nifty TrackDrive TD150T Series Assembly instructions
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TrackDrive
Operating & Safety Instructions
MODEL TD150T/TD42T SERIES
Manufactured by:
Niftylift Limited
Fingle Drive
Stonebridge
Milton Keynes
MK13 0ER
England
www.niftylift.com
e-mail: info@niftylift.com
Tel: +44 (0)1908 223456
Fax: +44 (0)1908 312733
M50334/02
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TrackDrive (TD) Series
Operating & Safety Instructions
English/USA 12/09 1
Table of Contents
1INTRODUCTION AND GENERAL INFORMATION PAGE
1.1 Foreword 2
1.2 Scope 3
1.3 Introducing the Track Drive 150T (TD) Series 3
1.4 General Specification 4
1.5 Identification 5-6
2 SAFETY
2.1 Mandatory Precautions 7-10
2.2 Environmental Limitations 10
2.3 Noise & Vibration 10
2.4 Test Report 11
3 PREPARATION AND INSPECTION
3.1 Unpacking 12
3.2 Preparation for Use 12
3.3 Pre-Operational Safety Check Schedules 13-14
3.4 Placard, Decals and Installation 15-16
3.5 Torque Requirements 17
4 OPERATION
4.1 Overview 18-24
4.2 Setting Up Procedures 25
4.3 Ground Control Operation 26-27
4.4 Platform Control Operation 28-31
4.5 Cage Weigh System 32-33
4.6 Transporting, Craneage, Storage and Setting to Work 34-36
5 EMERGENCY CONTROLS
5.1 General 37
5.2 Emergency Procedures - Incapacitated Operator 37
5.3 Emergency Procedures - Machine Failure 37
5.4 Incident Notification 37
6 RESPONSIBILITIES
6.1 Changes in Ownership 37
6.2 Manual of Responsibilities (USA only) 37
6.3 Inspection/ Service Check List 38-39
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Operating & Safety Instructions
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2
1 Introduction and General Information
1.1 FOREWORD
The purpose of these manuals is to provide the customer with appropriate safety operating and
maintenance instructions essential for proper machine operation.
All information in these manuals should be READ and fully UNDERSTOOD before any attempt is made
to operate the machine. THESE MANUALS ARE VERY IMPORTANT TOOLS - Keep them with the
machine at all times.
The manufacturer has no direct control over machine application and use, therefore
conformance with good safety practices is the responsibility of the user and his operating
personnel.
All information in these manuals is based on the use of the machine under proper operating
conditions. Alteration and/or modification of the machine are strictly forbidden.
One of the most important facts to remember is that any equipment is only as safe as those
who operate it.
DANGER, WARNING, CAUTION, IMPORTANT, INSTRUCTIONS AND NOTICE
Any place these topics may appear, either in this manual or on the machine, they are defined as
follows:
DANGER: If not correctly followed there is a high probability of serious injury or death to personnel.
WARNING OR CAUTION:If not correctly followed there is some possibility of serious injury or death to
personnel.
THE 'SAFETY ALERT' SYMBOL IS USED TO CALL ATTENTION TO POTENTIAL
HAZARDS THAT MAY LEAD TO SERIOUS INJURY OR DEATH, IF IGNORED.
IMPORTANT AND INSTRUCTIONS: Denotes procedures essential to safe operation and prevention of
damage to or destruction of the machine.
NOTICE: Indicates general safety rules and/or procedures relating to the machine.
It is the owner's/user's responsibility to know and comply with all applicable rules,
regulations, laws, codes and any other requirements applicable to the safe use of this
equipment.
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1.2 SCOPE
These operating instructions contain all the necessary information required to allow the safe operation
of the Niftylift TD150T (TD42T), mains electric (AC), diesel (D), petrol/gasoline (P) engine, or a
combination of these.
For further technical information, circuit diagrams and specific instructions for all maintenance which
may need to be carried out by specialist trained personnel, see the associated Workshop and Parts
manual for your model of Niftylift TD150T (TD42T).
1.3 INTRODUCING THE TD150T TRACK DRIVEN (TD) SERIES
Please note at the time of going to press all information, illustrations, details and descriptions contained
herein are valid. Niftylift reserves the right to change, modify or improve its products without any
obligations to install them on previously manufactured machines.
If you require further information after reading this manual, please do not hesitate to contact us.
Niftylift Ltd, Fingle Drive, Stonebridge, Milton Keynes MK13 0ER, Great Britain
Tel: +44 (0) 1908 223456 Fax: +44 (0) 1908 312733
Niftylift Inc, 32 Concourse Way, Greer, SC 29651 USA
Tel: +01 864 968 8881Fax: +01 864 968 8836
Nifty Pty Ltd, 265 King Street, Newcastle, NSW 2300, Australia
Tel: +61 (0) 2 4929 6700Fax: +61 (0) 2 4925 2570
The Niftylift TD150T (Track Drive) is an extremely versatile articulated boom platform of unique and
simple design. It is capable of placing two men and his tools up to a height of 14.70m (48ft 3 ins) or
an outreach of 7.55m (24ft 9in).
The booms are mounted via a 400opowered swing mechanism on to a compact base mounted on
rubber tracks. The fourth boom is telescopic, and when combined with the use of the articulating
booms gives an outstanding working envelope. The powered tracks enable the machine to reach areas
previously thought unattainable.
The four outriggers make a simple and swift set up possible. A unique pressure sensitive micro switch
system fitted to each outrigger prevents operation of the machine until all outriggers have been
correctly deployed and also provides a loud audible alarm warning of a possibly hazardous situation.
Standard build is four fully hydraulically operated outrigger legs, with integral load holding valves
mounted on each outrigger cylinder.
A simple, all-hydraulic proportional control system gives smooth, reliable movement of the platform
and maximum reliability in the harshest environments.
Models include the following:
DAC: - DIESEL & AC ELECTRIC PAC: - PETROL & AC ELECTRIC
D: - DIESEL ONLY PG: - PETROL & LPG (PROPANE)
P: - PETROL ONLY
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1.4 GENERAL SPECIFICATION
FEATURE TD150T (TD42T)
MAXIMUM HEIGHT - WORKING 14.7m
48ft 3 ins
MAXIMUM HEIGHT - PLATFORM 12.7m
41ft 9in
MAXIMUM HEIGHT - STOWED 2.0m
6ft 7in
MAXIMUM OUTREACH 7.55m
24ft 9in
MAXIMUM WIDTH – TRANSIT
1.4m
4ft 7in
JACK SPREAD 3.8m
12ft 6in
MAXIMUM LENGTH - STOWED 4.69m
15ft 5 ins
MAXIMUM CAPACITY - (EUROPEAN)
(USA)
225kg
500lbs
TURRET ROTATION 400º
TURRET TAIL SWING Zero
MAXIMUM TRAVEL SPEED 1.3 mph (High)
2.1 kph
0.65 mph (Low)
1.05 kph
PLATFORM SIZE - LENGTH X WIDTH 1.4m x 0.7m
55in x 27.5in
CONTROLS Full proportional hydraulic
HYDRAULIC PRESSURE 200bar
TRACKS 1745 x 250 Rubber
GRADEABILITY 45% (24º)
GROSS VEHICLE WEIGHT (MAXIMUM) 2025kg
4455lbs
MAXIMUM GROUND PRESSURE 0.043kN/cm2
8,634lb/ft2
POWER SOURCE P (G) (Petrol/Gasoline) models - Honda Engine
D (Diesel) models - Kubota 722E engine
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1.5 IDENTIFICATION (UK PLATE)
!"#$%& %'()*'%(+,&%(+-)#
)
.
/0/
123 4533
3 .3 63 45
/ 1 33 45
/ ./333
/ 1 .333 #78
1 0333 !5
/ 2/0 ./33 9$:
/ 3333
3 .333
0 00 3 /
2 00 33 /
.
This manufacturer’s plate is attached to Boom 1 on each machine at the time of
manufacture on every Niftylift. Please ensure all sections have been stamped and are
legible.
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1.5a IDENTIFICATION (USA PLATE)
! "
#$%&'( ')*+,)'*-.('*-/+%
0 1 2 32 10 $
434
323 5 55
2 00555
10555
!4 043 2455 2
!4 5555
5 2555
3 33 5 4
0 33 55 4
2"
This manufacturer’s plate is attached to Boom 1 on each machine at the time of
manufacture on every Niftylift. Please ensure all sections have been stamped and are
legible.
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2 Safety
2.1 MANDATORY PRECAUTIONS
When operating your Niftylift, your safety is of utmost concern. In order to fully appreciate all aspects
of the machines operation it should be ensured that each operator has READ and fully UNDERSTOOD
the relevant manual covering machine use, maintenance and servicing. If any doubts exist concerning
any points covered in your manual, contact your local dealer or Niftylift Ltd.
Before using any Niftylift, thoroughly inspect the machine for damage or deformation to all major
components. Likewise, check the control systems for hydraulic leaks, damaged hoses, cable faults or
loose covers to electrical components. At no time should damaged or faulty equipment be used -
Correct all defects before putting the platform to work. If in doubt, contact your local dealer or Niftylift
Ltd (see front cover for address).
THE MANUFACTURER HAS NO DIRECT CONTROL OVER THE MACHINE
APPLICATION AND USE. THEREFORE CONFORMATION WITH GOOD SAFETY
PRACTICES IS THE RESPONSIBILITY OF THE USER AND HIS OPERATING
PERSONNEL. FAILURE TO UNDERSTAND AND FOLLOW ALL SAFETY RULES
COULD RESULT IN SERIOUS INJURY OR DEATH.
2.1.1 Only trained persons will be permitted to operate the Niftylift.
2.1.2 Always operate the Niftylift in full accordance with the manufacturers Operating & Safety Instructions
for that model.
2.1.3 Before use each day and at the beginning of each shift the Niftylift shall be given a visual inspection
and functional test including, but not limited to, operating and emergency controls, safety devices,
personal protective clothing, including fall protection, air, hydraulic and fuel system leaks, cables and
wiring harness, loose or missing parts, tyres and wheels, placards, warnings, control markings and
Operating and Safety Manuals, guards and guard rail systems and all other items specified by the
manufacturer.
2.1.4 Any problems or malfunctions that affect operational safety shall be repaired prior to use of the
platform, with specific regard to any safety components refer to the Parts Manual for part numbers and
details. If in doubt, contact Niftylift Ltd (Details on page 3).
2.1.5 Always ensure that all warning labels, instructions, placards, control markings and Safety Manuals are
intact and clearly legible. If replacements are required contact your local dealer or Niftylift. Always
observe and obey safety and operating instructions on such labels.
2.1.6 Do not alter, modify or disable in any way the controls, safety devices, interlocks or any other part of
the machine.
2.1.7 Before the Niftylift is used and during use the user shall check the area in which it is to be used for
possible hazards such as, but not limited to, uneven ground drop-offs, holes, bumps, obstructions,
debris, floor and overhead obstructions, high voltage conductors, wind and weather, unauthorised
persons and any other possibly hazardous conditions.
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2.1.8 Never exceed the maximum platform capacity, as indicated on the decals and machine serial plate.
2.1.9 Only operate the Niftylift on a firm level surface.
2.1.10 Never position any part of the Niftylift within 4.0m, (12ft) of any electrical power line, conductor or
similar not exceeding 66kV. (Minimum span 125m) Other distances for increased voltages and
different spans are given in NZECP 34:1993.
THIS MACHINE IS NOT INSULATED.
If in doubt, contact the appropriate authorities.
2.1.11 On entering the platform, ensure that the drop down entry bar is closed afterwards.
2.1.12 Use of an approved safety belt and lanyard, hardhat and appropriate safety clothing is mandatory.
Fasten harness to designated harness securing points within the platform and do not remove until
leaving the platform whilst in the stowed position.
2.1.13 Always remain standing within the platform. Do not attempt to increase your
height or reach by standing and/or climbing on the platform guardrails or any
other object. KEEP YOUR FEET ON THE PLATFORM FLOOR. Do not sit, stand
or climb on the guardrail, mid rail or boom linkage. Use of planks, ladders or
any other devices on the Niftylift for achieving additional height or reach shall
be prohibited.
2.1.14 Do not use the platform levelling system to artificially increase the outreach of the platform. Never use
boards or ladders in the platform to achieve the same result.
2.1.15 Do not use the platform to lift overhanging or bulky items that may exceed the maximum capacity or
carry objects that may increase the wind loading on the platform. (e.g. Notice boards etc.)
2.1.16 The Niftylift shall not be operated from a position on trucks, trailers, railway cars, floating vessels,
scaffolds or similar equipment unless Niftylift Ltd in Great Britain approves the application in writing.
2.1.17 Always check the area below and around the platform before lowering or slewing to ensure that it is
clear of personnel and obstructions. Care should be taken when slewing out into areas where there
may be passing traffic. Use barriers to control traffic flow or prevent access to the machine.
2.1.18 Stunt driving and horseplay, on or around the Niftylift, shall not be permitted.
2.1.19 When other moving equipment and vehicles are present, special precautions shall be taken to comply
with local ordinances or safety standards established for the work place. Warnings such as, but not
limited to, flags, roped off areas, flashing lights and barricades shall be used.
2.1.20 It shall be the responsibility of the user to determine the hazard classification of any particular
atmosphere or location. Aerial platforms operated in hazardous locations shall be approved and of the
type required. (For the USA refer to ANSI/NFPA 505-1987.)
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2.1.21 The operator shall immediately report to his supervisor any potentially hazardous location(s)
(environment) which become evident during operation.
2.1.22 If an operator encounters any suspected malfunction of the Niftylift or any hazard or potentially unsafe
condition relating to capacity, intended use or safe operation he shall cease operation of the Niftylift
and request further information as to safe operation from his management, or owner, dealer or
manufacturer before further operation of the Niftylift.
2.1.23 The operator shall immediately report to his superior any problems or malfunctions of the Niftylift,
which becomes evident during operation. Any problems or malfunctions that affect the safety of
operation shall be repaired prior to continued use.
2.1.24 The boom and platform of the Niftylift shall not be used to jack the wheels off the ground.
2.1.25 The Niftylift shall not be used as a crane.
2.1.26 The Niftylift shall not be positioned against another object to steady the platform.
2.1.27 Care should be taken to prevent rope, electric cords and hoses from becoming entangled in the aerial
platform.
2.1.28 Batteries shall be recharged in a well-ventilated area free of flame, sparks or other hazards that may
cause explosion. Highly explosive hydrogen gas is produced during the charging process.
2.1.29 When checking electrolyte levels, great care should be taken to protect eyes, skin and clothing. Battery
acid is highly corrosive and protective glasses and clothing is recommended.
2.1.30
When the machine is not in use always stow the booms correctly. NEVER LEAVE
THE KEYS IN THE MACHINE,if it is to be left for any period of time. Use wheel
chocks if leaving on an incline.
2.1.31 If the platform or elevating assembly becomes caught, snagged or otherwise prevented from normal
motion by adjacent structure or other obstacles, such that control reversal does not free the platform,
all personnel shall be removed from the platform safely before attempts are made to free the platform
using ground controls.
2.1.32 The engine must be shut down while fuel tanks are being filled. Fuelling must be done in a well-
ventilated area free of flame, sparks or any other hazard that may cause fire or explosion. PETROL
(GASOLINE), LIQUID PROPANE AND DIESEL FUELS ARE FLAMMABLE.
2.1.33
NEVER START THE NIFTYLIFT IF YOU SMELL PETROL (GASOLINE), LIQUID
PROPANE OR DIESEL FUEL. THESE FUELS ARE HIGHLY FLAMMABLE
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2.1.34 The operator shall implement means provided to protect against use by unauthorised persons.
2.1.35 Never remove anything that may affect the stability of the machine such as, but not limited to, batteries,
covers, engines, tyres or ballast.
2.2 ENVIRONMENTAL LIMITATIONS
All Niftylift machines are limited to operation as previously described and any slopes must be adjusted
by use of the outriggers and jacks. Unless specifically configured otherwise, the machine will have
short time rating for operation in extreme temperatures, i.e. reduced battery cycle times for low
temperatures such as freezers, food storage etc. and cooling limitations for high temperatures as oil
temperature must remain between -23° and 93° Celsius.
Extended operation in dusty environments is not recommended and frequent cleaning will be
necessary. All dust, dirt, salt encrustation, excess oil or grease should be removed. Deposits of paint or
bitumen, particularly on legends or labels should also be removed.
All standard Niftylift machines are rated for a wind speed of 12.5 m/s, which equates to 45kph / 28mph
or force 6 on the Beaufort scale. No attempt should be made to operate a Niftylift in wind strengths
above this limit and if the operator has any doubts over the wind speed he / she should cease operation
immediately until it can be established that the wind speed has fallen to a safe level.
DO NOT USE THE NIFTYLIFT IN ELECTRICAL STORMS
2.3 NOISE AND VIBRATION
The airborne noise emission on the 150T range of machines does not exceed 85dB(A), measured at a
perpendicular distance of 10m, under equivalent continuous A-weighted sound pressure test
conditions. This was based on a Diesel powered machine, working under load. All other models will
exhibit significantly lower emissions than this figure, dependant on power option.
In normal operation the Vibration level to which the operator is subjected will not exceed a weighted
root mean square acceleration value of 2.5 m/s2.
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2.4 TEST REPORT
All Niftylift machine models are subjected to a comprehensive ‘type test’ which duplicates all
combinations of safe working load (SWL), overload, windage, inertia and pull force to assess the
various safe stability criteria. Self propelled machines are also subjected to kerb and braking tests at
the SWL to satisfy additional ‘worse case’ stability requirements.
Each individual machine is then subjected to static overload tests on flat level ground with 150% of the
SWL, exceeding the requirements of EN280 for power operated MEWPs. Self propelled machines are
also tested at the maximum working angle plus 0.5º with a test load of 125% of the SWL. Finally, on all
machines, a functional test is performed with 110% of SWL.
All safety devices are checked for correct operation, operating speeds are checked against benchmark
figures and the dynamic functions ensure that all acceleration and deceleration forces are within
acceptable limits. All noted defects are rectified and recorded before the machine is permitted to enter
into service.
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3 Preparation and Inspection
3.1 UNPACKING
Since the manufacturer has no direct control over the shipping or carriage of any Niftylift it is the
responsibility of the dealer and/or owner and/or hirer to ensure the Niftylift has not been damaged in
transit and a Pre-operational Report has been carried out by a qualified engineer before the aerial
platform is put into service.
A) Remove all ropes, straps and or chains used to secure the aerial platform during transit.
B) Ensure any ramp, loading dock or forklift used is capable of supporting or lifting the aerial
platform.
***Carry out the Pre-operational Report before placing machine in service.
3.2 PREPARATION FOR USE
Whilst every effort has been made at the Niftylift factory to ensure your machine arrives in a safe and
operable condition it is necessary to carry out a systematic inspection prior to putting the aerial
platform into service.
THIS IS NOT A REQUEST IT IS MANDATORY
To assist the user in this task you will find enclosed an Inspection Check List (see section 6.3), which
must be filled out upon delivery/receipt of the machine.
Before the user carries out the Inspection Check List he must have read and fully understood all the
contents of the Operating, Safety and Maintenance Manual.
WARNING - DO NOT OPERATE A POTENTIALLY DEFECTIVE OR
MALFUNCTIONING MACHINE. CORRECT AND REPAIR ANY DEFECTS
BEFORE OPERATING YOUR NIFTYLIFT.
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3.3 PRE-OPERATIONAL SAFETY CHECK SCHEDULES
Before use at the beginning of the work shift, the aerial platform shall be given a visual inspection and
functional tests including, but not limited to the following. It is recommended that these be performed
at regular intervals as indicated on each checklist.
3.3.1 DAILY SAFETY CHECKS
1) Check that all labels (decals) are in place and legible.
2) Visually inspect the machine for damaged or loose components.
3) Check that battery is charged.
4) Check the fuel level (if applicable).
5) Check that canopies/covers and guards are in place and secure.
6) Check that the boom rest switch is operable (if applicable).
7) Check that control levers are secure and operate freely.
8) Check that operating buttons and emergency stop buttons function properly.
9) Check the operation of the emergency hand pump.
10) Visually inspect all hydraulic hoses and fittings for damage or leaks.
11) Check operation of the stabiliser alarm.
12) Check that outrigger footpads are secure.
13) Check that the platform pivot pins and their tag bolts are secure.
14) Check security and operation of the boom clamp (if applicable).
15) Check the operation of the cage weigh system (If fitted). See section 4.5.3 for testing and
verification procedure.
3.3.2 WEEKLY SAFETY CHECKS
1) Inspect tracks and wheels for damage and wear.
2) Check tracks for correct tension – see manufacturers’ handbook.
3) Check battery fluid levels and specific gravity (after charging) and general condition.
4) Check hydraulic oil level , ISO Grade 22 (Europe), Grade 32 (Rest of World).
5) Inspect the engine air filter and clean or replace if necessary.
6) Check operation and security of stabiliser micro switches in conjunction with the alarm system.
7) Inspect hose track for damage or missing parts.
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3.3.3 MONTHLY SAFETY CHECKS
1) Check the engine oil level (if applicable).
2) Check outriggers for condition, security and operation.
3) Check that the slew gearbox is secured and correctly in mesh. Clean and re-grease.
4) Grease the slew ring.
5) Inspect the engine fuel tank for damage or leaks.
6) Check telescopic boom wear pads and nylon studs (if applicable).
7) Check that the end cap on the main knuckle pin is secure and the roll pin is in place.
8) Lightly oil the jack pad ball joints and outrigger housings.
9) Check and adjust if necessary the Nylatron studs around the telescope boom.
10) Every three months check and verify the calibration of the cage weigh system (If fitted).
See section 4.5.4 for the calibration procedure.
11 Every Six months perform a thorough examination in accordance with the ‘Lifting Operation
and Lifting Equipment Regulations’ (LOLER) 1998, Regulation (9)(3)(a).
3.3.4 ANNUAL SAFETY CHECKS
1) Check that all pivot pins and their tag bolts are secure.
2) Inspect for any cracks or badly rusted areas on booms and chassis.
3) Change the hydraulic oil and the oil filters.
4) Check that slew ringbolts are secure (torque 155ft lbs. 210Nm).
5) Inspect hose track for damage or missing parts.
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3.4 PLACARD, DECALS & INSTALLATION (UK SPEC)
ITEM DESCRIPTION NUMBER QTY
1 SWL 225kg P17328 1
4 Hydraulic Controls – 4 lever P14928 1
5 General Warning P20330 2
6 E-Stop Warning P14864 2
7 Head Protection P14921 1
8 Machine Plate P15383 1
9 Cage Gate Warning P18432 1
11 Crush Hazard P14782 7
12 Diesel Fuel Only P14414 1
14 Point Load 13kN P14965 4
15 Hydraulic Controls – 5 lever P14927 1
16 Emergency Hand Pump P19090 1
17 Outrigger Alarm P18842 2
20 Harness Points P14883 2
21 Component Stability P19708 1
22 No Step P14785 1
23 Outriggers P14841 4
26 Nifty TD150T P17595 2
27 Niftylift.com P14390 1
29 Tank Pressure P16365 1
30 Black/Yellow Warning Stripes N/A A/R
31 Cage Levelling P10853 1
32 Base Control Standard
Cage Weigh
P15881
P17219
1
1
33 Cage Control P19926 1
34 Variable Width P16366 1
35 Operating Instructions P14892 1
36 Overload Warning P18848 2
37 Noise Warning 85dB P17124 1
38 Daily Safety Check List P14908 1
39 Tie Down Point P14958 4
40 Drive/Outrigger Recovery P17569 1
41 Booms/Jacks changeover P17571 1
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3.4a PLACARD, DECALS & INSTALLATION (USA SPEC)
ITEM DESCRIPTION NUMBER QTY
1 Safe Working Load P17328 1
3 Cage gate warning P18432 1
4 Hydraulic Controls Base P14928 1
5 Danger P20330 2
7 Head Protection P14921 1
8 Machine Plate P15383 1
11 Crush Hazard P14782 9
12 Diesel Fuel Only P14414 1
14 Point Load 13kN P14965 4
15 Hydraulic Controls Platform P14927 1
16 Emergency Hand pump P19090 1
17 Outrigger Alarm P18842 2
20 Harness Points P14883 2
21 Component Stability P17203 1
22 No Step P14785 7
23 Outriggers P14841 4
24 Emergency Stop P14864 2
26 Nifty TD42T P17596 4
27 Niftylift.com P14390 1
29 Tank Pressure P16365 1
30 Black/Yellow Warning Stripes N/A A/R
31 Platform Levelling P10853 1
33 Rotating Machinery P15010 2
34 Daily Safety Check list P14908 1
37 Key Switch Base P15881 1
39 Variable Width P16366 2
40 Operating Instructions P14892 1
41 Drive/Outrigger Recovery P17569 1
42 Booms/Jacks Changeover P17571 1
43 Noise Warning 85dB P17124 1
44 Tie Down Point P14958 4
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3.5 TORQUE REQUIREMENTS
SCREW QUALITY/SIZE Tightening torque in ft lbs (Nm)
Grade 8.8 10.9
M 6 7.4 (10) 10 (14)
M 8 18.5 (25) 26 (35)
M 10 36 (49) 51 (69)
M 12 65 (86) 89 (120)
M 14 100 (135) 140 (190)
M 16 155 (210) 218 (295)
M 18 215 (290) 300 (405)
SLEW RING BOLTS 155ft lbs 210Nm
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4 Operation
4.1 OVERVIEW
4.1.1 CONTROL CIRCUIT COMPONENTS
CONTROL BOARD: - Situated under the canopy, the control board comprises a PCB (printed circuit
board) design which incorporates all of the relays to control the machine operation. The control board
is common between models with the same power source, and will contain, where appropriate, discrete
fuses for the circuits concerned.
KLAXON: - Also mounted on the base is a klaxon, which performs several functions: - Firstly, it can be
used as a manual alert, by pushing the “Horn” button at the platform control position. Secondly, it is
this device which sounds continuously is a jack goes light during operation, with the booms raised,
warning the operator of this condition. It will also sound if the Ground Control Key switch is turned to
“Platform” before the jacks are deployed properly.
BOOM-SWITCH: - Mounted on the side of Boom 2 near the knuckle and operated by contact with a
cam on boom 3, this switch controls the changeover function between jacks and platform. The jack
control function is not available unless this switch is engaged with the boom, ensuring that the
machine must be stowed to operate the hydraulic jacks. It is also similarly linked into the platform
control circuit, such that if the switch is not engaged with the booms, (i.e. machine is in operation)
then the outrigger sensors are active and would warn the operator of an unsafe condition, should one
of them loose contact with the ground. These control functions are of primary importance to safety of
the machine and operator; under no circumstances should this control function be isolated or by-
passed.
DIESEL ENGINE: - Generally a Kubota 722E engine, described in the maintenance section of the
Workshop Manual, driving a single bodied pump with direct mounted pump dump valve.
CONTROL BOX: - Located adjacent to the Diesel engine, the control box combines all of the functions
for Dual power operation (Bi-energy machines), as well as controlling the Diesel engine. The relays in
this box control Starting, High Throttle, Pump Dump, Duty Selector and Diesel stop timer. There is also
an integral Thermal trip, which protects the Throttle solenoid and other functions.
PETROL ENGINE: - Generally a Honda engine, described in the maintenance section of the Workshop
Manual, driving a triple body pump with direct mounted pump dump valve.
PETROL BOX: - Located adjacent to the Petrol engine, the Petrol Box combines all of the functions for
dual power operation, as well as controlling the petrol engine itself. The relays in this box control
Starting, High Throttle, Pump Dump, Duty Selector and Engine Stop. There is also an integral Thermal
Trip, which protects the Throttle solenoid and other functions.
Courtesy of Crane.Market
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