KLUBB K38P User manual

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USER MANUAL
K38P / K42P Model
Type 1B elevator
ORIGINAL MANUAL
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Table of contents
I. INTRODUCTION ................................................................................................................ 5
II. GENERAL INFORMATION................................................................................................. 6
A. Included documentation...................................................................................................6
B. Document data ................................................................................................................6
C. Recipient .........................................................................................................................6
D. Information property ........................................................................................................6
E. Specific terms..................................................................................................................7
F. General Characteristics ...................................................................................................8
 Size specifications ....................................................................................................... 8
G. Planned and unplanned uses ........................................................................................10
 Planned uses..............................................................................................................10
 Unplanned uses..........................................................................................................10
 Cases where the manufacturer cannot be held liable..................................................10
 Load limiter .................................................................................................................10
 Load selector (optional). .............................................................................................11
H. MEPP identification data................................................................................................11
I. Declaration of compliance .............................................................................................12
J. Warranty........................................................................................................................13
 General terms and conditions .....................................................................................13
 Request for service under warranty and relative arrangements ..................................13
K. After-sales service .........................................................................................................14
 Request for troubleshooting service............................................................................14
L. Use of manual ...............................................................................................................14
III. SAFETY INFORMATION ...............................................................................................15
A. Safety criteria ................................................................................................................15
B. Appointed staff aptitude.................................................................................................15
C. Signaling........................................................................................................................15
D. General safety prescriptions and provisions ..................................................................16
E. Before starting to work...................................................................................................17
F. Precautions while working .............................................................................................18
G. Precautions when finishing or interrupting work.............................................................19
H. Safety measures during servicing..................................................................................19
IV. TECHNICAL DESCRIPTION..........................................................................................21
A. Description of elevator parts ..........................................................................................21
V. ACTIVATION .....................................................................................................................26
A. Before use:....................................................................................................................26
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B. Position and description of the main elements...............................................................28
C. Elevator operation .........................................................................................................32
D. Stabilization outriggers ..................................................................................................34
VI. EMERGENCY MANEUVERING AND PROCEDURES...................................................35
A. Emergency shutdown ....................................................................................................35
B. Emergency pump ..........................................................................................................35
C. Override (optional).........................................................................................................35
D. Hydraulic distributors .....................................................................................................36
E. Actuator control .............................................................................................................37
VII. MAINTENANCE .............................................................................................................41
A. Daily inspection .............................................................................................................42
Weekly inspection .................................................................................................................43
Bimonthly inspection .............................................................................................................43
Six monthly inspection...........................................................................................................43
Compulsory servicing after one year or 500 hours of use (whichever comes first).................44
Hydraulic oils / filters .............................................................................................................45
Greasing................................................................................................................................45
 Slew ring.....................................................................................................................45
 Shafts .........................................................................................................................45
Warranty cover......................................................................................................................46
Diagnostic .............................................................................................................................46
VIII. ELIMINATION AND DEMOLITION.................................................................................49
A. Operator qualification.....................................................................................................49
Equipment deactivation .........................................................................................................49
Deactivation procedure..........................................................................................................49
Remaining risks after deactivation.........................................................................................49
IX. HYDRAULIC AND ELECTRIC DIAGRAMS....................................................................50
A. Hydraulic drawings ........................................................................................................50
B. Circuit drawings.............................................................................................................51
A. Writing instructions ........................................................................................................52
B. Delivery of platforms owner ...........................................................................................52
C. Successive ownership transfers ....................................................................................53
D. Replacement of parts.....................................................................................................54
E. Safety replacement........................................................................................................57
F. Checking / repairs / maintenance ..................................................................................59
G. Notes.............................................................................................................................62
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I. INTRODUCTION
Thank you for choosing KLUBB. This elevator has been made to provide its users with the best
equipment for work at a height. With the full control panel available in the bucket and the many
possible movements of the boom, the product offers flexibility, high performance and especially
efficiency at work.
Each user must always remember that this equipment requires regular upkeep that is very
important to keep its efficiency, avoid deterioration and increase its life duration.
This manual is designed to give you practical and essential information so that you can use your
elevator with optimal efficiency and safety. Using this elevator within the defined limits calls for
clear understanding of its capabilities and is the liability of the user. We advise you to read the
instructions carefully before you start to use the elevator.
WARNING:
 THIS MANUAL MUST BE CONSIDERED AS AN INTEGRAL PART OF THE
ELEVATOR AND MUST BE AVAILABLE TO THE USER AT ALL TIMES.
 READ THIS MANUAL CAREFULLY BEFORE YOU START TO USE THE
ELEVATOR.
With a concern for constant improvement KLUBB reserves the right to modify the technical
characteristics of its elevators without any obligation to upgrade any products it has already sold.
Your satisfaction is very important to KLUBB and special care has been taken to make this
manual as complete and user-friendly as possible.
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II. GENERAL INFORMATION
A. Included documentation
• User manual (this document)
• Circuit and hydraulic diagrams
B. Document data
Elevator user manual
K38P / K42P Models
Note: Some of the pictures and drawings in this manual may not correspond exactly to the
customer equipment. However, they supply all the information needed to allow clear
understanding of the instructions.
C. Recipient
• User
• Technician in charge of servicing
Question: Anybody receiving a copy of this manual, especially the technicians assigned to the
assembly and disassembly of the equipment, must observe the instructions it contains and in
particular not perform any operations stipulated as having to be performed by KLUBB or a
company certified by it.
D. Information property
This manual contains information representing reserved property. All rights reserved. These
instructions may not be copied fully or partially without the prior written consent of the company.
Only the customer who received this manual with the equipment may use it, and exclusively for
the use and maintenance of the device it refers to. The company certifies that the information
supplied in this manual is consistent with the equipment technical and safety instructions as
described in it. The Manufacturer cannot be held liable for any injury to people or animals or any
damage to property, direct or indirect, caused by the improper use of the equipment.
The company reserves the right to make unannounced changes or improvements to this manual
and to the equipment even for equipment of the same model type as that which the document is
designed, but having a different serial number.
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E. Specific terms
Qualified staff: Trained persons with required experience and knowledge of the standards and
prescriptions relative to all accident prevention measures and service conditions, and who are
specifically authorized by the Safety Manager for the performance of any necessary activities and
who are capable of detecting and avoiding any possible danger.
MEPP: Mobile Elevator Platform for Persons (Vehicle + Lift).
W.P: Working Platform (Bucket).
PTO; Power Take Off.
Danger: Danger indications give warning of procedures that, if not followed, may result in
serious injuries or even death, or that may endanger the health of the operator or exposed
persons.
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F. General Characteristics
Size specifications
1. 14m (K38P) with stabilizers
WITH A CONSTANT CONCERN FOR SAFETY AND QUALITY
THE COMPANY RESERVES THE RIGHT TO CHANGE THESE CHARACTERISTICS
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2. 15m (K42P) with stabilizers
WITH A CONSTANT CONCERN FOR SAFETY AND QUALITY
THE COMPANY RESERVES THE RIGHT TO CHANGE THESE CHARACTERISTICS
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G. Planned and unplanned uses
Planned uses
The MEPP consists of a carrier vehicle and the elevator which is an integral part of this machine.
It is designed for lifting people and tools according to indications; the maximum planned work
cycle of the MEPP is 100,000 cycles. According to the EN 280 standard, the 100,000 work cycles,
if executed on a regular basis for 10 years, should correspond to the following: use of machine
for 50 weeks/year, 40 hours per week, 5 cycles per hour.
The machine must be used by suitably trained personnel to guarantee absolute safety and avoid
any risks to third parties.
Unplanned uses
Any different use, not explicitly covered in paragraph II.L.1: Planned use
Cases where the manufacturer cannot be held liable
The Manufacturer is not liable in any of the following cases:
• Uses not provided for in this manual.
• Improper use of the machine or use by non-qualified persons.
• Uses not complying with standards.
• Lack of scheduled servicing.
• Unauthorized changes or operations.
• Removal of seals.
• Use of non-original spare parts.
• Failure to comply partly or fully with the instructions.
• Failure to fill in or sign the service sheet (See chapter XI. Inspection register).
Load limiter
In standard form, our lifts are not equipped with load limiters, They correspond to the real for
stability criteria of standard EN 280. I.e., stability tests with 150% of the nominal load (static) and
110% of the nominal load (dynamic) with a smaller size bucket.
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 Load selector (optional).
Monitoring the loading condition of the bucket is by three indicator lights on the right-hand side of
the upper station (see green box).
1. When the load in the bucket corresponds to conditions of use with 1 person, capacity less
than 120 kg, the green indicator light (see 1) is on.
2. If the load exceeds this value, it is considered that there is a change to the 2-person mode
and an audible alarm sounds for 5 seconds and the yellow indicator light (see 2) comes
on and the green indicator light goes out.
3. If the load finally exceeds 200 kg, the light changes over to the red indicator light (see 3)
and the supply to the upper station is cut off. Lowering can only be carried out using the
lowering remote control, using the override feature.
H. MEPP identification data
See the information stamped into the manufacturer nameplate to correctly identify the MEPP.
This plate is affixed on the column.
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I. Declaration of compliance
There follows a specimen of the CE compliance declaration:
CE compliance declaration relating to machines
Manufacturer
Company; KLUBB
Address; 12, av. James de Rothschild 77164 Ferrières en rie, France
Telephone; [phone]
Fax; [phone]
Product identification
Description; Mobile Elevator platform for persons (MEPP) type 1
Type; KLUBB K32
MEPP Serial Number: 150001
Vehicle; Renault Master L2H2
Vehicle Serial Number; VF6MFFESC53485528
Technical datasheet
Without prejudice to its intellectual property rights, the request for information duly motivated on the technical
report is possible by letter to the following address:
Adress : KLU - 12, av. James de Rothschild 77164 Ferrières en rie, France
Conformity This product was designed, manufactured and validated in compliance with the Machines
Directive of 17 May 2006 (2006/42/CE), the directive relating to electromagnetic compatibility of 15
December 2004 (2004/108/CE) and the directive relating to noise emission into the environment by
equipment used in open air of 8 May 2000 (2000/14/CE).
The assembly of the top structure of the MEPP and installation on the vehicle were carried out in compliance with
the methods defined by the manufacturer and the camber specifications given by the vehicle maker.
The results of all manufacturing inspections, examinations and qualification tests are registered in accordance to
the manufacturer quality process.
No modification to the control units, the safety components or options concerning safety of the elevator will be
authorized without explicit agreement by KLU .
CE Type revie
This acceptance by type has been approved by the following notified organization:
Name: APAVE Parisienne SAS
Identification number; 0060
Address; 17 rue Salneuve – 75854 Paris CEDEX
CE type certificate No.; 0060/ 5536 / 760 / 11/15 / 0001
Harmonized standards Design, manufacturing, installation, protection and tests of the MEPP have been
performed in compliance with European, international and national standards. The most important are
mentioned on the following list:
EN 280 MEPP – Design calculation – Stability criteria – uilding – Security – Tests and reviews
EN 349 Machines safety – Minimum distance to avoid risks of crushing human body parts
EN 13849-1 Machine safety - Parts of control systems relative to safety - Part 1: general design principles
EN 13849-2 Machine safety – Parts of control systems relative to safety - Part 2: validation
EN 60204-1 Machine safety – Machine electrical equipment - Part 1: General rules
ISO 20381 Mobile personnel elevators – Symbols used for operator controls and other indicators
Declaration location: Ferrières en rie, France Date; 23/11/2015
Person authorized person to write this statement.
Name: Julien ourrellis Position; CEO
Signature:
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J. Warranty
General terms and conditions
Warranty terms and conditions are specified in the following:
The company guarantees its equipment and undertakes to replace, free of charge and as quickly
as possible any faulty part (manufacturing and material defects) for a period of 12 months starting
from the date of delivery. Any action under warranty can be made only at the manufacturer’s
factory provided that the customer is up to date in its payments. The delivery of the equipment to
be repaired and its collection are at the expense of the customer.
The above warranty will be void if the customer does not submit the equipment to be repaired
within 30 days from the date of his claim which must be supplied in written form. Except in case
of fraud or major cases of negligence, the company cannot be held responsible with respect to
the customer for any damages concerning defects/damage to the sold equipment.
The guarantee is no longer applicable if the Customer makes changes to the equipment without
the prior and written agreement of the company and/or if the equipment is not used correctly and
suitably. Concerning the equipment and/or the vehicles used and built by the company, the
warranty covering any defect/damage is limited to a term of 30 days from the date of delivery. In
any case, any the defects/damage found in the term mentioned above shall be brought to the
attention of the Seller within 8 days from their discovery; otherwise the warranty becomes void.
The material warranty is valid only if the inspection instructions and servicing described in this
manual are complied with.
Request for service under warranty and relative arrangements
Spare parts orders or requests for troubleshooting under warranty must be sent to the company
as soon as a defect is detected, included within the planned conditions. Always specify the type
and serial number of the machine when ordering spare parts or requesting troubleshooting under
warranty. This information is stamped into the equipment nameplate.
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K. After-sales service
For the optimal use of the equipment and for the servicing operations, this manual cannot replace
the experience of the after sales service.
 Request for troubleshooting service
To contact our specialized technical staff, the Customer may contact the after sales service
directly.
L. Use of manual
Keep this manual in a place that is accessible and known to all users (operators and staff
assigned to servicing)
It is very important to read this manual in full before using the MEPP. For use on any
operation, for servicing or for elimination, see the corresponding chapter.
Looking for Consulting
Instructions, advice and safety
procedures.
Chapter II: General Information
Chapter III: Safety Information
Identification and description of machine. Chapter II: General Information
Chapter IV: Technical description
After sales service, ordering spare parts. Chapter II: General Information
Use of machine. Chapter V: Commissioning
Chapter VI: Maneuvering and emergency
procedures
Prevention and servicing Chapter VII: Maintenance
Final elimination or demolition Chapter VIII: Elimination and demolition
Question: For other information about the truck, see the appropriate instructions and
maintenance details.
This manual must be kept in a protected place in the driving cab of the vehicle so that it can
be found easily if needed for consultation during the entire lifespan of the equipment.
If you lose or damage the manual, ask the manufacturer for a new copy, specifying the
serial number of the equipment to be found on the specific nameplate. The Manufacturer is
committed to supplying you with a new copy.
If the used equipment is sold, also hand over this manual and the relative attachments; also
informed the Manufacturer of the name of the new owner (see para. IX.C: Successive
transfer of ownership).
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III. SAFETY INFORMATION
A. Safety criteria
During the design and manufacture of this machine, the criteria and expedients aimed at fulfilling
essential safety features provided for by the law were put into application, in particular:
In France:
- 2006/42/CE directive
- EN 280 Design calculations - Stability criteria - Engineering - Safety, testing and trials
B. Appointed staff aptitude
The operators appointed to the use of the elevator must be suitably trained, informed and skilled
in using the machine safely and must have a suitable training certificate. Operators must be adults
and considered as capable of performing these operations from the psychophysical standpoint.
In particular, the following requirements should be verified:
•Good eyesight and hearing,
•Not under the effect of the use of drugs or alcohol,
•Psychologically balanced with no evidence of depression or stress
The operators must be familiar with the legislation regarding the moment of the machine on the
road and its use. In addition, they must hold a driver’s license corresponding to the task.
Klubb cannot be held liable for any injury to person or damage to objects or for any other damages
resulting from:
- Failing to comply with safety instructions.
- The machine being used by unqualified operators,
- Failing to comply with the recommendations made in the supplied documentation.
It is highly advisable for the user to have a CACES certificate.
In addition, the user must have been familiarized on this equipment, specifically by the
manufacturer. When a new user is required, contact us immediately so that we can familiarize
him with the equipment.
C. Signaling
The following plates are applied to the equipment:
•Identification (see Fig. 1-1- Identification plate)
•Instructions
•Obligations/Interdictions
•Caution
•Danger
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Caution: Always observe safety instructions given on these plates. Any failure to comply with
these instructions could lead to serious injuries, or even death, or in any case a danger to exposed
operators and/or people. Always check that the plates are properly applied and legible. If not,
apply them or replace them.
D. General safety prescriptions and provisions
Respecting safety instructions and using safety devices properly enables operators to work
productively and safely, not only for themselves but also for others.
Check the trouble-free operation of the installations and protection and safety equipment.
Immediately report any malfunction to the person in charge in order to be able to perform the
servicing needed to reestablish original safety and reliability conditions.
It is prohibited to deactivate or modify any type of safety or protection equipment In such
cases, the warranty is voided and the company is relieved of any liability.
Danger: It is absolutely prohibited to disconnect any of the machine safety devices.
Danger: It is absolutely prohibited to use the machine when the safety devices are not activated.
According to the standards providing protection against accidents, when he is on the platform,
the operator must:
- wear a helmet
- wear and attach the safety harness to the fixed ring in the bucket
- The operator on the ground must also wear a helmet.
Also wear suitable protective clothes of an approved type (nonskid safety shoes, vest with
reflecting stripes …). Further, the operators must not wear rings, watches, jewels, open or loose
fitting clothes such as ties, torn clothing, scarves, unbuttoned jackets or unzipped shirts which
could catch on the moving gears.
Always keep the operator compartment, the surfaces, the steps of the stairs, the handrails and
the large supporting handles clean and free without there being any objects or marks left by oil,
mud or snow, to minimize any risks of sliding or tripping.
Always use stepladders, ladders, handles and dedicated handrails and never use the controls
and the flexible pipes as supports.
Clean the soles of your shoes before entering the MEPP.
Make sure that all the shelters and protections are correctly placed and that all the safety devices
are in place and operate efficiently.
Before use, it is essential to check the performance of the machine and its components. The
MEPP must be cared for and be in perfect condition according to the servicing program. Report
any operational irregularities to the servicing operators.
Many parts of the machines are made of special highly elastic steel: never weld the machine
without first obtaining the written authorization and instructions from KLUBB.
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The machine must never be maneuvered by anybody without the necessary skill and familiarity
as it would compromise the safety of the user and of other people.
In any case, every user or driver of the machine must conform to the applicable Highway
code in the country where he is located.
Read this manual carefully before carrying out startup, use and servicing operations, and any
other work on the machine.
The maximum noise level measured during the use of the MEPP is 90dB. If necessary, wear
suitable ear defenders.
This device is designed for outdoor use. If it is to be used indoors, as an exception, it is essential
for the premises to be properly ventilated.
It is FORBIDDEN to use the MEPP during stormy weather.
E. Before starting to work
Before starting the engine of the vehicle, always disconnect the Power Take Off (P.T.O).
Before driving off, check that the machine is in the operating position.
Always perform the specified daily checks.
Always ensure that the MEPP is level before beginning the work, by choosing the correct area
where the installation is to be positioned, ensuring that the surface is level, compact and stable.
Comply with the maximum inclination angles specified on the manufacturer's nameplate.
For vehicles equipped outriggers (option):
1: Apply the vehicle handbrake.
2: Pull the outriggers out, avoiding such items as manholes, drain networks or any similar
systems (unless double acceptance by APAVE is carried out).
Danger: Always take care not to lower the outriggers on your feet or those of 1/3 party. There is
a risk of serious injury.
For vehicles without outriggers:
1: Apply the vehicle handbrake.
2: Install the wheel chocks.
If the MEPP is required to work on the road, or if visibility is diminished, it is compulsory to signal
its presence by signs bearing diagonal red and white stripes, constantly lighting the flashers on
the cab of the truck (emergency warning lights, triple flashlight etc.).
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F. Precautions while working
Always make sure that no persons (or animals) are standing in the operating area of the MEPP.
In general, avoid contact with permanent obstacles (constructions etc.) or removing obstacles
(vehicles, lifting equipment, etc.).
It is prohibited to place ladders or any other device inside the platform increase the working
height, or any other element that could increase the effect of the wind.
It is prohibited to work near overhead high-voltage electricity lines and in all cases, the platform
must be at a minimum safety distance of 5 m from the cables.
It is prohibited to move the vehicle when the operator is on the platform (Type 1B elevator).
It is prohibited to use the MEPP as a crane.
It is prohibited to overload the MEPP (refer to the manufacturer nameplate to check the
permissible maximum load of the platform.
It is prohibited to move the vehicle if the MEPP is not fully folded.
Avoid allowing any object or device to fall from the platform.
It is prohibited to get in or out the platform during overhead work.
It is prohibited to lean the platform on any other fixed or mobile structures.
It is prohibited to use the MEPP if the wind speed exceeds the values specified on the
manufacturer nameplate.
Do not use the MEPP except within the permitted temperature range (-15°C to +50°C).
Do not use the MEPP if the visibility is insufficient.
It is prohibited to stay on the vehicle bed when the platform is being maneuvered.
It is prohibited to affix signs or banners to the elevator MEPP.
All the movements required to reach the desired service area must be carried out by the operator
on the platform (P.T.). Maneuvering on the ground is only allowed in emergencies.
When using the MEPP in an emergency on the ground, the operator is inside the working zone
of the MEPP, therefore incurring a risk of being crushed in case of an erroneous maneuver.
Carry out all movements as slowly and carefully as possible.
In case of oil leakage from the hydraulic system:
Danger: Do not move to close to the flow of oil because it is at high pressure in the hydraulic
systems and splashing is liable to cause injury.
1 : Press the emergency shutdown button
2 : Disconnect the Power Take Off (P.T.O)
It is prohibited to use the platform if the mobile access protection (small gate) is lifted, or to stop
it with the platform lifted.
It is prohibited to load/unload any object on the platform during overhead work. In the event of
danger, press the emergency shutdown button.
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Do not press the bucket of the MEPP platform on the ground.
Do not use the MEPP unless it complies with the permitted tilt angle as specified on the
manufacturer nameplate.
Ensure that the boom does not get in the way of the vehicle cab and/or with other parts of the
elevator.
It is prohibited to overload the MEPP. The lifting capacity of the MEPP corresponds to the service
load for which it was designed and includes the weight of the operators and tools needed for the
specified activities.
Never insert your body, appendages or fingers in the articulated openings which are sharp cutting
and pointed in certain parts of the machines, unless they have been checked and without suitable
protection, unless everything is very securely locked.
Danger When the machine is level, the following are absolutely prohibited
1 : Releasing the parking brake
2 : Engaging a gear
This prohibition is necessary to eliminate any risk of engaging a gear which could cause abnormal
and uncontrolled performance of the structure, in particular if the boom is not as rest, possibly
causing severe damage to the machine and injury to people located within the working zone of
the platform.
To prevent any movement of the vehicle when there is an operator in a bucket or if the elevator
has not been entirely folded away in the road running position, a motor cutoff system has been
installed. Furthermore, it is compulsory to use the wheel chocks supplied to prevent any
movement of the vehicle if it is parked on slope.
G. Precautions when finishing or interrupting work
If possible, take care when pulling the outriggers up (option).
It is prohibited to leave the MEPP unattended and without ensuring that the motor is off, the
parking brake engaged, the control panels blocked and the platform out of reach.
H. Safety measures during servicing
Any servicing not included in this manual must be carried out only by people authorized by
the company. Grease the MEPP while using suitable needs to guarantee absolute safety.
No servicing operation master be started until the emergency shutdown button has been
pressed and the motor brought to a stop. The elevator must also be at rest during servicing (folded
away or resting on a support).
Think about the environment: Prevent any oil from flowing out during filling or oil changing.
Eliminate spent oil according to the applicable standards.
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Never insert your body, appendages or fingers into articulated, sharp cutting and pointed
openings of machine parts unless all the safety precautions have been implemented (complete
shutdown, locking of machine movements …)
When using the machine from a low position (emergencies only), with the operator on the
platform, there is a constant risk of crushing in the event of a wrong maneuver. Carry out all
movements as slowly and carefully as possible.
Never use petrol or solvents or other flammable liquids to replace detergent; preferred the use
of authorized nonflammable and non-toxic off-the-shelf products.
While using compressed air to clean the parts, always wear safety glasses with lateral
protections keep air pressure to a maximum of 2 atm (1.9bar) maximum.
Never use bare flames as a means of lighting during maintenance operations.
Ensure that all elements of the hydraulic system are safely closed.
Before disassembling any part of the hydraulic system, ensure that there is no oil or other
liquid under pressure that could escape and cause serious injury. In the event of accidental injury
or absorption, contact a doctor immediately. Oil projections can be almost invisible and be strong
enough to penetrate through the skin. Never disassemble with your hands. In the event of the
liquid coming into contact with the skin, contact a doctor immediately; the lack of first-aid can lead
to serious infections and skin ailments.
KLUBB CANNOT BE HELD LIABLE FOR ANY ACCIDENTS OR FAILURE DUE TO FAILURE
TO COMPLY WITH THE SAFETY WARNINGS AND INSTRUCTIONS.
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