Operating and Maintenance Manual
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CONTENTS
Introduction 2
Operating Specications 3
Working Envelope Diagram 3
Do’s and Don’ts 4
Primary Components 5
Operating Procedures (Incl. Emergency Operation) 6-8
Maintenance Procedures 9-12
Castor Safety and Maintenance 13-14
Maintenance Frequency Summary 15
Transportation, Loading, Towing, Manoeuvring and
Storage 16-17
Key Spare Parts 18
Warranty Terms 19
Decal Placement 20-22
Wind Rated Machine
Operating Specications Appendix ‘A’
Wind Rated Machine
Operating and Safety Instructions Appendix ‘B’
Wind Rated Machine
Additional Maintenance Instructions Appendix ‘C’
Machines with ATEX Certication Appendix ‘D’
CONTENTS
2
INTRODUCTION
The Ecolift / Ecolift 2.2 (referred to as “the machine” in this manual) is a
simple, safe and ecient alternative to step-ladders, platform/podium
steps and small scaold towers. It does not require batteries (or charging)
or connection to an electricity supply. It works by a unique, patented stored
power mechanism which enables the platform to be elevated with very little
eort by the operator.
It is designed for working internally on at, level surfaces, and, as it has no
batteries, electric motor, electrics or hydraulics, it is very ecologically friendly.
It is ideally suited to working in a very wide range of applications from the
very ‘clean’ environments of hospitals, food and drinks production facilities,
pharmaceuticals and retail, to facilities maintenance, shop-tting and indoor
construction and even on zone 1/21 hazardous areas (If ATEX option is
tted).
It is suitable for any application provided it is used within its specied
operating parameters. If used for applications such as sand blasting,
welding, paint spraying or with any other hazardous materials, measures
must be taken to ensure it does not become damaged in any way which
may impair safety, or reliability. Additional protection for the operator may
be required in some cases, which is the responsibility of the operator and/or
the operator’s employer.
The purpose of this manual is to provide essential basic information required
to operate and maintain the machine.
This is not a workshop manual. Please contact the manufacturer or their
agent for specic operation or maintenance information if in doubt.
The health and safety of the operator or maintenance technician is the
responsibility of the individual and/or their employer and not
Power Towers Ltd.
OPERATING SPECIFICATIONS
3
OPERATING SPECIFICATIONS
Working Dimensions
Maximum working height: 4.20 m
Maximum platform height: 2.20 m
Platform dimensions: 850 mm (L) x 644 mm (W)
Working footprint: 1280 mm x 740 mm
Safe working load: 150 kg (1 person + tools)
Maximum manual force: 200 N
Maximum gradient for operation: 0 degrees
Maximum wind force: Internal use only,
0 (zero) mph
Maximum wheel force: 234 kg (2.29 kN)
Maximum castor point load: 234 kg (2.29 kN)
Sound pressure level: Less than 70dBA
Closed Dimensions
Length: 1280 mm
Width: 740 mm
Height: 1950 mm
Weight: 305 kg
Lift Cycles: Unlimited, subject to maintenance
program being adhered to.
2.0m
1.0m
4.2m
3.0m
DO’S and DON’TS
4
DO’S
1. Read, understand and adhere to the instructions on the machine
and in the Instruction Guide or Operating Manual.
2. Ensure pre-operation checks & operations are carried out in the
manner described.
3. Use only on hard, level surfaces able to support the weight
of the machine.
4. Use the machine internally only.
5. Ensure the operator is t and does not suer from a
fear of heights.
6. Ensure guardrail gates are closed before elevation.
7. Ensure work area around the machine is cordoned o from
pedestrians and other trac.
8. Ensure operator is wearing the correct safety equipment.
9. Ensure the platform is correctly positioned so as not to come into
contact with xed or moving objects.
10. Ensure that the safe working load is evenly distributed
on the platform.
11. Ensure the machine is being operated within the PUWER
(Provision and Use of Workplace Equipment Regulations).
12. Ensure the castor brakes are applied when leaving the machine
unattended.
DON’TS
1. Never exceed the safe working load 150kg (1 person plus tools).
2. Never use the machine as a goods lift or crane.
3. Never exceed horizontal forces, (maximum horizontal force 200N).
4. Never use in the vicinity of live conductors.
5. Never try to move the machine on its wheels when elevated.
6. Never extend the height of the platform by using boxes,
steps, ladders etc.
7. Never modify the machine in any way without the full written
approval of the manufacturer.
8. Never attempt to enter or exit the platform unless it is
fully lowered.
9. Never use the machine on sloping or uneven ground.
10. Never operate the machine outdoors, or anywhere it may be
aected by wind.
11. Never lift heavy components on the machine without the
use of the correct lifting equipment.
12. Never use the machine in an explosive environment.
13. Never use the machine if you are fatigued.
14. Never use the machine inappropriately or for ‘horseplay.’
15. Never use the machine if under the inuence of drugs or alcohol.
16. Never use the machine if suering from poor health or using
medication which might impair the safe operation of the
machine.
17. Never use the machine if vision is impaired by bright lighting.
18. Never push the machine on sloping surfaces without the use of a
safe method.
19. Never push or pull objects with the platform.
20. Never use on uneven surfaces.
PRIMARY COMPONENTS
PRIMARY COMPONENT LOCATIONS
5
Flywheel
Spirit Level Swivel Castor
Auto-Lok Braked Wheel
Emergency
Lowering Tool
Tool Tray
Gates
Platform
Tray
Flywheel
Handle
OPERATING PROCEDURES
6
OPERATING PROCEDURES
It is the owners and/or the users responsibility to ensure that the machine is
maintained and operated in accordance with the operation and maintenance
procedures contained within this manual.
It is essential to be familiar with the correct operating procedures.
The operator must have adequate training for this type of platform.
The machine is tted with a safety harness point. If after conducting a risk assessment
the operator chooses to wear a safety harness, an approved ‘fall restraint’ type harness
should be worn with a very short lanyard.
Operating procedures are divided into three key areas:
1. Pre-operation checks.
What to do before operating the machine.
2. Normal operation.
How to use the machine safely.
3. Emergency operation.
How to lower the machine in the event of operator incapacity.
PRE-OPERATION CHECKS
1. Visually inspect the machine for any signs of damage to handrails, platform tray,
chassis and mast lifting structure including mast xing bolts.
2. Check castors and wheels rotate freely and are undamaged.
3. Check castor axle bolts (Pic 1) and wheel split pins (Pic 2) are secure.
4. Check spirit level (Pic 3) is intact and bubble is centred to ensure machine is level.
5. Check gates, gate hinges, hinge springs and hinge xings are undamaged, and
that gates fully open and fully self close when released (Pic 4).
6. Ensure step is lowered and secure.
7. Check castors are not loose or distorted in any way. If okay, lock by stepping on
the pedal marked ‘lock’ or stepping on the red pedal, depending on which castor
is tted, then step into the basket.
8. When standing in the basket: check ‘y-wheel’ operating handle works correctly.
Hold handle rmly and pull operating knob towards you, release, knob should
spring back to lock wheel. Repeat but turn handle once clockwise with
knob held pulled towards you. Wheel should turn freely. Turn once
anti-clockwise to come down (Pic 5).
9. Check emergency lowering tool is attached on the chassis and is not damaged.
If any of the above items are faulty or do not work correctly then do not
use the machine.
NORMAL OPERATION
Only use the machine internally, on hard level surfaces. Ensure a person
is available at ground level to assist in case of emergency.
1. Position machine under application.
2. Check spirit level to ensure machine is level.
3. Ensure castors are in the locked position as described in pre-operation checks.
4. Step into platform through gates, ensure gates close behind you.
DO NOT ELEVATE IF THEY ARE NOT CLOSED.
5. Check there are no overhead obstructions.
6. To elevate: pull operating knob towards you and turn clockwise.
To stop, stop turning the handle and release handle knob to lock.
7. To descend repeat but turn handle anti-clockwise.
Note: Only turn the ywheel handle when standing within the platform guardrails.
Never operate when standing outside the guardrails, except when following the
“Emergency Lowering Procedure.”
OPERATING PROCEDURES
7
1
2
4
5
The user shall obtain the
guidance and approval of
the manufacturer in the
event of any special working
methods or conditions
outside those specied by
the manufacturer.
3
EMERGENCY LOWERING OPERATION
Never attempt to recover the machine/operator if there is any
possibility the machine is contacting any live wiring/cabling and is
therefore potentially ‘live’.
Never operate the emergency lowering without a person in the
platform otherwise serious injury may result.
The Emergency Lowering Procedure is for lowering the platform from
height with an incapacitated operator in the platform and for no other
purpose.
1. Locate emergency lowering tool on chassis (Pic 1), remove from
fixing. If tool is held captive with tie-wrap safety tag then break
tag to release tool.
2. Stand to side of machine, attach ‘hook’ end of emergency
lowering tool to flywheel handle knob in basket, releasing handle
knob, turn wheel anti-clockwise to bring platform down (Pic 2).
3. Keep clear of structure as it descends.
4. When lowered, always remove the lowering tool first before removing
the person in order to lock the platform in a stationary position.
5. Depending on the height of the elevated platform, it may be
necessary to extend the shaft of the tool.
Turn the shaft lock anti-clockwise to extend and retract the shaft,
and clockwise to lock to the desired position.
OPERATING PROCEDURES
8
Turn wheel anti-clockwise to bring platform down
1
2
Never remove the person without rst disengaging
and removing the lowering tool.
Please note that whilst the machine is extremely simple to
maintain, all work must be carried out by a competent person.
DAILY MAINTENANCE
Note: The telescopic mast is a sealed unit which contains a
pressurised cylinder and can only be dismantled by a trained person
authorised by the manufacturer.
The most important regular maintenance to be carried out by the
operator is visual inspection, as per the pre-operation checks.
Daily Checks
The safety critical items to inspect each work session, daily as a
minimum are:
1. Check there is no damage to the following: wheels and castors
and check that their xings are secure. These are the components
that connect the machine to the ground; if they are damaged then
operating the machine could be dangerous and may result in
serious injury.
2. Check that the guardrails are not damaged and all
xings are secure.
3. Check gates and gate hinges are secure and gates fully self close
when released. Ensure gates cannot open outwards.
4. Check chassis is not damaged and spirit level is intact and working.
5. Check mast xings are all present and secure.
6. Check ywheel handle operates correctly: step into the platform
to do this (do not attempt to operate the handle from outside
the basket). Pull ywheel handle knob towards you, release.
Ensure handle springs back to lock wheel. Turn wheel one
revolution clockwise then anti-clockwise; ensure handle
moves freely in either direction.
7. Check automatic wheel-brake works by: Ensure the castor brakes
are unlocked, repeat no. 6 when platform is elevated
approximately 100mm, and with the assistance of a colleague,
attempt to push the machine, machine should not move, wheels
should be braked.
8. Check emergency lowering tool is attached to chassis and not
damaged.
Monthly Checks
As daily checks (items 1-8).
MAINTENANCE PROCEDURES
9
NOTE: PUWER (The Provision and Use of Workplace Equipment
Regulations 1998) stipulates that suppliers such as hire
companies must ensure their equipment is maintained
correctly and fully serviced. Once on site, it is the hirer/
employer’s responsibility to ensure the machine remains in
serviceable condition. The hirer/employer must also ensure the
operator is properly trained and familiarised with the machine
and the manufacturer’s operating procedures.
The health and safety of any operator or maintenance
sta is the responsibility of the individual and/or
their employer.
SIX MONTHLY CHECKS - LOLER
1. In order to inspect the internal mechanisms of the machine the
following covers must be removed; tool tray (Pic A), mast cap plate
(Pic B, shows mast cap after tool tray is removed) and handle cover
(Pic C). Remove the tool tray using a 5mm allen key, then remove
the mast cap plate using a 6mm allen key. The mast cap screws
(Pic B, arrowed) are additionally secured with a threadlock
adhesive. If diculty is experienced removing these screws then
they will need to be heated with a heat gun for a few minutes.
Remove the handle cover using a special 5mm allen key, which
can be obtained from the manufacturer or his agent.
2. Inspect and lubricate gearwheels. Use Omega 73 no. 2 harsh
environment grease or equivalent. Do not use standard gear
grease because it will dry out prematurely and will lead to
premature gear wear.
3. Elevate the platform approximately 20mm so the back of the
belt clamp bracket and the two countersunk xing screws are
visible. Looking through the inspection hole (Pic D, boxed), check
the two screws are secure. Look inside the mast section from the
top to the rear of the clamp (Pic E), and ensure the two nuts are
secure.
Raise and lower the platform fully and inspect the drive belt
whilst doing so with the aid of a suitable light. Ensure the belt
remains on the top pulley (Pic F, arrowed), bottom pulley
(Pic G, arrowed) and drive cog. If it is found dicult to view the
lower pulley it may be necessary to look through the gap above the
mast roller (Pic H, circled). To do so remove the mast roller cover,
located underneath the platform, by slackening the two M12 nuts
and pulling the cover o (Pic I, shows cover removed and lower
pulley, arrowed).
Minor scung and wear of the belt surfaces, and visible steel
braided wires, is acceptable. However, there must be no signs of
wear or fraying of the steel braided wires. If the steel braided wires
are worn or frayed, please contact the manufacturer.
Inspect the belt retaining plate (Pic J, arrowed). Ensure that the belt
retaining plate does not move when the mast is raised and lowered.
When the internal inspection is complete, ret the mast cap plate
and ret screws with medium strength threadlock. Paint seal the
screws. Ret the handle cover and ret screws with medium
strength threadlock. Paint seal the screws. Ret the tool tray. It is
extremely important that all of these screws are replaced correctly.
4. Check the mast interlock is undamaged and is working correctly.
Check the casing for signs of damage and remove the end plate
(Pic K, arrowed). Insert a large at screwdriver (300mm long
approx.) between the stop screw and the lower pulley block
(Pic L, arrowed) and lever downwards by applying a force of no
more than 10kg. Care must be taken as applying too much force
will damage the stop screw. When moving the block, watch the end
of the interlock bolt (Pic M, arrowed) and ensure it moves inward
and outward as the block is moved down and up. Ret cover and
screw. Paint seal screw when retted.
5. Inspect condition of automatic wheel lock. Look under brush
strip at rear of chassis when platform is elevated so that mast outer
is clear of chassis. Check brake cam plates (Pic N and Fig A, page12)
are undamaged and that the two attaching screws are tight. With
an assistant to lower the platform, observe the action of the cams
and the movement of the brake pins. Ensure the movement is free
and the pins clear the wheel discs. When the platform is elevated
ensure the pins fully engage the brake discs. Ensure the pockets in
the wheels are in good condition.
MAINTENANCE PROCEDURES
10
MAINTENANCE PROCEDURES
11
C E
F G H I
A
D
B
J
K L M N O
MAINTENANCE PROCEDURES
6. Ensure platform entrance gates open and close freely and that
they self-close when released. Check pivots and springs for signs
of fatigue and damage.
7. Check crank handle knob is securely xed with M12 nyloc nut
and roll pin through plastic tip. Ensure handle springs back to the
locked position freely.
8. The machine should be subjected to the test procedure below:
a) Fully lower platform to the transport position.
b) With a calibrated digital spring balance apply a further 25kg
force to the drive handle in the anti-clockwise direction (lowering),
rst releasing the handle knob from the back plate to allow the
handle to turn (Fig B).
9. Check rear wheels for signs of damage and that they rotate freely.
Ensure there is no cut or wear to tyre that penetrates more than
4mm in depth. The original wheel diameter is 200mm. Check the
split pin retaining the rear wheels is undamaged and secure
(Pic O).
10. Check castor condition in accordance with the following
procedures show on pages 13 and 14. Refer to the machine serial
number to determine which procedure to follow.
11. Visually inspect the condition of the emergency lowering tool
ensuring that it is not damaged or bent in any way and that it is
securely clipped to the chassis.
12. Check all instruction labels are present and clear. Refer to the key
spare parts. Check aluminium specication plate is clear and
legible.
When replacing components for any reason, only use OEM
specication parts, either supplied from the manufacturer or
authorised in writing by the manufacturer. Warranties and design
approvals will be void if alternative components are tted.
It is essential to obtain manufacturer’s approval of any alteration
which might aect stability, strength or performance in writing
before proceeding.
When retting a rear wheel always use a new cotter pin
(4mm diameter x 32mm A2 stainless steel).
NEVER REFIT A USED COTTER PIN.
12
Max 25kg
Fig B
Cotton Reel
Wheel Lock Pin Cam
Platform Raised
Platform Lowered
Mast
Fig A
CASTOR SAFETY & MAINTENANCE
In order to ensure the castors are maintained in serviceable and safe
condition, regular inspection is required, especially where arduous
conditions are known to be involved or there is a suspicion of misuse or
abuse. The other key element to ensure is in safe serviceable condition, is
the castor xing bolt, the condition of which can usually be determined
from the condition of the castor bracket.
The castor is highly rated for the application so if visible distortion is
evident a signicant impact will have occurred and under these conditions
the castor and xing bolt must be replaced.
Typical signs of impact which would require castor and xing replacement:
It may be thought feasible to repair the castor in a number of these
instances, but serious structural damage will have occurred to the head
bearing and castor assembly as well as possibly damage to the main
xing bolt. THE CASTOR AND FIXING BOLT MUST BE REPLACED.
13
When inspecting a castor in order to
determine its serviceability, pay particular
attention to the head swivel bearing
(compare to a new one if possible) and the
boss/rivet which goes through the centre
of the swivel bearing and which clamps the
assembly together.
If the castor is in sound condition,
free from distortion then it may be adequate
to only replace the main xing
bolt with one of a higher tensile
strength, along with a spacer
washer that enables a higher
bolting torque to be applied.
This will improve the reliability of
the x, but will not increase the
strength of the castor assembly.
The new xing nut and bolt are
to be re-torqued to 80Nm.
In order to replace the xing bolt, the wheel axle
bolt, half nut and star washer will rst need to be
removed, along with the central bushing tube
and M12 end washers. This enables the wheel to
be removed so that the castor xing bolt can be
replaced. When retting the wheel, the axle bolt,
half nut and star washer, must be replaced with
OEM specication new parts and re-torqued to
40Nm (Pic A). Ensure the axle tube and assembly is lightly greased to
ensure a smooth action when operating the foot brake.
Power Towers Limited strongly recommends replacing any castor
assembly or xing bolt that is over 3 years old with a new one.
Side impact and foot
pedal distortion as a
result of a signicant side
impact.
Top mounting plate distortion as a
result of a single signicant impact
or multiple lower level impacts.
Even if the rest of the castor is
in good condition, it must be
replaced.
Foot pedal distortion as a result
of a signicant frontal impact; it is
likely the top plate and bearing will
be distorted as well.
M12 nyloc nut
torque to 80Nm.
M12 standard washer.
Special thin spacer
washer on top of swivel
bearing of castor.
M12X60 10.9 bolt.
Pic A.
Important.
These instructions apply to all machines BEFORE
Serial no. 8872815H (also including 9522915H,
9532915H, 9542915H, 9552915H, 10093115H).
Swivel bearing head
should feel free to rotate
and not loose
Castor xing bolt
Castor Fixing Bolt (M12): Torque - 80 Nm
Castor Axle Bolt: Torque - 40 Nm
CASTOR SAFETY & MAINTENANCE
14
When inspecting a castor in order
to determine its serviceability, pay
particular attention to the head
swivel bearing (compare to a new
one if possible) and the boss/rivet
which goes through the centre
of the swivel bearing and which
clamps the assembly together.
Swivel bearing head
should feel free to
rotate and not loose
Underside of Castor
CASTOR SAFETY & MAINTENANCE
In order to ensure the castors are maintained in serviceable and safe
condition, regular inspection is required, especially where arduous
conditions are known to be involved or there is a suspicion of misuse or
abuse. The other key element to ensure is in safe serviceable condition, is
the castor xing bolt, the condition of which can usually be determined
from the condition of the castor bracket.
The castor is highly rated for the application so if visible distortion is
evident a signicant impact will have occurred and under these conditions
the castor and xing bolt must be replaced.
Typical signs of impact which would require castor and xing replacement:
Foot pedal distortion as a result of a signicant impact; it is
likely the top plate and bearing will be distorted as well.
Mounting plate distortion as a
result of a single signicant impact
or multiple lower level impacts.
Even if the rest of the castor is
in good condition, it must be
replaced.
Castor Fixing Bolt (3/4 UNC): Torque - 120 Nm
Castor Axle Bolt: Torque - 40 Nm
Castor xing bolt
Important.
These instructions apply to all machines FROM
serial no. 8872815H (NOT including 9522915H,
9532915H, 9542915H, 9552915H, 10093115H).
It may be thought feasible to repair the castor in a number of these
instances, but serious structural damage will have occurred to the head
bearing and castor assembly as well as possibly damage to the main
xing bolt. THE CASTOR AND FIXING BOLT MUST BE REPLACED.
CASTOR SAFETY & MAINTENANCE
MAINTENANCE FREQUENCY SUMMARY
15
MAINTENANCE FREQUENCY SUMMARY
The table below summarises the frequency of checks that must be
carried out on the machine, as detailed on pages 9 to 14.
Item
Wheels & Castors
Guardrails
Gates
Spirit Level
Mast Fixings
Flywheel Handle
Auto-Lok Braked Wheels
Emergency Lowering Tool
Visual Inspection
Gearwheel Lubrication
Crank Handle Force
Crank Handle Knob Operation
Drive Belt
Mast InterLock
Castor Bolt Torque
Instruction Labels
Daily Monthly 6 Monthly (LOLER)
MAINTENANCE FREQUENCY TABLE
16
TRANSPORT INSTRUCTIONS
It is the responsibility of the transport driver to ensure the machine is
safely secured to the transport vehicle.
Ensure that the transport vehicle has the load capacity and
dimensions in order to safely carry the weight and size of the machine.
Ensure that loading straps/chains are of adequate capacity to safely
secure the machine for transport.
Always ensure that the machine is transported in the upright position.
Never lay at.
Ensure the transport vehicle is parked on a level surface and the
parking brake is applied.
The machine can be loaded via a forklift, tail-lift, or winch. Never push
the machine up a slope without the aid of a winch.
If using a forklift, raise the machine by approximately 50 - 100mm so
that the front wheel brakes engage.
Ensure the castor wheel locks are operated and that the forklift tines
are fully engaged through the chassis sockets.
Load the machine onto the transport vehicle, taking care to position
the machine so that straps can be located around the base of the
machine without the need for the driver to have to climb onto the bed
of the vehicle. Note; only trained qualied forklift drivers are to load
the machine.
Use at least two straps, with one strap over the chassis, around the
mast section and out to the rear of the machine. The other strap
should be fed through the front of the chassis and the straps taken
forward, so that the machine is tied down in four diagonal directions.
Never place the strap over the platform or handrails.
LOADING
If loading with the aid of a winch up a ramp to the trailer, connect the
winch cable to the castor/gate end of the chassis around the tops of
the swivel castors, and then connect the winch cable to the strap.
Ensure the castor brakes are unlocked, and that the platform is fully
lowered in the transport position. Before disconnecting the machine
from the winch cable, engage the castor brake.
If loading with the aid of a tail lift, ensure the tail lift has adequate load
capacity and dimensions in order to safely lift the machine. Ensure the
tail lift and vehicle is on at ground.
TRANSPORTATION, LOADING, TOWING, MANOEUVRING AND STORAGE
TRANSPORTATION, LOADING, TOWING, MANOEUVRING AND STORAGE
17
Ensure the platform is fully lowered to the transport position and
wheel onto the tail lift bed. Once correctly positioned on the bed,
lock the swivel castor brakes.
Raise the tail lift to the vehicle bed height. Unlock the castors and
manoeuvre to the desired location on the vehicle and tie down as
described above.
TOWING
It is the responsibility of the driver to ensure safe practice is
employed in order to access the vehicle bed in order to manoeuvre
the machine and then tie it down. One option is for the vehicle to be
tted with suitable guarding to prevent the possibility of the driver
from falling to the ground.
HOW TO MANOEUVRE
STORAGE
If the machine is due to be stored for periods in excess of one month,
the following precautions should be taken: ensure the machine is
fully lowered and ideally place a cover over the machine.
Only store or transport the machine in an upright position.
Upon removal from storage and prior to returning to use, ensure
machine pre-operation checks are carried out thoroughly, check
LOLER certicate is current.
18
Part No.
A Swivel Castor* PT-M-102
B Swivel Castor** PT-M-102-2
C Spirit level PEL-M-451
D Wheel ECL-M-600
E Tool Tray ECL-M-601
F Chassis Cover ECL-M-602
G Handle cover ECL-M-603
H Gates (pair) ECL-M-700
I Step ECL-M-701
J Emergency Lowering Tool ECL-M-703
K Platform Tray ECL-M-704
L Decal Set 1 ECL-M-800
M Decal Set 2 (Ecolift) ECL-M-802
Decal Set 2 (Ecolift 2.2) ECL-M-802-2
A B
C
D E
F
G H
I
J K L M
CASTOR CHANGES:
* (PIC A) BEFORE SERIAL NO. 8872815H
(also including 9522915H, 9532915H,
9542915H, 9552915H, 10093115H)
** (PIC B) FROM SERIAL NO. 8872815H
(Not including 9522915H, 9532915H,
9542915H, 9552915H, 10093115H).
KEY SPARE PARTS
Non-Powered, Powered Access
Non-Powered, Powered Access
WARRANTY TERMS
19
WARRANTY
Your Ecolift / Ecolift 2.2 or Ecolift WR / Ecolift 2.2 WR (The Machine) is
covered by an 18 month parts/components warranty.
The Manufacturer, Power Towers Ltd (The Company), undertakes to
replace or repair, free of charge, any defective part/component, which
the company considers to be due to faulty workmanship or material
within 18 months of the sale date, except for:
The telescopic mast is a sealed unit. If the mast is opened in any way
warranty may be invalid.
Defects arising from neglect, misuse or unauthorised modications.
Damage caused by abuse, misuse, dropping or other similar damage
caused by or as a result of failure to follow transportation, storage,
installation, loading or operation instructions.
Alterations, additions or repairs carried out by persons other than the
Manufacturer or their recognised distributors.
Transportation or shipment costs to and from the Manufacturer or
their recognised agents, for repair or assessment against a warranty
claim, on the machine or component.
Materials and/or labour costs to renew, repair or replace components
due to fair wear and tear.
Faults arising from the use of non-standard or additional parts, or any
consequential damage or wear caused by the tting or use of such
parts.
IMPORTANT
Warranty may, at the sole discretion of the Manufacturer, be voided if
the scheduled service/inspections are not carried out in accordance
with this manual.
The Manufacturer and/or their recognised agents, directors,
employees or insurers will not be held liable for consequential or
other damages, losses or expenses in connection with or by reason of
or the inability to use the machine for any purpose.
MODIFICATIONS
If additional equipment or any third party work, modications or
alterations are to be carried out on the machine which will involve
any welding, drilling or any form of cutting or distortion of materials,
full written approval must be obtained from the Manufacturer prior
to the work being carried out.
20
A
1
A
A
2
A
B
A
3
C
A
4
B
A
A
6
A
B
C
75
A
B
DECAL PLACEMENT
DECAL PLACEMENT
Picture Description Decal Location
1. A. 15kg Maximum load Inside tool tray, front face
2. A. Do not tie down over guardrails, x 4 Each side of cage near gates, upper and middle guardrails
3. A. 234kg Maximum wheel load, x 4 Left and right hand side of chassis, 2 each side, next to wheels
Note: For Wind Rated machine, use 245kg Maximum wheel load (decals are on same sheet)
B. Fork lift point, x 2 Left and right hand side of chassis, between forklift openings
C. Lock castors before elevating, x 2 Left and right hand side of chassis, next to maximum wheel load
4. A. Spirit level guidance Left hand side of spirit level, on chassis cover
Note: For Wind Rated machine, use wind rated spirit level guidance (decal is on same sheet)
B. Lifting & tie-down point, x 2 Front of chassis, next to lifting & tie-down points
5. A. Product logo, x 2 Left and right hand side of platform tray
B. Do not enter the area underneath... Centre of chassis cover, front of mast
6. A. Lifting & tie-down point, x 2 Rear of chassis, next to lifting & tie-down points
7. A. Operating Instructions Left hand gate, upper panel.
B. Use advisory decal Right hand gate, upper panel
Note: For Wind Rated machine, remove the “Internal use only” part of the decal before applying to machine
C. 150kg SWL Left hand gate, lower panel
8. A. Safety guidelines Middle of mast, internal face
B. Harness point Middle of mast, internal face
. A. Elevate Centre of handle cover
21
22
Picture Description Decal Location
10. A. Keep mast surfaces clean... Middle of mast, external face
11. A. Specication plate Bottom of mast, external face
B. Hand trap point Rear of chassis, next to brush strip
C. Emergency lowering procedure Chassis cover, left hand side of mast
12. A. Never release these bolts..., x 2 Both sides of mast, below tool tray
A
B
8
9
A
11
A
B
C
10
A
12
A
DECAL PLACEMENT
APPENDIX ‘A’ - OPERATING SPECIFICATIONS FOR ECOLIFT WR / ECOLIFT 2.2 WR
23
OPERATING SPECIFICATIONS FOR WIND RATED MACHINE
Working Dimensions
Maximum working height: 4.20 m
Maximum platform height: 2.20 m
Platform dimensions: 850 mm (L) x 644 mm (W)
Working footprint: 1280 mm x 950 mm
Safe working load: 150 kg (1 person + tools)
Maximum manual force: 200 N
Maximum gradient for operation: 3 degrees
Maximum wind force: Internal/External, 12.5 m/s
Maximum wheel force: 245 kg (2.4 kN)
Maximum castor point load: 245 kg (2.4 kN)
Sound pressure level: Less than 70dBA
Closed Dimensions
Length: 1280 mm
Width: 950 mm
Height: 1950 mm
Weight: 340 kg
Lift Cycles Unlimited, subject to maintenance
program being adhered to.
Wind Rated machine is operable on
gradients up to 3º and in winds up to 12.5m/s
3º
OPERATING PROCEDURES
It is the owners and/or users responsibility to ensure that the
Ecolift WR / Ecolift 2.2 WR (referred to as “the WR machine” in
this manual) is maintained and operated in accordance with the
operation and maintenance procedures shown in Appendices A, B &
C, in addition to the operation and maintenance procedures shown
on pages 1 to 22 of this manual.
It is essential to be familiar with the correct operating procedures.
The operator must have adequate training for this type of platform.
The WR machine is tted with a safety harness point. If after
conducting a risk assessment the operator chooses to wear a safety
harness, an approved ‘fall restraint’ type harness should be worn with
a very short lanyard.
PRE-OPERATION CHECKS
1. Visually inspect the WR machine; check for signs of damage to
structure including castors, wheels, operating handle.
2. Position the WR machine safely; ensure there are no overhead
obstructions or dangers.
3. Ensure ground conditions are suitable. The WR machine should
be used on hard, level surfaces up to 3° that will support the
WR machine and safe working load.
4. Ensure castors are locked before entering platform.
5. Check operating handle is working correctly by stepping into
basket through gates, ensure gates are fully closed behind you;
gently pull handle knob towards you, release: handle knob
should spring back to prevent handle turning. Do not use the
WR machine if handle knob is damaged or sticking.
6. Cordon o work area in accordance with guidelines.
7. Safe working load for the WR machine is 1 person only plus tools
with a total of 150kg including person. Never exceed the
safe working load.
NORMAL OPERATION
1. The WR machine must only be used on hard surfaces not sloping
more than 3°. Ensure a person is available at ground level to assist
in case of emergency.
2. Position the WR machine under application. Check for any
overhead obstructions or dangers.
3. Check spirit level on the WR machine chassis to ensure the
WR machine is level up to 3°. Do not use the WR machine unless
bubble remains within 3° circle.
4. To use the WR machine, step into platform through gates.
Ensure gates are fully closed behind you. Gently pull operating
handle knob towards you; turn handle clockwise to elevate. Always
check for overhead obstructions or dangers. To stop elevation: stop
turning handle; release handle knob. Turn handle anti-clockwise
(counter-clockwise) to descend.
Never attempt to move the WR machine when elevated.
EMERGENCY LOWERING OPERATION
Never attempt to recover the WR machine/operator if there is any
possibility the WR machine is contacting any live wiring/cabling and
is therefore potentially ‘live’.
Never operate the emergency lowering without a person in the
platform otherwise serious injury may result.
The Emergency Lowering procedure is for lowering the platform
from height with an incapacitated operator in the platform and for
no other purpose.
1. Remove emergency operation tool located on chassis. If tool is held
captive with tie-wrap safety tag then break tag to release tool.
2. Follow instructions on Emergency Lowering Procedure
instruction label and on page 8 of this manual.
24
APPENDIX ‘B’ - OPERATING AND SAFETY INSTRUCTIONS FOR ECOLIFT WR / ECOLIFT 2.2 WR
APPENDIX ‘B’ - OPERATING AND SAFETY INSTRUCTIONS FOR ECOLIFT WR / ECOLIFT 2.2 WR
25
DO’S
1. Read, understand and adhere to the instructions on the
WR machine and in the Instruction Guide or Operating Manual.
2. Ensure pre-operation checks & operations are carried out in the
manner described.
3. Use only on hard, level surfaces up to 3° able to support the
weight of the WR machine.
4. Ensure the operator is t and does not suer from a
fear of heights.
5. Ensure guardrail gates are closed before elevation.
6. Ensure work area around the WR machine is cordoned o from
pedestrians and other trac.
7. Ensure operator is wearing the correct safety equipment.
8. Ensure the platform is correctly positioned so as not to come into
contact with xed or moving objects.
9. Ensure that the safe working load is evenly distributed
on the platform.
10. Ensure the WR machine is being operated within the PUWER
(Provision and Use of Workplace Equipment Regulations).
11. Ensure the castor brakes are applied when leaving the
WR machine unattended.
DON’TS
1. Never exceed the safe working load 150kg (1 person plus tools).
2. Never use the WR machine as a goods lift or crane.
3. Never exceed horizontal forces (maximum horizontal force 200N).
4. Never use in wind exceeding 12.5m/sec.
5. Never use in the vicinity of live conductors.
6. Never try to move the WR machine on its wheels when elevated.
7. Never extend the height of the platform by using boxes,
steps, ladders etc.
8. Never modify the WR machine in any way without the full written
approval of the manufacturer.
9. Never attempt to enter or exit the platform unless it is
fully lowered.
10. Never lift heavy components on the WR machine without the
use of the correct lifting equipment.
11. Never use the WR machine in an explosive environment.
12. Never use the WR machine if you are fatigued.
13. Never use the WR machine inappropriately or for ‘horseplay.’
14. Never use the WR machine if under the inuence of drugs or
alcohol.
15. Never use the WR machine if suering from poor health or using
medication which might impair the safe operation of the
WR machine.
16. Never use the WR machine if vision is impaired by bright lighting.
17. Never push the WR machine on sloping surfaces without the use
of a safe method.
18. Never push or pull objects with the platform.
19. Never use on surfaces over a 3° gradient.
WHEELS AND CASTORS
It is absolutely essential that the wheels and castors are maintained in
good condition at all times, for two reasons:
The rst is that they act as the stabilisers, and whilst their load capacity
is over rated for the application, any failure could result in a serious
accident. Secondly, if the bearings become tight, then it will make the
machine dicult to manoeuvre.
A measure of horizontal push force can simply be made to determine
the condition of the wheel bearings. On a at smooth surface the
WR machine should move with a force of 9 – 10 kg at the mid guard
rail height. The maximum allowance is 20 kg. Obviously this force
is dependant upon the surface and gradient, but the above is the
recognised method of measurement, in accordance with HSE guidelines.
Check rear wheels to ensure retention cotter pin is securely tted and
undamaged.
When replacing components for any reason, only use OEM
specication parts, either supplied from the manufacturer or
authorised in writing by the manufacturer. Warranties and design
approvals will be void if alternative components are tted.
It is essential to obtain manufacturer’s approval of any alteration
which might aect stability, strength or performance in writing before
proceeding.
When retting a rear wheel always use a new cotter pin
(4mm diameter x 32mm A2 Stainless Steel).
NEVER REFIT A USED COTTER PIN.
APPENDIX ‘C’ - ADDITIONAL MAINTENANCE INSTRUCTIONS FOR ECOLIFT WR / ECOLIFT 2.2 WR26APPENDIX ‘D’ - ATEX CERTIFICATION
MACHINES WITH ATEX CERTIFICATION
The Ecolift / Ecolift 2.2 and Ecolift WR / Ecolift 2.2 WR
can be specied as ATEX approved, for zones 1 and 21.
This comes with third party approval by SGS Baseefa
(Certicate no. Baseefa 13ATEX0150).
There are no elements of the machine which were
identied as a potential hazard.
There are no specic additional maintenance
procedures required for the ATEX certied machine
except to ensure that the earthing strap is intact, and it
is in contact with the ground.
TEST RESULTS & NOTES
Description Work Carried out Date
ALTERATIONS & REPAIRS
Description Work Carried out Date
ECO-OP | UK | 06:17
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