°C, input must be ON
(+VBAT). If not:
‐ check sensor 40 Digital input
ST903 ‐ Extrem ambiant temperature sensor ACEX ‐ Frame s_I2 C.7
‐ check sensor supply fuse (FU3‐10A) (CNO.6) (HS)
‐ check sensor supply (wires 0=0V and 109=+VBAT)
If brake release switch is activated, input must be ON (+VBAT). If not:
Digital input
SA103 ‐ Brake release switch ‐ check switch supply fuse (FU3‐10A) ACEX ‐ Frame s_I1 C.2 21
(HS)
ANNEX 4B
If potholes are extended, input must be ON (+VBAT). If not:
‐ check sensors adjustment
SQ144_145 ‐ Potholes left/right position Digital input
‐ check sensors supply fuse (FU3‐10A) ACEX ‐ Frame s_I5 A.4 15
sensors (HS)
If platform enable switch is activated, input must be ON (+VBAT). If not:
37 (pin Digital input
SM901EN ‐ Enable switch ‐ Enable ‐ check switch supply fuse (FU3‐10A) CAN Tiller ‐ Platform ct_IN2 B.1
5) (HS)
If steering left function is activated from joystick rocker, input must be ON. If not:
‐ check rocker function
SM901L ‐ Joystick steering rocker ‐ Left ‐ check rocker supply fuse (FU3‐10A) CAN Tiller ‐ Platform ct_IN10 B.11
6) (HS)
‐ check rocker supply (wire 109=+VBAT)
If steering right function is activated from joystick rocker, input must be ON. If not:
‐ check rocker function
SM901R ‐ Joystick steering rocker ‐ Right ‐ check rocker supply fuse (FU3‐10A) CAN Tiller ‐ Platform ct_IN3 B.2
3) (HS)
‐ check rocker supply (wire 109=+VBAT)
If horn function is activated from platform control box, input must be ON (+VBAT). If not:
Digital input
SA907 ‐ Horn switch ‐ check switch supply fuse (FU3‐10A) CAN Tiller ‐ Platform ct_IN5 B.4 34
(HS)
If drive joystick is pulled, out of neutral input must be ON (+VBAT). If not:
‐ check joystick function
Digital input
SM901N ‐ Drive/Arm joystick ‐ Out of Neutral ‐ check joystick supply fuse (FU3‐10A) CAN Tiller ‐ Platform ct_IN6 B.5 75
(HS)
‐ check joystick supply (wire 109=+VBAT)
If drive selection switch is activated from platform control box, input must be ON (+VBAT). If
not:
SA908a ‐ Drive/Arm movement selection switch ‐ check switch function Digital input
CAN Tiller ‐ Platform ct_IN11 B.12 76
‐ Direction a ‐ check switch supply fuse (FU3‐10A) (HS)
If arm is selected using arm selection switch from platform control box, input must be ON
(+VBAT). If not:
SA908b ‐ Drive/Arm movement selection switch ‐ check switch function Digital input
CAN Tiller ‐ Platform ct_IN12 B.13 85
‐ Direction b ‐ check switch supply fuse (FU3‐10A) (HS)
ANNEX 4C
If both platform doors are closed, input must be ON (+VBAT). If not:
‐ check sensors adjustment
Digital input
SQ700_701 ‐ Platform doors position sensors ‐ check sensors supply fuse (FU3‐10A) CAN Tiller ‐ Platform ct_IN1 A.4 700
(HS)
‐ check sensors supply (wire 109=+VBAT)
If mast up function is activated from picking control box, input must be ON (+VBAT). If not:
Digital input
SA520U ‐ Mast switch (picking) up ‐ Raise ‐ check switch supply fuse (FU3‐10A) CAN Tiller ‐ Platform ct_IN7 B.8 201
(HS)
If mast down function is activated from picking control box, input must be ON (+VBAT). If
not:
‐ check switch function Digital input
SA520D ‐ Mast switch (picking) down ‐ Descent CAN Tiller ‐ Platform ct_IN8 B.9 202
‐ check switch supply fuse (FU3‐10A) (HS)
If picking tray control box enable switch is activated, input must be ON (+VBAT). If not:
Digital input
SB806 ‐ Enable switch (picking) ‐ check switch supply fuse (FU3‐10A) CAN Tiller ‐ Platform ct_IN9 B.10 203
(HS)
If Activ' Screen arm up switch is activated, input must be ON. If not:
SWITCH1 ‐ Mast switch (turret) up ‐ check Activ' Screen supply fuse (FU3‐10A) Screen1 ‐ Turret IN_1 Internal / Digital input
‐ check Activ' Screen supply (wires 0=0V and 02=+VBAT)
If Activ' Screen arm down switch is activated, input must be ON. If not:
SWITCH2 ‐ Mast switch (turret) down ‐ check Activ' Screen supply fuse (FU3‐10A) Screen1 ‐ Turret IN_2 Internal / Digital input
If Activ' Screen enable switch is activated, input must be ON. If not:
SWITCH3 ‐ Enable switch ‐ check Activ' Screen supply fuse (Fu3‐10A) Screen1 ‐ Turret IN_3 Internal / Logic Input
If Activ' Screen navigation up switch is activated, input must be ON. If not:
SWITCH5 ‐ Navigation Up ‐ check Activ' Screen supply fuse (FU3‐10A) Screen1 ‐ Turret IN_UP Internal / Logic Input
If Activ' Screen navigation down switch is activated, input must be ON. If not:
SWITCH6 ‐ Navigation Down ‐ check Activ' Screen supply fuse (FU3‐10A) Screen1 ‐ Turret IN_DOWN Internal / Logic Input
If Activ' Screen navigation confirm switch is activated, input must be ON. If not:
SWITCH7 ‐ Navigation Confirm ‐ check Activ' Screen supply fuse (FU3‐10A) Screen1 ‐ Turret IN_OK Internal / Logic Input
If Activ' Screen navigation cancel switch is activated, input must be ON. If not:
SWITCH8 ‐ Navigation Cancel ‐ check Activ' Screen supply fuse (FU3‐10A) Screen1 ‐ Turret IN_BACK Internal / Logic Input
ANNEX 4D
If machine is powered on with key and no emergency stop is pressed, output must be ON
(0V). If not: Logic Output
[DIGITAL_OUTPUTS] KAH ‐ Supply holding relay ‐ check supply fuses (FU3‐10A) CombiACX ‐ Frame m_O3 B.7 115 1.5 A (LS) 12A
‐ check key position selector (SA901) Peak
‐ check output wire continuity
If steering right function is requested, output must be ON (0V). If not, check Function
Diagnostic. If status is not OK:
Digital output
YV150R ‐ Steering front right valve ‐ check power supply fuse (FU2‐10A) CombiACX ‐ Frame m_O0 A.1 54
1.5A (LS)
‐ check power supply (103=+VBAT)
If steering left function is requested, output must be ON (0V). If not, check Function
Diagnostic. If status is not OK:
Digital output
YV150L ‐ Steering front left valve ‐ check power supply fuse (FU2‐10A) CombiACX ‐ Frame m_O1 A.8 53
1.5A (LS)
If turret control box buzzer function is requested output must be ON (0V). If not, check
Function Diagnostic. If status is not OK:
Logic Output
HA901 ‐ Buzzer (turret) ‐ check power supply fuse (FU2‐10A) CombiACX ‐ Frame m_O4 A.9 04
35 mA (LS)
If potholes out movement is requested, output must be ON (0V). If not:
‐ check valve function
YV144 ‐ Pothole lift down ‐ check valve supply fuse (FU2‐10A) CombiACX ‐ Frame m_PWM B.3 56 PWM output
‐ check valve supply (wire 103=+VBAT)
If potholes in movement is requested, output must be ON (0V). If not:
‐ check valve function
Digital output
YV145 ‐ Potholes lift up ‐ check valve supply fuse (FU2‐10A) CombiACX ‐ Frame m_O2 A.2 57
1.5A (LS)
‐ check valve supply (wire 103=+VBAT)
If horn function is requested, output must be ON (0V). If not, check Function Diagnostic. If
status is not OK:
Logic Output
‐ check relay
KA1 ‐ Horn relay ACEX ‐ Frame s_O3 B.7 70 1.5 A (LS) 12A
‐ check power supply fuse (FU2‐10A)
Peak
If arm raise, potholes or steering movement is requested, output must be ON (0V). If not,
check Diagnostic/Function. If status is not OK:
Digital output
YV903 ‐ Pump unloading valve ‐ check power supply fuse (FU2‐10A) ACEX ‐ Frame s_O2 A.2 55
1.5A (LS)
ANNEX 4E
If flashing light function is requested, output must be ON (0V). If not check function
diagnostic. If status is not OK:
‐ check power supply fuse (FU2‐10A)
31 Digital output
KA2 ‐ Flashing light relay ‐ check power supply (103=+VBAT) ACEX ‐ Frame s_O1 A.8
(CNO.3) 1.5A (LS)
‐ check relay
‐ check flashing light
If lamp is not active at power ON or if status is not OK:
‐ check LED PCB
Logic Output
HL420 ‐ Light lifting mode ‐ check LED supply fuse (Fu3‐10A) CAN Tiller ‐ Platform ct_LED1 E.6 46
18 mA (LS)
‐ check LED supply (wire 109=+VBAT)
‐ check LED PCB
Logic Output
HL100 ‐ Light Drive selection ‐ check LED supply fuse (FU3‐10A) CAN Tiller ‐ Platform ct_LED2 E.7 94
18 mA (LS)
‐ check LED PCB
Logic Output
HL802 ‐ Light overload ‐ platform ‐ check LED supply fuse (FU3‐10A) CAN Tiller ‐ Platform ct_LED4 F.1 44
18 mA (LS)
‐ check LED PCB
Logic Output
HL904 ‐ Light Low Battery ‐ check LED supply fuse (FU3‐10A) CAN Tiller ‐ Platform ct_LED5 F.2 42
18 mA (LS)
‐ check LED PCB
Logic Output
HL800 ‐ Light tilt ‐ check LED supply fuse (FU3‐10A) CAN Tiller ‐ Platform ct_LED6 F.3 45
18 mA (LS)
‐ check LED PCB
HL903 ‐ Light Impacting Machine Behaviour Logic Output
‐ check LED supply fuse (FU3‐10A) CAN Tiller ‐ Platform ct_LED8 F.5 43
Failure(s) 18 mA (LS)
ANNEX 4F
If picking control box is selected and picking enable switch is active and valid, output must be
ON (0V). If status is not OK:
‐ check switch SA723 Logic Output
SA723S ‐ Picking tray switch ‐ Supply Voltage CAN Tiller ‐ Platform ct_O3 E.3 200
‐ check position sensors SQ724‐SQ725 1.5 A (LS)
‐ check relays KAS1‐KAS2
‐ check relays supply fuse (FU3‐10A)
‐ check relays supply (109=+VBAT)
ANALOG INPUTS MOT_D_I ‐ Right engine current ECU CombiACX internal sensor. CombiACX ‐ Frame I_mot_m Internal Internal motor current
If drive forward is ongoing, value must be greater than 0Hz.
SV300 ‐ Motor speed sensor 1 If drive reverse is ongoing, value must be lower than 0Hz. CombiACX ‐ Frame V_mot_m D.1/4 63‐64 motor speed
If no movement is ongoing, value must be equal to 0Hz.
Motor 1 (M370) temperature sensor. Temperature must be close to ambient temperature motor
ST302 ‐ Motor temperature sensor 1 CombiACX ‐ Frame T_mot_m D.3 26‐27
when machine has just been started. temperature
ECU
ECU CombiACX internal sensor. Temperature must be close to ambient temperature when
ECU_TEMP ‐ ECU internal temperature CombiACX ‐ Frame T_var_m Internal Internal temperature
machine has just been started.
(in °C)
CombiACX internal variable giving hydraulic pump current consumption.
Variable must be equal to 0mA when no movement is ongoing.
PUMP_I ‐ Pump current CombiACX ‐ Frame I_Pump Internal Internal Pump current
Variable must be greater than 0mA when arm raise, steering or potholes movement is
ongoing.
Steering angle sensor input must be between [0;12]V and increase when wheels are turned
on the right. If not:
Analog input 0‐
SR150 ‐ Front wheels angle sensor ‐ check sensor mounting (ref. instructions) ACEX ‐ Frame s_AN1 C.4 47
10V
‐ check sensor supply (wires 49=0V and 48=+12V)
MOT_G_I ‐ Left engine current ECU ACEX internal sensor. ACEX ‐ Frame I_mot_s Internal Internal motor current
If drive forward is ongoing, value must be greater than 0Hz.

SV301 ‐ Motor speed sensor 2 If drive reverse is ongoing, value must be lower than 0Hz. ACEX ‐ Frame V_mot_s D.1/4 67‐68 motor speed
If no movement is ongoing, value must be equal to 0Hz.
Motor 2 (M371) temperature sensor. Temperature must be close to ambient temperature motor
ST303 ‐ Motor temperature sensor 2 ACEX ‐ Frame T_mot_s D.3 71‐72
when machine has just been started. temperature
ECU
ECU ACEX internal sensor. Temperature must be close to ambient temperature when
ECU_TEMP ‐ ECU internal temperature ACEX ‐ Frame T_var_s Internal Internal temperature
machine has just been started.
(in °C)
If drive joystick is OK, input is variable between [0.5;4.5]V. If not:
‐ check joystick function
Analogue
SM901 ‐ Drive/Arm joystick ‐ check joystick 5V supply (wires 0=0V and 51=+5V) CAN Tiller ‐ Platform ct_AN5 A.10 73
input 0‐5V
‐ check joystick center position (approx. 2.5V)
ANNEX 4G
If picking control box is selected and picking enable switch is active and valid, input must be
ON (>4V) if plate switch is active.
Otherwise, output must be OFF 0V .
Analogue
SA723 ‐ Picking tray switch If status is not OK: CAN Tiller ‐ Platform ct_AN3 A.1 710
input 0‐5V
‐ check switch ( SA723 )
‐ check diods D1 and D3
‐ check input supply wire ( 109) and wire continuity
If emergency stops are not pressed, input must be ON (+VBAT). If not:
Analog input
AU_INFO ‐ Emergency stop (plateform) status ‐ check supply fuse (FU3‐10A) Screen1 ‐ Turret AN_4 X2.3 109
[0‐32V]
If mast raise or descent function is requested, output must be ON (0V). If not, check
Diagnostic/Function. If status is not OK:
ANALOG OUTPUTS YV520 ‐ Mast valve ‐ check power supply fuse (FU2‐10A) ACEX ‐ Frame s_PWM B.3 19 PWM output
ANNEX 5A
Category Name Item Values Unit Description & References
INTERNAL Power part state Init
Wait
Alarm
Alarm 1
Alarm 2
Alarm 3
Power contactor closing
Power contactor test
Electrovalve initialization
Ready
Movement
Movement selection setpoint None
Drive/Steering
Mast
Steering angle mechanical stop Left
Right
Steering left limit pts
Steering right limit
Machine Active control box None
Chassis
Platform
Picking
Chassis control box Inactive
Active
Platform control box Inactive
Active
Picking Control Box Inactive
Active
Machine is considered as unfolded if :
‐ Arm is not folded
Machine unfolded
‐ or Boom is not down
‐ or Boom telescope is not retracted
Tilt
Hourmeter h
Platform enable pedal state Inactive
Active but not valid (>8s)
Active and valid
Chassis enable switch state Inactive
Active but not valid (>8s)
Active and valid
Battery level %
Battery voltage mV
Unbraking enabled
User identified Not identified
Identified
ANNEX 5B
User identification
Running calibration None The following calibration is running
Steering angle
Overload of Picking
Max number of EEPROM queries (R/W)
ECU
into the stack
Current number of EEPROM queries
(R/W) into the stack
Current EEPROM status READY
BUSY
Number of EEPROM stack errors
Number of EEPROM status errors
Execution time of 4ms task ms
CombiACX Zapi failure Code
ACEX Zapi failure Code
CAN Tiller software version
Number of initialization tries
Internal setpoint secured coming from active control box and formatted from 0 to
Drive Drive movement setpoint Value %
100% for a given direction
Direction Neutral
Forward
Reverse
Status OK
Function not active
Neutral not detected after
power ON
Joystick/switch failure
engine start
Joystick/switch must be
released
Enable switch/pedal not valid
Percentage of the internal setpoint really applied from 0 (no movement) to 100% (no
Drive movement slowdown Value %
slowdown)
Number
ANNEX 5C
A cutting number nonzero, means that the movement in this direction is prohibited
by the cutting conditions of the operating logic:
‐ 0.00 : no cutting
‐ 0.01 to 0.32 : Enable cuttings
‐ 1.01 to 1.32 : General cuttings
Drive forward cuttings Cutting number 1 ‐ 2.01 to 2.32 : Simultaneous Movement cuttings
‐ 3.01 to 3.32 : Overload cuttings
‐ 4.01 to 4.32 : Tilt cuttings
‐ 5.01 to 5.32 : Reach Limit cuttings
‐ 6.01 to 6.32 : Failure cuttings
‐ 7.01 to 7.32 : Specific cuttings
Cutting number 2
Cutting number 3
Drive reverse cuttings Cutting number 1 ‐ 2.01 to 2.32 : Simultaneous Movement cuttings
Cutting number 2
Cutting number 3
Internal control generated from the internal setpoint (if no cuttings) and formatted
Drive movement control Value % from 0% to 100% for a given direction, using ramps and min/max speeds.
The control is sent to the actuators of the machine
Direction Neutral
Forward
Reverse
Drive speed Micro
High
Speed reduction Right motor reduction %
Left motor reduction
Brake release control (drive) Brakes opened OFF/ON
Type Automatic control
Automatic control but
possible to force brakes
closure
ANNEX 5D
Manual control
Right motor speed setpoint Hz
Left motor speed setpoint Hz
Steering Steering movement setpoint Value %
Direction Neutral
Left
Right
Status OK
Function not active
power ON
engine start
released
Steering movement slowdown Value %
slowdown)
Number
Steering left cuttings Cutting number 1 ‐ 2.01 to 2.32 : Simultaneous Movement cuttings
Cutting number 2
Cutting number 3
ANNEX 5E
Steering right cuttings Cutting number 1 ‐ 2.01 to 2.32 : Simultaneous Movement cuttings
Cutting number 2
Cutting number 3
Steering movement control Value % from 0% to 100% for a given direction, using ramps and min/max speeds.
Direction Neutral
Left
Right
Wheels steering angle °
Steering left limit
Steering right limit
Steering angle calibration performed
Potholes Potholes movement setpoint Value %
Direction Neutral
Extend
Retract
Status OK
Function not active
power ON
engine start
released
ANNEX 5F
Potholes out cuttings Cutting number 1 ‐ 2.01 to 2.32 : Simultaneous Movement cuttings
Cutting number 2
Cutting number 3
Potholes in cuttings Cutting number 1 ‐ 2.01 to 2.32 : Simultaneous Movement cuttings
Cutting number 2
Cutting number 3
Potholes movement control Value %
Direction Neutral
Extend
Retract
Mast Mast movement setpoint Value %
Direction Neutral
Raise
Descent
Status OK
Function not active
power ON
ANNEX 5G
engine start
released
Mast movement slowdown Value %
slowdown)
Number
Mast raise cutouts Cutting number 1 ‐ 2.01 to 2.32 : Simultaneous Movement cuttings
Cutting number 2
Cutting number 3
Mast descent cutouts Cutting number 1 ‐ 2.01 to 2.32 : Simultaneous Movement cuttings
Cutting number 2
Cutting number 3
Mast movement control Value % from 0% to 100% for a given direction, using ramps and min/max speeds.
Direction Neutral
Raise
Descent
ANNEX 5H
Picking Picking tray movement setpoint Value OFF/ON Internal setpoint secured coming from active control box
Status OK
Function not active
power ON
engine start
released
Picking tray movement cutouts Cutting number 1 ‐ 2.01 to 2.32 : Simultaneous Movement cuttings
Cutting number 2
Cutting number 3
Internal control generated from the internal setpoint (if no cuttings)
Picking tray movement control
Threshold of the picking overload A Current's threshold from which the picking is on overload state.
The variable is ON state if the current drawn by the picking motor is higher than the
Instantaneous picking overload alarm
overload thershold.
The variable is ON state if the current drawn by the picking motor is higher than the
Overload alarm of the picking
overload thershold during 500ms.
Maximum current during a picking During a picking movement, this variable records the maximum current drawn by the
A
movement. motor. This variable is reset after each end of picking movement.
Current drawn by the picking motor. A Current measured on the picking motor.
Offset current A Offset current during no picking movement.
Mean current during a picking During a picking movement, this variable records the mean current drawn by the
A
movement. motor. This variable is reset after each end of picking movement.
[REF_VARIABLE] Tilt
[REF_VARIABLE] Machine unfolded
ANNEX 5I
Mast raise cutouts Cutting number 1 ‐ 2.01 to 2.32 : Simultaneous Movement cuttings
Cutting number 2 [REF_VARIABLE] Power part state
Cutting number 3 [REF_VARIABLE] Machine unfolded
[REF_VARIABLE] Tilt
Mast descent cutouts Cutting number 1 ‐ 2.01 to 2.32 : Simultaneous Movement cuttings
Cutting number 2 [REF_VARIABLE] Machine unfolded
Cutting number 3
Mast movement control Value % from 0% to 100% for a given direction, using ramps and min/max speeds.
Direction Neutral [REF_IO] YV520 ‐ Mast valve

Raise [REF_IO] YV903 ‐ Pump unloading valve
Descent [REF_IO] PUMP_I ‐ Pump current
Picking Picking tray movement setpoint Value OFF/ON Internal setpoint secured coming from active control box
Status OK [REF_VARIABLE] Chassis control box
Function not active [REF_VARIABLE] Platform control box
power ON
ANNEX 5J
engine start
released
Picking tray movement cutouts Cutting number 1 ‐ 2.01 to 2.32 : Simultaneous Movement cuttings
Cutting number 2 [REF_MODEL] Standard/STAR6
Cutting number 3
Internal control generated from the internal setpoint (if no cuttings)
Picking tray movement control
[REF_IO] SA723S ‐ Picking tray switch ‐ Supply Voltage
HYDRAULIC SCHEMATIC
HYDRAULIC
HYDRAULIC‐‐ POTHOLE
Discharge valve YV 903 =1

+
Pothole descent YV144 =1
Or
Pothole retract YV145 = 1
HYDRAULIC
HYDRAULIC‐‐ STEERING

+
Steer Left YV150L =1
Or
Steer Right YV150R = 1
HYDRAULIC
HYDRAULIC‐‐ LIFTING

+
Lift/Descente YV520 =1
HYDRAULIC
HYDRAULIC‐‐ LOWERING
Lift/Descent YV520 =1
ELECTRIC SCHEMATIC
SCHEMATIC‐‐ 1/3
VDC
24V
ELECTRIC SCHEMATIC
SCHEMATIC‐‐ 2/3
+ 12VDC
+ 5VDC
RR
RL
ELECTRIC SCHEMATIC
SCHEMATIC‐‐ 3/3
Platform
MAST LIFTING
LEVAGE MAT
3x 40/30 S1068
POTHOLE
32/20 S88
G1/4 G1/4
STEERING
DIRECTION
40/20 S153
G1/4 G1/4
Chassis
Ø0,9
Ø1,8 A2 B2 A1 B1
YV520 G1/4 G1/4 G1/4 G1/4
A B A B
9/16-18 UNF P T P T
YV144 YV145 YV150L YV150R
YV903
C
G1/4
T
Test port Steel plug
G1/4 G3/8
85b 0/+5b
Flow = 10l/mn @ 80b
M 3.5cc
MOTOR
2500W - 24VDC
24 VDC
5,5L
4000353410.A
Platform
MAST LIFTING
LEVAGE MAT
3x 40/30 S1068
POTHOLE
32/20 S88
G1/4 G1/4
STEERING
DIRECTION
40/20 S153
G1/4 G1/4
Chassis
Ø0,9
A2 B2 A1 B1
YV520 G1/4 G1/4 G1/4 G1/4
Ø2,2
A B A B
9/16-18 UNF P T P T
YV903
C
G1/4
T
G1/4 G3/8
100b 0/+3b
Flow = 10l/mn @ 80b
M 3.5cc
MOTOR
2500W - 24VDC
24 VDC
5,5L
4000531280.A
Platform
MAST LIFTING
LEVAGE MAT
4x 40/30 S1327
POTHOLE
32/20 S88
G1/4 G1/4
STEERING
DIRECTION
40/20 S153
G1/4 G1/4
Chassis
YV520 Proportionnal Ø0,9
valve A2 B2 A1 B1
Ø2,2 G1/4 G1/4 G1/4 G1/4
9/16-18 UNF A B A B
SAE 6
P T P T
YV903
C
G1/4
T
G1/4 G3/8
103b 0/+2b
Flow = 10l/mn @ 80b
M 3.5cc
MOTOR
2500W - 24VDC
24 VDC
5,5L
4000569910.A
4000246640.F
4000311490.E
4000315590.F
4000416430.B
4000426170.D
4000426170.E
4000429210.H
4000555770.A

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STAR 6 - STAR 6 PICKING

4000598840 E 11.16 USA / GB

2 4000598840 E 11.16 USA / GB

STUDY OF THE ELECTRIC SCHEMATICS

2 - List of actuators and sensors . . . . . . . . . . . . . 36

You will find there the elements as following :

You will find there the elements as following : E

It will include the following elements: : G

It will include the following elements: :

4000598840 E 11.16 USA / GB 7

It will include the following elements: :

Section F : Repair guide

It will include the following elements: :

Section G : Summary of the versions

It will include the following elements: :

8 4000598840 E 11.16 USA / GB

B - Main features and functions

Main features and functions A

CE, AS and EAC standards

CE, AS and EAC standards

4000598840 E 11.16 USA / GB 9

B - Main features and functions

2 - Primary machine components

10 4000598840 E 11.16 USA / GB

B - Main features and functions

4000598840 E 11.16 USA / GB 11

B - Main features and functions

12 4000598840 E 11.16 USA / GB

B - Main features and functions

4000598840 E 11.16 USA / GB 13

B - Main features and functions

Controls and indicators

MARKING DESCRIPTION FUNCTION

14 4000598840 E 11.16 USA / GB

B - Main features and functions

Controls and indicators

MARKING DESCRIPTION FUNCTION

4000598840 E 11.16 USA / GB 15

B - Main features and functions

• Bar gets filled up.

3 Status icon of the machine

16 4000598840 E 11.16 USA / GB

B - Main features and functions

Screen identification + Screen software version

4000598840 E 11.16 USA / GB 17

B - Main features and functions

Alarm status displayed as applicable - samples shown below

18 4000598840 E 11.16 USA / GB

B - Main features and functions

• Platform control box E-stop button pressed in (de-energized) C

4000598840 E 11.16 USA / GB 19

B - Main features and functions

General view STAR 6 - STAR 13

20 4000598840 E 11.16 USA / GB

B - Main features and functions

4000598840 E 11.16 USA / GB 21

B - Main features and functions

MARKING NAME DESCRIPTION FUNCTION

30 HL802 Overload indicator Not used