Instruction Manual

Transcript

INSTRUCTION MANUAL INTRODUCTION INSTRUCTION MANUAL Operation and maintenance of Mini 61 BSS edition For power lift with serial no: Instruction manual nr: IB Mini BSS - 61 Date of issue: 05-01-10 Supplier: MaxMove Industrier AB Industrivägen 9 S-916 31 Bjurholm SWEDEN Copyright: MaxMove Industrier AB 2 INTRODUCTION Read this first! 4 Contents of the instruction manual ............................................................ 4 Saftey regulations 5 Warning signs ............................................................................................ 5 Personnel ................................................................................................... 6 Enviroment ................................................................................................ 6 Moving ...................................................................................................... 7 During operation ........................................................................................ 8 After operation ........................................................................................... 8 Transport.................................................................................................... 9 General safety during repair .................................................................... 10 Design and function 11 Technical data Mini 61 ....................................................................... 12,13 Over and under carriage .......................................................................... 14 Motor and drive system ........................................................................... 15 Electrical system ................................................................................. 16,17 Sensors ..................................................................................................... 18 Sensors, Air outlet ................................................................................... 19 Hydraulic ................................................................................................. 20 Scissor and platform ................................................................................ 21 Control Box, Movement ..................................................................... 22,23 Handling 20 Starting and stopping ............................................................................... 23 Moving .................................................................................................... 24 Lifting function and working from the platform ..................................... 25 Transport, lift and storage ........................................................................ 26 Charging the battery ................................................................................ 27 Maintenance 29 Important points on the hydraulic system ................................................ 29 Daily inspection ....................................................................................... 30 Weekly checks and maintenance ............................................................. 30 Six-monthly maintenance ........................................................................ 31 Maintenance after a periode of storage ................................................... 32 Refilling hydraulic fluid .......................................................................... 34 Troubleshooting 35 Diagrams 36 Hydraulics ................................................................................................ 36 Electrics ................................................................................................... 38 Declaration of conformity ...................................................................... 42 Contact ..................................................................................................... 43 3 INTRODUCTION PLEASE READ FIRST! Before using the machine it is of the utmost importance that you have read and understood the contents of this instruction manual. It is vital to follow all instructions on handling and maintenance both in order not to endanger the safety of the operator and those in the vicinity and to avoid damage to buildings and the machine. Supervisors and all those working with or from a machine should read the instruction manual. In an emergency it may be crucial for all those working on the platform, and not just a selected operator, to have a command of lifting platform procedure. Bear in mind that your employer is responsible for ensuring that you have adequate knowledge of how to handle this equipment. Do not hesitate to contact your supervisor if you feel in any way uncertain as how to do your job. CONTENTS OF THE INSTRUCTION MANUAL The instruction manual comprises the following main sections: • Safety regulations. Study these with extra care! • A general description of the machine with technical data. This section tells you what kind of danger a warning light indicates and how the hydraulic system works. • Operating instructions with step-by-step instructions on how to operate the lifting platform. • The maintenance schedule and relevant instructions. • A troubleshooting chart. • Schemes and Declaration of conformity. • Contact MaxMove Industrier AB 4 SAFETY REGULATIONS SAFETY REGULATIONS Before using the machine, you must read these safety regulations and the rest of the instruction manual. Working with a scissors lift will always involve certain risks as the work is often being carried out at great heights. There is also the risk of being crushed between the lift and adjacent walls, striking your head on beams or other hanging objects, or nearing electrical conductors. The risk of accidents is greatest when moving the lift with the platform raised. Good judgement and extreme care is demanded of the operator. It is important to consider your safety as well as that of your co-workers and the equipment when carrying out the work. The responsibility of operating the lift must not be handed over to anybody lacking the necessary knowledge or experience. WARNING SIGNS The instruction manual warns of tasks that may cause accidents if the instructions are not followed. Because of the accident risk and the possible consequences such an accident may have, the warnings are divided into four levels. DANGER! DANGER! warns of accidents that may lead to serious injury or death CAUTION! CAUTION! indicates risks that can cause serious injury if handled incorrectly. Attention! Attention! indicates risks that can cause injury if handled incorrectly. Note! Note! means that the instructions should be followed to avoid damaging the equipment 5 SAFETY REGULATIONS PERSONAL CAUTION! Only trained personnel may use the lift.Incorrect handling can lead to serious injury or damage to the surroundings. Note! The operator is responsible for inspecting the lift regularly, conducting daily service and rectifying any faults. In short, the operator is responsible for keeping the lift in such a condition that the safety of other people, as well as their own, is not put at risk. ENVIROMENT Note! - The lift intended for indoor use only. - The machine must never be operated in water deeper than 1 inch.Electrical equipment may be damaged if water reaches and enters it. DANGER! The machine must not be operated in premises classed as an “explosion hazard”. 6 SAFETY REGULATIONS MOVING Attention! - Never move the lift without first inspecting the area in the direction of travel. Check the condition of the surface, that there are no objects or persons in the direction of travel and that there are no objects near the platform. - Check the surface is firm and plane before moving the machine. - Objects must not protrude from the platform when it is being moved. Note! - If the ground inclines more than 3 degree along or 0.5 degree sideways the platform must be in its lowest position whenever it is moved. - If the platform is heavily loaded, it must always be in its lowest position before the lift is moved. - The machine must not be used to tow or push trailers or any other objects. DANGER! - The machine must not be moved while the power cable (to the battery charger) is connected. The cable may be damaged and make the machine current carrying. - It is essential to follow the instructions in the “Handling” chapter when lowering the platform in emergencies. - Check the surroundings when lowering the platform in emergencies. - Check the bearing capacity of the surface before lifting the platform. DANGER! All lifting involves risk of crush injuries and other personal injury. The lift and surrounding objects can also be damaged if care is not taken. The following points are therefore important when lifting. • Make sure nobody is on the machine or in its vicinity. • Remove all tools and other objects from the lift. • Make sure no part of the machine knocks against any surrounding. • Do not lift higher than necessary. 7 SAFETY REGULATIONS Note! Attention! - No objects may be suspended from the lift. Suspended objects can start swinging and damage the scissors, other objects or people. Swinging objects may also cause the lift to tip over. - The lift must never be left unsupervised when the platform is raised. AFTER OPERATION Note! Always remove the key from the main power switch after completing work. This will prevent unauthorised persons starting the machine. DANGER! Always charge the batteries in premises where there is no risk of sparks. The oxyhydrogen gas that is formed during charging can be ignited and explode. 8 SAFETY REGULATIONS TRANSPORT Note! - The machine must never be pulled, towed or pushed. - The lift can be lifted with a fork lift truck of sufficient lifting capacity. The lifting forks must be inserted in the fork pockets under the chassi. - Make sure that the forks are not inserted so far that the lift slides forward with the Maxwheel standing on the surface. This will damage the rotation framework and the wheel. - The machine can also be lifted with a crane or telpher of sufficient lifting capacity. Follow the directions later in this manual. Make sure nobody is standing under a suspended machine. - The platform must be in its lowest position during all lifts. - Always remove any tools and other objects from the platform before lifting. No persons may be on or near the machine when it is being lifted. - When transporting on a truck, for instance the machine must be well secured with straps and wheel chocks. - The machine must be secured so that it will not move during transport. The Maxwheels and drive system can be damaged if the lift is moved by external forces. - Do not tighten the straps over the platform or to any details forming part of the platform, the scissors or the scissor mountings. The scissors can be damaged if the straps are too tight. CAUTION! The machine can be damaged or top over if the forks are inserted outside the lift zone or are too short. 9 SAFETY REGULATIONS GENERAL SAFETY DURING REPAIRS DANGER! Never start servicing or repairs under the platform or on the scissors without first securing the scissors with the safety stay. Note! - Only authorized service engineering may carry out repair with the electric and hydraulic system. - Any faults or damage must be rectified immediately. Do not operate the machine until such faults have been rectified. - Use only original spare parts for repairs and servicing. HYDRAULIC CAUTION! - Never operate the lift if you suspect a fault in the hydraulic system. - Never attempt to stop a leaking or damaged hydraulic hose with your hand. Atomized fluid can penetrate the skin and cause serious injury. DANGER! Observe the risks of working on the hydraulic system. Follow repair directions thoroughly. Cleanliness is of extreme importance. Take care when working on components that may be under pressure even when the machine has been turned off. Always secure moving parts when working on them. ELECTRIC Note! - Note that only persons with the necessary experience of electrical components may perform testing with instruments. - Only authorized service engineers may open the electronics box and perform repairs. The batteries must be disconnected before working on the electronics box in order to avoid damage. - Note that a blown fuse means that there is a fault some where. Try to localize and rectify the fault before resetting the fuse. - Check the function and condition of the control box regularly. A malfunctioning control lever or button must be replaced immediately. 10 DESIGN AND FUNCTION DESIGN AND FUNCTION Mini is an automatic, electrically powered scissors lift with unrivalled motive powers thanks to the unique drive wheel. The lift can move in all directions and even around its own centre point. Chassis, scissors and platform are made of steel. This gives a stable and durable construction while maintaining flexibility. The platform has an extending section to give a total working area of over 2.5 square foot. The approx. 3 metre long platform offers the ability for two people to cover a large working area. The lift is delivered with 6,1 metre platform height. Mini is fitted with an advanced control system including sensors to detect the height of the platform and adapt the speed accordingly. There are also sensors that detect inclination. 11 DESIGN AND FUNCTION L I C A K D E F B M H G A) B) C) D) E) F) G) H) I) K) L) M) Dimensions (ft) Maximum platform height Minimum platform height Hand rail height Overall height Transport height folded hand rail (Option) Transport height demounted hand rail Maximum lenght Maximum width Platform lenght Platform width Platform extended length Ground clearence 20.1 3.4 3.6 7.1 5.8 4.0 6.4 3.1 6.5 2.6 10.1 0.3 Weight/Capacity (lb) Product weight Maximum platform load Maximum platform extension load Performance Maximum drive speed-lowered (miles/h) Maximum drive speed-elevated (miles/h) Lift/Lower time (s) Turning radius-inside (mm/ft) Turning radius-outer (mm/ft) Maximum lateral inclination Maximum longitudinal inclination Gradeability (%) 3064 500 242 2 0.3 40/25 0 3.4 at 9 ft 3,5° at 18 ft 0,5° 3° 15%, 7° 12 DESIGN AND FUNCTION ELECTRICAL SYSTEM DC system 24 V Batteries 2 x 12V Battery capacity 97Ah Mains connection Battery charger 110 V, 10 A 10 A Electric motors • Drive motor (high speed) 24 V DC / 600 W • Drive motor (low speed) 24 V DC / 80 W • Steering motor 24 V DC / 120 W Main fuse • Located in battery box 60 A Maxifuse Fuses on logic card: • Control logic circuit 5 A Autofuse • Emergency stop circuit 1 A Autofuse • Control logic circuit sensors 5 A Autofuse HYDRAULIC SYSTEM Lift / Swing axle Hydraulic system capacity Pump type Pump motor approx 1 gallon Gear pump OHE2C125N14C10100N 24V DC 1 kW Max. operating pressure Lifting-cylinder Swing axle-cylinder 195 bar ESHL 4032965-91081 ESHL 633290OK-91081 13 DESIGN AND FUNCTION OVER AND UNDER CARRIAGE The structural chassis is the combining element for the wheel gear, swing axle and scissors. It also includes the spaces and mountings for the batteries and control system. The chassis is manufactured in pressed and welded 1/4” steel plate. The protective covers are in vacuum-formed plastic and are curved to avoid fastening to obstacles and make them easy to clean. Two drive wheel and two caster wheels are located diagonally opposite under the chassis. The front wheels, one drive wheel and one caster wheel, are suspended on a common swing axle to form a transverse bogie. A swing axle cylinder fitted to the bogie allows the lift to be manoeuvred on uneven surfaces without any of the wheels losing contact with the ground. S The scissor is consist of a couple of scissor legs, connected to the chassis and platform. The number of scissor par decide the platform height. The platform consist of a working floor, railing and a extension.. MOTOR OCH DRIVESYSTEM Low speed Drive motor Ball bearing Clutch Drive Belt Worm gear Motor Relay High speed Drive motor MOTOR AND WORMGEAR The drive wheels are driven by a 24 V electric motor on each wheel. Transmission takes place directly from the motors via worm gears to the drive wheels, but when driven by the lowspeed motor the transmission goes by the belt down to the high speed motor to the wormgear The wheels are steered, i.e. rotated horizontally, by two steering motors underneath the chassis. The transmission of power from the steering motors is connected directly to the drive unit. HIGH/LOWSPEED GEARBOX The machine is fitted with an high / lowspeed option for smooth operation. Lowspeed activates when the clutch is energized by setting an switch on the control box. DRIVE WHEEL Drive wheel The two drive wheels are used for both driving and steering the lift. Unlike normal wheels that can only roll forward and backward, the drive wheel can rotate around its own axis and therefore move the lift in all directions. By running the wheels in opposite directions, the entire lift can be rotated around its centre. CASTER WHEEL Steer motor The rotating caster wheels follow the motion of the lift and adapt themselves to the relevant direction of travel. The caster wheels are manufactured in solid polyurethan with aluminium hubs. 14 DESIGN AND FUNCTION 1 2 3 4 RIGHT SIDE 1. Rear drive motors 2. Electronics box 3. Hydraulic pump (lift) 4. Cylinder cover 5. Emergency stop 6. Emergency lowering handle 6 5 5 6 LEFT SIDE 1. Main Switch 2. Charger connection 3. Main fuse 4. Battery 5. Plc for sensors 6. Charger 7. Connection box for sensors 1 2 3 4 7 15 DESIGN AND FUNCTION ELECTRICAL SYSTEM ELECTRONIC BOX Electronic box The electronic box is located on the right-hand side. The electronic box contains the fuses and all the electronic equipment needed for driving and steering. MAIN SWITCH / EMERGENCY STOP The main switch disconnects all the lift functions. It is operated with a handle located on the left-hand side of lift, on the front of the black plastic cover. Main switch Emergency stop There are two emergency stops, one on the control box and one on the right black plastic cover. Disconnect all function when pressed, restores by rotate and pull out the red button and restart with the ignition key switch. BATTERIES On the left-hand side of machine, under the black plastic cover, there are two 12 V batteries. The batteries are used for normal operation. If the battery voltage drops below 20 V, the speed of the lift will be reduced to compensate for the voltage loss. Note, however, that the platform can always be lowered manually from the ground by following the directions on chapter ”Handling”. Battery BATTERY CHARGER Connect the charger to an earthed outlet with ac mains voltage. The charging starts after a few seconds and the status indicator, Orange led is lit up. Orange led remains on until the battery is fully charged. If the charger is connected to a fully charged battery the charger will be charging for 1 hour. This is the minimum charging time. Green led, is lit up when the battery is ready to be used. Maintenance charging will continue as long as the battery is connected. The charger will be reset as soon as the charger is switched off and then on or if the mains connector is disconnected and then connected again. The charging time depends on the size of battery and the depth of discharge. Red flashing led may mean that the battery is not properly connected. 3 1 1 Led 2 Fan 3 Charger ABC 24/20 2 Check cables, connection terminals, plugs and other connections to the battery. Rectify if possible. Measure the voltage at the battery and at the charger. If the connecting points and the voltage is correct. OBS: Switch off the charger before the battery is disconnected. If the battery is disconnected without switching of the charger, sparks may be produced. 16 DESIGN AND FUNCTION SCISSORS HEIGHT SENSOR Scissor height sensor On the rear scissors member there is a scissors height sensor that registers the height of the platform. The height affects the manoeuvring speed of the machine and when the tilt protection should be activated. TILT SENSOR Tilt sensor The Tilt sensor controls the inclination of the scissor and sending signals to the machine plc and warn when inclination is to high for the machine. The tilt protection breaks all the functions except lowering if the lift is tilted more than 3° along, more than 3° sideways and the platform is over three metres hight. At 236 inches the maximum tilt sideways is 1°. The sensor is located under the chassie directly below the electronics box AMBER BEACON Amber beacon Located to the right in the front of the machine is the beacon, it is active when the machine is moving or lifting. 110 VAC OUTLET ON PLATFORM Outlet Platform On the platform there is an outlet for 110v to drive electrical machines. The intake for the outlet is located at the rear end of the machine by the ladder. Inlet ladder Sensor System SENSORS The machine is equipped with an tuchless bumper system that consist of 18 photoelectric sensors. When an sensor is activated by an obstical an signal goes to sensor plc and stops all machine functions as long as tha obstical is present. 17 DESIGN AND FUNCTION Power on led (Green) Sense led (Yellow) The scanning distance can be simply and quickly adjusted by using the teach buttons or with the fine adjustment option. Put an object in front of the sensor at the distance that you want to sens on, press both yellow buttons in the back of the sensors for 2 sec. Teach buttons The sensors yellow light should now light, until you remove the object in front of the sensor. For fine adjustment press either + or the - switch to get the correct sensing distance. Make sure to keep the sensor head clean at all time for best function. SENSOR CONNECTION BOXES There are two connection boxes for the sensors, one is located on the platforms rights side and the other is located on the left side in the battery compartment, here is also the sensor plc located. PLATFORM CONNECTION BOX Signal Cable Spare Sensor Cables In the connection box are all of the eight platform sensors connected for power to the sensors and signals down to the sensor plc. For future use there is possible to connect one moore sensor on the platform, at connection point 24 to 25 is an jumper when there is no extra sensor connected. Se instructions below for how to connect an extra sensor. 1. Remove jumper on 24, 25 2. Connect the sensors cables according to the instruction below 24 = Brown cable + . 25 = White cable sense . 26 = Blue cable - . 3. Calibrate the new sensor at suitable scanning distanse. 4. Do an function test of the new sensor, put an object in front of the sensor, an alarm should now sound and stop when you remove the object. CHASSIE CONNECTION BOX In the connection are all of the ten chassie sensors connected for power to the sensors and signals to the sensor plc. For future use there is possible to connect one moore sensor on the chassie, at connection point 33 to 34 is an jumper when there is no extra sensor connected. Se instructions below for how to connect an extra sensor. 1. Remove jumper on 33, 34 2. Connect the sensors cables according to the instruction below 33 = Brown cable + . 34 = White cable sense . 35 = Blue cable - . 3. Calibrate the new sensor at suitable scanning distanse. 4. Do an function test of the new sensor, put an object in front of the sensor, an alarm should now sound and stop when you remove the object. 18 DESIGN AND FUNCTION Bumper override button On the control box there is and override button, this button can be activated if one of the sensors is sensing an object and you still want to manouvre the machine. Press the button to activate machine functions (alarm will still be active until the object is out of range)and drive away from the object. CAUTION! - When override button is active the sensor bumber system is out of function, only use it when nesessery Tube roller Air In/Outlet On the chassi is an air inlet that is connected to an tube roller on the platform to make it possible to drive airpressure tools at height. Air inlet Air outlet 19 DESIGN AND FUNCTION 3 4 2 5 1 2 3 4 5 HYDRAULIC SYSTEM The hydraulic system consists of a tank with an electric powered hydraulic pump, a proportional lowering valve, emergency lowering and a pressure sensor. HYDRAULIC AGGREGATE WITH TANK (LIFT) The hydraulic system is filled with 1 gallon of hydraulic fluid at the factory. The hydraulic fluid level must be topped-up at regular intervals. The hydraulic pump has an integrated strainer and since the system is completely self-contained, it is not necessary to change it provided thorough cleanliness is observed when changing oil. On the hydraulic pump, there is a emergency lowering valve and a pressure sensor. The proportional lowering valve is located under the machine at the rear. 1 Pressure sensor Emergency lowering Pump Filler cap Tank HYDRAULIC CYLINDERS (LIFT) Lifting is accomplished by two cylinders, one on each side of the scissors assembly. They are both single-action. The minus side is free and if there is an internal leak, the oil will be returned to the tank. By-pass Valve block VALVE BLOCKS ON LIFTING CYLINDER Valve blocks is fitted on each lifting cylinder. The blocks consists of a electrical valve with a manual by-pass valve for emergency lowering. A valosity fuse valve is fitted in the lower connection of the hydraulic cylinder. SWING AXLE CYLINDER Swing axle cylinder Pressure tank This is a cylinder with a continuous through piston rod. The chambers on each side of the cylinder are coupled to each other. In the coupling pipe, there is a shut-off valve of sealed-seat type. Opening the valve allows the axle to swing. The swing axle is locked when the valve is closed. The pressure tank is loaded with 100 bar overpressure. 20 DESIGN AND FUNCTION SCISSOR AND PLATFORM Scissor and platform is manufactured in steel and is a durable construction SCISSOR The scissor have a couple of scissor legs connected with axle taps and sliding blocks. PLATFORM Plattform have a under carriage, rail and a extension part that is manoeuvreable with two handles on the the railings. SAFETY STAY The machine is equipped with a safety stand that can be folded up between the scissors and is used to secure the platform in raised position. When servicing involves working under the platform, for example, the safety stand must be folded up in accordance with directions on chapter ”Handling”. Railing Platform Extension Scissor 21 DESIGN AND FUNCTION CONTROL BOX 1. Emergency stop 2. Rotary key switch 3. Accelerator 4. Horn 5. Cover plate 6. High / Lowspeed 7. Transport/working mode - 3D 8. Rotation 9. Sensor Override 10. Lift/Lower 11. Warning indicator 12. Lift / Driving 13. Battery indicator 13. Steering wheel All machine movements, i.e. moving, raising/lowering and manoeuvring of the extension are controlled with the control box. The control box is mounted on the right-hand side of the platform. 8 9 7 10 6 5 4 11 12 13 3 14 1 2 The control box includes a steering control for direction of movement, an accelerator, a number of buttons/function switches and a warning lamp. The bottom of the control box contains a rotary key switch and an emergency stop. Another emergency stop is located next to the emergency lowering control on the right-hand side of the chassis. The emergency stop can be reset by pulling it out. The driver controls the speed of all the movements with the accelerator. The selected movement commences when the accelerator is moved backward/forward. The more the accelerator is moved, the faster the lift movement will be. The operator controls the direction of movement with the steering control. Above the steering control and accelerator, there is a number of function switches for work/transport mode, rotation and raising/ lowering the platform. The control box also contains a warning lamp that with varying flashes warns of low battery voltage, inclination and overload. The control box can easily be removed from its holder for safe storage or simple servicing. 22 DESIGN AND FUNCTION SELECTING MOVEMENT MODE Thanks to the design of the Maxwheel and the computerised control system, Micro can be moved by selecting working mode-3D, rotation or transport mode. All movements are proportional to the lever movement. WORKING MODE-3D When in working mode-3D, it is possible to move the machine in any direction. This mode of movement is preferable when the machine is being positioned and/or manoeuvred in confined spaces. ROTATION The lift will rotate around its axes. That will make it easier to change transport direction etc. TRANSPORT MODE This movement will be according to the same principle as for a car, i.e. only the front Maxwheel will turn and the rear one is locked straight ahead. This mode of movement is preferable when the machine is being transported to the worksite or for long distances under its own power. RAISING/LOWERING THE PLATFORM In this mode, the platform can be raised/lowered. WARNING LAMP AND SIGNAL The control box contains a warning lamp and signal that with varying flashes warns the operator. 1. Lamp flashing on and off for equally long periods = Low battery voltage. ----___----___----___----___----___----_ 2. Three short flashes followed by a long period off = Tilt protection activated. ----___----___----_________----___---3. Short flash then a longer period when the lamp is off = Emergency stop depressed. ----_______________----___________ 4. Lamp lights continuous = Overloading the platform. ------------------------------------------------ 1. Lamp flashing rapidly on and off for equally long periods = Bumper protection. ----___----___----___----___----___----_ Restore following incidents, see chapter ”Handling”. 23 HANDLING HANDLING Read the safety regulations before using the machine. If you have not used the machine before, practice operating it in a wide open space first. It is essential that you do not have to reflect on how to manoeuvre the machine in a critical situation. Incorrect handling can lead to injury or damage to the equipment. STARTING AND STOPPING BEFORE STARTING The following points must have been carried out each morning and before starting work on a new site. Steps 1-2 apply only after transport. 1. Make sure there is no transit damage on the machine. 2. Inspect the premises in which the lift is to be used. Pay attention to obstructions, level changes and doors or other openings. 3. Carry out the daily inspection. ”See Maintenance”. STARTING 1. Remove the power cable if connected. 2. Turn on the main switch 3. Insert the key into the rotary key switch on the control box and turn it. 4. Select the desired movement mode on the control box. 5. Move the accelerator forward/backward to start the selected function. STOPPING 1. Release the accelerator so that it returns to neutral position. 2. Turn on the rotary main switch on the control box. 3. Remove the key from the lock. 4. Turn off the main switch RESTORE WARNING LAMP AND SIGNAL - When lowering the platform and the scissor nearing the the lowest position, first the platform automaticly stop and one warning signal goes on. After that the lowering function continued. - If the lift incline to much, a warning signal will start and all functions will interrupt. Restores by lowering the platform. - If any of the two emergency stop is pulled in, all the function stops on and a sound and light signal shows on the controlbox. Restores by rotate and pull out the red emergency stop button. - Overloading the platform a warning lamp and signal start and stops all function. - If one of the bumber sensors detects an object a warning lamp and signal start and brakes all machine functions. Remove object or press down the override button and drive away. 23 HANDLING MOVING MOVING: HIGH / LOWSPEED MODE 1. Choose your travelspeed with the switch. 2. Wait for approx 2 sec for the gear box change. Note. high / lowspeed change will only function when the machine not is moving. MOVING: WORKING MODE 3D 1. Select “moving” and then “3D” on the control box. 2. Check the direction of movement on the control box steering control. ”Moving” 3. Adjust the direction of movement if necessary by turning the steering control to the right or left. 4. Make sure there are no persons or objects in the direction of movement. Note that you must check the entire height of the lift, from the ground to the platform! 5. Carefully move forward the accelerator. 6. Move the accelerator further forward to increase speed and back towards neutral to reduce speed. Release the accelerator to stop. ”Working mode” MOVING: ROTATION MODE Rotates the lift around its own centre. 1. Select “moving” on the control box and then hold down the button for moving mode “rotation”. ”Moving” 2. Make sure there are no persons or objects in the direction of movement 3. Move the accelerator forward to rotate to the left and backward to rotate to the right. Move the accelerator backward/forward to increase speed and towards neutral to reduce speed. Release the accelerator to stop rotation. ”Rotation mode” MOVING: TRANSPORT MODE 1. Select “moving” mode and then “transport” on the control box. 2. Check the direction of movement on the control box steering control. 3. Adjust the direction of movement if necessary by turning the steering control to the right or left. ”Moving” 4. Make sure there are no persons or objects in the direction of movement. Note that you must check the entire height of the lift, from the ground to the platform! 5. Move the accelerator carefully forward to move the lift forward and backward to move the lift backward. ”Transport mode” 6. Move the accelerator further forward/backward to increase speed and back towards neutral to reduce speed. Release the accelerator to stop. Note that the lift brakes automatically when the accelerator is in neutral position. 24 HANDLING LIFTING FUNCTION AND WORKING FROM THE PLATFORM ”Platform” RAISING - LOWERING 1. Select “platform” mode on the control box. 2. Press the “raise/lower” button on the control box. 3. Move the accelerator carefully backward to raise the platform and carefully forward to lower it. 4. Move the accelerator further backward to increase speed and back towards neutral to reduce speed. Release the accelerator to stop raising. ”Platform raise/lower” MOVING WITH RAISED PLATFORM The lift can be moved with the platform raised but the higher the platform the slower the maximum speed will be. The platform should be lowered completely for transporting long distances. MAXLOAD The platform can be maximum loaded according to the technical data. Observe the maxload including all objects that is loaded on the platform: peronnel, material, machines, etc. Maxload on the extension is 110 kg. Take care when moving the machine when it is heavy loaded and the platform is raised. EMERGENCY LOWERING It is possible to lower the lift to the ground manually if a problem arises when it is in raised position. 1. Open the bypass valves on both lift cylinders. 2. Pull out the emergency lowering control to lower the lift. Emergency lowering handle EMERGENCY STOP Both emergency stops on the lift will cut the power supply completely. One emergency stop is located on the control box on the platform and the other one on the right-hand side of the chassis. The emergency stop must be reset by pulling it out and the lift restarted with the starter key before it can be manoeuvred again. SAFETY STAY The scissor must always be secured with the safety stand before any repairs or work that needed doing under the scissor and platform. 1. 2. 3. 4. Put down any possibly loadings that is on the platform. Raise the platform. Fold up the safety stand. Lower the platform so that the safety stand stands against the upper scissor leg. Proceed in the reverse order to restore the safety stand. 25 HANDLING TRANSPORTING, LIFTING AND STORAGE LIFTING WITH FORKS The machine can be lifted with a forklift truck or wheel loader provided it has sufficient capacity. The lifting forks must be inserted from the side of the machine into the special fork pockets marked for the purpose. The forks must be at least 3 ft long. 1. Lower the platform. 2. Insert the forks into the fork pockets under Maxlift. 3. Make sure nobody is in close vicinity and then lift carefully. Fork pockets 3 Lifting eyes LIFTING WITH STRAPS Maxlift can also be lifted with straps. 2 1. Fasten the straps to the four holes on the bottom of the chassis. 2. Run the straps under the railing on the platform and join them in the centre of the platform 3. Attach the straps to any lifting device. 1 TRANSPORTING ON ANOTHER VEHICLE When transporting on a lorry or trailer the machine must be tightly secured. 1. Secure Maxlift with straps that can be fastened to special holes in the chassis 2. Tighten so that the lift cannot move. 3. Place chocks in front of and behind the wheels STORAGE The machine can only be storage in dry indoor environment. Remember to disconnect the battery. Before any use of machine after storage, Check the ”Maintenance after a period of storage, chapter ”Maintenance”. 26 HANDLING CHARGING THE BATTERIES The batteries must be charged after each working period or at least every eighth operating hour. The batteries can be charged either from the mains or from a reserve power source. CHARGING THE BATTERY FROM THE MAINS 1. Turn off the lift with the main power switch. 2. Connect the machine to an earthed outlet with AC mains voltage. The outlet must be fused for 10 A. Charging cable The charging starts after a few seconds and the status indicator, Orange led is lit up. Orange led remains on until the battery is fully charged. If the charger is connected to a fully charged battery the charger will be charging for 1 hour. This is the minimum charging time. Green led, is lit up when the battery is ready to be used. Maintenance charging will continue as long as the battery is connected. The charger will be reset as soon as the charger is switched off and then on or if the mains connector is disconnected and then connected again. The charging time depends on the size of battery and the depth of discharge. Red flashing led may mean that the battery is not properly connected. Check cables, connection terminals, plugs and other connections to the battery. Rectify if possible. Measure the voltage at the battery and at the charger. If the connecting points and the voltage is correct. OBS: Switch off the charger before the battery is disconnected. If the battery is disconnected without switching of the charger, sparks may be produces. 27 MAINTENANCE MAINTENANCE Maintenance directions must be followed to guarantee the safety of the operator and so that the operating life of the lift is not put at risk. Maintenance must be carried out by qualified personnel. If a fault should occur on the machine or if it is damaged during operation, it must be repaired before work is continued. Even minor damage and faults can cause serious damage or injury. Remember that the scissor must be secured with the safety stay before any work under the scissor and platform. IMPORTANT POINTS ON THE HYDRAULIC SYSTEM! The hydraulic system is extremely sensitive to impurities. Particles only a few µm (0.001 mm) large can jam in a valve and cause serious interruptions and accidents. Impurities also increase the wear on components and can damage seals, valves and other moving parts. Damaged piston rods will allow impurities to enter the hydraulic system. Impurities can also enter the hydraulic system during repairs unless sufficient cleanliness is observed. Internal damage to pumps, cylinders and other moving parts can also be the source of metal particles entering the system. Be observant to unusual sounds or noise from the hydraulic system and abnormal heat radiating from hydraulic system components. Be also observant to leaks and check the fluid level in the tank when necessary. Never fill the machine with used fluid. Think about the environment and avoid fluid spillage. Always leave waste fluid to an authorized company for disposal. Always read the fluid manufacturer’s directions for use. Avoid longterm skin contact with hydraulic fluid and be careful not to allow it to splash in your eyes. 29 MAINTENANCE DAILY INSPECTION Check the following points before starting work: • Inspect the lift for exterior damage. • Check also that control devices and signs are not damaged. • Make sure there are no leaks in the hydraulic system. (Oil stains under the machine.) • Make sure the scissors height sensor is located correctly. (See illustration.) • Test run the lift function and make sure the emergency stop is working. CLEANING Clean the lift and the sensors whenever necessary. The lift should be kept clean for reasons of both safety and job satisfaction. Certain functions can be affected by extreme contamination, warning signs can become difficult to read and it may be difficult to detect oil leaks, for example. Scissor height sensor WEEKLY CHECKS AND MAINTENANCY 1. Remove any oxidation from round the battery terminals with a wire brush. Use protective gloves and take care not to get acid on hands or clothes. Lubricate the terminals with petroleum jelly to counteract oxidation. 2. Check the fluid level in the batteries. The battery acid must cover the plates in the battery. Top up with distilled water as necessary. 3. Check the hydraulic fluid level in the tank. Circlip 4. Inspect wheels and treads. Tap 5. Check scissor mountings and joints, making sure all pins are secured with circlips. (See illustration.) 6. Check the swing axle. 1. Start by turning off the machine. 2. Raise the machine on one side of the swing axle with a jack or similar lifting device. The two wheels must be approx. 2 inch above the ground. The swing axle must be completely rigid and maintain the same position as when it was on the ground. 3. Turn on the power and move the accelerator in any direction. The swing axle should now turn so that one of the wheels makes contact with the ground. If this happens, the swing axle and swing axle cylinder are performing their tasks. 7. Checking the tilt sensor. 1. Drive the machine "lateral" on a sloped floor over 3°. Raise the platform from it`s lowest position to 118 inch. Driving funktion should stop and the warning lamp turns on. Lower the platform, driving funktion and warning lamp restores. x2 Lateral > 3º x2 > 3º Longitudinal 2. Drive the machine "longitudinal" on a sloped floor over 3°. Raise the platform from it`s lowest position to 118 inch. Driving funktion should stop and the warning lamp turns on. Lower the platform, driving funktion and warning lamp restores. Important! The same procedure must be carried out in all four directions. 30 MAINTENANCE SIX-MONTHLY MAINTENANCE Note that a maintenance interval of 6 months assumes the machine is used under normal conditions. Use in dirty environments or under difficult conditions may entail a shorter interval. Also, check the points for daily and weekly inspection. CHECKING THE SCISSOR AND THE LIFT FUNCTION 1. Loosen the control box from its mounting. 2. Raise the lift to a suitable height while holding the control box. 3. Open the bypass valves. 4. Pull the emergency lowering control and make sure the platform drops slowly. CHECKING THE UNDERCARRIAGE 1. Secure the scissors with the safety stand. 2. Inspect the hydraulic cylinder mountings for fractures or other damage. 3. Inspect electrical connections and protectors on electric motors and hydraulic pump. Rectify any defects. 4. Check all cables in the undercarriage and on the scissors. Pay attention to chafing, pinching and damaged staples. Rectify as necessary. Replace damaged cables immediately. 5. Remove the covers on the drive wheels. 6. Check and retighten bolted joints on the worm gears above the drive wheels. 7. Remove the security cover and check the height sensor under the scassi. 8. Reset the safety stand. 31 MAINTENANCE MAINTENANCE AFTER A PERIOD OF STORAGE CLEANING AND GENERAL MACHINE CHECK 1. Clean the lift. Remember! water and damp can destroy the electrical and drive system. 2. Inspect the lift for exterior damage. 3. Check the control devices and signs are not damaged or indistinct by dust and dirt. HYDRAULIC AND ELECTRICAL SYSTEM 1. Make sure there are no leaks in the hydraulic system. "Oil stains under the machine". 2. Check the hydraulic oil level in the tank. 3. Remove any oxidation from round the battery terminals with a wire brush. Use protective gloves and take care not to get acid on hands or clothes. Lubricate the terminals with petroleum jelly to counteract oxida tion. 4. Check the fluid level in the batteries. The battery acid must cover the plates in the battery. Top up with distilled water as necessary. 5. Make sure the both emergency stop is working. CHECKING THE SCISSOR AND THE LIFT FUNCTION 1. Make sure the scissors height sensor is located correctly. 2. Loosen the control box from its mounting. 3. Open the bypass valves. 4. Raise the lift to a suitable height while holding the control box. 5. Pull the emergency lowering control and make sure the platform drops slowly. Checking the tilt sensor. 1. Drive the machine "lateral" on a sloped floor over 3°. Raise the platform from it`s lowest position to 118 inch. Driving funktion should stop and the warning lamp turns on. Lower the platform, driving funktion and warning lamp restores. x2 > 3º Lateral 2. Drive the machine "longitudinal" on a sloped floor over 3°. Raise the platform from it`s lowest position to 118 inch. Driving funktion should stop and the warning lamp turns on. Lower the platform, driving funktion and warning lamp restores. x2 > 3º Important! The same procedure must be carried out in all four directions. Longitudinal 32 MAINTENANCE CHECKING THE SWING AXLE 1. Start by turning off the machine. 2. Raise the machine on one side of the swing axle with a jack or similar lifting device. The two wheels must be approx. 2 inch above the ground. The swing axle must be completely rigid and maintain the same position as when it was on the ground. 3. Turn on the power and move the accelerator in any direction. The swing axle should now turn so that one of the wheels makes contact with the ground. If this happens, the swing axle and swing axle cylinder are performing their tasks. 33 MAINTENANCE REFILLING HYDRAULIC FLUID HYDRAULIC MOTOR (SCISSOR RAISING): Hydraulic fluid: Shell Tellus TX 32 or equivalent Consumption: 1 gallon. 1. Lower the platform. 2. Clean around the filler cap on the hydraulic tank. 3. Detach the blue return hose from the pump before filling with fluid. 4. Unscrew the filler cap. 5. Fill with fluid of correct grade. Filler cap N.B! Changing of hydraulic fluid will only be done on larger reparation or if there are condensing water in the oil tank. Max. level 34 TROUBLESHOOTING TROUBLESHOOTING This troubleshooting schedule is in no way comprehensive but provides tips on the components that should be checked for some of the most common problems. The lift must be returned to the supplier or an authorized service company for more extensive troubleshooting and repair. Always get in touch with the supplier or trained service personnel if you are not sure of how to rectify a fault. NOTHING HAPPENS WHEN THE KEY ON THE CONTROL BOX IS TURNED TO START. 1. Make sure the emergency stops have been pulled out. (2 off) 2. Check for triggered fuses in the electronics box. 3. Make sure the batteries are charged. 4. Make sure that the control cable running between the control box and the electronics box is secure at both ends and that none of the pins is damaged. 5. Call qualified service personnel. BATTERIES NOT CHARGED DESPITE THE MAINS CABLE BEING CONNECTED. 1. Make sure the red LED on the charger is on when the mains cable is connected. This indicates that power is being supplied to the charger. 2. Check that the mains voltage is correct. 3. Check battery connections and fluid level. 4. Call qualified service personnel. CERTAIN FUNCTIONS ON THE CONTROL BOX ARE NOT WORKING 1. Check that the control cable running between the control box and the electronics box is secure at both ends. 2. Make sure none of the connector pins are bent. 3. Call qualified service personnel. MACHINE DOSENT MOVE AT ALL, ALARM ON AT ALL TIME 1. Press the overrride button, if the machine now starts to function and alarm is still on. 2. Check the sensors, Green led should be lit and the yellow shuold be black. If one of the sensors dosent have green light, check connections or change the sensor. 3. Call qualified service personnel. 35 SCHEME SCHEME 16 17 SÄTESVENTIL. ELMAN HYDR.CYL GENOMG. KSTG 63/32/90 MANOMETERUTTAG 2 2 HYDRAULCYL 40/32/965 SLANGBROTTSVENTIL ELMOTOR 1KW 3000 RPM 24V 2 SÄTESVENTIL EL/MAN BACKVENTIL TANK ÖVERSTRÖMSVENTIL INLOPPSFILTER PROPORTIONALVENTIL HYDR. PUMP MAXMOVE AB R11 76 722 MINI 61 00-09-26 HYDRAULSCHEMA 36 SCHEME 37 SCHEME 38 SCHEME 39 SCHEME 40 SCHEME 41 SCHEME DECLARATION OF CONFORMITY Manufacturer: MAXMOVE INDUSTRIER AB Company INDUSTRIV. 9 916 31 BJURHOLM 0932-405 60 Address Telephone Hereby declare under sole responsibility that the product: MINI 61 Type Serial number To which this declaration refers is manufactured to conform with Council Directive 89/392/EEC dated June 14 1989 as amended by Council Directive 91/368/EEC dated June 20 1991. BJURHOLM Place 050113 Date Peter Berntsson Name Signature 42 SCHEME CONTACT Manufacture/ Repair Industrivägen 9 91631 Bjurholm Sweden Phone: +46 0932-405 60 Fax: +46 0932-105 60 MaxMove Business Centre Augustendalsvägen 46 SE-121 26 Nackastrand Sweden tel. +46 (0) 8 716 2020 fax. +46 (0) 8 55 36 06 44 Mobil +46 0() 70 69 49 991 website: www.maxmove.se Copyright: MaxMove Industrier AB 43