CTE PIANOPLAN 600 J SPEEDY STANDARD User manual

Operator’s and maintenance manual
PIANOPLAN 600 J
SPEEDY STANDARD
CODE
504196-UK ED. 06/09
SERIAL NUMBER ____________

Operator’s and Maintenance Manual
Pianoplan 600 J Speedy Standard
CODE
504196
2
Dear Customer,
Congratulations for having purchased the Pianoplan.
Your new Pianoplan is able to transport loads up to 600 Kg on flights of stairs and
ramps, reducing the physical effort and the risk of accidents.
We are sure that your purchase, together with the correct use of the equipment, will
benefit your company.
We kindly inform you that:
BEFORE USING THE PIANOPLAN, IT IS MANDATORY TO READ
AND UNDERSTAND THIS MANUAL AND TO IMPLEMENT THE
CONTENTS.
Yours faithfully,
CTE S.p.A.
Via Caproni, 7 – Z.I. 38068 ROVERETO (TN) -
ITALY
Tel. [phone] Fax [phone]
web: www.ctelift.com
e-mail: [e-mail]
OWNER :

Operator’s and Maintenance Manual
Pianoplan 600 J Speedy Standard
CODE
504196
3
Index
Preliminary information........................................................................................................... 5
-Content of the instructions ............................................................................................... 5
-Measures to take immediately ........................................................................................... 5
-Measures to take in case of re-sale ................................................................................... 5
- Use and retention of the manual ...................................................................................... 5
1. MANUFACTURE DATA OF THE MACHINE............................................................6
1.1. Address of the manufacturer..................................................................................... 6
1.2. Specification data ........................................................................................................ 6
1.3. Classification................................................................................................................ 6
1.4. After-sales and spare parts dept. ............................................................................... 7
2. GENERAL INFORMATION FOR THE SAFE USE OF THE MACHINE...........8
2.1. Explanation of the symbols and of their meaning ................................................. 8
2.1.1 Symbol: WARNING - DANGER 8
2.1.2 Indication: ATTENTION 8
2.1.3 Indication: NOTE 8
2.2. General safety .............................................................................................................. 8
2.3. General information for use...................................................................................... 9
2.3.1 Checks 10
2.3.2 Foreseen conditions of use and limits of exercise 10
2.3.3 Safety parts and systems 12
2.3.4 Maintenance and repair 13
2.3.5 Residual risk 14
2.3.6 Warnings for the implementation of the practical instructions 15
2.3.7 Referring rules and provisions of the law 16
3. TECHNICAL DATA ........................................................................................................ 17
3.1. Type: Pianoplan 600 J..............................................................................................17
3.2. Model: SPEEDY STANDARD .............................................................................17
3.3. Construction features ...............................................................................................17
4. DESCRIPTION OF THE MACHINE.......................................................................... 18
4.1. Mechanical components description ......................................................................18
4.2. Controls and movements description ....................................................................19

Operator’s and Maintenance Manual
Pianoplan 600 J Speedy Standard
CODE
504196
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5. MACHINE OPERATION............................................................................................... 21
5.1. Extension of the loading platform..........................................................................21
5.2. Steering bar positions ...............................................................................................21
5.3. Position of the load to transport.............................................................................22
5.4. Instructions to fasten the load.................................................................................23
5.5. Use of the loading platform.....................................................................................24
6. TRANSPORT OF THE LOAD ...................................................................................... 25
6.1. Manoeuvre of stairs climbing ..................................................................................25
6.2. Arriving on the landing ............................................................................................26
6.3. Manoeuvre on the landings......................................................................................26
6.4. Going down the stairs ..............................................................................................29
6.5. Arriving to the landing .............................................................................................29
6.6. Manoeuvre of independent steering.......................................................................31
6.7. Manoeuvre on flat surfaces......................................................................................31
7. INSTRUCTIONS TO CHARGE THE BATTERIES................................................. 32
8. TRANSPORT OF THE EQUIPMENT ........................................................................ 35
9. DISMANTLING ................................................................................................................ 35
10. MAINTENANCE .............................................................................................................. 36
10.1. Maintenance program...............................................................................................37
10.2. Summary table of maintenance ...............................................................................38
10.3. Checks to do before using the machine.................................................................40
10.4. Three-month checks.................................................................................................42
10.5. Annual checks............................................................................................................43
10.6. Placement of decals and plates................................................................................47
10.7. Repairs ........................................................................................................................48
11. HYDRAULIC SYSTEM.................................................................................................... 49
12. ELECTRICAL SYSTEM................................................................................................... 51

Operator’s and Maintenance Manual
Pianoplan 600 J Speedy Standard
CODE
504196
5
Preliminary information :
1. CONTENT OF THE INSTRUCTIONS:
In this manual you will find instructions regarding:
- appropriate use;
- residual risks;
- safety;
- use of the machine;
- routine maintenance;
- dismantling.
These instructions for the use and the maintenance contain important information that
will enable you to use the Pianoplan in a safe and appropriate way. These instructions
are particularly addressed to:
- the personnel employed in the use of the machine;
- the personnel employed in the routine maintenance.
2. MEASURES TO TAKE IMMEDIATELY:
Before starting to use the machine, carefully read these instructions, respecting all the
information and particularly the ones regarding the safety.
3. MEASURES TO TAKE IN CASE OF RE-SALE:
If you sell your Pianoplan, it is obligatory to hand over this manual, the maintenance
register and the list of the spare parts to the buyer. In case of loss, please ask for a
new/replacement manual from the supplier.
4. USE AND RETENTION OF THE MANUAL:
This manual is addressed to the following persons:
- the user of the machine;
- the supervisor of the working area;
- the person in charge of the transport of the equipment;
- the person in charge of the maintenance of the machine;
- the person in charge of the final dismantling.
A copy of the manual is supplied with the machine and must always be together with the
machine in order to consult it rapidly and in a precise way.
In the case you loose or damage this important document, contact immediately our Spare
Parts Department.
This manual must be considered as an integral part of the machine and must follow the
machine throughout its entire working life.
CTE S.p.A., Pianoplan manufacturer, reserves the right to update either the production
or the manuals, without any obligation of communication. The present manual reflects
the technical state of the product as of date of manual and is drawn up in compliance
with the EC Directive 98/37 (Machine Directive), attachment I, paragraph 1.7.4.

Operator’s and Maintenance Manual
Pianoplan 600 J Speedy Standard
CODE
504196
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1. MANUFACTURE DATA OF THE MACHINE
1.1. Address of the manufacturer
Your Pianoplan has been constructed by:
CTE S.p.A. Via Caproni, 7
38068 Rovereto - Trento - Italy
tel. [phone] - fax [phone]
1.2. Specification data
Under the steering bar, on the front part of the Pianoplan, you will find the specification
board with the specifications data.
1.3. Classification
The machine has a projected life of 10 years, comparable to 120,000 operating cycles with
a medium/high load rate (i.e. 10 years, 50 weeks per year, 40 hours per week, 6 cycles per
hour). Within the forecast number of years, the Pianoplan must be completely overhauled
and checked by the constructor. In case of particularly frequent use, the overhaul must be
anticipated. We advise you to check the machine each two years and to overhaul it each 5
years at least.

Operator’s and Maintenance Manual
Pianoplan 600 J Speedy Standard
CODE
504196
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1.4. After-sales and spare parts dept.
To order spare-parts or in case of assistance, please contact:
CTE ITALY
Spare-Parts Dept
CTE S.p.A.
After-Sales Dept
tel. [phone]
fax [phone]
[e-mail]
CTE UK
Spare-Parts Dept
CTE UK
After-Sales Dept
tel. [phone]
fax [phone]
[e-mail]
always indicating
Model
Serial number
Year of construction
of your Pianoplan

Operator’s and Maintenance Manual
Pianoplan 600 J Speedy Standard
CODE
504196
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2. G
ENERAL INFORMATION
FOR THE SAFE USE OF THE MACHINE
2.1. Explanation of the symbols and of their meaning
2.1.1 Symbol: WARNING - DANGER
This symbol is in front of all the safety signs for which there is a risk of an
accident that could result in a fatality.
Respect these indications and carefully follow the instructions given in the
safety manual.
2.1.2 Indication: ATTENTION
This indication informs you that you must stop or avoid damage to the
machine.
2.1.3 Indication: NOTE
This indication informs you about a favourable economical use of the machine
or refers to the correct work procedure.
2.2. General safety
In order to ensure the maximum levels of reliability, CTE has carefully chosen the
materials and the components used in the construction of the Pianoplan, making regular
tests and inspections before delivering. The efficiency of the machine also depends on a
good use and on correct preventive maintenance, according to the instructions written in
this manual.
All the constructed elements, couplers and controls have been designed and
manufactured to the highest standards, able to resist to normal working stress or in any
case superior to the one indicated in this manual. The materials are of the best quality and
the delivery procedure, storage and ultimate use in the assembly shop are controlled, in
order to guarantee lack of damage, deteriorations or malfunctions.
DANGER: the non-compliance of these SAFETY INSTRUCTIONS can
cause serious accidents or death.
The Pianoplan must be used by people who, thanks to their professional training, their
experience and understanding of the relative danger, are able to guarantee professional
and safe use.
These persons must have the following qualifications:
-to be 18 years old;
-to know the content of this manual;
-to be duly trained and instructed on the possible dangers and on the correct use;
-to be authorized to use this machine by a responsible person in the company.

Operator’s and Maintenance Manual
Pianoplan 600 J Speedy Standard
CODE
504196
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2.3. General information for use
DANGER! The non-
compliance of the instructions and of the safety rules
written in this manual, as well as the ones foreseen by the law for accident
prevention, can cause serious accidents or death.
Before using the Pianoplan, it is obligatory to read this manual.
Authorized persons, properly instructed and trained, must only use the
Pianoplan.
IT IS ABSOLUTELY PROHIBITED TO TRANSPORT PERSONS.
THE PIANOPLAN HAS ONLY BEEN CREATED TO TRANSPORT
MATERIAL WITH A MAXIMUM WEIGHT OF 600 KG.
Never allow unqualified or unauthorized persons to use the machine.
They could cause serious accidents.
Do not permit access in the working area to persons who are not
authorized or qualified for the use of the Pianoplan due to the danger of
loads falling down.
For the Health & Safety reasons, it is obligatory to restrict with
crush barriers the working area using ap
propriate equipment,
such as extensible safety barrier (white and red), plastic columns
with chains (white and red), signalling bands (white and red).
IT IS OBLIGATORY
to always dress suitably and to wear safety shoes.
Remove, loose fitting clothing a
nd objects such as rings and chains. There is the
risk of accident due to catching or dragging.
DANGER:
INCORRECT USE OF THE PIANOPLAN CAN CAUSE:
-Danger of accident or death for the operator and third parties;
-Damage to the Pianoplan and to other equipment.

Operator’s and Maintenance Manual
Pianoplan 600 J Speedy Standard
CODE
504196
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2.3.1 Checks
Before using the Pianoplan, it is obligatory to proceed with a series of checks and
maintenance indicated in this manual chapter 10.
The following people can do these checks:
-qualified workers
-mechanic chiefs
-specialists having the correct training
-mechanics of the CTE After-sales Dept.
The operator of the Pianoplan must conduct himself in a manner observing all safety
rules and regulations, always being aware of their own responsibility to themselves, the
machinery, property and others nearby. The Pianoplan must be thoroughly checked,
inspected and maintained in line with this manual and for the use in the country where
the machine is used.
2.3.2 Foreseen conditions of use and limits of exercise
IT IS OBLIGATORY to secure the load with the
belts and straps provided, and to centre the
barycentre of this load before operating.
THE OPERATOR MUST always be upstream of
the Pianoplan.
IT IS PROHIBITED to stay near the Pianoplan
or to stay below it.
IT IS PROHIBITED to go up and down the
stairs with more than 45 degrees inclination.
IT IS PROHIBITED to operate with wet belts on
wet stairs or with ice.
IT IS PROHIBITED to operate on a slippery
surface, on broken or wrap-around steps.

Operator’s and Maintenance Manual
Pianoplan 600 J Speedy Standard
CODE
504196
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IT IS OBLIGATORY to check the suitability,
integrity and load bearing of the stairs and of the
floor before operating. The Pianoplan weights 325
kg and can carry till 600 kg.
IT IS PROHIBITED to use the Pianoplan if the
ground surface is not strong enough to take the
weight. That is why, it is necessary to check the
integrity of the floor for trapdoors or drain covers
in the floor, in which case it is necessary to create, in
advance, a suitable surface for the stability of the
machine with the use of planks of wood, etc
IT IS PROHIBITED to carry persons.
THE PIANOPLAN CAN ONLY BE USED TO TRANSPORT
MATERIALS.
IT IS PROHIBITED to transport material with more than 600 Kg.
IT IS PROHIBITED
to stay in the working area of the Pianoplan due to the
possible danger of loads falling off.
IT IS PROHIBITED
to use the Pianoplan if visibility or lighting conditions are
insufficient.
IT IS PROHIBITED to use the Pianoplan in case of rain.
IT IS PROHIBITED to interfere with or to bridge the security systems such as:
limit switches, sensors or other devices. It is prohibited to move the protection
carters.
IT IS PROHIBITED
to move the Pianoplan if the Pianoplan, a part of it or the
load are a danger for people.
In case of a sudden danger for the personnel or for the machine, you can stop
the engine, pressing the emergency button.
IT IS PROHIBITED to use the Pianoplan if there are anomalies, damages or
structural insufficiencies verified during the daily analyses or during its use.
Stop immediately the Pianoplan and repair it thus not to compromise the
safety use.
The repair is only permitted to duly instructed and authorized personnel.
Please contact the nearest CTE After-Sales Dept.
IT IS PROHIBITED to use the Pianoplan in a potentially explosive
atmosphere.
IT IS PROHIBITED to use the Pianoplan with a temperature inferior to -
5°C
or superior to + 40°C.

Operator’s and Maintenance Manual
Pianoplan 600 J Speedy Standard
CODE
504196
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2.3.3 Safety parts and systems
The Pianoplan has safety parts and systems to avoid accidents to persons and damage to
objects.
-Emergency stop button
Pressing the emergency stop button, all the
controls stop.
-Micro switch for the control of the lifting platform
This system is inside the Pianoplan. The micro switch controls the locking of the lifting
platform. If the rollers are not completely inside, the red pilot light on the steering bar
(Fig. 4.2 Pos. 3) remains illuminated and if the driving manoeuvre is attempted an audible
warning alarm sounds.
-Negative electro-magnetic brake
On each drive motor of the Pianoplan there is a negative electro-magnetic brake. In case
of any electric damage or loss of energy, the machine and all the functions stop.
-Block valves
Each cylinder has a block valve. In case of hydraulic break, the machine and all the
functions stop.
-Safety start system
This system is inside the Pianoplan. When the manipulator is activated, during the
starting stroke, it is not possible to move and the system is blocked. The operator has to
release the manipulator to re-activate the systems.

Operator’s and Maintenance Manual
Pianoplan 600 J Speedy Standard
CODE
504196
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2.3.4 Maintenance and repair
DANGER! Before s
tarting any service or maintenance operation,
remove the ignition key and disconnect the system.
•The MAJOR maintenance and repair must always be done, exclusively, by specialized
persons, instructed and authorized (technical maintenance).
•For the ROUTINE maintenance, the operator is responsible for the machine which
has to be clean from extraneous bodies such as debris, oil or other components. That
is why, it is necessary to clean the machine having finished working with it. During
the cleaning the machine must be stopped, in a stable position.
IT IS PROHIBITED DURING THE CLEANING OF THE
MACHINE TO USE HIGH PRESSURE AIR OR WATER.
IT IS PROHIBITE
D TO USE INFLAMMABLE FLUID DURING
THE CLEANING.
When the cleaning of the machine is finished, the operator must check there are no worn,
damaged or loose parts (if necessary, ask immediately for the intervention of the
maintenance technician).
Protection and safety systems for the machine must ONLY be removed if you
have to repair and/or to service the machine.
In any case, before using the mach
ine, all protections and security parts must be
replaced and reset
IT IS OBLIGATORY FOR THE OPERATOR TO STOP USING THE
PIANOPLAN IF A BREAKDOWN, WHICH CAN COMPROMISE
THE PHYSICAL INTEGRITY OF THE NEXT USER OR
IRRETRIEVABLE DAMAGE TO THE EQUIPMENT, HAS B
EEN
FOUND.
When the maintenance operations are finished, the operator must move away from the
machine all the objects which are not integral part of the machine (for example the tools
used after an intervention, cables used for the transport of parts, objects, etc.
USE ONLY SPARE PARTS CONFORMING TO THE TECHNICAL
REQUIREMENTS OF THE MANUFACTURER.
WE RECOMMEND YOU ONLY TO USE ORIGINAL CTE SPARE PARTS.

Operator’s and Maintenance Manual
Pianoplan 600 J Speedy Standard
CODE
504196
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It is prohibited to make modifications!
THE OPERATOR, THE ASSISTANT AND THE MAINTENANCE
TECHNICIAN MUST DRESS IN SUITABLE PROTECTIVE
CLOTHES, ACCORDING TO THE NECESSITY AND THE
CHARACTERISTIC OF THE WORK TO DO WITH THE
MACHINE, OR AROUND IT, SUCH AS:
•Safety helmet in case of falling material;
•safety glasses and masks against the splinters projections or the existence
of intense dust (if you use compressed air as drainage system it is better to
use a dust collector system);
•safety gloves and shoes;
•ear protection (earplugs or earmuffs) if the acoustic noise level is superior
to 85 dB (A).
2.3.5 Residual risk
Even if all safety regulations are observed there remains residual risks during the
operation of the Pianoplan. There are potential risks which are not immediately
obvious and that you cannot avoid without compromising the functionality of
the Pianoplan, such as:
•accidents due to un-coordinated works;
•accidents due to the collision between other working vehicles;
•danger due to unexpected breakdowns at the control panel;
•danger during works to the electric and hydraulic systems;
•danger due to the subsidence of the ground;
•danger due to atmospheric discharge or to static current.

Operator’s and Maintenance Manual
Pianoplan 600 J Speedy Standard
CODE
504196
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2.3.6 Warnings for the implementation of the practical instructions
The practical instructions are rules written by the manufacturer in order to use the
machine in a safe way. These are binding instructions, introduced by the manufacturer in
his area of competence. The accident prevention rules oblige the employees to respect
these instructions.
The general engagements of the manufacturer regarding the implementation and the
communication of the practical instructions are written in the relative rules for the
accidents prevention (in Italy decree law 81 of 2008). According to these rules, the
manufacturer is obliged to offer safe working methods to prevent accidents. Furthermore,
the operators must be instructed about the danger of their activity and informed about
the necessary countermeasures. The operator with the use of practical instructions can
fulfil these obligations.
These instructions for the use of the machine must be completed by the national rules for
accident prevention and for the protection of the environment.
For example, in Italy:
Decree law 81 of 2008 (called security consolidating act)
The operators must be informed:
-about the danger regarding handling the specific load material, about the necessary
safety and behaviour measures, and also about the dispositions in case of dangerous
situations, and first aid measures;
-about the different type of procedures and control of the Pianoplan to achieve
different working requirements in order to work in safe conditions;
-about the maintenance;
-about the elimination of functional anomalies;
-about the protection of the environment;
-about the safe use of electrical systems.
Through appropriate dispositions and controls, the undertaker must guarantee the
cleaning and the order where the Pianoplan is used.
The responsibility for the use, the transport and the maintenance must be clearly and
unequivocally established (and respected by all the personnel), in order to avoid
misunderstandings that could compromise safety.
The operator can use the Pianoplan only if it is in a good condition. The operator must
inform his superiors if he has noted any faults in using the machine that could
compromise the machine safety.
The operator has to respect the indication and warning plates put on the Pianoplan.
The operator has to assure that no unauthorised personnel are nearby the Pianoplan.

Operator’s and Maintenance Manual
Pianoplan 600 J Speedy Standard
CODE
504196
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2.3.7 Referring rules and provisions of the law
The manual instructions must be completed and integrated by the RULES FOR
ACCIDENTS PREVENTION and for the HYGIENE OF THE WORK, for ex.:
Decree law 81 of 2008 (called security consolidating act)
D.P.R. 15
th
of Aug. 1991 n° 277 implementation of the directives n. 80/1107/CEE, n.
I 82/605/CEE, n. 83/477/CEE, n. 86/188/CEE and n.
88/642/CEE, on the subject of the workers protection
against the risks resulting from expositions of chemical,
physical and biological agents during the work, according to
art. 7 from the law 30
th
of July 1990, n. 212
NOTE: THIS LIST IS NOT EXHAUSTIVE

Operator’s and Maintenance Manual
Pianoplan 600 J Speedy Standard
CODE
504196
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3. TECHNICAL DATA
3.1. Type: Pianoplan 600 J
3.2. Model: SPEEDY STANDARD
3.3. Construction features
3
LENGTH (stowed position)
WIDTH
HEIGHT (stowed position)
MAXIMUM WORKING HEIGHT
WEIGHT
MAXIMUM LOADING
MAXIMUM WORKING SLOPE
SPEED TRACTION
POWER
TRACTION POWER (2 ENGINES)
HYDRAULIC POWER
HYDRAULIC PUMP
MAXIMUM EXERCISE PRESSURE
CAPACITY OF THE HYDRAULIC TANK
1280 mm
540 mm
325 mm
700 mm
300 Kg
600 Kg
45°
12 m/min
2 x 12 V 65 Ah BATTERY
2 x 700 W at 2850 Rpm
500 W
GR1 1,6 CC-giro
110 Bar
3 litres

Operator’s and Maintenance Manual
Pianoplan 600J Speedy Standard
CODE
504196
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4. DESCRIPTION OF THE MACHINE
4.1. Mechanical components description
FRONT PART BACK PART
Ahead Back
1. Control box
2. Steering bar
3. Loading platform
4. Extending small platform
5. Rubber track
6. Roller lifting system decals
7. Roller lifting system
8. Outlet for battery charger
9. Strap securing loops/anchor points
10. Primary strap securing position
Fig. 4.1

Operator’s and Maintenance Manual
Pianoplan 600J Speedy Standard
CODE
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4.2. Controls and movements description
1
PROPORTIONAL DRIVING CONTROL (MANIPULATOR)
With this control you can proportionally move the pianoplan: ahead, back, to the left, to
the right
It is also possible to rotate it on itself (one chain track moves ahead while the other one
moves back).
2
EMERGENCY STOP BUTTON
When the button is pressed, all Pianoplan operations are disabled.
3
RED LED ROLLER LIFTING SYSTEM
This LED switches on when the Pianoplan is lifted on the roller lifting system. In this case,
if you drive, a buzzer sounds advising that the manoeuvre is not correct.
4
KEY SELECTOR
On the ON position, the Pianoplan is switched on.
On the OFF position, the Pianoplan is switched off.
Fig 4.2

Operator’s and Maintenance Manual
Pianoplan 600J Speedy Standard
CODE
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5
WHITE LED STARTING
This led informs you if the machine is ON. It lights on when the key selector is on the
ON position.
6
CONTROL BUTTON FOR THE ROLLER LIFTING SYSTEM
This button enables the roller lifting system control only for the lifting manoeuvre.
7
HOUR COUNTER
This instrument counts the hours during which the machine is ON (key selector on ON).
8
DRIVE SPEED SELECTOR
This button selects the drive speed: slow/fast
9
PILOT LIGHT FOR DRIVING SPEED AND ALARM
Green = slow speed
Orange = fast speed
Red = error
10
PILOT LIGHT FOR BATTERIES CHARGER
Green = 100 % charged
Orange = 50% charged
Red = discharged
11
DRIVE CONTROL LIGHT
With this button you enable the driving control.
If the machine is not used for more than 1 minute, this control will automatically switch
off.
12
CONTROL BUTTON FOR THE PLATFORM MOVEMENT
“Ahead” Pushing the button “ahead”, the platform moves forward.
“Back” Pushing the button “rearward”, the platform retracts.
13
CONTROL BUTTON FOR THE ROLLER LIFTING SYSTEM
Pushing the button “rearward”
, the roller lifting system goes down and the Pianoplan
lifts up.
Note: this manoeuvre can be done with button position 6.
Pushing the button “ahead”, the roller lifting system lift
s up and the Pianoplan goes
down.