Power Towers EcoLift Operating instructions

Operating and
Maintenance Manual
www.powertowers.com
4.2m Non-Powered, Powered Access
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CONTENTS
Introduction 2
Operating Specications 3
Working Envelope Diagram 3
Do’s and Don’ts 4
Primary Components 5
Operating Procedures (Incl. Emergency Operation) 6-8
Maintenance Procedures 9-11
Castor Safety and Maintenance 12
Transportation, Towing, Lifting and Manoeuvring 13-14
Storage 15
Key Spare Parts 16
Warranty Terms 17
Decal Placement 18-21
Wind Rated Chassis - Operating Specications Appendix ‘A’
Wind Rated Chassis - Operating and
Safety Instructions Appendix ‘B’
Wind Rated Chassis. Additional
Maintenance Instructions Appendix ‘C’
Machines with ATEX Certication Appendix ‘D’
CONTENTS
2
INTRODUCTION
The Power Tower Ecolift is a simple, safe and ecient alternative to step-
ladders, platform/podium steps and small scaold towers. The Ecolift does
not require batteries (or charging) or connection to an electricity supply. It
works by a unique, patented stored power mechanism which enables the
platform to be elevated with very little eort by the operator.
The Ecolift is designed for working internally on at, level surfaces,
and as it has no batteries, electric motor, electrics or hydraulics it is very
ecologically friendly. It is ideally suited to working in a very wide range of
applications from the very ‘clean’environments of hospitals, food and drinks
production facilities, pharmaceuticals and retail, to facilities maintenance,
shop-tting and indoor construction and even on zone 1/21 hazardous
areas (If ATEX option is tted).
The Ecolift is suitable for any application provided it is used within its
specied operating parameters. If used for applications such as sand
blasting, welding, paint spraying or with any other hazardous materials,
measures must be taken to ensure the Ecolift does not become damaged in
any way which may impair safety, or reliability. Additional protection for the
operator may be required in some cases, which is the responsibility of the
operator and/or the operator’s employer.
The purpose of this manual is to provide essential basic information required
to operate and maintain the Ecolift.
This is not a workshop manual. Please contact the manufacturer or their
agent for specic operation or maintenance information if in doubt.
The health and safety of the operator or maintenance technician is the
responsibility of the individual and/or their employer and not Power
Towers Ltd.
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OPERATING SPECIFICATIONS
3
OPERATING SPECIFICATIONS
Working Dimensions
Maximum working height: 4.20 m
Maximum platform height: 2.20 m
Platform dimensions: 850 mm (L) x 644 mm (W)
Working footprint: 1280 mm x 740 mm
Safe working load: 150 kg (1 person + tools)
Maximum manual force: 200 N
Maximum gradient for operation: 0 degrees
Maximum wind force: Internal use only,
0 (zero) mph
Maximum wheel force: 234 kg
Maximum castor point load: 234 kg (2.29kN)
Sound pressure level: Less than 70dBA
Closed Dimensions
Length: 1280 mm
Width: 740 mm
Height: 1950 mm
Weight: 305 kg
Lift Cycles: Unlimited, subject to maintenance
program being adhered to.
2.0m
1.0m
4.2m
3.0m
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DO’S and DON’TS
4
DO’S
1. Read and adhere to the instructions both on the machine and in
the Instruction Guide or Operating Manual.
2. Ensure pre-operation checks & operations are carried out in the
manner described.
3. Use only on hard, level surfaces able to support the weight
of the machine.
4. Use the Ecolift internally only.
5. Ensure the operator is t and does not suer from a
fear of heights.
6. Ensure guardrail gates are closed before elevation.
7. Ensure work area around the machine is cordoned o from
pedestrians and other trac.
8. Ensure operator is wearing the correct safety equipment.
9. Ensure the platform is correctly positioned so as not to come into
contact with xed or moving objects.
10. Ensure that the safe working load is evenly distributed
on the platform.
11. Ensure the machine is being operated within the PUWER
(Provision and Use of Workplace Equipment Regulations).
12. Ensure the castor brakes are applied when leaving the machine
unattended.
DON’TS
1. Never exceed the safe working load (1 person plus tools, 150kg).
2. Never use the Ecolift as a goods lift or crane.
3. Never exceed horizontal forces, (maximum horizontal force 200N).
4. Never use in the vicinity of live conductors.
5. Never try to move the Ecolift on its wheels when elevated.
6. Never extend the height of the platform by using boxes,
steps, ladders etc.
7. Never modify the Ecolift in any way without the full written
approval of the manufacturer.
8. Never attempt to enter or exit the platform unless it is
fully lowered.
9. Never use the Ecolift on sloping or uneven ground.
10. Never operate the Ecolift outdoors, or anywhere it may be
aected by wind.
11. Never lift heavy components on the Ecolift without the
use of the correct lifting equipment.
12. Never use the Ecolift in an explosive environment.
13. Never use the machine if you are fatigued.
14. Never use the machine inappropriately or for‘horseplay.’
15. Never use the machine if under the inuence of drugs or alcohol.
16. Never use the machine if suering from poor health or using
medication which might impair the safe operation of the Ecolift.
17. Never use the Ecolift if vision impaired by bright lighting.
18. Never push the Ecolift on sloping surfaces without the use of a
safe method.
19. Never push or pull objects with the platform.
20. Never use on uneven surfaces.
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PRIMARY COMPONENTS
PRIMARY COMPONENT LOCATIONS
5
Flywheel
Spirit Level Swivel Castor
Auto-Lok Braked Wheel
Emergency
Lowering Tool
Tool Tray
Gates
Platform
Tray
Flywheel
Handle
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OPERATING PROCEDURES
6
OPERATING PROCEDURES
It is essential to be familiar with the correct operating procedures.
The operator must have adequate training for this type of platform.
The Ecolift is tted with a safety harness point. If after conducting a risk assessment the
opertator chooses to wear a safety harness, an approved‘fall restraint’type harness should be
worn with a very short lanyard.
Operating procedures are divided into three key areas:
1. Pre-operation checks.
What to do before operating the Ecolift.
2. Normal operation.
How to use the Ecolift safely.
3. Emergency operation.
How to lower the Ecolift in the event of operator incapacity.
It is the owners and/or the users responsibility to ensure that the machine is maintained
and operated in accordance with the operation and maintenance procedures contained
within this manual.
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PRE-OPERATION CHECKS
1. Visually inspect the Ecolift for any signs of damage to handrails, platform tray,
chassis and mast lifting structure including mast xing bolts.
2. Check castors and wheels rotate freely and are undamaged.
3. Check castors (pic 1) and wheel xings (pic 2) are secured with split pin.
4. Check spirit level (pic 3) is intact and bubble is centred to ensure machine is level.
5. Check gates, gate hinges, hinge springs and hinge xings are undamaged and
that gates open and close correctly (pic 4).
6. Ensure step is lowered and secure.
7. Check castors are not loose or distorted in any way. If okay, lock by stepping on
the pedal marked ‘lock’ or stepping on the red pedal, depending on which castor
is tted, then step into the basket.
8. When standing in the basket: check‘y-wheel’operating handle works correctly.
Hold handle rmly and pull operating knob towards you, release, knob should
spring back to lock wheel. Repeat but turn handle once clockwise with
knob held pulled towards you. Wheel should turn freely. Turn once
anti-clockwise to come down (pic 5).
9. Check emergency lowering tool is attached on the chassis.
If any of the above items are faulty or do not work correctly then do not
use the machine.
NORMAL OPERATION
Only use the Ecolift internally, on hard level surfaces. Ensure a person
is available at ground level to assist in case of emergency.
1. Position machine under application.
2. Check spirit level to ensure machine is level.
3. Ensure castors are in the locked position as described in pre-operation checks.
4. Step into platform through gates, ensure gates close behind you.
DO NOT ELEVATE IF they are not closed.
5. Check there are no overhead obstructions.
6. To elevate: pull operating knob towards you and turn clockwise.
To stop, stop turning the handle and release handle knob to lock.
7. To descend repeat but turn handle anti-clockwise.
Note: Do not attempt to turn the ywheel handle when there is NO payload in the
platform .i.e. when standing outside the platform guardrails.
OPERATING PROCEDURES
7
12
3 4
5
The user shall obtain the
guidance and approval of
the manufacturer in the
event of any special working
methods or conditions
outside those specied by
the manufacturer.
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EMERGENCY LOWERING OPERATION
Never attempt to recover the machine/operator if there is any
possibility the machine is contacting any live wiring/cabling and is
therefore potentially ‘live’.
To lower the platform in the event of the operator being
incapacitated (unable to operate the ywheel handle in the
basket):
1. Locate emergency lowering tool on chassis (pic 1), remove from
fixing.
2. Stand to side of machine, attach‘hook’ end of emergency
lowering tool to flywheel handle knob in basket, releasing
handle knob, turn wheel anti-clockwise to bring platform down
(pic 2).
3. Keep clear of structure as it descends.
5. Depending on the height of the elevated platform, it may be
necessary to extend the shaft of the tool.
Turn the shaft lock anti-clockwise to extend and retract the shaft,
and clockwise to lock to the desired position.
OPERATING PROCEDURES
8
Turn wheel anti-clockwise to bring platform down
1
2
Never attempt to engage the emergency lowering
tool without an operator in the platform.
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Please note that whilst the Ecolift is extremely simple to maintain,
all work must be carried out by a competent person.
DAILY MAINTENANCE
Note: The telescopic mast is a sealed unit which contains a
pressurised cylinder and can only be dismantled by a trained person
authorised by the manufacturer.
The most important regular maintenance to be carried out by the
operator is visual inspection, as per the pre-operation checks.
Daily Checks
The safety critical items to inspect each work session, daily as a
minimum are:
1. Check there is no damage to the following: wheels and castors
and check that their xings are secure. These are the components
that connect the machine to the ground; if they are damaged then
operating the machine could be dangerous and and may result in
serious injury.
2. Check that the guardrails are not damaged and all
xings are secure.
3. Check gates and gate hinges are secure and gates close freely.
Ensure gates cannot open outwards.
4. Check chassis is not damaged and spirit level is intact and working.
5. Check mast xings are all present and secure.
6. Check ywheel handle operates correctly: step into the platform
to do this (do not attempt to operate the handle from outside
the basket).Pull ywheel handle knob towards you, release.
Ensure handle springs back to lock wheel. Turn wheel one
revolution clockwise then anti-clockwise; ensure handle
moves freely in either direction.
7. Check automatic wheel-brake works by: repeat no. 6 when
platform is elevated approximately 100mm, and with the
assistance of a colleague, attempt to push the machine, machine
should not move, wheels should be braked.
8. Check emergency lowering tool is attached to chassis and not
damaged. Check pivot and spring for signs of fatigue
Monthly Checks
As daily checks (items 1-8).
MAINTENANCE PROCEDURES
9
NOTE: PUWER (The Provision and Use of Workplace Equipment
Regulations 1998) stipulates that suppliers such as hire
companies must ensure their equipment is maintained
correctly and fully serviced. Once on site,it is the hirer/
employer’s responsibility to ensure the machine remains in
serviceable condition. The hirer/employer must also ensure the
operator is properly trained and familiarised with the machine
and the manufacturers operating procedures.
The health and safety of any operator or maintenance
staff is the responsibility of the individual and/or
their employer.
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SIX MONTHLY CHECKS - LOLER
1. Remove handle cover using suitable security screw tool
and inspect and lubricate gearwheels. Use Omega 73 no. 2 harsh
environment grease or equivalent. Do not use standard gear
grease because it will dry out prematurely and will lead to
premature gear wear. Paint seal screws when retted.
2. The machine should be subjected to the test procedure below:
a) Fully lower platform to the transport position.
b) With a calibrated digital spring balance apply a further 25kg
force to the drive handle in the anti-clockwise direction (lowering),
rst releasing the handle knob from the back plate to allow the
handle to turn (see g A).
3. Inspect the drive belt for signs of wear. In order to do this, remove
the tool tray and mast cap plate. The mast cap screws are
additionally secured with a threadlock adhesive. If diculty is
experienced removing these screws then they will need to be
heated with a heat gun for a few minutes. With this cover removed
a full visual inspection of the belt and pulleys can be made. The
platform can be raised and lowered fully whilst viewing the
belt and pulleys. Minor scung and wear is acceptable, but there
should be no signs of the inner braided wire or Kevlar cords visible.
If there are any signs of excessive wear, contact the manufacturer
or authorised distributor. When complete, ret the mast cover and
ret the xing screws with a medium strength threadlock. Paint
seal screws when retted. Ret tool tray. It is extremely important
that these bolts be replaced correctly.
4. Check the mast interlock is undamaged. Check the casing for signs
of damage and remove the end plate. (Pic 1, shows mast
interlock with cover on). Check the plunger is free to move by
holding end with long nosed pliers and pulling outward and then
releasing (Pic 2). Ensure plunger springs back freely. Ret cover
and screw. Paint seal screw when retted.
5. Inspect condition of automatic wheel lock. Look under brush
strip at rear of chassis when platform is elevated so that mast outer
is clear of chassis. Check brake cam plates (Pic 3 and Fig B) are
undamaged and that the two attaching screws are tight. With an
assistant to lower the platform, observe the action of the cams and
the movement of the brake pins. Ensure the movement is free and
the pins clear the wheel discs. When the platform is elevated
ensure the pins fully engage the brake discs. Ensure the pockets in
the wheels are in good condition.
6. Check all instruction labels are present and clear. Refer to the key
spare parts. Check aluminium specication plate is clear and
legible.
7. Check crank handle knob is securely xed with M12 nyloc nut and
roll pin through plastic tip. Ensure handle springs back to the
locked position freely.
When replacing components for any reason, only use OEM
specication parts, either supplied from the manufacturer or
authorised in writing by the manufacturer. Warranties and design
approvals will be void if alternative components are tted.
It is essential to obtain manufacturer’s approval of any alteration
which might aect stability, strength or performance in writing
before proceeding.
When retting a rear wheel always use a new cotter pin (4mm
diameter x 32mm A2 stainless steel). NEVER REFIT A USED COTTER
PIN.
MAINTENANCE PROCEDURES
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