PennyHydraulics MezzLift User manual

Service and
Operation Manual for
Penny Hydraulics
Lifts
1000kg MezzLift
Station Road
Clowne
Chesterfield
Derbyshire
S43 4AB
Tel: [phone]
Fax: [phone]
E-mail: [e-mail]
Website: www.pennyhydraulics.com
© This document, the MezzLift logo and the MezzLift machines are the property of Penny Hydraulics Limited and must not
be copied or amended in part or in whole unless prior, express written permission is obtained from the Company.

1 Issue 1 –ER - Oct 2019
Introduction and Intended Use
Thank you for purchasing a Penny Hydraulics MezzLift. This is a unique design that is built in our
factory to your specification. Each one is tailor-made and we trust that it meets with your approval
and will provide you with a safe, efficient and trouble free means of moving goods for many years.
This manual tells you what you need to know about its operation together with some useful guidance
on safety and general care. It also explains the servicing requirements and the availability of a service
agreement should you wish to take advantage of it. We have our own engineers around the country
lead by our Central Service Department to give an exceptional after-sales service.
We strongly recommend that each operator of the MezzLift be trained in its use and read all the
details set out in this booklet.
This MezzLift is designed to be used by trained persons in a workplace to move goods between two
levels. It has hold-to-run control buttons, with the control circuits remaining live whilst the motor is
running. Any gates or doors will unlock automatically as the lift platform docks at that level and vice
versa. Generally, any shaft or hoist run should be clearly visible by the operator so that they have
complete control over the lifting operation. The lift is not suitable for carrying persons.
Accessories
We provide a wide range of accessories for your MezzLift and we can make bespoke items to suit
your exact requirements.
Service
With our service contract you can be sure of continued safe, reliable use of the equipment and full
compliance with current legislation. We have our own team of service engineers around the UK and
their vans are well stocked with spares enabling most visits to be a first-time fix reducing downtime to
a minimum. We understand that safe and reliable deliveries are essential to your business.

2 Issue 1 –ER - Oct 2019
Contents
Introduction and Intended Use................................................................................................................1
Accessories .............................................................................................................................................1
Service ....................................................................................................................................................1
Contents..................................................................................................................................................2
Safety Warning.......................................................................................................................................2
Method of Operation...............................................................................................................................4
Fault Finding...........................................................................................................................................5
Penny Hydraulics Limited Warranty Policy...........................................................................................6
Maintenance............................................................................................................................................7
Service Contract....................................................................................................................................11
Technical Data......................................................................................................................................12
Survey, Installation and Commissioning..............................................................................................13
Declaration of Conformity....................................................................................................................15
General Arrangement………………………….………………………………………………………16
Spares List.............................................................................................................................................17
Hydraulic Diagram................................................................................................................................19
Electrical Diagrams...............................................................................................................................20
Training Register ..................................................................................................................................25
Record of Revision ...............................................................................................................................26
Safety Warning
These signal words mean:
–You CAN be KILLED or SERIOUSLY HURT if you don’t follow
instructions.
–You CAN be HURT if you don’t follow instructions.
Notice: –Your equipment can be damaged if you don’t follow instructions.
WARNING
CAUTION

3 Issue 1 –ER - Oct 2019
In the interest of safety, all personnel involved in the lifting
operation must read the operation manual and comply with
the following;
1. The lift must not be used for man riding.
2. Do not step on the forks or platform.
3. As a minimum requirement, the lift should be inspected every 6 months and serviced annually
by a competent person. The lift also requires a thorough examination and certificate of test as
determined by the competent person at least every 12 months. See the Service Contract
section for full statutory responsibilities.
4. Do not use the lift if it is not supported with valid documentation recording a thorough
examination being carried out by a competent person within the last 12 months.
5. Do not interfere with the factory settings
6. Do not modify or re-install this machine without seeking guidance from Penny Hydraulics
Ltd. Only use correct and certified lifting accessories. Any lifting or securing attachments
must be formally certified by thorough examination every 6 months.
7. Only use genuine parts and accessories.
8. The lift must not be overloaded. Refer to the Max Working Load signs attached to the
equipment
9. Always park the lift at the bottom when not in use.
10. The lift must only be operated by trained and competent personnel. A training register is
included at the back of this manual.
11. Whilst the transfer of goods is in progress, access to the area should be restricted to those
personnel essential to the operation.
12. No persons should go near the forks or platform whilst they are raised.
13. All safety notices must be read and complied with at all times.
14. Never interfere with the unit, it should run smoothly at all times. If in doubt call the
HELPLINE telephone Number 01246 811475.
15. Keep the MezzLift properly maintained by a competent person.
16. Where barriers, guards and/or safety gates are fitted, always ensure that they are in place
before commencing any work.
17. Isolate, immobilize and lock off the equipment before commencing any maintenance routine.
Please note that any control panel may remain live, even when the motor is not running.
WARNING

4 Issue 1 –ER - Oct 2019
Method of Operation
Before operation, please read the operating instructions and ensure all persons
involved in the operation are familiar with the equipment and site requirements.
Read all safety warnings and instructions carefully. Failure to do so could
result in seriously injury or death.
Standard operation is via a hold to run, push button control. The person at the controls is in a safe
position and no one should pass them whilst the lift is in motion.
Notice: Operate the buttons until the platform stops. DO NOT try to judge the top or bottom
by releasing the buttons before the platform reaches the stops. The lift can be stopped at any time by
releasing the hold-to-run button.
1. Clear the working area of unnecessary people or obstructions, erect any barriers required by
house procedures then open the entrance doors and make them secure.
2. Turn on the lift at the mains power switch if a lockable isolator is installed.
3. Ensure that the platform is locked at the correct level. Open the safety gate.
4. Load the platform. Do not overload.
5. Use the button control to send the lift to the next level by holding the appropriate button.
6. Unload the platform once it reaches the correct level. The operator must not operate the
button until they are certain it is safe. The safety gates will not be able to be opened until the
platform is locked in to the set level.
7. Once unloaded, close the safety gates and the operator can use the buttons to return the
platform to the original level.
8. The process can be repeated until the delivery is complete.
9. When finished, ensure that all gates and doors are closed and the platform is docked at the
lower landing.
The control panel remains live, even when the motor is not running.
WARNING
WARNING

5 Issue 1 –ER - Oct 2019
Fault Finding
Power failure. Should the power supply to the MezzLift be cut off for any reason during operation,
the platform will be held in position by the hydraulic brake on the end of the hydraulic motor.
1. The electric motor has thermal overload protection that may operate after prolonged use.
Leave the unit turned off for an hour to cool before trying for normal operation, if this is
suspected.
2. Occasionally a surge in power may cause a circuit breaker to trip. Switch off the power and
check the appropriate circuit breaker at the distribution board in the building. Reset if possible
and restore the power.
If the problem continues, phone the HELPLINE or have an electrician check the circuit.
The platform does not descend when buttons are operated.
1. A door or gate is not fully closed. The “Gate Open” light should be illuminated on the main
control panel. Ensure that all gates are closed and that the “Gate Open” light is not lit.
2. An emergency stop button has been activated. Check that all emergency stop buttons are out
by gently pulling and turning each one anti-clockwise.
Oil appears at the base of the lift. There has been an internal oil leak. It is still safe to continue
operating the unit but see below. Phone the HELPLINE to arrange for an engineer to call.
The lift operates slowly and will not go up or down. There is an oil leak, and the tank is empty. Call
the HELPLINE. Do not attempt to refill the tank.
Minor oil leaks from hose connections or the power pack. These are not serious but call the
helpline for prompt attention.
IF IN DOUBT CALL THE HELPLINE ON 01246 811475

6 Issue 1 –ER - Oct 2019
Penny Hydraulics Limited Warranty Policy
This Policy is intended to provide our customers with the best possible support to ensure trouble-free
use of their new Penny Hydraulics lifting equipment.
Products sold by the Company are guaranteed to be free from defective material and workmanship for
a period of one year from the date of invoice, or from the date of the commissioning certificate.
This warranty applies only under the following conditions:
a) The unit or part must not have been subject to neglect or abuse or operated under abnormal
conditions or in an unapproved application.
b) The responsibility of the Company is restricted to what is, in their judgement an adequate
repair or replacement of the Company’s product.
c) An authorised engineer must carry out a six-monthly inspection.
d) The warranty is void if examination reveals that the unit or part has been repaired or adjusted
other than by an authorised engineer.
e) Normal service repairs carried out by authorised engineers are supported by their own
warranty.
f) Warranty does not extend to consumable items requiring replacement due to normal wear and
tear.
Any claim under warranty must be made in the first instance by contacting Penny Hydraulics Ltd
Service Department on 01246 811475 or via email at [e-mail]. The decision will
then be made on how best to proceed after consultation with the customer.
UK Mainland
We will normally have one of our own engineers based around the country visit the site to rectify the
problem. This policy may be varied at our discretion, but it is our aim to give the very best possible
response to minimize product downtime and inconvenience.
Other locations
Warranty is limited to a parts-only service, but in certain areas we may have service partners who may
be able to assist. Any defective item should be returned to Penny Hydraulics Ltd for inspection and
any valid warranty claim will include reasonable carriage costs both ways. A replacement part will
then be sent to the customer.
No variation of the warranty as stated in the Company’s Standard Terms and Conditions of Sale is
authorised unless agreed in writing by a Director of the Company. This is the only warranty given and
the Company accepts no other responsibility.

7 Issue 1 –ER - Oct 2019
Maintenance
It is the premises duty holder’s legal responsibility to ensure the lift is maintained in accordance
with the manufacturer’s specification. This will also ensure the continued safe and reliable
operation of your lift for many years to come.
Your lift is subject to the Lifting Operations and Lifting Equipment Regulations (LOLER) which is a
statutory requirement to record on a formal document, the safe working condition of the lift,
attachments and mounting structure. Penny Hydraulics Ltd support team offers a service package to
meet customer requirements and to conform to LOLER certification. Please see service contract form
enclosed.
The following planned maintenance schedule is designed to ensure the safe working order of the lift
and includes a thorough examination by a competent person as required by LOLER. LOLER also
requires that a thorough examination is carried out following any exceptional circumstance that may
affect the safety of the equipment.
Any defects that are found that are, or could become dangerous to persons, whilst carrying out the
planned maintenance schedule must be reported and recorded, and the equipment taken out of
operation until sufficient action by a competent person is undertaken. The planned maintenance
schedule may require the use of parts and consumables.
A list of recommended spares and lubricants is attached.
Item
Lubricant
Specification
General Lubrication
Lithium-based Grease
LEP2
Roller Chain
Chain Grease –Aerosol
Proprietary Chain Grease
Power Pack
Hydraulic Oil
Tellus 32 or Equiv.
Planned Maintenance schedule
A competent person must carry out a thorough examination and test every six months. In addition to
this there are various service operations that must be done on an annual basis. These are indicated in
bold. Various split pins, oils, greases and sealant are required to complete a full service.
Before starting work on site always inform the manager/site foreman what operation is to be carried
out and of any health and safety issues. The manager/site foreman may have additional requirements
that must be followed.
Never leave an open shaft unguarded. Treat ladders with respect and fasten them into position. Never
work beneath the cradle or platform without setting safety sprags.

8 Issue 1 –ER - Oct 2019
Mountings
Check top and bottom mountings for security. These are to be re-examined under
full load conditions during the testing procedure and inspected for movement.
Cradle chain type
Visually check chain attachment points on cradle.
Check for free movement of cradle.
Check rollers for free movement and wear.
Apply LEP grease to any grease nipples.
Chain sets
Examine both drive & suspension chains for damage and wear.
Visually check coupling points for security.
Examine all sprockets & clear any debris from behind the bottom sprocket.
Grease all four chains.
Grease the motor and two bottom bearings via the grease nipples.
Check suspension chain tensions with the platform near the top. They should be
even with only hanging tension in the fall from the cradle to the bottom sprocket
but no bunching of the chain when the cradle is lowered. Adjust as necessary
using the two adjusters beneath the top sprocket.
Check the drive chains for even tension. There should be no bunching of the
chain when under load. If they need adjusting loosen the motor mounting plate
bolts and use a bottle jack to push the assembly up so tightening the chains.
Retighten the plate bolts.
Hydraulic system
Check that power pack is securely mounted.
Check power pack and hose ends for leaks.
Check oil level and top up as necessary using Tellus 32 hydraulic oil.
Check that relief valve is not causing motor to stall by driving the platform into
the end stops.
Examine visible hose run for leaks and damage.
Check and reposition hoses at the top of the column to ensure clearance on cradle
rear axle.
Check the ram whilst removed from the column for leaks or scoring to the piston.
Do not attempt any ram repair on site but replace the complete unit if necessary.
Check internal hose run or leaks and damage.
Test
Run up and down five times unloaded. It may not always be possible to go to the
top. Check for smooth running and correct relief valve operation.
Load with the largest standard load and run up and down five times. Check that
the flow control valve gives the correct speed of descent. Check for partial
porting of the control valve leading to loss of control over descent. Adjust relief
valve to give constant speed of ascent. Examine hoist mountings.
Repeat the unloaded test. Check for leaks. Check rope or chain tensions.

9 Issue 1 –ER - Oct 2019
General
Check for correct operation of all door locks.
Check for correct operation of all proximity switches.
Check for correct operation of all control buttons.
Check existing guarding and assess the general safety of the installation.
Check that all signage is in position. Replace signs as necessary.
Check that there is an Operation & Service Manual available.
Training
Train staff if requested and complete the training register.
Reporting
Note any defects found, remedial action taken or work still required to be done on
the test certificate and in the schedule at the back of the handbook. If the
inspection was a Statutory Thorough Examination under LOLER then any defect
that is or could become a danger to persons must be notified to the relevant
enforcing authority and the lift taken out of use.
Leave a copy of the test certificate on site. Inform the Manager of any defects.