KLUBB KAT 42 User manual
KLUBB KAT 42 User Manual
Taking choice, support and quality to new heights
KLUBB
12 avenue James de Rothschild
77164 FERRIERES-EN-BRIE-FR
Phone: +33 1 60 31 28 18
Email: contact@klubb.com
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CHAPTER 1: INTRODUCTORY INFORMATION 2
SECTION 1.1: ABOUT THIS MANUAL 3
SECTION 1.2 SAMPLE CERTIFICATES 4
SECTION 1.3: IDENTIFYING THE MACHINE 5
CHAPTER 2: SAFETY INFORMATION 6
SECTION 2.1: GENERAL INFORMATION 8
SECTION 2.2: CONDITIONS FOR OPERATION 11
SECTION 2.3: RECOMMENDATIONS FOR USE 16
SECTION 2.4: OPERATING PERSONNEL 18
SECTION 2.5: SAFETY DEVICES 25
SECTION 2.6: SAFETY DECALS 21
CHAPTER 3: TECHNICAL INFORMATION 24
SECTION 3.1: MACHINE OVERVIEW 25
SECTION 3.2: MACHINE OVERVIEW: HYDRAULICS 27
SECTION 3.3: AIR SUSPENSION 29
CHAPTER 4: OPERATION 32
SECTION 4.1: PREPARING TO OPERATE THE MACHINE 33
SECTION 4.2: CAB CONTROLS 34
SECTION 4.3: MAIN CONTROL BOX 35
SECTION 4.4: DECK CONTROLS 36
SECTION 4.5: BASKET CONTROLS 37
SECTION 4.6: STABILISING THE PLATFORM 39
SECTION 4.7: RAISING THE PLATFORM 40
SECTION 4.8: CLOSING THE PLATFORM 41
SECTION 4.9: EMERGENCY PROCEDURES 42
CHAPTER 5: MAINTENANCE 44
SECTION 5.1: INTRODUCTION 45
SECTION 5.2: SAFETY NOTICES 46
SECTION 5.3: ROUTINE CHECKS 47
SECTION 5.4: REGULAR MAINTENANCE CHECKS 50
TABLE OF CONTENTS
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CHAPTER 1
INTRODUCTORY INFORMATION
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1.1 ABOUT THIS MANUAL
Please ensure that you have read and understood the informaon outlined in this manual prior to operang the machine. All of
the instrucons in this manual are based on the use of the machine when it is working correctly, without any modicaons to
the original model. Any alteraons are strictly forbidden without prior authorisaon from KLUBB.
This manual MUST be kept in the vehicle cab at all mes
• The instrucons, drawings and documents in this manual, which contain condenal technical informaon, are the
property of the manufacturer and may not be reproduced in any way, either enrely or parally.
• In terms of product development and use of devices and instruments, the manufacturer has always aimed to incorporate
the most modern and advanced technology, while also meeng customer’s needs and oering bespoke designs. This
could result in dierences between the instrucons in the manual and the device itself.
• No legal acon may be taken by the operator, user company, or service centres on the basis of any instrucons,
illustraons, or descripons contained in this instrucon manual.
• The manual must be kept for future reference unl the machine is scrapped.
• If the machine is sold on or hired out, the seller or hirer must pass on the manual to the new owner or user.
• The informaon in the manual is arranged into topic-based chapters.
• The table of contents allows quick and easy reference to the various topics.
• The instrucon manual must be made available to operators.
• This manual assumes that the machine will be used in compliance with applicable work safety regulaons in the country of
use.
• If the manual is lost or damaged, a copy may be obtained from the dealer by specifying the model data, serial number and
year of construcon.
• This manual shall not replace any kind of vocaonal training.
• Use of the manual for any purposes other than machine use and maintenance is prohibited.
• If any unauthorised modicaons are made to the machine, the manufacturer is not responsible for altering the manual to
suit these alteraons.
• For repair, service and warranty assistance, please call Nacelle Assistance and Service +33 1 64 68 39 43
• To get the best out of your machine, always use spare parts that are recommended by the manufacturer. Again, please
contact KLUBB Head Oce for more informaon.
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1.2 SAMPLE CERTIFICATES
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1.3 IDENTIFYING THE MACHINE
There are machine idencaon plates xed onto your machine: The idencaon plates are stamped with the following
details which must be quoted to the manufacturer or dealer in any dealings with them. It is strictly prohibited to alter the
informaon on this plate.
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CHAPTER 2
SAFETY INFORMATION
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2.1 GENERAL INFORMATION
ILLUSTRATIONS
For ease of understanding, some illustraons in this manual will show the machine with the guards, covers or panels
removed. Never use the machine without covers or guards.
The drawings of the machine in this manual are provided for illustrave purposes only. These may not be accurate to your
parcular design.
TECHNICAL ASSISTANCE
The mobile elevated work plaorm is covered by warranty, as stated in the general condions of sale. During and aer the
warranty period, the KLUBB Service Department is at your disposal to provide any services you may need.
Please note that any alteraons made by the user, without the manufacturer’s express wrien permission, will render the
warranty null and void and release the manufacturer from any liability for damage caused by a defecve product. This is
parcularly true when such changes concern a safety device, reducing its eecveness. The same consideraons apply if non-
original spare parts are used or any parts other than those specied by the manufacturer. For these reasons, we recommend
you always contact your dealer.
DISCLAIMER NOTICE
The manufacturer cannot be held responsible for the following:
- Improper use of the machine;
- Unauthorised alteraons or work on the machine;
- Failure to follow the highway code and regulaons concerning machine transportaon from one work site to another;
- Total or paral failure to comply with instrucons herein;
- Lack of maintenance;
- Use of non-original spare parts or parts not designed specically for the model concerned;
- Exceponal environmental condions.
MOVEMENT STABILISATION
Be aware of obstacles e.g. bridges Check ground stability prior to using the machine
VEHICLE LEVELLING Do not exceed the maximum inclinaon
Ensure the vehicle is on level ground prior to operaon
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2.1 GENERAL INFORMATION
WORKING AREA
Place barriers around working area. When working on the road, cone o and sign
post the area as per highway regulaons. Do not extend the boom structure into
lanes open to trac.
EMERGENCY STOP
If there is an emergency or any danger. Stop the machine. Ensure that the dangerous
situaon is over prior to operang the machine again.
OBSTACLES AND ELECTRIC LINES
Make sure that there are no electric lines within the safe distance guidelines.
PUSHING OR LOWERING AGAINST OBSTACLES
Extending the boom against obstacles (opening/closing and/or liing/
lowering/rotang) may create structural damage to the machine and
have a serious risk of pping over the plaorm. Before and during any
movements, always verify visually any obstrucons are clear of the
machine structure in all direcons (with parcular aenon to the
hidden parts, such as the lower part of the basket).
WIND
It is recommended to always use safety harnesses. Do not operate plaorm if wind
is exceeding 12.5 m/s. Do not take equipment in the basket that has a large surface
area as this will increase wind load. Always take into account the wind condions
as this could cause the MEWP to lose stability and cause death or serious injury.
PROTECTION
When performing special work, always safeguard yourself with the
appropriate PPE as well as safeguarding the machine.
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2.1 GENERAL INFORMATION
IN THE BASKET
Never use ladders, boards or other objects to reach out of the basket.
It is forbidden to exit the basket when it is raised.
Never exceed the loading capacity allowed in the basket as
this could p the machine over or damage the MEWP. In turn
this could cause death or serious injury.
LIFTING
Never use the plaorm as a liing device, not even for small weights as this could
p the machine over or damage the MEWP. In turn this could cause death or serious
injury.
SAFETY HARNESS AND HELMETS
It is recommended to always use safety harnesses. Helmets should be worn if working
near overhead obstacles. Do not fasten harnesses to structures outside the basket.
REPAIRS AND MODIFICATIONS
Do not carry out any repair or modicaons unless it is through an authorised
repair centre.
ATTENTION! LOADING AT HEIGHT
Do not load the basket while the boom is extended as this could p the machine over.
In turn this could cause death or serious injury.
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2.2 CONDITIONS FOR OPERATION
INTENDED USE
The machine is designed to move people to overhead posions in order to perform operaons from inside the work plaorm.
Use of the machine is permied if the instrucons shown in this manual are complied with.
Any other use than that specied, or not included or inferable from this manual, should be considered mishandling and
therefore is not permied.
UNAUTHORISED USE
Any uses not outlined by regulaon UNI EN 280 fall under the direct responsibility of the user, who is required to comply with
the legal provisions in force regarding health and safety in the workplace.
NOTE!! The machine cannot be put back into use aer undergoing structural alteraons or addions of other components
which do not come under roune and special maintenance unless a new declaraon of conformity is issued.
TEMPERATURE
The machine operates properly in the following environmental condions:
- Minimum temperature: - 10°C
- Maximum temperature: + 40°C
- Humidity: 80% at 40°C
If used in a cold climate, start the machine and allow the oil, equipment, and systems to warm up.
Upon rst use, take special care during manoeuvres.
Constantly check that the baeries are charged.
Minimum starng temperature: - 20°C
For use in condions other than those specied above, always contact the manufacturer.
Use of the machine in any other installaon condions than the original conguraon supplied by the
manufacturer is prohibited, as is use of the machine in any way other than that stated herein.
Use is prohibited in the event of funconal anomalies and non-compliances with the use and safety
requirements stated in this manual. In the event, request and wait for the authorised personnel.
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WIND SPEED
To gauge the wind speed, use an anemometer and refer to the chart below for guidance only.
STABILITY
Use of the machine is only permied when the vehicle is correctly stabilised and levelled.
There is a spirit level in the stabilisaon controls area.
• Air bubble in the middle > the vehicle is horizontal
• Air bubble in between the two circles > vehicle lted by between 0° and 5°
GROUND CONDITIONS
Ensuring ideal ground condions when the MEWP is resng on the ground is crucial for the machine’s stability. Steep slopes
may yield under the weight of the outriggers or the wheels, in which case the machine may end up in an unstable posion with
a risk of overturning. Therefore before moving, using or posioning a MEWP, it is essenal to assess the type of ground (its
properes) and the gradient of the area where the machine will be standing. If you are even the slightest bit concerned that the
ground could give way, check the level of the machine regularly and adjust the outriggers, support plates and ground shoring.
2.2 CONDITIONS FOR OPERATION
Wind Force Wind Speed
Eect of wind inland
Beaufort
Number Name m/s km/h
0calm <0.3 1Calm, smoke moves directly upwards
1light air 0.3 - 1.5 1- 5 Wind direcon only indicated by the movement of smoke, not by a weather cock
2light breeze 1.6 - 3.3 6 - 11 The wind can be felt against your face, leaves rustle, weathercocks move
3gentle breeze 3.4 - 5.4 12 - 19 Leaves and branches move, the wind unfolds wind sleeves
4moderate breeze 5.5 - 7.9 20 - 28 The wind picks up loose paper and cardboard, moves branches and thin poles
5fresh breeze 8.0 - 10.7 29 - 38 Small hardwoods begin to wave, wave foam appears on lakes
6 strong breeze 10.8 - 13.8 39 - 49 Poles move violently, telephone cables whistle, it is dicult to use an umbrella
7 moderate gale
(or near gale) 13.9 - 17.1 50 - 61 All the trees move, it is slightly dicult to move against the wind
8 fresh gale
(or gale) 17.2 - 20.7 62 - 74 Branches break o trees, it is considerably dicult to walk outside
9 strong gale 20.8 - 24.4 75 - 88 Slight damage to houses (chimney tops and roof les are swept o)
10 whole gale
(or storm) 24.5 - 28.4 89 - 102 Trees are uprooted, considerable damage to houses
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2.2 CONDITIONS FOR OPERATION
ASSESSMENT OF THE GROUND
Analysis of the ground can consist of a visual inspecon of the surface or a detailed geotechnical survey.
Nevertheless, it is essenal that the assessment be carried out by personnel with enough experse and experience to be aware
when advice must be sought from someone more skilled.
Assessing the load capacity of the underlying ground
is the primary task of a civil engineer.
1) Loose ground
All forms of loose ground, including just laid
surfacing (gravel, sand, mud, etc.) must be
avoided.
2) Non-compacted lling material
Areas of ground may have been lled with soil or
other materials without it being properly
compacted. Cracks appearing around the
perimeter of a dug area are signs that the area
has not been properly compacted.
3) Proximity to dug areas
The machines must not be posioned near the edges of earthworks or other excavaons as they are likely to subside
without warning. If the machine has to be posioned near the edge of a slope or a dug area with the outriggers or wheels
in a ‘hazardous area’, a technical assessment report should be sought from a skilled geotechnical engineer before seng up
the MEWP and rendering it operaonal.
The safety distances and slope angles stated must be maintained (see drawing).
A - Safety distance
B - Hole/trench depth
C - Distance from the edge of the embankment
- If the truck/machine assembly has a GVW of up to 12t, the distance must be …..≥ 1.00 m
- If the truck/machine assembly has a GVW of over 12t, the distance must be …….≥ 2.00 m
Y - Load transfer angle
- If “Y” ≤ 30° on ground which is loose or non-compacted ……………………….. “A” ≈ 2 x “B”
- If “Y” ≤ 45° on compacted ground ……………………………….……………............. “A” ≈ 1 x “B”
X - Embankment angle
Unless the stability is proved mathemacally, the following embankment angles must not be exceeded:
a) for non-compacted or loosely compacted ground …………………….………..“X” = 45°
b) for rm ground or semi-solid, compact ground, ……………………….….…….“X” = 60°
c) for rock …………………………………………………………………….……………………….. “X” = 80°
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2.2 CONDITIONS FOR OPERATION
ASSESSMENT OF THE GROUND (connued…)
4) Paved areas, basements, and semi-basements
Many paved areas, basements, and semi-basements are unable to withstand the load of a plaorm and could collapse
without warning. The suitability of the ooring and the locaon of the basements and semi-basements must be taken into
account.
5) Areas paved with slabs
Paving slabs can appear strong while hiding a weak oor underneath. Cauon must always be taken with pavements as
they could have been made from poor quality materials or might hide work that has been carried out underneath the
surface. If a road is subject to constant heavy goods trac and does not show any signs of wear, then it may be less
hazardous than a car park or a less-used country road.
6) Underground works
All underground cavies, such as sewerage, drainage canals, wells, manholes, pipelines for gas, water, power cables, and
other pipelines, tunnels, abandoned cemeteries, old water holding tanks, sepc tanks, etc. could be damaged by the weight
of the machine or could even cave in, either leaving the machine unstable or causing it to overturn.
7) Weather condions
Heavy rain or extended rainy periods could alter the condions of the ground, causing outriggers and wheels to sink. If you
suspect subsidence in the ground where the MEWP needs to stand, check the level of the machine regularly and make the
appropriate adjustments to the outriggers, ground shoring, etc. Regular checks must also be made when icy
ground begins to thaw, as it could look much stronger than it actually is.
Spreader Plates
These spreader plates with built-in handle are made of an abrasion-resistant synthec
material and can be supplied by KLUBB to suit your MEWP.
Divide the maximum support reacon specied on the warning decal on the outriggers by the surface area of a spreader plate
(in cm²). The result is the pressure applied by the machine to the ground (when using spreader plates) which must be compared
against the pressure values stated on the decal.
For example: maximum outrigger reacon (see rang plate) = 22000 N, surface area of a 40 cm x 40 cm spreader plate = 1600
cm², soil compression = 13.75 N/cm²
According to this calculaon, it is clear that when using the spreader plate, the supporng surface area is enlarged to such an
extent that the bearing capacity of ground with a road surface is never exceeded. In areas with loose soil, be aware that the use
of spreader plates may sll not be enough!
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Do not stack plates on top of each other as they could slide o.
When lowering the outrigger onto the spreader plate it must always be posioned so that it is in the centre
of the recessed area.
The surfaces of the spreader plate and of the outrigger must be touching completely, with neither resng on
the edges. The outriggers must always be properly supported.
Both sides of the spreader plates must always be kept clean. The plates must be dry and must have no oil or
grease on them, nor ice, lubricants, or any other slippery products.
Make sure you use the spreader plates properly and ensure uniform support.
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2.2 CONDITIONS FOR OPERATION
CORRECT OUTRIGGER POSITIONING
A1 - Correct
A2 - Outrigger not centred on plate
B1 - Plate on top of a hole
B2 - Suitably lled hole
C - Loose ground which has been swept away by rain
D - Outrigger posioned on top of a cavity
OVERHEAD POWER LINES
Great care must be taken when operang near overhead power lines. The access plaorm has no insulaon properes so a
safe distance must be maintained at all mes. If the unit is ed with a plasc basket this can oer a minimal amount of
protecon to the personnel in the basket but only in the right condions.
Only access plaorms cered as Insulated Aerial Device (IAD) can work near overhead power lines.
A minimum safe distance must always be kept between the overhead lines and the closest point of the MEWP when fully
extended. This distance is 15m with overhead lines mounted on steel towers and 10m with lines mounted on poles of wood.
These distances are measured horizontally at ground level from a posion vercally below the outermost conductor at the
tower or pole posion.
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2.3 RECOMMENDATIONS FOR USE
NEVER USE THE MACHINE:
• in a work area exposed to re risks; during thunderstorms; or in corrosive, ammable, or explosive atmospheres, or in
the presence of harmful dusts.
• with the engine running in an area which is not well venlated. When using the machine indoors or in poorly venlated
areas, adopt all necessary precauons to prevent build-up of toxic exhaust gas.
• at night or in poorly lit environments if not equipped with a oodlight.
• in the presence of intense electromagnec (EM) elds (e.g. telecommunicaons pylons, radar systems or suchlike) unless
a suitable technical assessment of the situaon has been made. Generally speaking, the distance to be maintained
between the system installaon area – which can be dened as a “controlled-access area” in relaon to EM exposure –
and the other freely accessible work areas, depends on the technological characteriscs of the equipment and must be
taken into account by the responsible person who carries out the risk assessment.
• on public roads. If the machine is used on roads open to trac, suitable signs must be set up and the work area
cordoned o, both for safety purposes and to comply with laws in force.
• with unauthorised persons standing or moving within the work area. The operator must stop the machine and clear the
work area of any unauthorised persons that may be there.
• at events and shows without taking certain precauons to prevent accidental movements and to protect the general
public. Bear in mind any changes in the environmental condions which could alter the consistency of the ground; the
wind; and possible hydraulic leakage.
• if a failure has been detected. All work must be stopped unl the fault has been remedied.
• when the machine has not been properly inspected and serviced.
• without safety devices.
• as a crane, for liing loads or to pull or tow anything.
• with loads over the level permied on the work plaorm (people + equipment).
• with a lateral force in the plaorm over the level permied.
• if there are obstrucons on the plaorm.
• when it is loaded on vehicles, ships, scaolding or such like.
• with material or objects suspended from the structure.
• as an earth for the welding machine.
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2.3 RECOMMENDATIONS FOR USE
ALWAYS COMPLY WITH THE FOLLOWING INSTRUCTIONS:
• Do not allow unauthorised persons to use the machine. Make sure the machine cannot be accessed by any unauthorised
persons when out of use. Remove the access/ignion keys when the machine is not in use.
• Wear personal protecve clothing and equipment, as per applicable regulaons. To nd out what should be worn,
contact your employer or safety manager.
• Always follow the instrucons and the signs axed to the machine.
• Do not remove any of the machine’s parts, nor the ballast. Stability is only guaranteed if all parts of the machine are
ed in the same way as when the machine was delivered.
• Do not tamper with the control systems or the safety devices in order to increase performance.
• Be careful not to lower the outriggers onto anyone's feet.
• Aer stabilising the machine, check that the plate on each outrigger is resng on the ground properly.
• Do not access the work plaorm once the structure is extended or leave it if it is not in the resng posion.
• Wipe up any oil or grease found on the footboards, deck, or handrails.
• Keep a rm hold on the handrails when boarding or exing the plaorm.
• Never control the machine from the ground when there is an operator on the work plaorm, unless the working
condions allow no other safer and/or beer alternaves in terms of the safety of the operator controlling the machine,
in which case the relave risks must be assessed beforehand (by the employer). Furthermore, the ground control
operator’s view of the work plaorm and the surrounding work area must be sucient to allow the worker to perform
manoeuvres safely.
• Only load the work plaorm when it is fully lowered and resng on the ground.
• Do not climb on the work plaorm crossbeams; use ladders or any other device provided to reach higher levels.
• When working, do not lean out of the plaorm or take up precarious posions.
• Be careful not to drop objects or equipment from the plaorm and make sure they are placed correctly inside the
plaorm. Likewise, these objects must be placed on the plaorm using a handling cable.
• Take measures to prevent risks of objects falling from the work plaorm and onto the machine's structure in general.
Mechanical risk: Contact with the machine's moving parts can lead to the risk of crushing and shearing of body parts.
Thermal risk: Contact with hot parts may cause burns.
Fire risk: Fuel leaking from the tank during machine use or during refueling may lead to a re risk. Never ll the
fuel tank near naked ames.
Collision risk: Prior to any machine use, the operator is required to evaluated the risks overhead.
Risk of high-pressure spurts: A pipe or hose breaking or high-pressure oil leakage may lead to injuries and skin
Risk of slipping or falling: Oil, grease, snow, or ice on the steps used to access the manoeuvre staons or on the work
plaorm oor may cause the operator to slip and fall.
Risk of swinging/overturning: Subsidence (be careful during thaw periods in the winter). In the event of sudden gusts of
wind (with parcular reference to swinging overhead power lines).
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