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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