Sky Climber SKYMASTER User manual

SKY CLIMBER LLC –1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
Website: http://www.skyclimber.com
N.V. SKY CLIMBER EUROPE S.A. - Boomsesteenweg 14 - 2630 Aartselaar - Belgium
Email: [email protected] - Tel: [phone] - Fax: [phone]
Artesia Bank 550 33 14700 09 - BTW: BE 407 249 055 - HRA 185.015
SKYMASTER®
Owners Manual

SKY CLIMBER LLC
1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
Website: http://www.skyclimber.com
2
© Sky Climber, 2006
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any
form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written
permission of the publisher.
Revision History:
Revision #
Description
06/24/09
Draft Review
08/1/09
Initial Release
09/11/09
Clarification to Page 34, Connecting Rod Installation
12/3/09
Updated Images with New Dog Design

SKY CLIMBER LLC
1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
Website: http://www.skyclimber.com
3
© Sky Climber, 2006
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any
form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written
permission of the publisher.
FOREWORD
Welcome to Sky Climber.
Congratulations on your new Sky Climberproduct. All Sky Climber
products are designed and certified to the highest worldwide industry
standards. Our continuous quality control ensures this product is
manufactured to relevant codes.
It is your responsibility to READ AND UNDERSTAND the contents of
this manual. If you have any questions whatsoever, contact your dealer
or Sky Climbercustomer service.
Sky Climber“Owners Manuals” are designed for easy and efficient
use. Each part can be recognized easily with the use of exploded views.
Part numbers are shown near the assembly. The parts list, with part
numbers and descriptions, are in chronological order.
Sky Climberreserves the right to continually improve its products.
Every effort has been made to make this manual as accurate as possible
at the time of production; however there may be product changes, which
are not detailed in this manual.
We remind you to always wear personal fall protection equipment.
You’re Sky ClimberTeam

SKY CLIMBER LLC
1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
Website: http://www.skyclimber.com
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© Sky Climber, 2006
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any
form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written
permission of the publisher.
CONTENTS: SKYMASTER®
COVER PAGE
........................................
1
REVISION HISTORY
........................................
2
FOREWORD
........................................
3
CONTENTS
........................................
4
SAFETY GENERAL
GUIDELINES
........................................
5-13
OPERATOR & OPERATION
SAFETY
........................................
14-20
INSPECTIONS
........................................
21-24
PRODUCT DESCRIPTION
........................................
25
ASSEMBLY METHODS
........................................
26-38
PRODUCT OPERATION
........................................
39-41
DISASSEMBLY
METHODS
........................................
42-44
CHECK LIST
........................................
45-46
OSHA AND ANSI
........................................
47
LOG BOOK REQUIREMENTS
........................................
48
GUIDE TO ORDER SPARE
PARTS - SKYMASTER
........................................
49
QUESTIONS / CONTACTS
........................................
50

SKY CLIMBER LLC
1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
Website: http://www.skyclimber.com
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© Sky Climber, 2006
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any
form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written
permission of the publisher.
GUIDELINES
The SKYMASTER® System was designed and integrated using Sky
Climber products. The entire functionality, design intent, integrity and
performance were built around the SSU Staging and Sky Climber
Hoists.
•Maximum Height = 200 Feet
•Maximum SSU Width Between Masts = 15 Meters
TO EMPLOYER AND/OR RENTAL AGENCY
It is imperative that this manual be given to the operator of Sky Climber
equipment and that they read, fully understand, and follow all
instructions contained herein.
WARNING
Any use of this equipment, other than in strict accordance with
these instructions, shall be at the Operator's risk and
may result in serious injury to themselves or others.
REMEMBER SAFETY IS THE RESPONSIBILITY
OF BOTH YOU AND THE OPERATOR.

SKY CLIMBER LLC
1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
Website: http://www.skyclimber.com
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© Sky Climber, 2006
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any
form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written
permission of the publisher.
Safety is of the utmost importance when installing and
using the SKYMASTER® System equipment.
This section covers general guidelines. Follow your Manufacturer's
Instructions for proper equipment assembly. Follow all applicable
Federal, State, and Local rules and regulations.
Test your system before going aloft.
Continue to check to be sure your system remains safe throughout
the entire use on the job.
Make certain there are no obstructions to the vertical platform
travel.
RIGGING:
WARNING Rigging is the responsibility of the user. Do not
attempt to rig a job unless you are qualified. Failure of rigging may
result in serious injury or death.
Consult a professional structural engineer or the building owner to
verify safety of the Building or Structure to be rigged. Have them
clearly identify the construction and strength of all components used
in the rigging process.

SKY CLIMBER LLC
1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
Website: http://www.skyclimber.com
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© Sky Climber, 2006
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form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written
permission of the publisher.
Wire Rope Handling and Storage:
Always wear gloves to protect your hands when working with wire
rope.
Store wire rope in a coil or on a spool.
Protect rope from physical abuse, inclement weather, and corrosive
materials.
Do not drop wire rope from any height.
Uncoil wire rope carefully to avoid kinking or inducing a twist.
Do not uncoil by tossing coil over the edge of a structure.
Avoid dragging wire rope in dirt or around objects that could
scrape, crush, bend, or damage it.
Galvanized wire rope specified by Sky Climber, LLC is lubricated
at the factory and under normal conditions does not require further
lubrication.
Wire Rope Preparation:
Always use 5/16 inch wire rope of the proper length and
construction.
5/16 inch, G, XIP, RL, PRF**
Braze both ends a maximum of ½ inch in length.
WARNING:Wire rope is an expendable item. It begins
to wear when it is put into use. Do not use kinked, bird-
caged, excessively worn or damaged wire rope. Such use
may result in injury or death to yourself or others.
WIRE ROPE:

SKY CLIMBER LLC
1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
Website: http://www.skyclimber.com
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Air cool, then grind the tip to a blunted point.
G=Galvanized
XIP= Extra Improved Plow
RL=Right Lay
PRF= Preformed
Wire Rope Rigging:
Sky Climber only recommends a hand-tucked eye splice with
protective thimble, poured zinc socket, swaged socket or
compression fitting should be used to connect the suspension
cable to the anchorage point ofthe “Carriage”connection on the
SKYMASTER® System.
NEVER use U-type clamps which can crush wires and reduce wire
rope strength.
NEVER use J-clamps or Fistgrips at the Carriage connection
point.
These style Clamps will loosen; and require being torque at the
beginning of each shift.
Use a 5/16 inch thimble and a 5/8 inch shackle.
Use insulated thimbles when welding from platform. Minimum of
four J-type clamps, evenly spaced, are required.
Wire rope must support 6:1 safety factor.
A properly made 5/16 inch wire rope will have a minimum
breaking strength of least 9,400 lbs.
Store extra rope neatly coiled, tied, and protected from the
weather.
Wire rope must be rigged to remain vertical with suspension points
directly above the hoist entry guide or lead-in device.

SKY CLIMBER LLC
1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
Website: http://www.skyclimber.com
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© Sky Climber, 2006
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any
form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written
permission of the publisher.
Wire Rope Replacement:
Wire rope is critical to safe and trouble-free operation.
Replacement rope shall be to Sky Climber’s specifications. Use of
wire rope obtained from sources other than those specified by Sky
Climber could result in serious personal injury, property damage,
and/or equipment breakdown.
SSU PLATFORMS:
Follow the platform load specification.
Check stirrup bolts daily for soundness and tightness.
Use toe boards, handrails and mid-rails on all open sides.
Acids can destroy aluminum platforms. Replace platform
immediately if exposed to acids or corrosive materials.
Operate platform in level position only.
Work from deck of platform only. Do not stand on guardrails, toe
boards, platform/work cage supported objects or lean out from
ends of the platform. Do not use ladders etc. to get at higher
elevations.
Do not bridge from one platform to another, or to any structure or
other equipment.
Do not horizontally transfer a work platform while it is suspended
in the air. Perform all transfer operations ONLY with the platform
resting on a safe surface.

SKY CLIMBER LLC
1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
Website: http://www.skyclimber.com
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© Sky Climber, 2006
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form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written
permission of the publisher.
WELDING:
Use the following precautions when welding to prevent the possibility of
electric shock to personnel and/or the possibility of welding current
passing through the wire rope.
Attach each wire rope to its suspension point with a suitable
insulated thimble. Insulate extra rope stored on the roof to prevent
grounding, or terminate the suspension rope at the insulated
thimble.
Cover the supporting wire rope with insulating material above and
below the Sky Climber® Hoist.
Use a length of split rubber tube taped in place around the cable as
follows:
oExtend above the Sky Lock brake for 4 to 5 feet (more if
required by local codes).
oExtend below the Sky Climber® Hoist, far enough to insulate
the tail line from the platform. Guide and/or retain the
portion of the tail line below the platform so that it does not
become grounded.
Cover each Sky Climber Hoist, Sky Lock Brake, and Wire Winder
with protective covers made from insulating material.
Connect a grounding conductor from the platform to the work
piece. The size of this conductor must be equal to or greater than
the size of the stinger lead.
NOTE: This must be a secondary conductor and must not be in series
with the primary conductor between the welder and the work piece.

SKY CLIMBER LLC
1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
Website: http://www.skyclimber.com
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© Sky Climber, 2006
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any
form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written
permission of the publisher.
SAFETY:
Accidents can be prevented if you follow the instructions in this
manual. Once the equipment leaves Sky Climber’s control, the
Operator is responsible for its safe use, operation, and maintenance.
Safety Prevents Accidents:
Know and understand the operation of this equipment.
All Federal, State, and local codes and regulations that apply to
this equipment and its safe use must be followed.
Do not alter any Sky Climber Hoists, Sky Locks, SKYMASTER
parts or Accessories. Use only Sky Climber original parts in your
Sky Climber equipment.
Thoroughly inspect all equipment before use. Do not use any
equipment that has any apparent difficulty.
Wear hard hats at all times when servicing, erecting,
disassembling, or using this equipment.
Provide protection for workers from falling objects both above and
below the equipment.
Keep all persons from beneath SKYMASTER® System
equipment.
Never work alone on the SKYMASTER® platform, and ensure
help is available in an emergency.
Do not overload the equipment or exceed the maximum rated
capacity as noted in this manual.
Do not wear loose clothing while operating this equipment.
Always disconnect the AC power, when not in use.
SAFETY IS IMPORTANT
Use Commons Sense … Do NOT Take Chances!

SKY CLIMBER LLC
1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
Website: http://www.skyclimber.com
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© Sky Climber, 2006
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any
form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written
permission of the publisher.
Safety Guidelines
Operator’s Safety:
•All persons who service, install, dismantle or use SKYMASTER®
access equipment must fully comprehend and act in accordance with this
manual and all appropriate regulations. A competent person is a
designated person, suitably trained, and qualified by knowledge and
practical experience to carry out the required task safely.
Training, manuals and other documentation are available at Sky
Climber®. Do not hesitate to contact us for more details.
•Operators must be emotionally and physically able to withstand the
stress of working at elevations. Do not work at elevations if subject to
seizures or loss of physical control. Operators must be safety conscious,
responsible and not under the influence of alcohol, drugs or other
substances.
WARNING: Do NOT use the SKYMASTER® System,
Sky Climber Hoists, Sky Locks, or any other equipment that
is damaged or worn beyond normal tolerances.

SKY CLIMBER LLC
1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
Website: http://www.skyclimber.com
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© Sky Climber, 2006
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any
form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written
permission of the publisher.
•All persons using SKYMASTER® access systems must at all times
wear safety harnesses attached by lanyards and rope grabs to
independent anchorage point. Lifelines shall be fastened to an
independent anchorage point rated at 5000 lbs. or the use of a pre-
engineered “Dog Line” system affixed to a modified SSU stage. Do not
disconnect or remove harnesses or lanyards until safely on the ground or
until completely disembarked from SKYMASTER® System at a safe
location.
•Safety helmets should be worn at all times when servicing,
disassembling or using the equipment.
•Provide protection for operators from collision with overhead obstacles
and falling objects.
•Provide adequate protection below the SKYMASTER® system to
prevent injury to persons from falling objects. Keep all persons from
beneath suspended platforms.
•Maintain contact with your supervisor at all times.
•Make a copy of this manual available to every person using, erecting
and assembling this equipment.

SKY CLIMBER LLC
1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
Website: http://www.skyclimber.com
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© Sky Climber, 2006
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form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written
permission of the publisher.
Operation Safety:
•All SKYMASTER® access equipment must be handled with care:
during handling of equipment, installation and use (place loads gently on
platform).
•Inspect and test the equipment before use, rigging, re-rigging, after de-
rigging and at regular intervals to make sure that it is maintained in a
safe workable condition. The supervisor should assign a competent
person for inspection purposes. In case of equipment failures or
difficulties noticed during testing and inspection prior to use, contact
your nearest Sky Climber® representative and do not use the
equipment until it is repaired or replaced. Only use Sky Climber®
spare parts. Do not alter any equipment. Maintenance may only be
carried out by Sky Climber® representatives.
•Ensure that the electrical cable connection is routed safely. Make
certain that it can not get snagged or caught on any obstructions. Also
be sure that no materials could be dropped on the cable and cause
damage.
•Verify if all decals and nameplates are properly affixed and legible. If
they are obscured or missing, replacements are available from Sky
Climber®.
•Always verify the entire SKYMASTER® system is safe for use prior
to and during each shift. This would include but not limited to the safety
of the Mudsills, Base, Masts, Wall-Ties, Mast-Ties, Carriage, Wirerope,
SSU Staging & Components, Wall Anchor Bolts, and any other
Components included as part of the erected System. This includes the
inspection of all components listed.

SKY CLIMBER LLC
1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
Website: http://www.skyclimber.com
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© Sky Climber, 2006
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any
form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written
permission of the publisher.
•Never overload the platform above the indicated safe working load.
SEE SSU STAGING LIMITATIONS AND SAFE LOADING DECALS
INCLUDED IN THIS MANUAL.
•In case of an emergency during operation press the red emergency stop
button on the hoist or control unit. The platform will halt immediately
power is cut off, brakes are activated). Always solve the problem first,
prior to further use.
•Do not use hoists in conjunction with cableless control systems.
•Never use the SKYMASTER® System for transportation of passengers
from one level to another.
•Keep the vertical travel zone of the platform free of obstructions. When
running into an obstruction immediately stop the platform. Inspect the
platform and the obstruction for possible damage and/or hang-up.
Proceed in a safe direction. Take care not to overload the system or get
in slack rope situations when running into an obstacle.
•Beware of obstacles when there is too small of a clearance between
platform and façade. Use long-handled tools when working at large
distances between platform and facade.
•Do not handle suspended loads in conjunction with suspended
platforms.
•Never attempt to leave a SKYMASTER® platform in mid-air, always
return the system to the safety of ground level before exiting the system.
Otherwise; serious injuries and/or damage can occur.
•Hazardous situations occur when it is not possible to lower the
SKYMASTER® System to a safe position, over water and public roads.
•Never alter equipment once the SKYMASTER® System is suspended.
Keep all equipment out of reach of unauthorized persons.

SKY CLIMBER LLC
1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
Website: http://www.skyclimber.com
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form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written
permission of the publisher.
Group
Category
Condition
Temp
Application
Inspection
1
-
Normal
>0C/32F
Inspections, light
maintenance,
window washing.
Prior to each work shift.
2
A
B
C
Contaminated
Contaminated
Contaminated
>0C/32F
>0C/32F
>0C/32F
Abrasive
materials; sand
grit, dust,
welding.
Caustic materials;
corrosive
chemicals
Adhesive
materials; cement,
plaster, paint,
caulking,
compound
Prior to each work shift.
Service Every 3 months
Service Every 3 months
3
-
Freezing
0C/32F
All
Prior to each work shift.
Every hour.
•Do not use the SKYMASTER® System in severe conditions: extreme
environmental conditions, corrosive environment, strong magnetic
fields, and explosive atmospheres.
•Do not use the SKYMASTER® System when handling loads that
could lead to dangerous situations: molten metal, acids/bases,
radioactive materials, brittle loads.
Hoist Service & Inspections

SKY CLIMBER LLC
1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
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form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written
permission of the publisher.
•Always read your MSDS sheets on any product that will cause
Corrosion to Aluminum, Steel, or Rubber. Immediately clean and care
for any corrosive or caustic attacks on any of the materials used within
the SKYMASTER® System.
WIND SPEED CONDITIONS:
•NEVER use the SKYMASTER® System when wind speeds exceed
(31) MPH, (50km/h or 14m/s). The entire SKYMASTER® System is to
be lowered to the ground level and parked until weather conditions
improve. You may want to tether the SSU to the ground, so as to prevent
possible damage. Always unplug the Electrical supply when not in use!
•Do not use the SKYMASTER® System when hazards could arise from
wind pressure acting on loads having a surface area in excess of 2m²
(21.5 SQFT).
•There are scales of wind forces which are accepted internationally and
used when communicating weather conditions. These scales represent
certain strength and velocity of wind at 33ft. above ground level in open
spaces.
•A typical representation of wind conditions is shown in Table 18.1

SKY CLIMBER LLC
1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
Website: http://www.skyclimber.com
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form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written
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Wind
Description
Results
mph
m/s
Calm
Smoke rises vertically
0-1
0-0.2
Light Air
Direction of wind shown by
smoke
1-3
0.3-1.5
Light Breeze
Wind felt on face, leaves
rustle
4-7
1.6-3.3
Gentle Breeze
Leaves and small twigs in
constant motion, wind extends
light flag
8-12
3.4-5.4
Moderate
Breeze
Raises dust and loose papers,
small branches move
13-18
5.5-7.9
Fresh Breeze
Small Trees begin to sway
19-24
8.0-10.7
Strong Breeze
Large branches in motion,
whistling heard in telephone
lines
25-31
10.8-13.8
Near Gale
Whole Trees in motion,
resistance felt when walking
into the wind
32-38
13.9-17.1
Gale
Breaks twigs off trees,
impedes progress
39-46
17.2-20.7
Strong Gale
Slight structural damage
occurs, slate or shingles could
be removed
47-54
20.8-24.4
Table 18.1

SKY CLIMBER LLC
1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
Website: http://www.skyclimber.com
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form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written
permission of the publisher.
NOTE:
Remove the SSU staging from the SKYMASTER® System when wind
speeds are expected to exceed the Strong Gale force wind speeds of 54
MPH.
High Voltage Power-lines:
•Refer to regulations, federal, state and local codes when working in the
vicinity of electrical overhead power-lines. Consult the local power
company for safe operating procedures.
•The minimum separation between live power lines and
SKYMASTER® System platform is 3m (10’).
•Touching live power-lines may result in death or serious injury.
Welding:
•During welding, the electrocution hazard and the risk of the welding
current passing through the steel wire ropes shall be eliminated by taking
the following precautions:
Use insulated thimbles at each suspension point. Insulate surplus steel
wire rope stored on roof to prevent grounding or, terminate steel wire
rope at insulated thimble.

SKY CLIMBER LLC
1800 Pittsburgh Drive - Delaware - Ohio 43015 - U.S.A
Email: [email protected] - Tel: [phone] - Fax: [phone]
Website: http://www.skyclimber.com
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form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written
permission of the publisher.
•Cover steel wire rope above hoist and Sky Lock for a distance of ±
1.2m (4’) with insulating material: rubber hose taped in place. Insulate
tail line below hoist: extend downward sufficiently to prevent contact
with platform. The portion of tail line hanging free below platform must
be guided and/or retained so that it does not become grounded.
•Cover each hoist, Sky Lock and wire winder with protective covers
made out of insulating material.
•Connect a ground conductor from platform to work piece. The size of
this conductor shall be equal to or greater than the size of the stinger
lead. It must be a secondary conductor and shall not be in series with the
primary conductor between welder and work piece.
Marine Environment:
• Salty environments may deteriorate aluminum & steel components.
Frequently inspect equipment.
• Excess material accumulation; Make sure that excess material does not
clutter up the any of the working parts on the SKYMASTER® System,
Hoist, Sky Lock, Wirerope or Platform.