Snorkel SPM20 User Manual

Serial Number 000001 and after
OPERATORS
MANUAL
Partnumber 511147-000-EN
1
November 2012
EC
DECLARATION
OF
CONFORMITY
FOR MACHINERY
MACHINERY:
Powered Aerial Platform known as: Type: SPM20
E. C. Type Examination Certificate No:
Note: Modification of the specified unit renders this declaration invalid
OPERATION
WARNING
All personnel shall carefully read, understand and follow all safety rules and operating instructions before operating
Electrocution Hazard Tip Over Hazard Collision Hazard Fall Hazard
THIS MACHINE
INSULATED!
IS NOT
or performing maintenance on any Snorkel aerial work platform.
Safety Rules
NEVER
drive the machine while elevated
unless the machine is on a firm,
elevate the platform or
level surface.
NEVER
overhead obstructions or other
position the platform
without first checking for
hazards.
MANUAL
NEVER
platform guardrails or midrail.
climb, stand, or sit on
USE OF
used for the job. It is designed for repair and assembly jobs and assignments at overhead workplaces (ceilings, cranes, roof structures, buildings etc.). All other uses of the aerial work platform are prohibited!
THIS
electrical equipment! Exceeding the specified permissible maximum load is prohibited! See “Special Limitations” on page 4 for details. The use and operation of the aerial work platform as a lifting tool or a crane (lifting of loads from below upwards or from up high on
down) is prohibited!
NEVER DISTRIBUTE NEVER
debris; and avoiding them.
OPERATE NEVER IN CASE OF IF
Climbing up the railing of the platform, standing on or stepping from the platform onto buildings, steel or prefab concrete structures, etc., is prohibited!
Dismantling the swing gate or other railing components is prohibited! Always make certain that the swing gate is closed and
securely locked! It is prohibited to keep the swing gate in an open position (held open with tie-straps) when the platform is raised! To extend the height or the range by placing of ladders, scaffolds or similar devices on the platform is prohibited!
NEVER INSPECT
damaged cables or hoses before using.
VERIFY NEVER To bypass any safety equipment is prohibited and presents a danger for the persons on the aerial work platform and in its
working range.
NEVER Modifications to the aerial work platform are prohibited or permissible only at the approval by Snorkel AFTER
The driving of MEWPs on the public highways is subject to regulations made under the Road Traffic Acts.
THE
AERIAL WORK
AERIAL WORK
exceed the manual force allowed for this machine. See “Special Limitations” on page 4 for details.
all platform loads evenly on the platform.
operate the machine without first surveying the work area for surface hazards such as holes, drop-offs, bumps, curbs, or
machine only on surfaces capable of supporting wheel loads.
operate the machine when wind speeds exceed this machine’s wind rating. See “Beaufort Scale” on page 4 for details.
EMERGENCY
ALARM
SOUNDS
perform service on machine while platform is elevated without blocking elevating assembly.
the machine thoroughly for cracked welds, loose or missing hardware, hydraulic leaks, loose wire connections, and
that all labels are in place and legible before using.
use a machine that is damaged, not functioning properly, or has damaged or missing labels.
charge batteries near sparks or open flame. Charging batteries emit explosive hydrogen gas.
USE, secure the work platform from unauthorized use by turning both keyswitches off and removing key.
PLATFORM
while platform is elevated, STOP, carefully lower platform. Move machine to a firm, level surface.
PLATFORM: This aerial work platform is intended to lift persons and his tools as well as the material
IS NOT
push EMERGENCY STOP switch to deactivate all powered functions.
INSULATED!
For this reason it is imperative to keep a safe distance from live parts of
2
FOREWORD
This manual is a very important tool! Keep it with the machine at all times. The purpose of this manual is to provide owners, users, operators, lessors, and lessees
with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose.
Due to continuous product improvements, the manufacturer reserves the right to make specification changes without prior notification. Contact the manufacturer for updated information.
Other Publications Available:
Illustrated Parts Manual…………………………………………………. ……………………
3
SAFETY
ALERT
SYMBOLS
This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
AND
SAFETY SIGNAL
WORDS
DANGER
INDICA TES
SERIOUS INJURY
IN
AN
IMMINENTLY HAZARDOUS SITUATION. IFNOT AVOIDED,
OR DEATH.
WILL RESULT
WARNING
INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD RESULT INSERIOUS INJURY
OR DEATH.
CAUTION
INDICA TES MINOR
A
POTENTIALITY HAZARDOUS SITUATION.IFNOT AVOIDED, MAY RESULT
OR
MODERA TE INJURY.
IT MAY ALSO ALERT AGAINST
UNSAFE
PRACTICES.
IN
INDICA TES PROCEDURES ESSENTIAL
IMPORT
FOR SAFE OPERATION.
ANT
WARNING
THIS THE MANUFACTURER OR IT’S LOCAL AUTHORIZED REPRESENTATIVE FOR INFORMATION ISSUED
THE MANUFACTURER SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OFTHIS MACHINE. CONT ACT CURRENT OWNER RECORDS
THE IT’S OR DEATH OF PERSONAL PROPERTY
PRODUCT
FOR
MANUFACTURER
PRODUCTS
MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT
REGARDING
THIS
PRODUCT.
HAVE BEEN
PERSONNEL
SAFETY-RELATED
IMPORT
THE
ARE
UPDATED
IMPORT
MUST BE
OR THE PRODUCT.
NOTIFIED IMMEDIATELY INVOLVED OR WHEN SUBSTANTIAL DAMAGE HAS
BULLETINS WHICH MAY HAVE BEEN
ANT
MANUFACTURER
AND ACCURATE.
ANT
IN AN
ACCIDENT INVOLVING
IN ALL
TO
ENSURE
INSTANCES
BODILY INJURY
OCCURRED
THAT THE
WHERE
TO
4
SUBJECT-SECTION,
TABLE OF
PARAGRAPH PAGE NO.
CONTENTS
FOREWORD ................................................................................................................2
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS ....................................3
SECTION
1 -
SAFETY
PRECAUTIONS
1. 1 GENERAL ...........................................................................................................7
1. 2 PRE-OPERATION. .............................................................................................. 7
Operator Training And Knowledge ......................................................................7
Workplace Inspection ..........................................................................................8
Machine Inspection ............................................................................................. 8
1. 3 OPERATION .......................................................................................................8
General ...............................................................................................................8
Trip and Fall Hazard ............................................................................................9
Electrocution Hazard ...........................................................................................9
Safety Rules for Electrical Cont rol System ...................................................... 10
Tipping Hazard .................................................................................................. 11
Crushing And Collision Hazard ......................................................................... 11
1. 4 TOWING, LIFTING, AND HAULING .................................................................12
1. 5 Plates and Warning Labels ...............................................................................12
Nameplate and CE mark ...................................................................................12
Warning labels ..................................................................................................13
SECTION
2 -
PREPARATION
AND INSPECTION
2.1 PERSONNEL TRAINING .............................. ....................................................18
Operator Training .............................................................................................. 18
Training Supervision .........................................................................................18
Operator Responsibility .....................................................................................18
2.2 PREPARATION, INSPECTION, AND MAINTENANCE ....................................18
2.3 PRE-START INSPECTION ...............................................................................19
2.4 DAILY WALK-AROUND INSPECTION ............... ..............................................20
2.5 FUNCTION CHECK ..........................................................................................21
SECTION
3 -
MACHINE CONTROLS, INDICATORS
AND OPERATION
3.1 GENERAL ............................................................................................... ......... .24
3.2 MACHINE DESCRIPTION ................................................................................24
3.3 MACHINE OPERATION ...................................................................................24
Getting Started ..................................................................................................24
3.4 BATTERY CHARGING ........................................................................ .............24
Battery Low Voltage Warning Indicators ...........................................................25
To Charge Batteries ..........................................................................................26
Battery Charging Status Indicators ...................................................................26
5
3.5 GROUND CONTROL STATION OPERATION ............................................... 26
Main Power Key Switch .......... .................... ..... ..........................................26
Emergency Stop/Shut Down Button .................................................................27
Platform Up ............................................................................. ..........................27
Platform Down .................................................................................................. 27
Manual Descent Control Valve ..........................................................................27
3.6 PLATFORM CONTROL CONSOLE OPERATION ............................................ 28
At Ground Control Station .................................................................................28
Emergency Stop/Shut-Down Button ................................................................29
Driving Machine ................................................................................................ 29
Elevating/Lowering the Platform .......................................................................30
3.7 PARKING MACHINE .........................................................................................31
3.8 PLATFORM CONFIGURATIONS .....................................................................31
3.9 FALL PROTECTION – LANYARD ATTACHMENT............................................. 32
3.10 QUICK-CHANGE PLATFORM MOUNTING ...................................................... 33
Platform Removal ............................................................................................. 33
Platform Installation ..........................................................................................33
3.11 TRANSPORTING, LIFTING PROCEDURES ................................................... 34
General .............................................................................................................34
Truck Transport ............................................................................ ..................... 34
Fork Lift Truck Transport ...................................................................................35
SECTION
4 -
EMERGENCY
PROCEDURES
4.1 GENERAL INFORMATION ...............................................................................36
4.2 EMERGENCY OPERATION .............................................................................36
Operator Unable to Control Ma chine ...............................................................36
Platform caught Overhead ................................................................................36
4.3 INCIDENT NOTIFICATION ...............................................................................36
6
SECTION
5 -
GENERAL SPECIFICATIONS
AND
OPERATOR
MAINTENANCE
5.1 INTRODUCTION .............................................................................................. 37
5.2 GENERAL SPECIFICATIONS ..........................................................................37
Machine Specifications .....................................................................................37
Machine Dimension ..........................................................................................38
Machine Operating Area ...................................................................................39
Electrical Specifications ....................................................................................39
Platform Data .................................................. ..................................................40
Machine Component Weights ...........................................................................40
Serial Number Locations ...................................................................................40
5.3 OPERATOR MAINTENANCE ...........................................................................40
Lubrication ........................................................................................................40
Hydraulic Diagram ............................................................ ................................ 41
SECTION
6 -
INSPECTION
AND
REPAIR
LOG
LIST OF
FIGURES
2-1. Daily Walk-Around Inspection for SPM20 Machines ..................................................21
3-1. Battery Charger Location ........................................................................................... 25
NO. TITLE PAGE
FIGURES
NO.
3-2. Ground Control Station. (Machine Rear View) ..........................................................28
3-3. Platform Control Console. ......................................................................................... 28
3-4. Forklift Truck Lifting Pockets and Machine Tie Down Bar Locations ..........................35
LIST OF TABLES
TABLE NO. TITLE PAGE
NO.
1-1 Minimum Safe Approach Distance (M.S.A.D.). .........................................................10
2-1 Inspection and Maintenance Table .............................................................................19
3-1 Machine Operating Specifications ..............................................................................23
5-1 Lubrication Specifications .......................................................................................... 42
5-2 Lubrication Intervals for Various Components ............................................................42
6-1 Inspection and Repair Log ......................................................................................... 44
7
1.1 GENERAL
SECTION
1.
SAFETY
PRECAUTIONS
This section outlines the necessary precautions for proper and safe machine usage and maintenance. For proper machine use, it is mandatory that a daily routine be established based on the content of this manual. A maintenance program, using the information provided in this manual and the Service and Maintenance Manual, must also be established by a qualified person and must be followed to ensure that the machine is safe to operate.
The owner/user/operator/lessor/lessee of the machine should not accept operating responsibility until this manual has been read, training is accomplished, and operation of the machine has been completed under the supervision of an experienced and qualified operator.
If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact the manufacturer.
FAILURE
TO
COMPLY WITH
COULD RESULT
WARNING
THE
SAFETY PRECAUTIONS LISTED
IN
MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY
IN
THIS
MANUAL
OR
DEATH.
1.2
PRE-OPERA
Operator Training And Knowledge
Read and understand this manual before operating the machine.
TION
Do not operate this machine until complete training is performed by authorized persons.
Only authorized and qualified personnel can operate the machine.
Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating
instructions on the machine and in this manual.
Use the machine in a manner, which is within the scope of its intended application set by the manufacturer.
All operating personnel must be familiar with the emergency controls and emergency
operation of the machine as specified in this manual.
8
Read, understand, and obey all applicable employers, local, and governmental regulations as they pertain to operation of the machine.
Workplace Inspection
The operator is to take safety measures to avoid all hazards in the work area prior to
machine operation.
Do not operate or raise the platform while on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless approved in writing by the manufacturer.
This machine can be operated in temperatures of –20 c to 40 c . Consult the manufacturer for operation outside this range.
Machine Inspection
Before machine operation, perform inspections and functional checks. Refer to Section 2 of this manual for detailed instructions.
Do not operate this machine until it has been serviced and maintained according to
requirements specified in the Service and Maintenance Manual.
Ensure all safety devices are operating properly. Modification of these devices is a safety violation.
MODIFICATION OR ALTERATION ONLY
WITH PRIOR WRITTEN PERMISSION FROM
WARNING
OF AN AERIAL WORK
PLATFORM
THE MANUFACTURER
SHALL BE MADE
Do not operate any machine on which the safety or instruction placards or decals are
missing or illegible.
Avoid any build up of debris on platform floor. Keep mud, oil, grease, and other slippery substances from footwear and platform floor.
1.3 OPERATION
General
Do not use the machine for any purpose other than positioning personnel, their tools and
Never operate a machine that is not working properly. If a malfunction occurs, shut down
Never slam a control switch or lever through neutral to an opposite direction. Always
Do not allow personnel to tamper with or operate the machine from the ground with
Do not carry materials directly on platform railing unless approved by the manufacturer.
equipment, or for hand stock picking.
the machine.
return switch to neutral and stop before moving the switch to the next function. Operate controls with slow and even pressure.
personnel in the platform, except in an emergency.
Always ensure that power tools are properly stowed and never left hanging by their cord
from the platform work area.
Fully lower mast assembly and shut off all power before leaving machine.
9
When performing welding operations at elevation, precautions must be taken to protect all machine components from contact with weld splatter or molten metal.
Battery fluid is highly corrosive. Avoid contact with skin and clothing at all times.
Charge batteries on in a well ventilated area.
Trip and Fall Hazard
The manufacturer recommends that the operator in the platform wear a full body harness with a lanyard attached to an authorized lanyard anchorage point. For further information regarding fall protection requirements on the products, contact the manufacturer.
Before operating the machine, make sure all railing and gates are fastened in their proper position.
Keep both feet firmly positioned on the platform floor at all times. Never use ladders, boxes, steps, planks, or similar items on platform to provide additional reach.
Never use the mast assembly to enter or leave the platform.
Use extreme caution when entering or leaving platform. Ensure that the mast assembly is
fully lowered. Face the machine when entering or leaving the platform. Always maintain
“three point contact” with the machine, using two hands and one foot or two feet and one
hand at all times during entry and exit.
Platform-to-structure transfers at elevated positions are discouraged. Where transfer is necessary, enter/exit through the gate only with the platform within 1 foot (0.3m) of a safe and secure structure. 100% tie-off is also required in this situation utilizing two lanyards. One lanyard must be attached to the platform with the second lanyard attached to the structure. The lanyard connected to the platform must not be disconnected until such time the transfer to the structure is safe and complete.
Electrocution Hazard
10
VOLTAGE
RANGE
(PHASE
TO PHASE)
MINIMUM
SAFE APPROACH
DISTANCE-Feet
(m)
0-50KV 10(3)
Over 50KV to 200KV
15(5)
Over 200KV to 350KV
20(6)
Over 350KV to 350KV
25(8)
Over 500KV to 750KV
35(11)
Over 750KV to 1000KV
45(14)
NOTE: This Minimum Safe Approach Distance shall apply except where employer, local,
or governmental regulations are more stringent.
Table
1-1.
Minimum
Safe
Approach Distance (M.S.A.D.)
Maintain a clearance of at least 10 ft (3m) between any part of the machine and its occupants, their tools, and their equipment from any electrical line or apparatus carrying up to 50,000 volts. One foot (0.3m) additional clearance is required for every additional 30,000 volts or less. The minimum safe approach distance may be reduced if insulating barriers are installed to prevent contact, and if the barriers are rated for the voltage of the line being guarded. These barriers shall not be part of (or attached to) the machine. The minimum safe approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier. This determination shall be made by a qualified person in accordance with
employer, local, or governmental requirements for work practices near energized equipment.
Safety Rules for Electrical Control System
Only personnel who are properly trained and have adequate knowledge and skill should
undertake all electrical/electronic troubleshooting and repair.
Do not alter or bypass protective interlocks.
Before starting, read and observe all warning labels.
When trouble shooting make sure the power source has been disconnected and main
switch has been locked.
Take extra precautions in damp areas to protect you from accidental grounding.
Before applying power to any equipment it must be established, without a doubt, that all
persons are clear.
Do not open the electrical control panel unless it is necessary to check the electrical
equipment.
Do not alter the electrical circuits unless authorized to do so by the manufacturer.
When replacing electrical components, make sure they conform to the manufacturers
specifications, including proper color coding.
Do not wear metal frame glasses, metallic necklaces or chains while working on any electrical equipment. Also do not wear any ring, watch or bracelet while operating electrical equipment.
11
Tipping Hazard
The user should be familiar with the surface before driving. Do not exceed the allowable side slope and grade while driving.
Do not elevate platform or drive with platform elevated while on a slope, or on an uneven or soft surface.
Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces.
Never exceed the maximum platform capacity. Distribute loads evenly on platform floor.
Keep the chassis of the machine a minimum of 2 ft. (0.6m) from holes, bumps, drop-offs,
obstructions, debris, concealed holes, and other potential hazards at the ground level.
Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure.
Do not increase the platform size with unauthorized deck extensions or attachments, increasing the area exposed to wind will decrease stability.
If mast assembly or platform is caught so that one or more wheels are off the ground, the operator must be removed before attempting to free the machine. Use cranes, forklift trucks, or other appropriate equipment to stabilize machine and remove personnel.
Crushing And Collision Hazard
Personal protection equipment must be worn by all operating and ground personnel.
Check work area clearances above, on sides, and bottom of platform while driving and
lifting or lowering platform
During operation, keep all body parts inside platform railing.
Always post a lookout when driving in areas where vision is obstructed.
Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving
operations.
Limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors causing hazards of collision or injury to personnel.
Be aware of stopping distances in restricted or close quarters or when driving in reverse.
12
Do not drive at high speeds in restricted or close quarters or when driving in reverse.
Exercise extreme caution at all times to prevent obstacles from striking or interfering with
operating controls and persons in the platform.
Ensure that operators of other overhead and floor level machines are aware of the aerial work platforms presence. Disconnect power to overhead cranes.
Warn personnel not to work, stand, or walk unde floor as necessary.
1.4
TOWING, LIFTING,
Never allow personnel in platform while towing, lifting, or hauling.
This machine should not be towed, except in the event of emergency, malfunction, power
failure, or loading/unloading. Refer to the Emergency Procedures Section of this manual for emergency towing procedures.
Ensure platform is fully retracted and completely empty of tools prior to towi hauling.
Do not assist a stuck or disabled machine by pushing or pulling except by pulling at the
chassis tie-down bars.
When lifting machine with a forklift, position forks only at designated areas of the machine. Lift with a forklift of adequate capacity.
Refer to the Machine Operation section of this manual for lifting information.
AND HAULING
r a raised platform. Position barricades on
ng, lifting or
1.5 Plates and Warning Labels
Upon unpacking, check the plates and warning labels. Do not operate the machine on which the plates or labels are missing or illegible. Contact the dealer immediately. The following plates are visible on the machine.
Nameplate and CE mark
13
Warning labels
14 15
WARNING
16 17
18
2.1
PERSONNEL
SECTION
TRAINING
2.
PREPARATION
AND INSPECTION
The aerial platform is a personnel-handling device; so it is necessary that it be operated and maintained only by trained personnel. Persons under the influence of drugs or alcohol or who are subject to seizures, dizziness or loss of physical control must not operate this machine.
Operator Training
Operator training must cover:
1. Use and limitations of the controls in the platform and at the ground, emergency controls and safety systems.
2. Control labels, instructions, and warnings on the machine.
3. Rules of the employer and government regulations.
4. Use of approved fall protection device.
5. Enough knowledge of the mechanical operation of the machine to recognize a
malfunction/
6. The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, depressions, holes, drop-offs are present.
7. Means to avoid the hazards of unprotected electrical conductors.
8. Specific job requirements or machine application.
Training Supervision
Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee has developed the ability to safely control and operate the machine.
Operator Responsibility
The operator must be instructed that he/she has the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site.
NOTE: The Manufacturer or Distributor will provide qualified people for training assistance
with the first unit(s) delivered and from that time forward as requested by the user or
2.2
The following table covers the periodic machine inspections and maintenance recommended by the manufacturer. consult local regulations for further requirements for aerial work platforms. The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.
THE HAS PRODUCT
his/her personnel.
PREPARATION, INSPECTION,
AND MAINTENANCE
IMPORT
ANT
MANUFACTURER RECOGNIZES A QUALIFIED MECHANIC SUCCESSFULLY COMPLETED
THE
SERVICE TRAINING
MODEL.
AS A
PERSON
WHO
FOR THE SPECIFIC
19
TYPE
FREQUENCY
PRIMERY
RESPONSIBILITY
SERVICE
QUALIFICATION
REFERENCE
Pre-Start Inspection
Before using each day,
or whenever theres an
Operator change.
User or Operator
Operator and Safety Manual
Pre-Delivery Inspection (See Note)
Before each sale, lease, or rental delivery.
Owner, Dealer, or
User
Qualified
Mechanic
Service and Maintenance Manual and applicable
Inspection form
Frequent
Inspection
In service for 3 months or 150 hours, whichever comes first; or; Out of
service for a period of more than 3 months; or
Purchased used.
Owner, Dealer, or
User
Qualified
Mechanic
Service and Maintenance Manual and applicable
Inspection form
Annual Machine
Inspection
Annually, no later than 13
months from the date of
prior inspection.
Owner, Dealer, or
User
Qualified
Mechanic
Service and Maintenance Manual and applicable
Inspection form
Preventative Maintenance
At intervals as specified
in the Service and
Maintenance Manual.
Owner, Dealer, or
User
Qualified
Mechanic
Service and Maintenance
Inspection form
NOTE: Inspection forms are available from the manufacture. Use the Service and Maintenance Manual to perform inspections.
SUCCESSFULLY COMPLETED
Table
THE
SERVICE TRAINING
PRODUCT MODEL.
2-1.
Inspection and Maintenance Table
FOR THE
SPECIFIC
2.3
PRE-START
INSPECTION
The Pre-Start Inspection should include each of the following:
1. Cleanliness – Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel.
2. Decals and Placards – Check all for cleanliness and legibility. Make sure no decals or placards are missing. Make sure all illegible decals and placards are cleaned or replaced.
3. Operators and Safety Manuals – Make sure a copy of the Operation and Safety Manual, Safety Manual, and Manual of Responsibilities is enclosed.
4. Daily Walk - Around Inspection – (See Section 2.4)
5. Battery – Charge as required.
6. Hydraulic Oil – Check the hydraulic oil level.
NOTE: Check Service Manual for instructions and hydraulic oil specification before adding.
DO NOT OVERFILL.
20
7. Function Check – Check all machine controls for operation. (See Section 2.5)
If optional equipment is installed on this machine refer to Section 3 for specific Pre-Start Inspection and Operation instructions.
2.4 DAILY
WALK-AROUND INSPECTION
Begin the “Walk – Around Inspection” at item one (1) as noted on the diagram. Continue around machine check each item in sequence for the conditions listed in the following checklist.
TO AVOID AROUND
POSSIBLE
INJURY, BE SURE MACHINE
INSPECTION”.
WARNING
POWER
IS “OFF”
DURING “WALK-
DO NOT
DO THIS DAMAGE.
NOTE: On all components, make sure there are no loose or missing parts, that they are
1. Drive and Caster Wheels – Check for any debris stuck to or around wheels.
2. Base Frame – Check pot-hole-protection system components; check for loose wires or
3. Manual Descent Control Valve – See note above.
4. Motor/Pump/Reservoir Unit – No evidence of hydraulic leaks.
5. Batteries – Battery cables; no corrosion.
6. Platform Assembly and Gate – Quick-Change platform mounting and mounting screws;
7. Platform Control console – Platform control; placards secure and legible; emergency stop
OPERATE MACHINE UNTIL
NOT OVERLOOK VISUAL INSPECTION
AREA FOR OBJECTS OR
ALL
MALFUNCTIONS
IMPORT
ANT
OF THE BASE
DEBRIS, WHICH
HAVE BEEN CORRECTED.
FRAME UNDERSIDE.
COULD CAUSE
EXTENSIVE
securely fastened, and that no visible damage, leaks or excessive wear exists in addition to any other criteria mentioned.
cables dangling below the base.
platform fasteners; platform railings; entry bar or gate in proper working order.
switch reset for operation; Control markings legible.
CHECK
MACHINE
8. Ground Control Station – Main Power Selector Switch operable; placards secure and legible; emergency stop switch operates properly.
9. Mast Assembly – Mast sections; slide pads; mast chains; sequencing cables; platform control and power cables (on side of mast); power cables properly tensioned and seated in sheaves; cable sheaves rotating freely.
21
Figure
2-1.
Daily Walk-Around Inspection for
SPM20
Machines.
1. Drive and Caster Wheels
2. Base Frame
3. Manual Descent Control Valve
2.5
FUNCTION
CHECK
Once the “Walk-Around” Inspection is complete, perform a function check of all systems in an area free of overhead and ground level obstructions. Refer to Section 3 for more specific operating instructions.
IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOT
OPERATE Perform a Function Check as
THE
MACHINE UNTIL
1. From the ground controls with no load in the platform:
a. Operate ground control functions, platform lift up and lift down.
4. Motor/Pump/Reservoir Unit
5. Batteries (Open Cover Doors)
6. Platform Assembly
WARNING
IT IS
DECLARED
follows:
SAFE FOR OPERATION.
7. Platform Control Console
8. Ground Control Console
9. Mast Assembly
22
NOTE:
Ensure Pot-Hole-Protection device is fully engaged (both bars down) when the platform is elevated. b. Ensure that all machine functions are disabled when the Emergency Stop Button is
activated.
c. Check Manual Control valve is operating properly.
2. From the platform control console:
a. Ensure that the control console is properly mounted and secure.
b. Raise and lower platform 2 ft. to 3 ft. (.61m to .92m) several times. Check for smooth
elevation and lowering of platform. c. Operate all functions and check all limit and cutout switches. d. Ensure that all machine functions are disabled when the Emergency Stop Button is
activated.
3. With platform in the transport (stowed)
a. Drive the machine on a grade, not to exceed the rated grade ability, and stop to ensure
the brakes hold. b. Check the 1.0 degree tilt sensor alarm to ensure proper ope
position:
ration.
23
1
SECTION
3.
MACHINE CONTROLS, INDICATORS
AND
OPERATION
Table 3-1 Machine Operating Specifications
SPM20
Maximum Occupants:
Maximum Work Load (Capacity):
Maximum Travel Grade (Grade ability): 15-20%
Maximum Travel Grade (Side Slope):(Platform STOWED ONLY)
Maximum Height (Platform Stowed)
Maximum Vertical Platform Height:
Maximum Wheel Load (Per Wheel):
Maximum Drive Speeds (Operator
Variable):
Max. Platform Speeds (w/Max. Load):
Platform Up:
Platform Down:
150kg
2100mm
6m
360kg
0.6 - 8 km/h
27-36 sec.
30-35 sec.
Gross Machine Weight (Standard
Equipment/Platform Empty):
1050kg
24
3.1 GENERAL
IMPORT
THE
MANUFACTURER
OPERATION.
THE
WITH GOOD SAFETY
This section provides the necessary information needed to understand control function and
HAS
USER
AND
PRACTICES.
DIRECT CONTROL OVER MACHINE APPLICATION
OPERATOR
ANT
ARE
RESPONSIBLE
AND
FOR CONFORMING
operation.
3.2
MACHINE
DESCRIPTION
The SPM20 Model Lifts are electric self-propelled machines with an aerial work platform mounted to an elevating aluminum mast mechanism. The personnel lifts intended purpose is to personnel access to areas above ground level.
The primary control station is located in the platform. From the Platform Control Console the operator can drive the machine and raise or lower the platform.
The controls of the programmable Ground Control Station are to be used during machine power-up, machine maintenance or in case of emergency should the operator in the platform be unable to lower the platform.
Vibrations emitted by these machines are not hazardous to an operator working in the platform.
The continuous A-Weighted sound pressure level at the work platform is less than 70db (A).
3.3
MACHINE
OPERATION
Getting Started
The following control conditions must be met before the machine can be operated from either
the Ground or Platform Controls.
The batteries contain enough voltage to operate the machine.
The Main Power Selector Switch on the Ground Control Station must be set for either
Ground Control Mode or Platform Control Mode.
Both Emergency Stop Switches, one on the Ground Control Station the other on the Platform Control Console must be in the RESET position.
If equipped, the On/Off Key Switch on the Platform Console must be set to the ON position.
3.4
BATTERY
CHARGING
SPM20 machines are equipped with an AC voltage input/DC voltage output battery charger. The charger automatically terminates charging when the batteries reach full capacity.
NOTE:
The machine’s platform drive function is disabled when the battery charger is plugged into an
AC receptacle.
25
Figure
Battery Voltage and Charging Status Indicators
The Ground Control Station indicate battery voltage ,Battery state-of-charge: 10-bar, tri-color LED (5-bar green 3-bar yellow 2-bar red)
.
3-1.
Battery Charger Location.
Battery Charger Front
Battery Indicators
Panel
26
NOTE: (a) To maximize battery life, it is recommended that the factory supplied batteries
be charged continuously for a minimum of 4 hours or until 8 bars are lit on the
ground station LCD Display before operating the machine. When drained to
Warning Level 2 or 3, batteries must be charged until 8 bars are lit on the ground station LCD display to clear the fault code.
To Charge Batteries
1. Park machine in a well ventilated area near an AC voltage electrical outlet.
2. Closed key switch.
NOTE:
The batteries on SPM20 machines require approximately five (5) hours to fully charge when drained to LOW BATTERY VOLT AGE warning on the Ground Control Module LCD display.
3. Plug a heavy duty AC extension cord into the Charger AC Input Receptacle on the
center rear cover of the machine.
Battery Charging Status Indicators
3.5
GROUND CONTROL
STATION-OPERATION
(See Figure 3-2.)
Main Power Key Switch
Set the Main Power Key Switch to on Station
POWER
OFF
POWER
ON
TURN CLOCKWISE TURN COUNTERCLOCKWISE Key Switch Key Switch
27
Emergency Stop/Shut Down
POWER
OFF
PUSH IN-To Engage
Emergency Stop
Button
POWER
ON
TURN CLOCKWISE and RELEASE-To Reset
Emergency Stop
Platform Up Platform Down
TURN UP Left Toggle Switch, TURN UP Left Toggle Switch, And TURN UP Right Toggle Switch And TURN DOWN Right Toggle Switch Toggle Switch Toggle Switch
Manual Descent Control Valve
DRAW-OUT TO LOWER Platform RELEASE TO –STOP Platform Descent
28
Figure
3-2.
Ground Control Station. (Machine Rear View)
1. Emergency Stop 2. Hour Run/BCI Meter
3. Main Power Key Switch 4. Deadman Toggle Switch, on-(on)
5. Toggle Switch (on)-off-(on) 6. Charger A/C Input Receptacle
7. Manual Descent Control Valve
3.6
PLATFORM CONTROL CONSOLE OPERATION
Figure
3-3.
Platform Control Console
1. Emergency Stop 2. Horn Button
3. Joystick with Enable Button 4. Toggle switch SPDT on-on
29
Emergency Stop/Shut-Down
Button
POWER-OFF
PUSH IN-To Engage TURN CLOCKWISE and RELEASE-To Reset
Emergency Stop Emergency Stop
Driving Machine
WHEN DRIVING WITH PLATFORM LOWERED, A RAMP
(GRADE)
WARNING
OF
GREATER
THAN
TWENTY
POWER-ON
DO
NOT ATTEMPT
PER
CENT (20%),
TO
DRIVE
AS TIPPING
MACHINE
COULD
UP
OCCUR.
POINT
& GO®
The Joystick can be moved in any direction off center. Drive Power is applied proportionally the further the Joystick is moved off center.
1. PRESS and RELEASE the Drive Function Button.
2. While the Drive Function is active. PRESS and HOLD the enable button on side the
joystick.
30
3. Move the joystick the desired direction of travel. TO STOP the machine return the joystick
back to center.
Elevating/Lowering the Platform
WARNING
IF THE TILT ALARM HAS BEEN ACTIVATED, THE PLATFORM WILL NOT ELEVATE. ALSO THE DRIVE
LOWERED.
IF THE TILT
FUNCTION
ALARM
HAS BEEN ACTIVATED WHEN THE PLATFORM IS
WILL BE DISABLED UNTIL THE PLATFORM IS COMPLETELY
ELEVATED,
1. Drive the machine to the area where overhead work is to be performed and position the machine into its approximate work position.
2. PRESS and RELEASE the Platform Function Button.
3. While the Platform Function is active. PRESS and HOLD the Enable Button on side the Joystick.
4. Push the Joystick FORWARD from center TO ELEVATE the Platform. TO STOP platform movement return the joystick back to center. Pull the Joystick BACK from center TO LOWER the Platform.
5. If necessary, reposition (drive) lift using platform controller joystick to bring work object within
reach.
31
Model
Max. Capacity
SPM20
150kg
1. Sliding Bar Entry Gate 3. Platform Control Console
2. Extension Slide/Lock Handle 4. Sliding Extendible Section
3.7
PARKING
MACHINE
1. Drive machine to a well-protected and well-ventilated area.
2. Ensure the platform is fully lowered, turn the main power key switch to the OFF position (centered).
NOTE:
If required, charge batteries in preparation for next workday.
3.8
PLATFORM
CONFIGURATIONS
EXTENDIBLE PLATFORM (SLIDING
BAR
ENTRY
)
32
3.9
FALL
THE FULL BODY ANCHORAGE
PROTECTION
– LANYARD ATTACHMENT
MANUFACTURER RECOMMENDS
HARNESS WITH
A LANYARD
POINT.
CAUTION
THE
OPERATOR
ATTACHED TO
IN THE
AN
PLATFORM WEAR
AUTHORIZED
The main lanyard attach point for all SPM20 machines is located on the lower right side of
the mast platform header, just behind the operators platform.
AFTER ENTERING CLOSE
THE
PLATFORM ENTRY
CAUTION
THE
PLATFORM, BEFORE BEGINNING OPERATION
GATE (S).
ALWAYS
A
LANYARD
33
3.10 QUICK-CHANGE PLATFORM
MOUNTING
SPM20 Model Lifts are equipped with quick-change platform mount, which allow quick removal and installation of currently available quick-change platform.
NOTE: SPM20 Models require the installation of the Quick-Change mount kit to use Quick-
Chang Platforms.
1. Upper Platform Mount
2. Upper Mount Fasteners
3. Lower Platform Mount
4. Lower Mount Fasteners
Platform Removal
1. Remove the platform control console from the platform and lay aside.
2. Remove both upper and lower mount fasteners securing the platform support rails to the mast mounting channels.
3. Swing and lift the platform out of the mounts and lay aside.
Platform Installation
1. Set platform in upper and lower mounts.
2. Install mount fasteners in upper and lower mounts.
3. Attach platform control console to platform rail.
WARNING
ENSURE
ALL
FASTENERS
ARE
INSTALLED
AND
SECURE PRIOR
TO OPERATION.
34
3.11 TRANSPORTING, LIFTING
General
AND TIE
DOWN
PROCEDURES
All SPM20 Series Model Personnel Lifts may be transported to a work site using the following methods:
Driving the machine around on its base wheels if travel surface area permits.
Loaded, IN AN UPRIGHT POSITION ONLY onto a heavy-duty vehicle with the payload
capacity capable of supporting the full weight of the machine (Check machine gross weigh in the Operating Spec Chart at the beginning of this Section).
Moved with a forklift truck using the forklift pockets in the base frame.
Truck Transport
DO NOT OF
TRANSPORT
BATTERY
HYDRAULIC
THE
ACID
FROM
RESERVOIR.
CAUTION
MACHINE IN A HORIZONTAL POSITION
THE
BATTERIES
OR
HYDRAULIC
FLUID
DUE TO LEAKAGE FROM
THE
The machine may be winched onto a tilted roll-back truck bed (see important note following), which has been rolled back to ground level. Disengage the brakes and always winch (pull) from the mast (rear) end of the machine.
IMPORT
DO
NOT ATTEMPT TILTED THE THE
ROLL-BACK SPM20 MACHINES POWER MODULE COULD SUSTAIN SERIOUS UNIT
IS
PUSHED,
TO
DRIVE MACHINE ONTO,
TRUCK
OR
BED.
TOWED
AT
SPEEDS GREATER
ANT
OFF OF, OR
PUSH MACHINE ONTO
DAMAGE WHEN
THAN 2 MPH.
A
WHEN TOWING RE-ENGAGE
AND
READY
OR
WINCHING,
THE BRAKES
ONCE MACHINE
FOR TIE DOWN.
THE
MACHINE’S
BRAKES
IS IN PLACE
MUST
BE DISENGAGED.
WITH TRUCK
BED LEVEL
Machine Tie-Down
With machine in position to be tied down and brakes engaged, use the following guidelines for restraining the machine during transport.
IMPORT
USE OF CAUSE
1. Secure machine with an adequate chain attached through the tie down loops located at
2. The chain should be securely tightened with a force of approximately 100 lb. applied two
EXCESSIVE FORCE WHEN SECURING MACHINE (DRIVE WHEEL
DAMAGE TO THE
MACHINES DRIVE WHEEL
the front and rear of machine. (See Figure 3-11.)
feet from the pivot handle.
ANT
LOAD), CAN
COMPONENTS.
35
NOTE: Lifting devise must be capable of handling the gross weight of the machine, see the
Operating Specifications table at the beginning of this Section.
Fork-Lift Truck Transport
All SPM20 Model Lifts are equipped with wide forklift pockets running through the base frame. (See Figure 3-11.) This allows the machine to be either transported around a work area or lifted onto a higher level using a standard fork-lift truck.
NOTE: Fork-lift trucks must be capable of handling the gross weight of the machine, see the
Operating Specifications table at the beginning of this Section.
2
Figure
3-4.
Forklift Truck Lifting Pockets and Machine Tie Down Bar Locations.
2
3
1. Rear Tie-Down Loop 2. Fork Lift Pockets 3. Front Tie-Down Loop
36
4.1
GENERAL
SECTION
INFORMATION
4.
EMERGENCY PROCEDURES
This section explains the steps to be taken in case of an emergency situation during
operation.
4.2
EMERGENCY
Operator Unable to Control Machine
OPERATION
IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TO OPERATE OR CONTROL THE MACHINE:
1. Other personnel should operate the machine from ground controls only as required.
2. Only qualified personnel in the platform may use the platform controls. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION PROPERLY.
3. Cranes, forklift trucks or other equipment can be used to remove the platform occupant and stabilize motion of the machine.
Platform Caught Overhead
If the platform becomes jammed or snagged in overhead structures or equipment, rescue the platform occupant prior to freeing the machine.
4.3
INCIDENT
NOTIFICATION
The manufacturer must be notified immediately of any incident involving an SPM20 product. Even if no injury or property damage is evident, the factory should be contacted by telephone and provided with all necessary details.
Failure to notify the manufacturer of an incident involving a product within 48 hours of such
an occurrence may void any warranty consideration on that particular machine.
IMPORT
FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE AND TEST ALL
FUNCTIONS PLATFORM CONTROL DO
NOT LIFT
REPAIRED,
IF
FIRST FROM THE GROUND CONTROL STATION, THEN FROM THE
CONSOLE.
ABOVE 10
REQUIRED,
FT. (3M) UNTIL YOU
AND
THAT
ALL
ANT
ARE
SURE THAT
CONTROLS
ALL
ARE
OPERATING
DAMAGE
CORRECTLY.
HAS BEEN
37
SECTION
5.
GENERAL SPECIFICATIONS
AND OPERATOR
MAINTENANCE
5.1 INTRODUCTION
This section of the manual provides additional necessary information to the operator for
proper operation and maintenance of this machine.
The maintenance portion of this section is intended as information to assist the machine operator to perform daily maintenance tasks only, and does not replace the more thorough Preventive Maintenance and Inspection S
Other Publications Available Specific to this Machine:
Service and Maintenance Manual
Illustrated Parts Manual
5.2
GENERAL
Machine Specifications
SPECIFICATION
Gross Machine Weight (Platform
Empty):
Machine Height (Platform Stowed): 2100mm
Maximum Ground Bearing Pressure: (per wheel)
Maximum Operating Incline:
Maximum Travel Grade (Grade ability): (Platform STOWED ONLY)
Maximum Travel Grade (Side Slope): (Platform STOWED ONLY)
Maximum Drive Speeds (Operator
Variable):
Maximum Base Overall: (Width Length)
Maximum Wind Speed:
Maximum Horizontal Manual Side Force:
SPECIFICATIONS
chedule inc
x
luded in the Service and Maintenance Manual.
SPM20
1050kg
360kg
1.0
°
15-20%
5
°
1.1- 4.0 km/h
76cm x 136cm
0 km/h-Machine rated for indoor use only
200 N
Maximum Hydraulic System Pressure: (Recommended initial
setting)
Hydraulic Reservoir Capacity:
12MPa
5L
38
Machine Dimension
Model
SPM20
Max. platform
height
mm mm kg
6000
Max. working
height
7700 150
Rated load
The number of
persons allowed
on platform
Person(s)
Platform
size AxB
mm mm
1
695x800 1360x800x2096
Stored
dimension
LxWxH
39
SPM 2 0 Machine Operating Area
SPECIFICATION
SPM20,
System Voltage:
24 Volts DC
Battery Specifications: Battery Type:
V
oltage:
Amp Hour (AH) Rating:
12 Volts DC
100 Amp Hr. @20Hr.
Battery Charger (DC Models) Input:
Output:
120/240 Volts AC-50/60 Hz –Voltage Selectable
24 volt, 20 Amp Output – with 2 Amp Finish
Electrical Specifications
40
Platform Data
SPECIFICATION
Occupants: (Persons allowed in Platform)
Maximum Work Load Standard:
Platform Height – Mast Fully Extended
(Ground to Platform Floor):
Platform Cycle Performance: Lift Up:
(in seconds, rated load ) Lift Down:
SPM20
1
150kg
6 m
27-36 sec.
30-35 sec.
Machine Component Weights
SPECIFICATION
Platform : Standard Platform:
(Quick-Change Platforms)
Battery: (per battery)
SPM20
32kg
20kg
Serial Number Locations
For machine identification, a serial number plate is affixed to the machine. The plate is located on the back of the mast, just above the mast support bracket.
5.3
OPERATOR
MAINTENANCE
Lubrication
Hydraulic Oil (HO)
HYDRAULIC
OPERATING TEMPERATURE
+0° F to +180° F (-18° C -83°C )
+0° F to +210° F (-18° C -99°C ) 10W-20, 10W-30
+0° F to +210° F (-18°C - 99°C) 20W-20
SYSTEM
RANGE
SAE
VISCOSITY
GRADE
10W
Hydraulic oils must have anti-wear qualities, and sufficient chemical stability for mobile hydraulic system service. The manufacturer recommends Mobil fluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152.
For cold weather applications, i.e. When temperatures remain consistently below +20 ° F (­7 c ) T he manufacturer recommends using Mobil DTE 13 hydraulic oil.
Aside from The manufacturers recommendations, it is not ad
visable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobil fluid 424 is desired, contact the manufacturer for proper recommendations.
41
Hydraulic Diagram (SPM20)
42
ITEM
KEY
SPECIFICATIONS
MPG-
Multipurpose Grease having a minimum dripping point of 350 ° F. Excellent wat er resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.)
EPGL-
Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or MIL -Spec MIL –L-
2105.
HO-
Hydraulic Oil. ISO-Vg grade 32, 46.
CL-
Chain Lube. Use a good quality chain lubricant
Table 5-1. – Lubrication Specifications
NOTE:
Refer to Lubrication Chart, Table 5-2 for specific lubrication locations on machine
Table
5-2.
Lubrication Intervals for Various Components
COMPONENT
Hydraulic oil
1
Fill the
NO/
Reservoir HO-Check Hyd.
(a)
TYPE
LUBE
POINTS
LUBE/METHOD
Oil
Level
HO-Change Hyd.
Oil
3
MONTHS 6 MONTHS 1 YEAR 2 YEARS
INTERVAL
Caster
2
Axles 2-
Grease
Fittings MPG-Pressure
Gun
(b)
COMMENTS
Check fluid level every day. (c)
Change hydraulic oil
every 1 year.
43
3
Swivel Raceways
2-Front
Casters
MPG-Pressure
Gun
4
Mast Chains
2-Per Mast
Section
CL-Brush or
Spray
Inspect,
lubricate if
dry or rusting.
Key to Lubricants: MPG- Multipurpose Grease
HO- Hydraulic Oil – ISO-Vg grade 32, 46. CL- Chain Lube. Use a good quality chain lubricant
Notes: (a) Be certain to lubricate like items on each side of the machine.
(b) Recommended lubricating intervals are based on normal use. If machine is subjected
to severe operating conditions, such as a high number of cycles, location, corrosive/dirty environment, etc., user must adjust lubricating requirements accordingly. (c) Prior to checking hydraulic oil level, operate machine through one complete cycle of lift function (full up and down). Failure to do so will result in incorrect oil level reading on the hydraulic reservoir.
44
Date
Comments
SECTION
6.
INSPECTION
Machine Serial Number:
Table
6-1.
Inspection and Repair Log
AND
REPAIR LOG
45
Date
Comments
Table
6-1.
Inspection and Repair Log
46
BATTERY WARNING
Battery posts,
terminals and related accessories contain lead and
lead compounds, chemicals known to cause cancer
and reproductive harm.
Batteries also contain other harmful chemicals.
WASH
HANDS AFTER HANDLING!
Local Distributor / Lokaler Vertiebshändler / Distributeur local
El Distribuidor local / ll Distributore locale
EUROPE, MIDDLE EAST
AFRICA & ASIA
PHONE: +44 (0) 845 1550 058
FAX: +44 (0) 845 1557 756
NORTH & SOUTH AMERICA
PHONE: +1 785 989 3000
TOLL FREE: +1 800 225 0317
FAX: +1 785 989 3070
AUSTRALIA
PHONE: +611300 700 450
FAX: +61 2 9609 3057
NEW ZEALAND
PHONE: +64 6 3689 168
FAX: +64 6 3689 164
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