Mace Bumpa Petrol 6m User manual

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Operators manual
Bumpa Petrol
6m 8m 10m
MANUFACTURERS ORIGINAL INSTRUCTIONS MCE-BUMPA-21-A1.4

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Table Of Contents
CONTENTS ...........................................................................................................................................2
IMPORTANT..........................................................................................................................................3
SAFETY RULES....................................................................................................................................4
ELECTROCUTION HAZARD ................................................................................................................5
Explosion and Fire Hazards............................................................................................................6
SETUP HAZARD ...................................................................................................................................7
FALL HAZARD.......................................................................................................................................8
Bodily Injury Hazard ........................................................................................................................9
Damaged Machine Hazard ............................................................................................................10
COMPONENT DAMAGE HAZARD.....................................................................................................10
LEGEND...............................................................................................................................................11
CONTROLS.........................................................................................................................................12
PRE-OPERATION INSPECTION........................................................................................................13
MAINTENANCE...................................................................................................................................16
Check main belt tension and tracking:........................................................................................17
Check wheel brakes.......................................................................................................................18
Scheduled Maintenance................................................................................................................19
FUNCTION TESTS..............................................................................................................................20
WORKPLACE INSPECTION...............................................................................................................23
OPERATING INSTRUCTIONS............................................................................................................25
TRANSPORT INSTRUCTIONS...........................................................................................................32
DECALS...............................................................................................................................................33
SPECIFICATIONS...............................................................................................................................35
DIMENSIONS ......................................................................................................................................36
OPERATING ANGLES........................................................................................................................37
CONTENTS

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Important
Read, understand and obey these safety rules and operating instructions
before operating this machine.
Only trained and authorized personnel shall be permitted to operate this
machine. This manual should be considered a permanent part of your
machine and should remain with the machine at all times. If you have any
questions, please call Mace Industries.
Contact us
Mace Industries Limited
Units 1-3 Macadam Road
Earlstrees Industrial Estate
Corby
NN17 4JN
Web: www.maceindustries.co.uk
Tel: [phone]
Fax: [phone]
IMPORTANT

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Danger
Failure to obey the instructions and safety rules in this
manual will result in death or serious injury.
Do Not Operate Unless:
You learn and practice the principles of safe machine operation contained in this
operator's manual.
1 Avoid hazardous situations.
Know and understand the safety rules before going on to the next section.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey:
Manufacturer's instructions and safety rules—safety and operator's manuals and
machine decals employer's safety rules and worksite regulations applicable to
governmental regulations.
SAFETY RULES

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Electrocution Hazards
This machine is not electrically insulated and will not provide protection from
contact with or proximity to electrical current.
Do not operate the machine during lightning or storms.
Do not use the machine as a ground for welding.
Ensure safe routing of power cable to minimise risk of electrocution.
Maintain safe distances from electrical power lines and apparatus in accordance
with applicable governmental regulations and the following chart:
Voltage Minimum Safe Phase to Phase Approach Distance
Voltage
Feet
Metres
0 to 300V
Avoid
Contact
Avoid
contact
300V to 50KV
10
3.05
50KV to 200KV
15
4.60
200KV to
350KV
20
6.10
350KV to
500KV
25
7.62
ELECTROCUTION
HAZARD

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Allow for machine movement, electrical line sway or sag and beware of strong
or gusty winds.
Keep away from the machine if it contacts energized power lines. Personnel
must not operate or move the machine until energized power lines are shut off.
Do not operate the machine during lightning or storms .
Do not use the machine as a ground for welding.
Ensure safe routing of power cable to minimise risk of electrocution.
Explosion and Fire Hazards
Do not operate the machine in hazardous locations or locations where
potentially flammable or explosive gases or particles may be present.

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Setup Hazards
Check work area for overhead obstructions or other possible hazards.
Do not use the machine whilst under the influence of alcohol or drugs.
Ensure machine is securely fastened at the top and brakes are on before use.
Do not alter or disable machine components that in any way affect safety and
stability.
Do not replace items critical to machine stability with items of different weight or
specification.
Be aware of ground surface prior to installation.
Do not place ladders or scaffolding against any part of this machine.
Do not use the machine on a moving or mobile surface or vehicle.
Ensure all tyres are in good condition and cotter pins are properly installed.
Do not ride on machine.
Do not alter or disable limit switches or remote handset.
Do not operate the machine in strong or gusty winds.
When erecting the machine, ensure shackles and or ties are secure before lifting.
SETUP HAZARD

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Fall Hazards
Always erect a safety barrier to prevent access through underside of machine.
Failure to do so could result in serious injury.
Do not lean over machine while belt is moving.
Do not lean over discharge head of machine whilst loading / unloading.
Ensure loading guides are set central to the load and machine frame.
Do not ride on machine.
Keep the loading platform / scaffold free from debris.
FALL HAZARD

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Bodily Injury Hazard
Use common sense and planning when installing and operating the machine.
Keep hands and limbs away from moving belt.
Always wear correct PPE.

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Component Damage Hazards
When using a generator, ensure it is fitted with a voltage regulator before use.
Do not over load the machine 80kg MAX belt load.
Do not over load individual carriers 20kg MAX per carrier.
Do not use machine as a ground for welding.
Damaged Machine Hazard
Do not use a damaged or malfunctioning machine.
Conduct a thorough pre-operation inspection of the machine and test all functions
before each work shift. Immediately tag and remove from service a damaged or
malfunctioning machine.
Be sure all maintenance has been performed as specified in this manual and the
appropriate Mace Industries service manual.
Be sure all decals are in place and legible
COMPONENT
DAMAGE HAZARD

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1. Bogey
7. Angle inidicator
13. Scaffold stand
2. Controls
8. Belt Carrier
14. Top belt guide
3. Stop gate
9. Machine trestle
15. Adjuster head
4. Loading guides
10. Hinge
16. Shute
5. Wheel
11. Remote handset
17. 10m prop
6. Hondda GX120
12. Remote socket
LEGEND

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1. Base emergency stop
4. Engine stop switch
2. Pull start
5. Handset Stop
3. Choke
CONTROLS

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Do not operate unless:
You are trained, authorised and have learnt and practiced the principles of safe machine
operation contained in this operator's manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation inspection.
Know and understand the pre-operation inspection before going on to the next
section.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
PRE-OPERATION
INSPECTION

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Fundamentals
It is the responsibility of the operator to perform a pre-operation inspection and
routine maintenance.
The pre-operation inspection is a visual inspection performed by the operator prior
to each work shift.
The inspection is designed to discover if anything is apparently wrong with a
machine before the operator performs the function tests.
The pre-operation inspection also serves to determine if routine maintenance
procedures are required. Only routine maintenance items specified in this manual
may be performed by the operator.
Refer to the list on the next page and check each of the items and locations for
modifications, damage or loose or missing parts.
A damaged or modified machine must never be used. If damage or any variation
from factory delivered condition is discovered, the machine must be tagged and
removed from service.
Repairs to the machine may only be made by a qualified service technician,
according to the manufacturer's specifications. After repairs are completed, the
operator must perform a pre-operation inspection again before going on to the
function tests.
Scheduled maintenance inspections shall be performed by qualified service
technicians, according to the manufacturer's specifications.

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Pre Operation Inspection tasks:
Be sure that all decals are legible and in place. See Decals section.
Be sure the main belt is properly tensioned and in good condition.
Be sure the belt carriers are secure and in good condition.
Be sure the correct accessories are present. See parts list.
Check the following components or areas for damage, modifications and improperly
installed or missing parts:
oElectrical components
oLimit switch
oHandset
oWiring
oStop gate
oDrive motor
oTyres and wheels
oBrakes
oPower on lights
oNuts, bolts and other fasteners
oScaffold clamp
Check entire machine for:
o Cracks in welds or structural components
o Dents or damage to the machine
o Be sure that all structural and other critical components are present and all
associated fasteners and pins are in place and properly tightened.

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Observe and Obey
Only routine maintenance items specified in this manual shall be performed by
the operator.
Scheduled maintenance inspections shall be completed by qualified service
technicians, according to the manufacturer's specifications and the requirements
specified in the responsibility’s manual.
Maintenance symbols legend
The following symbols have been used in this manual to help communicate the
intent of the instructions. When one or more of the symbols appear at the
beginning of a maintenance procedure, it conveys the meaning below.
Indicates tools will be needed to carry out this operation.
MAINTENANCE

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Check main belt tension and tracking:
Maintaining the proper belt tension is essential to good machine performance and
service life. Operating the machine with an improper belt tension can damage
machine components.
Check belt tension whilst power is off.
1. The main belt will only need to be tensioned if it is slipping under load.
2. When the Bumpa is unfolded, measure the distance between the
underside of the frame and the belt at the central hinge pivot point.
3. The measurement should be no more than 15cm
4. If measurement is over 15cm –tension as required.

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Check wheel brakes
Maintaining the brakes is an essential aspect of machine maintenance. Whilst
erecting a machine the operator depends on the brakes functioning.
Check brake function whilst machine is flat on the ground.
1. Move the brake arm back and forth to its extent of travel. Ensure it moves
freely.
oIf brake won’t move or is stiff grease and retry.
2. Ensure wheel cannot be moved whilst brake is operated.
___________________________________
Check Honda GX120 engine:
Maintaining the engine oil level and condition is essential to good machine
performance and service life. Operating the engine without proper oil levels can
damage machine components.
Complete all checks whilst engine is off and has sufficient time to cool down.
1. Check oil level on dipstick
oIf oil level is low, top up with 10w-30 motor oil
oIf oil leel is too high remove drainage bolt and drain oil as required.
Ensure any old oil is disposed of carefully and is consistent with local authority
standards.

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Scheduled Maintenance
Maintenance performed quarterly and annually must be completed by a person
trained and qualified to perform maintenance on this machine according to the
procedures found in the service manual for this machine.
Machines that have been out of service for more than three months must receive the
quarterly inspection before they are put back into service.
____________________________________________________________________________

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Do not operate unless:
You learn and practice the principles of safe machine operation contained in this
operator's manual.
1 Avoid hazardous situations.
2 Always perform function tests prior to operation.
Know and understand the function tests before going on to the next
section.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
FUNCTION TESTS