Boughton Power-Reach PR12 Manual

Engineering Limited
Document – S1005-ML-029 Issue 01 - May 2016
Operation & Maintenance Manual
Power-Reach
Skiploader
Incorporating Optional
Sheeting System

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Contents
If you are reading this manual as an electronic document, click on the contents
description to go to the relevant section. To return to the contents page click on return
to contents at the bottom of each page Page
Introduction……………………………………………………………………………....1
1. General Function and Limitations………………………………………………....2
2. Skiploader General Arrangement……………………………………………….... 5
3. Skiploader Weights & Dimensions………………………………..........….......... 6
4. Intacova Dimensions………………………………………………………………. 7
5. Main Control Valve Block Overview……………………………………………… 8
6. Remote Operation Hand Held Controller Overview……………………………. 10
7. Adjustable Skip Stops………………………………......................……………... 12
8. Warning Lights……………………………………………………………………... 13
9. General Safety Checks Prior to Operating…………………………………….... 16
10.Operating The Skiploader Equipment…………………………………………… 19
10.1. Loading a Skip…………………………………………………………… 21
10.2. Deploying Intacova Sheeting System…………………………………. 23
10.3. Retracting Intacova Sheeting System…………………………………. 24
10.4. Unloading a Skip………………………………………………………….25
10.5. Tipping a Skip……………………………………………………………..27
11. Maintenance………………………………………………………………………...30
Safety........................................................................................................... 30
Schedule………………………………………………………………………......31
Daily Checks by the Vehicle Operator (Driver)............................................. 31
Maintenance Schedule – Workshop............................................................. 31
Maintenance Procedure 1 – Check and Fill Hydraulic Tank………………....32
Maintenance Procedure 2 – Filter Check/Change………………………….... 33
Maintenance Procedure 3 – Chain Inspection………………………………... 34
Maintenance Procedure 4 - Grease Points…………………………………….35
Maintenance Procedure 5 – Grease Stabiliser Leg Stanchions……………..35
Maintenance Procedure 6 – Check Nut & Bolt Torque Values……………....36
Maintenance Procedure 7 – Renew Hydraulic Fluid…………………………. 37
Maintenance Procedure 8 – Remote Controller Maintenance……………… 38
12. Further Information…………………………………………………………….......39
© All rights reserved. This document remains the property of the author. Nothing in this publication
may be copied or distributed without the prior consent of Boughton Engineering Limited.

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Introduction
This manual has been produced, by Boughton Engineering Limited, to ensure that
users of the PR12 Skiploader have all the information required to operate the
equipment safely.
It is the responsibility of the operator’s management to ensure that all health and
safety requirements relating to the use of this equipment are assessed, and that all
personnel who use the equipment are aware of its functionality and limitations.
Only trained personnel should use this equipment.
This manual should be kept in a safe place in the vehicle cab. All users of the
equipment should be made aware of the location of the manual and should be
instructed to read through and familiarise themselves with its contents prior to
operating the equipment.
The following symbols have been used, in this publication, to bring certain items
relating to safety to the attention of the user of the equipment:-
Please take note of these symbols and take action to avoid unsafe operation of the
equipment.
The information contained in this manual is correct at the date of publication.
Boughton Engineering Limited reserves the right to modify the design and/or
construction of its products, at any time.
Highlights a risk to personnel or the general public which
could result in serious injury or death.
Highlights a risk to the equipment due to improper use.
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1. General Function and Limitations
The PR12 skiploader is designed for transporting materials contained in skips. The
equipment allows the operator to lift and load empty and loaded skips onto the bed of
the vehicle or lift and unload empty and loaded skips onto the ground.
In addition this equipment can be used to tip skips, provided that they have been
designed for this purpose.
NOTE: This equipment you are using has been supplied to meet your specific
requirements. Please ensure that only skips which meet the requirements of the
original specification are used with this equipment.
Before lifting ensure that the skip dimensions are compatible with the equipment and
that the skip is in sound condition.
Refer to CHEM TS14 – Skip Group B for guidance on the general dimensions for
skips which are suitable to be used with this equipment.
It is the responsibility of the user to determine the suitability of the equipment for
loading and unloading skips which deviate from the specifications contained in this
standard.
WARNING
Failure to observe the limitations of the equipment and using non
approved skips may result in serious injury and/or damage to the
equipment.
This equipment must never be used:-
•To carry persons or animals.
•To raise the vehicle to change a tyre or carry out any other
maintenance.
•To lift or pull any item other than approved skips.
The maximum permitted payload, for which this equipment is
approved to lift and carry, is quoted on the load plate.
Maximum transferable loads are quoted for lifting from ground
level.
For lifts below ground level the maximum transferable load will
decrease.
Your Skiploader has been individually load tested after fitting to
the chassis. It will operate with complete safety, provided the
maximum transferable load, quoted on the load plate, is not
exceeded.
Due to the variety of skip sizes that may be loaded, responsibility to ensure that the
vehicle axle loads remain within the limits specified by the chassis manufacture and
meet the requirements of any applicable legislation remains with the driver.
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MAX
TRANSFERABLE
6000 KG
AT GROUND LEVEL
MINIMUM REACH
MAX
TRANSFERABLE
3500 KG
AT GOUND LEVEL
MAXIMUM REACH
DO NOT EXCEED
PLATED AXLE
WEIGHTS OR
VEHICLE G.V.W.

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Note: The equipment maximum transferable loads, quoted on the load plate, may
exceed the maximum payload for which the vehicle is plated. Do not drive the vehicle
on the highway if there is any doubt that the payload is within the limits required for
the vehicle to operate legally.
Failure to observe plated and legislated axle loads may result in prosecution and /or
damage to the vehicle.
WARNING
Failure to observe the maximum permitted payload and/or plated
axle loads may result in instability of the equipment during loading
and unloading and/or instability of the vehicle when driving. Serious
injury or damage to the vehicle or skiploader equipment may result.
This manual also includes operating instructions for the Boughton Engineering
Limited’s Intacova sheeting system. This system is optional and may not be fitted to
all vehicles.
The Intacova sheeting system is designed to make sheeting of loaded skips a quick
and safe operation. Sheeting of the load is achieved remotely via the control block.
Loaded skips should be sheeted to ensure that the contents remain within the skip
during operation on the highway.
Boughton Engineering Limited has designed and manufactured this equipment to
meet all relevant safety regulations. The equipment design has taken into account
ease of operation and maintenance, conforms to the requirements of the EU
Machineries Directive 2006/42/EC and is CE marked in accordance with this
directive.
This machinery emits A-weighted sound power up to a maximum
level of 110 dB measured by tests laid down in SI 2001/170.
It is recommended that, when operating this equipment for
prolonged periods, ear defenders are worn.
WARNING
Always keep clear of moving parts when the skiploader equipment is
operating. Failure to observe this warning may result in serious
injury from pinching and crushing hazards.
As with all machinery, during operation there are moving parts which pose a risk of
pinching or crushing. Always apply the clearance zone rule, Section 9 point 3, when
operating the equipment, to ensure that any risk to the public or animals is limited.
The operator of the equipment should also consider pinching and crushing hazards
and keep clear of all moving parts.
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Any maintenance required on the skiploader equipment should be carried out by a
qualified technician.
Spare parts used during repair and maintenance procedures must be approved by
Boughton Engineering Limited.
Please refer to the equipment maintenance section of this manual, Section 10, and
spare parts catalogue S1005-ML-032 for information on procedures for maintaining
the equipment in a safe operational condition.
WARNING
Correct maintenance of this equipment is essential for safe
operation. Always maintain the equipment to the schedule
prescribed in the maintenance manual.
NEVER operate the equipment if there is a known fault. Take the
vehicle out of service and affect a repair before returning into
service.
ALWAYS use approved spares and recommended fluids and
lubricants. Non approved items may seriously affect the
performance and will increase the risk of a failure which may result
in serious injury or damage to the equipment.
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2. Skiploader General Arrangement
* All skiploaders will have flat feet (Pad) rear stabilisers fitted unless the chassis is fitted with front axle
parking brakes, in which case, roller stabilisers can be fitted
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Access Cover
Main Control
Valve Block
Hydraulic Fluid Tank
Intacova Sheeting System
(Optional)
Telescopic Lifting Arm
Main Lifting Arm
Stabiliser – Option Roller*
Access Ladder (Both Sides)
Lift Chain Stowage
Tiphooks
Adjustable Skip Stops - Front
Adjustable Skip Stops - Lateral
Main Lift Arm Hydraulic
Cylinder
Cab Guard
Load Bed
Stabiliser – Option Pad*

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3. Skiploader Weights & Dimension
Model: Power-Reach – PR12 (Standard Model Only)
`
A Bed Length (Standard equipment only) 3342 mm
B Height from top of chassis 1870 mm
C Arm extension 1370 mm
D Chassis cut-off to load centre 1966 mm
E Overall length 4510 mm
F Chassis cut-off to stabiliser (raised) 254 mm
G Bed width 1950 mm
H Distance between lift arms 2026 mm
J Distance between tip hook centres 610 mm
K Overall width 2460 mm
L Overall height from top of chassis to top of cab guard 1718 mm
M Chassis bed height 313 mm
N Top of chassis to stabiliser (raised) 555 mm
P Top of chassis to stabiliser (lowered) 961 mm
Q Maximum lift from below ground 2568 mm
R Load arm angle of rotation 142°
S Cab guard overhang 390 mm
Weight of Skiploader including PTO/Pump and hydraulic
oil (excluding sheeting system)
2500kg
Safe working load (SWL) - arms in 6000kg
Safe working load (SWL) - arms out
3500kg
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4. Intacova Dimensions
The information in this section relates to the Intacova sheeting system. This system
is an optional fitment and may not be installed on all vehicles.
IntaCova Dimensions
A Height from top of chassis 2002 mm
B Maximum width 2456 mm
C Main arm maximum radius 3120 mm
D Secondary arm radius 1376 mm
Cycle Times
To sheet at 1500rpm
22 seconds
To unsheet at 1500rpm
28 seconds
Container Sheeting Range
4yd³ (3.06m³) - 16yd³ (12.23m³)
Containers should comply with C.H.E.M. standards
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5. Main Control Valve Block Overview
The skiploader equipment is operated using the hydraulic control block situated on
the vehicle offset behind the cab.
Lever A – Hold to run lever - must be in either the up or down position when
operating the equipment.
Note:All levers operate on the dead man principle and return to the neutral position if
released. To activate any of the controls the user must apply pressure to leverAat all
times.
Levers H and Ioperate the Intacova sheeting system. These levers will not be
present if the Intacova system is not fitted to your vehicle.
Standard Control Functions – Levers B, D, E, F & G
Levers - A B C D E F G H I
Lever
Up
Lever
Down
Lever B
Main
Arms
Lever D
Telescopic
Arm - LH
Lever E
Telescopic
Arm - RH
Lever F
Stabiliser
LH
Lever G
Stabiliser
RH
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Note: When extending or retracting the telescopic arms and stabiliser legs operate
both levers at the same time to synchronise left and right sides. Fine tune to level off
by operating one or other lever.
Standard Control Functions – Lever C
Lever C will raise and lower the tip hooks. When tipping the tip hooks must be in the
raised position. For all other operations the tip hooks must be lowered.
Optional Control Functions – Levers H & I
Levers H & I are only present on the control panel if the optional Intacova sheeting
system is fitted to the vehicle.
Lever
Up
Lever
Down
Lever H
Sheeter Main
Arms
Lever I
Sheeter Secondary
Arms
Operate Levers Together To
Synchronise.
Lever Up
To Raise
Lever Down
To Lower
TIP HOOKS
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6. Remote Operation Hand Held Controller Overview
The Boughton remote operation hand held controller is an optional system which
may not be fitted to your vehicle.
The Boughton remote operation hand held controller is a portable wireless unit which
can be used to operate all skiploader functions with the exception of the tiphooks.
Tiphooks must be operated using the hand operated body mounted control.
Remote Control Main Controls
1 - Start Button
2 - Emergency Stop Button
3 - Hold to Run Button
4 - Push Button Keypad
5 - Sheeting System Toggle - Main Arms
6 - Sheeting System Toggle - SecondaryArms
7 - Indicator LED
8 - Indicator LED
Item 4 - Push Button Keypad Functions
Right Button Functions
Main Arms - Load
TelescopicArm - Retract Both
TelescopicArm - Right (OS)-Extend
TelescopicArm - Right (OS)-Retract
Stabiliser - Right (NS) - Retract
Stabiliser- Right (OS-Retract
Left Button Functions
Main Arms - Off Load
TelescopicArm - Extend Both
TelescopicArm - Left (NS)-Extend
TelescopicArm - Left (NS)-Retract
Stabiliser - Left (NS)-Extend
Stabiliser- Left (OS)-Extend
5
1
2
6
3
4
7
8
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All buttons operate the equipment at a single speed with the button depressed either
halfway or fully.
A summary of the skiploader functions, operated by the push buttons, are detailed
below:-
Items 5 & 6 - Toggle Switch Functions (Where Fitted)
Main
Arms
Telescopic
Arm - Left
Telescopic
Arm - Right
Stabiliser
Left
Stabiliser
Right
Offload
Telescopic
Arm -
Extend
Extend
Extend
Extend
Extend
Retract
Retract
Retract
Retract
Retract
Load
Sheeting
System
Main Arms
Sheeting
System
Secondary
Arms
Retract
Extend
Retract
Extend
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7. Adjustable Skip Stops
This vehicle is fitted with sockets towards the front and along the sides of the load
platform.
Six skip stop blocks are supplied with the vehicle, two for positioning at the front of
the platform and two pairs for positioning down the sides.
The skip stops, when fitted, restrain any potential forward or sideways movement of
any skip loaded onto the vehicle.
Each stop is asymmetrical giving two stop positions for each socket depending on
which way around the stop is inserted into the socket.
For the front stops there are effectively 6 positions.
For the side stops there are effectively 6 positions.
Side skip stop positions should be chosen so that the guides are the tightest
practical fit to the width of the skip
Front stop positions should be chosen to ensure that if a skip shifts forward on the
platform no part of the skip can come in contact with the cab guard at the front of the
load bed.
Adjustable Front Skip Stops
Adjustable Lateral Skip Stops
Skip Stop Width and
Length Options
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8. Warning Lights
WARNING
It is the drivers’ responsibility to always ensure that the vehicle is
operated within overall heights specified on the vehicle height notice
located in the cab.
Failure to ensure that the vehicle height is within this limit may result
in a collision which may cause damage to the vehicle and/or other
structure.
Always ensure that, before driving on the highway, all warning lamps
are extinguished.
A warning system is fitted to advise drivers when the skiploader equipment has not
been returned to the correct position to give the minimum travel height.
The warning system also indicates when the rear stabilisers have not been retracted
to a safe driving position
Note: The minimum travel height is the height of the skiploader equipment with the
telescopic arms fully retracted and the main arms in the fully down position. The
height quoted on the vehicle height notice, located in the vehicle cab, relates to the
equipment when at the minimum travel height.
Operating the vehicle outside the overall height limit specified on the vehicle height
notice may result in prosecution.
A single warning light is located either within the cab dashboard display or as a
separate light positioned on the dash (exact location is dependent on the base
vehicle make and model).
The warning lamp will illuminate when sensors detect:-
1. Stabiliser feet not in fully raised position.
2. Telescopic arms not in fully retracted position.
3. Main arms not in fully down position.
If the warning light illuminates the vehicle driver should leave the cab and ascertain
which of the above items is out of position.
The vehicle is fitted with a display, located on the front of the skiploader bulkhead,
indicating which item(s) is out of position.
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The driver should check the display to see which lights are illuminated, indicating an
item out of position.
Note: The pressure switch lamp is illuminated when a signal is sent to set auto revs
when operating the equipment. When illuminated this lamp does not indicate that the
equipment is out of its minimum height position and does not indicate that there is a
fault with the system.
The driver should engage the power take off (P.T.O) and using the appropriate lever,
see section 5. , operate the equipment to reposition the item(s) indicated by the
display warning light.
When all the lights are extinguished, on the body warning light module, the driver
should check to see that the in cab warning light is also extinguished.
A further visual check of the equipment must be made, by the driver, before the
vehicle is driven on the highway.
Always ensure that the vehicle is not driven on the highway until all of the warning
lamps have been extinguished and the P.T.O is disengaged.
It is recommended that the vehicle driver carries out a check when the equipment
has been operated and:-
a) the P.T.O is engaged.
b) the stabilisers are extended
c) the telescopic arms are extended
d) the main arms are rotated to the rear.
Location of Body
Warning Light Module
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With the equipment in this state check the body warning light module display, located
on the front of the skiploader bulkhead. All lights on the display must be illuminated
indicating that the auto revs signal is active and all of the proximity sensors are
detecting equipment is out of the minimum travel height position.
In addition check the in cab warning light. If operating correctly this light must also be
illuminated.
If any light fails to illuminate the vehicle should be taken for repair by a qualified
technician.
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9.General Safety Checks Prior To Operating
WARNING
NEVER operate the equipment if there is a known fault. Take the
vehicle out of service and affect a repair before returning into
service.
Only qualified technicians should carry out repair of faulty
equipment.
Continued use of faulty equipment may result in serious injury, death
or damage to the equipment.
When operating the skiploader equipment it is essential that all precautions are
taken to ensure the safety of the driver and the general public.
Operators of commercial vehicles will have procedures in place to minimize risks.
These procedures should always be followed. In addition the following safety checks
are specific to skiploader operations and should be carried out prior to any lifting
operations:-
1. A general visual inspect of the skiploader equipment should be undertaken.
Walk around the vehicle looking for any signs of damage to components.
Look for patches of fluid under the vehicle. If fresh fluid is detected inspect the
vehicle in the area above the patch to see if there are any leaks.
If damage or leaks are detected take the vehicle for repair by a qualified
technician.
2. Before loading or unloading a skip check the ground onto which the vehicle
must drive to ensure it is stable enough to support the loads imposed through
the stabilising legs.
The ground should be essentially level although the stabilising jacks will level
off a limited amount of inconsistency. Excessive slopes may result in an
unstable lift.
3. Ensure that the area around the skip is clear. DO NOT carry out a loading or
unloading operation if any person or animal is close to the vehicle or skip. It is
recommended that a 1.5 metre clearance zone around vehicle and skip is
applied.
Clearance Zone
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4. Check the area above the vehicle and lifting equipment. DO NOT lift if there is
any risk of a collision.
5. When unloading, ensure that there is adequate space to accommodate the
skip. To reduce the risk of a crushing hazard it is recommended that there is
space all around the skip when unloaded.
6. Check the skip prior to lifting to ensure that it is in sound condition. Take
particular note of the condition of the lifting lugs and, if tipping, the tipping bar.
If loaded check that the load is safely inside the skip and cannot fall out during
the lift.
It is the operator’s responsibility to ensure that a skip is not overloaded. Check
the skip load. If there is any doubt that the skip may be overloaded DO NOT
attempt a lift.
7. Check the lifting chains to ensure that they are in sound condition. Make sure
that the chains are not knotted or twisted.
WARNING
Lift chains are critical safety components.
DO NOT attempt to modify the lift chains by changing their length.
DO NOT attempt repair of chains by cutting or welding.
If a chain is damaged or worn beyond usable limits it must be
replaced.
Serious injury and/or damage to the vehicle may result from using
damaged or worn lift chains.
Refer to Maintenance Procedure 3 for details relating to the inspection of the
lift chains.
8. Where a vehicle is fitted with an optional remote operation hand held
controller the following procedures must be followed:-
8.1. Before proceeding to the operating instructions, which follow, operators
must familiarise themselves with the location and function of each
button/switch as described in the overview section above.
8.2. Operator must leave the vehicle cab after engaging the PTO and
ensuring that the remote control system switch is in the "REMOTE"
position. Operators must remain outside the vehicle during any
skiploader operation.
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