NIFTYLIFT HR21 4x4 Operating/Safety Instructions Manual Download

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Height

rider

Operating & Safety Instructions

MODEL HR21 SERIES

MK2

Manufactured by:

Niftylift Limited

Chalkdell Drive

Shenley Wood

Milton Keynes

MK5 6GF

England

www.niftylift.com

e-mail: [email protected]

Tel: +44 (0)1908 223456

Fax: +44 (0)1908 312733

M50541/03

Summary of Contents for HR21 4x4

Page 1: ...der Operating Safety Instructions MODEL HR21 SERIES MK2 Manufactured by Niftylift Limited Chalkdell Drive Shenley Wood Milton Keynes MK5 6GF England www niftylift com e mail info niftylift com Tel 44...

Page 2: ...fixed object and cage overload has disabled the machine move machine slightly using steps 1 2 The overload alarm and visual warning will cease and normal controls are available 4 Restart engine with s...

Page 3: ...PARATION FOR USE 14 3 3 PRE OPERATIONAL SAFETY CHECK SCHEDULES 15 3 4 PLACARD DECALS INSTALLATION UK SPEC 18 3 5 TORQUE REQUIREMENTS 21 4 Operation 22 4 1 CONTROL CIRCUIT COMPONENTS 22 4 2 GROUND CONT...

Page 4: ...e machine are strictly forbidden One of the most important facts to remember is that any equipment is only as safe as those who operate it DANGER WARNING CAUTION IMPORTANT INSTRUCTIONS AND NOTICE Any...

Page 5: ...enley Wood Milton Keynes MK5 6GF Great Britain Tel 44 0 1908 223456Fax 44 0 1908 312733 Niftylift Inc 1525 S Buncombe Road Greer SC 29651 USA Tel 01 864 968 8881Fax 01 864 968 8836 Nifty Pty Ltd 11 Ke...

Page 6: ...HEELBASE 2 30m 7ft 6in TURNING RADIUS OUTSIDE 3 89m 12ft 9in TURRET ROTATION 3550 TURRET TAIL SWING 0 45m 1ft 6in TRAVEL SPEED 0 6 0kph 0 3 7mph PLATFORM SIZE 1 80m x 0 85m 5ft 11in x 2ft 9in HYDRAULI...

Page 7: ...ons English USA 07 17 Original instructions 5 1 5 IDENTIFICATION UK PLATE This manufacturer s plate is attached to the chassis on each machine at the time of manufacture on every Niftylift Please ensu...

Page 8: ...ns English USA 07 17 Original instructions 6 1 5a IDENTIFICATION USA PLATE This manufacturer s plate is attached to the chassis on each machine at the time of manufacture on every Niftylift Please ens...

Page 9: ...Height Rider SP Series Operating Safety Instructions English USA 07 17 Original instructions 7 1 6 EC DECLARATION OF CONFORMITY Typical...

Page 10: ...the beginning of each shift the Niftylift shall be given a visual inspection and functional test including but not limited to operating and emergency controls safety devices personal protective cloth...

Page 11: ...ntering the platform ensure that the drop down entry bar is closed afterwards 2 1 14 Use of an approved full body harness and short lanyard hard hat and appropriate safety clothing is mandatory Fasten...

Page 12: ...ersonnel 2 1 25 The aerial platform shall not be driven on grades side slopes or ramps exceeding those for which the aerial platform is rated by the manufacturer 2 1 26 It shall be the responsibility...

Page 13: ...ucted e g by tools or equipment and clear access to the Emergency Stop is available at all times 2 1 43 All persons in the cage must take suitable precautions to prevent items falling or being ejected...

Page 14: ...or labels should be removed All standard Niftylift machines are rated for a wind speed of 12 5 m s which equates to 45kph 28mph or force 6 on the Beaufort scale No attempt should be made to operate a...

Page 15: ...h individual machine is then subjected to static overload tests on flat level ground with 150 of the SWL exceeding the requirements of BS EN280 2013 for power operated MEWPs Self propelled machines ar...

Page 16: ...out the Pre operational Report Refer to Section 6 3 before placing machine in service 3 2 PREPARATION FOR USE Whilst every effort has been made at the Niftylift factory to ensure your machine arrives...

Page 17: ...control levers are secure and operate freely 8 Check that operating buttons and emergency stop buttons function correctly 9 Check the operation of the manual hand pump 10 Visually inspect all hydraul...

Page 18: ...for wear 5 Check that slew ring bolts are secure torque 218ft lbs 295Nm Toughcage Niftylift toughcage is fully UV stabilised for outdoor use in the most demanding climates However the user and machine...

Page 19: ...N IRAN AUSTRALIA WESTERN SOUTH QUEENSLAND 7 years NORTH AFRICA SAUDI DUBAI AUSTRALIA NORTHERN TERRITORY 6 years Note The date of manufacture of the toughcage floor is located on its underside Niftylif...

Page 20: ...ating Instructions P14892 1 15 Chain Inspection P16535 1 16 Hydraulic Levers Base P29667 1 17 Manual Descent P29668 1 18 Hydraulic Oil Low Temperature Bio Oil P14415 P23622 1 1 19 Pressurised tank P16...

Page 21: ...ift com P14389 1 45 Travel Direction P29066 2 46 Hazard tape N A N A 47 Power to Cage Socket 240V P26427 2 48 Power to Cage Socket 110V P26426 2 49 Generator to cage Option P28828 1 50 Compliance stat...

Page 22: ...Height Rider SP Series Operating Safety Instructions English USA 07 17 Original instructions 20...

Page 23: ...based on the following assumptions 1 Bolts to ISO 898 1 Mechanical properties of fasteners made of carbon steel and alloy steel 2 For unplated bolts all grades Hex head bolts Black oxide steel bolt w...

Page 24: ...to disable both the beacon and sounder If a safety critical situation occurs the sounder will emit a ricochet sound to alert the user and nearby personnel This warning occurs even if the motion sound...

Page 25: ...using the Joystick See Section 4 3 1 In addition the Brake Release Valve BRV is also incorporated into this valve block It is a solenoid operated valve which controls the brake function on the machine...

Page 26: ...n Twist to Enable Operation 2 Green Power Button Push and hold for Power Release to Cease operation 3 Base Platform Selector Clockwise for Platform Centre for Base 0 for all power off 4 Engine Glow St...

Page 27: ...ops are out and engine battery disconnect knob is turned fully clockwise 2 Turn key switch at ground control station to Ground Single turn clockwise 3 For Battery powered operation go to step 7 4 For...

Page 28: ...ols fail the cage overload is activated due to contact with a fixed object or a cage operator is incapacitated the booms can be operated from the base location as described below If normal controls ar...

Page 29: ...ontrol is returned to its neutral position and a deliberate action is taken to move the function after the green button or footswitch is pressed 3 Joystick Trigger timeout warning If the joystick trig...

Page 30: ...Up for Tele In Down for Tele Out 15 Operates the Flyboom Up for Up Down for Down 16 Generator switch Option Turn Clockwise to activate generator More than one function can be operated at the same tim...

Page 31: ...condition has been detected the safety warning lamp on the Platform Control Panel and Base Control Panel will also illuminate Advisory Main screen Release E Stop Machine will not operate as one or bo...

Page 32: ...tform controls selector switch located on ground controls must be turned clockwise Refer to Section 4 2 1 Item 3 Generator Generator is switched on and in use Auxiliary Auxiliary power is in use Statu...

Page 33: ...ror Red Critical error Press Button 1 for further information 4 3 4 MENU SCREENS DIAGNOSTICS To access this screen press button 1 This displays options to access Error Codes Software Version Joystick...

Page 34: ...hilst operating any cage control paddle The coloured squares on the screen should move in the same direction as the paddle Safety Switches A GREY square indicates that particular machine function is n...

Page 35: ...tylift will supply a code which must be entered by using the arrow keys SETTINGS To access this screen press button 4 Beacon Sounder Select Language and Cage Rotate Ground Controls ONLY options are di...

Page 36: ...e a language for the menu screens Cage Rotate Ground Controls Only This allows the operator to rotate the cage from the Ground Controls Push and hold green power button on the ground control panel Pre...

Page 37: ...turn the Diesel Glow Start selector to the Start position clockwise and the engine will fire Note Unless the diesel engine is running the HR21 Hybrid will automatically default to the electrical power...

Page 38: ...not operate the drive function If the engine is running it will stop once the override button is pressed 4 3 6 SiOPSTM LOAD SENSING CONSOLE WHEN OPERATING THIS MACHINE THE USER MUST BE AWARE OF ANY O...

Page 39: ...peed drive on to level ground 100 then release and reactivate the joystick or footswitch 4 Select drive joystick from the platform control panel Push forward for FORWARD DRIVE Pull backwards for REVER...

Page 40: ...of the safe working limit The design of the unit meets the requirements of both BS EN 280 and ISO 13849 with a safety integrity level of Category 3 PL d Refer to Appendix A The current load in the ca...

Page 41: ...automatically switch off once the batteries are fully charged It is recommended to reconnect the charger to a suitable power supply when the machine is not in use to maintain good battery condition Ch...

Page 42: ...ied the charger will restart automatically Attention should also be given to the use of extension cables as power leads Excessive cable lengths from the supply point to the battery charger will result...

Page 43: ...recovery has been achieved BATTERY CONTROLLER This machine is fitted with a Battery Management System that monitors battery condition A main component of this is the Battery Controller Unit If for any...

Page 44: ...and to ensure that creepage during transport does not permit the machine to come into contact with other goods being shipped or the container itself Some movement of the machine structure might occur...

Page 45: ...er to the relevant procedure for disengagement of the gearboxes GEARBOX DISENGAGEMENT TYPE 1 The drive gearboxes located on the front and rear wheel hubs must be disengaged as follows 1 To disengage t...

Page 46: ...gearbox drive is free to engage before pushing the pin home If necessary jack up each wheel rotate slightly to allow re engagement of pin 4 7 3 CRANEAGE 1 Observe all of the limitations relating to st...

Page 47: ...ll safety devices and controls operate in accordance with the instructions 8 If necessary perform a load test to establish the machine stability before putting the machine to work 9 On completion of a...

Page 48: ...n the fastest method of lowering the platform to the ground Note If the machine is fitted with a cage overload system and the cage comes into contact with a fixed object whilst operating at height thi...

Page 49: ...important step is required so that any relevant Technical Bulletins are able to reach the registered owner of each machine without delay Please note warranties are not transferable 6 2 MANUAL OF RESPO...

Page 50: ...of suspension dampers Pivot pins and swing bolts secure BASE Operation of Emergency Stop button Operation of Base control valve and buttons Operation of all booms over full range Platform maintains l...

Page 51: ...manufacturers Operating Manual as supplied All cables and terminals secure All hose connections secure Charger control box secure Battery secure Hydraulic oil level SLEWING Slew gearbox and motor are...

Page 52: ...Height Rider SP Series Operating Safety Instructions English USA 07 17 Original instructions 50 Comments remedial work required etc INSPECTED BY DATE...

Page 53: ...e Cage E Stop to the PLC Ensure contact blocks are securely in position Check Cage E Stop wiring from the switch contacts to the PLC 01A40000 There is an error with the signals from the Load Sensing s...

Page 54: ...ansducer 01AD0000 The drive pressure in elevated mode is too high Avoid sharp changes of direction Contact a Niftylift approved service centre 01B10000 The Links Paddle was out of the neutral position...

Page 55: ...00 The Drive Joystick was out of the neutral position before the Green Button or Footswitch was pressed Return the Drive Joystick to the neutral position and release the Green Button and Footswitch Pr...

Page 56: ...Remove objects that are obstructing the trigger Replace the drive joystick 01D30000 The Chassis Inclination Sensor is at an angle side to side across the machine that is too great to allow zero to be...

Page 57: ...is secure Replace the Telescope Paddle 01E60000 There is a problem with the signal from the Drive Joystick in the cage Return the Drive Joystick to neutral and attempt to operate the Joystick again C...

Page 58: ...ation interlock or Tilt System is PL c in accordance to with ISO 13849 1 2008 as required by BS EN 280 2013 A1 2015 1 The limits of the safety related parts to the category selected and any fault excl...

Page 59: ...will be available regardless of angle of inclination If the drive forward or backwards functions are selected when off the boom rest the output from the tilt sensor not being present will deny drive...

Page 60: ...not touch directly boards transducers and boxes with flushing or degreaser fluids under pressure Do not hole the board box Seal the box and or the panel who contains the electronic board to reveal an...

Page 61: ...maintenance and repair shall be given to ensure the continued justification of the fault exclusion s Do not alter modify or disable in any way the controls safety devices interlocks or any other part...

Page 62: ...e the complete item such as Safety Switch PLC or Hydraulic valve block Do not attempt to open the booms switches other than to check the condition of the wiring to the switches Do not attempt maintena...

Page 63: ...nal instructions 61 13 Information explaining the applications for use relevant to the category to which reference is made Not applicable 14 Checking test intervals where relevant Check the operation...

Page 64: ...icant than if the machine were stowed Reasonably foreseeable misuse 2 The limits of the SRP CS and any fault exclusion for which when essential for maintaining the selected category or categories and...

Page 65: ...being detected the alarm can be silenced by releasing the green button or footswitch Suspension of the function will continue until the overload has been safely removed 9 Control modes The load sensin...

Page 66: ...3 Press the base green button and observe that the machine is ready to function with no load in the cage Machine runs pump flow is available for machine functions 4 Select the Cage control position an...

Page 67: ...ooms move there is a previously undetected fault with the system and the Niftylift must not be used until this fault has been repaired Repair must be carried out by a competent person s with appropria...

Page 68: ...fects of deviations from the specified performance on the safety function s If the levelling system of the product does not function as intended the angle of the cage may not be maintained If the angl...

Page 69: ...of air from the hydraulic system if the product is left unused for long periods of time 11 Ease of accessibility and replacing of internal parts Replacement of parts should only be carried out by app...

Page 70: ...afety devices interlocks or any other part of the machine Maintenance must only be carried on by appropriately trained and competent persons who are conversant with all modes of operation speeds and c...

Page 71: ...ration of the load sensor system 1 Power on the Niftylift and select the base control location 2 Allow the power circuits to cycle and ensure the machine is ready for the command signal 3 Press the ba...

Page 72: ...be carried on by appropriately trained and competent persons 3 The effects of deviations from the specified performance on the safety function s If the load holding system of the product does not func...

Page 73: ...rom the hydraulic system if the product is left unused for long periods of time 11 Ease of accessibility and replacing of internal parts Replacement of parts should only be carried out by appropriatel...

Page 74: ...ine Maintenance must only be carried out by appropriately trained and competent persons who are conversant with all modes of operation speeds and characteristics of this model 3 The effects of deviati...

Page 75: ...iginal and supplied parts shall be used 12 Means for easy and safe trouble shooting To check the operation of the travel control interlock 1 Power on the Niftylift and select the cage control location...

Page 76: ...odes of operation speeds and characteristics of this model 3 The effects of deviations from the specified performance on the safety function s If the Emergency stop system does not function as intende...

Page 77: ...er fluids under pressure Do not pierce the board box Seal the box and or the panel who contains the electronic board to reveal any not authorized access or tampering 11 Ease of accessibility and repla...

Page 78: ...esting This two channel system must be proof tested to identify unrevealed failures every six months by a competent person with appropriate safety function experience Emergency stop system Test 1 1 Id...

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