JLG Power Towers Nano Operating instructions

Operating and
Maintenance Manual
www.powertowers.com
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CONTENTS
Introduction 2
Operating Specifications 3
Working Envelope Diagram 3
Do’s and Don’ts 4
Primary Components 5
Operating Procedures (Incl. Emergency Operation) 6-8
Maintenance Procedures
(Incl. Castor Safety and Maintenance) 9-13
Storage 14
Key Spare Parts 15-16
Electric Circuit Diagram 17
Hydraulic Circuit Diagram 18
Warranty Terms 19
CONTENTS
2
INTRODUCTION
The Power Tower Nano is designed to be a simple, quick and safe
powered alternative to a portable scaffold tower, podium or a step
ladder, for internal construction site and maintenance applications.
It can be used in applications where previously portable scaffolding
towers are erected on castors, and moved about on hard level
surfaces. These types of tower are open to incorrect assembly, and
are difficult and time consuming to work from. The Nano eliminates
many of the risks associated with portable scaffold towers.
The Nano is suitable for any application provided it is used within
its specified operating parameters. If used for applications such as
sand blasting, welding, paint spraying or with any other hazardous
materials, then measures must be taken to ensure the Nano does not
become damaged in any way which may impair safety, or reliability.
Additional protection for the operator may be required in some cases,
which is the responsibility of the operator and/or the operator’s
employer.
The purpose of this manual is to provide essential basic information
required to operate and maintain the Nano.
This is not a workshop manual. Please contact the manufacturer or
their agent for specic operation or maintenance information if in
doubt.
The health and safety of the operator or maintenance technician is
the responsibility of the individual and/or their employer and not
Power Towers Ltd.
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OPERATING SPECIFICATIONS
3
Working Dimensions
Maximum working height: 4.50 m
Maximum platform height: 2.50 m
Platform dimensions: 1.00 m x 0.73 m
Working footprint: 1.19 m x 0.75 m
Safe working load: 200 kg (1 person plus tools)
Maximum manual force: 200 N
Max. gradient for operation: 0°
Max. wind force: Indoor use 0 mph
Manual push force on level ground: 9 kg
Maximum total weight Inc payload: 485 kg
Maximum castor point load: 180 kgs (1.77 kN)
Max. wheel force: 1.75 kN
Closed Dimensions
Length: 1.195 m
Width: 0.750 m
Height: 1.560 m
Weight: 285 kg
Power Source
Standard 12v DC Electric Motor
Or 240V AC Electric Motor 13A Supply
Or 110V AC Electric Motor 16A Supply
Battery Charger Specification
Input Voltage:
If single voltage: 90-135V AC (UK)
180-265V AC (non-UK)
If dual voltage: 90-265V AC
Frequency: 45-65 Hz
Output: 12V DC, 7A
Power sound level: Less than 70dBA
Emission EN 55014N, EN 61000 – 3 – 2
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4
DO’S and DON’TS
DO’S
1. Read and adhere to the instructions both on the machine
and in this manual.
2. Ensure pre-operation checks and operations are carried
out in the manner described.
3. Use only on hard, level surfaces able to support the weight
of the machine (e.g. concrete oor, tiled oor, hard wood
oor).
4. Use the Nano internally only.
5. Ensure operator is t and does not suer from a fear of
heights.
6. Ensure the Nano is correctly positioned with castor brakes on.
7. Ensure guardrail gate is closed and latched before elevation.
8. Ensure work area around the machine is cordoned o
from pedestrians and other trac.
9. Ensure operator is wearing the correct safety equipment.
10. Ensure the platform is correctly positioned so as not to
come into contact with xed or moving objects.
11. Ensure that the safe working load is evenly distributed
on the platform.
12. Never leave the Nano unattended without the castor
brakes on.
DON’TS
1. Never exceed the safe working load (1 person, 200kg).
2. Never use the Nano on sloping or uneven ground.
3. Never use the Nano as a goods lift or crane.
4. Never exceed horizontal forces; never use in wind
(maximum horizontal force 200N).
5. Never use in the vicinity of live conductors.
6. Never try to move the Nano on its castors
when elevated.
7. Never extend the height of the platform by using boxes,
steps, ladders etc.
8. Never modify the Nano in any way without the
full approval of the manufacturer.
9. Never attempt to enter or exit the platform unless it is
fully lowered.
10. Never operate the Nano outside.
11. Never ax the pendant controller to the guardrails or toolbox
area of the platform; stow in its holster when not in use.
12. Never use the Nano in an explosive environment.
13. Never use the Nano if fatigued.
14. Never use the machine inappropriately or for‘horseplay.’
15. Never use the machine if under the inuence of drugs or alcohol.
16. Never use the machine if suering from poor health or using
medication which might impair the safe operation of the Nano.
17. Never use the Nano if vision impaired by bright lighting.
18. Never push the Nano on sloping surfaces without the use of a
safe method.
19. Never push or pull objects with the platform.
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PRIMARY COMPONENTS
PRIMARY COMPONENT LOCATIONS
5
Control
Box
Entrance
Gate Latch
Spirit
Level
Swivel
Castor
Auto-Lok
Braked Wheel
Emergency
Stop/Battery Isolator
Emergency
Lowering Valve
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OPERATING PROCEDURES
OPERATING PROCEDURES
It is essential to be familiar with the correct operating procedures as outlined in this
manual
The operator must have adequate training for this type of platform.
The Nano is fitted with a safety harness point as standard. If the operator chooses to
wear a safety harness, an approved ‘fall restraint’ type harness should be worn.
Operating procedures are divided into three key areas:
1. Pre-operation checks.
What to do before operating the Nano.
2. Normal operation.
How to use the Nano safely.
3. Emergency operation.
How to lower the Nano without power or in the event of
operator incapacity.
There is no specific legal requirement to wear a safety harness. However,
there is an employers’ requirement to ensure the correct equipment is
used for a task and that is used correctly and safely. For this requirement
to be met, a risk assessment should be conducted to assess the potential
risks and if an increase in operator safety can be achieved with a safety harness, then
use a ‘fall restraint’ type harness only.
It is the owners and/or the users responsibility to ensure that the machine is
maintained and operated in accordance with the operation and maintenance
procedures contained within this manual.
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PRE-OPERATION CHECKS
1. Ensure there are no obvious signs of mechanical damage to the handrails,
platform, lifting structure or chassis.
2. Check platform access gate closes when released and that the latch
engages correctly.
3. Check castors and wheels rotate freely and are undamaged.
4. Check castor wheel and castor xings. Check circlip (red ring) is correctly located
on end of stub axle and retained with hub cap (See pic A.)
5. Check emergency lowering is functioning correctly (refer to procedure on p.8).
6. Ensure the battery (where applicable) is fully charged, referring to the battery
condition dial indicator.
7. Ensure the hydraulic oil level is at the correct level. Do not overll.
8. Check there are no hydraulic oil leaks and that all hydraulic connections
are tight.
9. Cordon o area around machine in accordance with guidelines.
NORMAL OPERATION
Only use the Nano internally, on hard level surfaces. Ensure a person is available at
ground level to assist in case of emergency.
Position machine under application. Refer to working envelope
diagram if necessary.
1. Apply both castor brakes.
2. Check spirit level to ensure machine is level.
3. Ensure the emergency lowering valve is closed (push and twist 90º,
release - do not force).
4. Turn key switch in emergency stop button (located at the base of the
machine), then pull to release.
5. Battery condition dial indicator on control box will indicate battery charge.
6. Check there are no overhead obstructions.
7. Enter platform via step and gate and ensure the gate is closed
and latched correctly when in platform. Do not elevate if the access gate is
not closed and latched.
8. Press arrowed button to elevate. Press arrowed button to descend.
9. In case of uncontrolled platform elevation or descent, depress
red emergency stop button (on control box or at base of
machine - refer to pics 4 & 5).
The user shall obtain the guidance and approval of the manufacturer in
the event of any special working methods or conditions which are outside
those specified by the manufacturer.
OPERATING PROCEDURES
7
Locked
1Unlocked
1
2
4
3
5
5
Pic. A
Never ax the pendant controller to the guardrails or
toolbox area of the platform
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EMERGENCY LOWERING OPERATION
In case of platform control failure or operator incapacity:
To lower the platform:
1. Locate emergency lowering valve at base of machine (see, pic
right). Push, twist 90 degrees anti-clockwise and release
the knob. The platform will lower. Pushing and twisting the knob
clockwise will stop the descent at anytime.
2. Check the area below the platform is free from obstructions
when lowering.
3. Keep clear of descending structure.
4. Do not force the release knob.
BATTERY CHARGING
The battery charger is located under the checkerplate cover A.
The charging lead (usually tted with a yellow 110V plug) is on the
exterior of the machine base (this lead can be tted with 230V plug if
required) B. Dual voltage chargers are fully voltage sensitive, so there
is no voltage selection to do when connecting to dierent voltages. If
tted with a single voltage charger, the input voltages are 90-135V AC
for UK and 180-265V AC for non-UK.
Ensure the battery isolator is switched on when charging. Plug into
an available power supply and ensure the green LED (top of charger)
illuminates. The adjacent amber LED has three modes C. 1. Rapid
ash, indicates maximum charge rate. (Note, when switching charger
on, the amber light must rapid ash. If not, there is a fault, check
fuse* and connections). 2. Slow pulse, indicates slower charging. 3.
Continuous illumination indicates oat charge. Both lights go“o”
when fully charged. Additionally the battery charge indicator dial on
the control box will indicate charge level D.
The battery charger can be connected to the mains supply at any
time or left for extended periods.
The machine can be operated when the charger is connected, although
this is not recommended.
All mains supply should be protected with a suitable RCD.
Only charge in a well-ventilated area.
*Note: The charger is tted with a 15A automotive spade fuse (blue). If the
fuse has failed, the indicator lights will still operate. The fuse may have failed
if the battery is heavily discharged and the motor is run when the charger is
switched on. In such an event, the fuse is simple to replace; ensure battery
isolator is switched o and that the mains supply is disconnected before
attempting to check or change fuse.
OPERATING PROCEDURES
8
AB
C D
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Please note that whilst the Nano is extremely simple to maintain,
all work must be carried out by a competent person.
When removing checkerplate cover for maintenance purposes,
first switch off by depressing the emergency stop/battery isolator
button located at the base of the machine. Use appropriate
safety/personal protective equipment where necessary.
DAILY MAINTENANCE
Tilt cage by releasing gate latch on cage mount (see pic). Pull cage
frame from gate end and cage will lift and tilt assisted by gas strut.
Ensure gas strut is fully extended and that the safety chock is in place.
You can now access the powerpack housing. Unscrew the black
retaining knobs and lift out the checkerplate cover.
1. Check Battery Electrolyte Level:
Remove battery cover and battery caps. Ensure the electrolyte
covers the plates by no more than 1mm – 2mm. Replenish with
distilled water to this level, only if the electrolyte level is below
the top of the plates.
2. Check Hydraulic Oil Level:
Ensure the tank is not overfilled.The level must only be checked
when the machine is in the transport position.The correct level
in this condition is approximately 3/4 from the base of the tank,
as indicated by the line.
3. Ensure there is no obvious mechanical damage to the handrails,
entrance gate, post or structure of chassis. Also check the castors
and wheels are undamaged, rotate freely and are secured
to machine.
4. Check hydraulic connections around the pump and base of
cylinder are tight and undamaged.
5. Check the spirit level to ensure it is clearly legible and
undamaged.
6. Check all functions operate correctly including movement alarm
and emergency stops.
7. Ensure mast surfaces are clean and not greased.
WEEKLY MAINTENANCE
Check battery terminal connections are tight.
MONTHLY MAINTENANCE
Check Battery Specific Gravity:
On a monthly basis check the specific gravity in each of the
battery cells.When a battery is correctly fully charged the
specific gravity should be 1.27 - 1.3.The specific gravity
reading should be equal across the cells, if not repeat the full
charge cycle.
Check rollers and mast surfaces for damage. Ensure brushes are fitted
correctly and brush against mast surface.
MAINTENANCE PROCEDURES
9
Cage mount
gate latch
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MAINTENANCE PROCEDURES
HYDRAULIC OIL
The hydraulic oil must be replaced on an annual basis. If the oil is not
replaced, then premature wear and failure of components will occur.
To drain the hydraulic tank, the mast must be in the transport
position, and the platform tilted to allow access to the motor/pump
unit.The only practical method to remove the oil from the tank is to
use a syringe suitable for hydraulic oil, which are easily obtainable,
or a vacuum system for hydraulic oil.The hydraulic steel pipe
connection to the cylinder must not be disconnected, unless by a
competent person. If the connection has been disconnected, then a
full pressure test of the system must be conducted prior to placing
the machine back into service. No leaks must be evident when the
pressure test is conducted.
Refill with grade 32 mineral oil.
WHEELS AND CASTORS
It is absolutely essential that the wheels and castors are maintained in
good condition at all times, for two reasons:
The first is that they act as the stabilisers, and whilst their load
capacity is over rated for the application, any failure could result in a
serious accident. Secondly, if the bearings become tight, then it will
make the machine difficult to manoeuvre.
A measure of horizontal push force can simply be made to determine
the condition of the wheel bearings. On a flat smooth surface the
machine should move with a force of 9 – 10 kg at the mid guard rail
height. The maximum allowance is 20 kg.
Obviously this force is dependant upon the surface and gradient, but
the above is the recognised method of measurement, in accordance
with HSE guidelines.
Check rear wheels to ensure retention circlip is securely fitted to
end of stub axle and plastic cap is fitted over it.
MOTOR CONTACTOR SOLENOIDS
When conducting the six monthly LOLER inspection, check the
correct functioning of the two motor contactors.
Fit new contactors after every three years.
When replacing components for any reason, only use OEM
specification parts, either supplied from the manufacturer or
authorised in writing by the manufacturer.Warranties and design
approvals will be void if alternative components are fitted.
It is essential to obtain manufacturer’s approval of any alteration
which might affect stability, strength or performance in writing
before proceeding.
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