operating- and maintenance instructions - mälarlift · 2017. 6. 22. · daily commissioning ... we...

1

SCISSOR LIFT

PB S131-19 E

TOP 19 SCH13119007505HBF00

Operating- and Maintenance Instructions

Scissor Lif ts – Electr ic Boom Lif ts – Art iculat ing Boom Lif ts – Vert ical Li f ts – Telescope Lif ts – Special designs

- TRANSLATION OF THE ORIGINAL OPERATING AND MAINTENANCE INSTRUCTIONS -

PB Lifttechnik GmbH

Gewerbegebiet Gassenäcker 89429 Oberbechingen Germany

Telefon +49 (0) 9077- 9500 - 0

Telefax +49 (0) 9077- 9500 - 40

E-Mail: [email protected] Internet: http://www.pbgmbh.de

Service : 070095009600

Service : [email protected]

TABLE OF CONTENTS SCH13119007505HBF00

subject to technological modifications / advances 3

Table of Contents

FIRST OF ALL A FEW WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

PURPOSE OF THE MANUAL ......................................................................................... 7

FUNDAMENTAL NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

HANDBOOK .................................................................................................................... 8 Safety- and warning notices ...................................................................................................... 9

Other pictograms ..................................................................................................................... 10

USER ............................................................................................................................. 11

NOT ALLOWED WORKING CONDITIONS ................................................................... 12

INSET OF THE AERIAL WORK PLATFORM ................................................................ 13

APTITUDE OF THE MACHINE ...................................................................................... 16

OTHER HAZARDS ........................................................................................................ 16

TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

REGULAR TESTS ......................................................................................................... 18

EXTRAORDINARY TESTS ............................................................................................ 19

MACHINE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

DESIGNATION / TYPE PLATE ...................................................................................... 20

ASSEMBLY GROUPS ................................................................................................... 21

FUNCTIONAL PRINCIPLE ............................................................................................ 21

TECHNICAL DATA ........................................................................................................ 22

FLOOR LOADS ............................................................................................................. 25

WORKING DIAGRAM .................................................................................................... 26

FEATURES AERIAL WORK PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

HYDRAULIC .................................................................................................................. 27 Lifting – Lowering .................................................................................................................... 27

Driving ..................................................................................................................................... 28

Steering ................................................................................................................................... 28

ELECTRONICS ............................................................................................................. 28

SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

EMERGENCY- STOP AT THE CONTROL PANEL ....................................................... 29

BATTERY MASTER SWITCH AT THE CHASSIS ......................................................... 29

GROUND OPERATION ELECTRICAL .......................................................................... 30 Schwarz - Weiss (SW)-LOWER with the button on the ground operation ............................... 31

Display report ground operation .............................................................................................. 32

KEY SWITCH AT THE CONTROL PANEL .................................................................... 33



START BUTTON ........................................................................................................... 33

INCLINE CONTROL ...................................................................................................... 34

SPEED REGULATION ................................................................................................... 34

LOAD MEASURING EQUIPMENT (WEIGHT CONTROL) ............................................ 35

CRUSHING PROTECTION AT THE LIFTING SYSTEM ............................................... 36

FASTENING EYE FOR SAFETY BELT ......................................................................... 36

SAFETY SUPPORT FOR LOCKING THE SCISSOR MECHANISM ............................. 37

OPERATION AERIAL WORK PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

GENERAL ...................................................................................................................... 38 First commissioning ................................................................................................................. 39

Daily commissioning ................................................................................................................ 40

Decommissioning and Disassembling ..................................................................................... 41

WORKING POSITIONS OF THE MACHINE ................................................................. 42 Basic- and transport position ................................................................................................... 42

Drive position fast motion ........................................................................................................ 42

Drive position creep motion ..................................................................................................... 42

CONTROL PANEL (CONTROL EQUIPMENT) .............................................................. 43 EMERGENCY STOP .............................................................................................................. 44

Key switch ............................................................................................................................... 44

Console ................................................................................................................................... 45

Flares ...................................................................................................................................... 45

Joystick .................................................................................................................................... 46

Movement of the Joystick 46

PLATFORM EXTENSION .............................................................................................. 47

CONTROL EQUIPMENT ON THE PLATFORM ............................................................ 48

MOVEMENT POSSIBILITIES ........................................................................................ 49 Driving – Steering .................................................................................................................... 49

Lifting – Lowering .................................................................................................................... 50

on level surface: 50

on inclined surface: 50

EMERGENCY OPERATING WITH HAND PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

EMERGENCY LIFTING / EMERGENCY LOWERING ........................................... 51

TOWING THE AERIAL WORK PLATFORM .................................................................. 52

RETRACT / EXTEND PLATFORM EXTENSION .......................................................... 53

TRANSPORTATION OF THE AERIAL WORK PLATFORM . . . . . . . . . . . . . . . . 54

NOTES FOR TRANSPORTATION ................................................................................ 54

HANDRAIL HINGED ...................................................................................................... 55

LASHING EYES AND LIFTING LUGS ........................................................................... 56 in the front: .............................................................................................................................. 56



rear: ......................................................................................................................................... 56

LOADING WITH A LOADING RAMP ............................................................................. 57

LOADING WITH A CRANE ............................................................................................ 57

LOADING WITH A FORKLIFT TRUCK .......................................................................... 58

SERVICE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

GENERAL REMARKS ................................................................................................... 59 Remarks for working at hydraulic equipment .......................................................................... 60

Weekly maintenance ............................................................................................................... 61

Yearly maintenance ................................................................................................................. 62

Inspect and test log book ........................................................................................................ 64

REPAIRS AND REGULATIONS .................................................................................... 64 Ground operation for Service ................................................................................................. 66

FILLING THE LOAD CELL OF THE WEIGHT CONTROL ............................................. 67

- SAFETY SUPPORT FOR LOCKING THE SCISSOR MECHANISM .......................... 67

MAINTENANCE OF THE HYDRAULIC UNIT ................................................................ 68 Start the hydraulic unit ............................................................................................................. 68

Hydraulic oil level .................................................................................................................... 69

Operating temperature ............................................................................................................ 69

Condition of the pressure liquid ............................................................................................... 69

Change pressure liquid ........................................................................................................... 70

Hoses and hose lines .............................................................................................................. 70

Filter change ............................................................................................................................ 71

Outer leakage .......................................................................................................................... 71

Settings ................................................................................................................................... 71

Other checks ........................................................................................................................... 72

Fault finding ............................................................................................................................. 72

Fault clearance ........................................................................................................................ 72

THE BATTERIES ........................................................................................................... 73 Acid level ................................................................................................................................. 74

Charging condition and battery control .................................................................................... 75

Charging batteries ................................................................................................................... 76

WIND SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

BEAUFORT-SCALE ...................................................................................................... 78

OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

WORKING HEADLIGHTS: ............................................................................................. 79

BATTERIES: .................................................................................................................. 79

CURRENT TRANSFORMER: ........................................................................................ 79

MINI - DAT (OPERATING DATA ENTRY): .................................................................... 79

MINI - DAT RC (OPERATING DATA ENTRY): .............................................................. 79



BIODEGRADABLE HYDRAULIK OIL ............................................................................ 79

TIRES: ........................................................................................................................... 80 rain tires: .................................................................................................................................. 80

Vulkollan - tires: ....................................................................................................................... 80

SPECIAL LINES TO THE PLATFORM: ......................................................................... 80

SPECIAL LACQUERING: .............................................................................................. 80

WARNING DEVICE: ...................................................................................................... 80

LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

ARRANGEMENT AT THE MACHINE ............................................................................ 81

ALLOCATION GENERAL LABELS ................................................................................ 81

ALLOCATION SPECIAL LABELS .................................................................................. 81

GENERAL LABELS ....................................................................................................... 82

SPECIAL LABELS ......................................................................................................... 83

OPERATING INSTRUCTIONS OF CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

HYDRAULIC CIRCUIT DIAGRAM / ELECTRIC CIRCUIT DIAGRAM . . . . 86

Edition 48/14/1115 (cw/year/from Serial.-No.)

Update status 11/14 (month/year)

FOREWORD SCH13119007505HBF00


Service: 0700 95009600

www.pbgmbh.de

ARBEITSBÜHNEN

First of all a few words Please read this preamble carefully before you page down. We congratulate you to the buy of the scissor lift PB S131-19 E.

Purpose of the manual This manual offers guidelines and information for

your safety while working with the machine,

structure of the maschine,

functions,

operating,

emergency operating,

transport,

service and maintenance,

optional equipment,

charger

testing of aerial work platforms.

If you follow the operating- and maintenance instructions the self-propelled aerial work platform will fulfill your expectations. If there come out questions or problems that can’t be cleared by means of this manual, please do not hesitate to contact us.

STOP!

We do not assume liability technical statements, written in this handbook, improvement and changes on our machines are subject to alterations without relevant changes in the existing handbook.

i

FUNDAMENTAL NOTICE SCH13119007505HBF00


Fundamental Notice

Handbook This handbook is part of the machine. It is the user’s duty to keep these in mind!

Before using the aerial work platform instructions have to be read and understood.

This manual has to be placed within always accessible reach of the user. This operating handbook is not suitable for replacing the necessary accommodation that every user needs.

It is the entrepreneur’s obligation that the regulation for the usage of the working platform will be thoroughly used and explained.

Read the handbook carefully and pay attention to the following notes. It is for your own safety, the safety of your environment, and for successful use of the machine. Please make sure that the instructions are in a neat, readable and complete

condition.

Pay attention to that the operating instructions are written in the mother language, and the language of the country, which it will be used in, are available.

Be in charge for the people who you are trusting in with the machines, to where they are able to ensure the safety regulations for the usage of the machine.

The stated requests and limits as well as safety instructions, which are explained in this operating instruction, are to be used unconditionally. Any use beyond it is not conventional.

Box for handbook

Whoever does not know the operat ing instruct ions, is not al lowed to use the plat form!

Danger



Safety- and warning notices

This table shows you the classification of the symbols (pictograms) and notes to the existing danger and the (possible) consequences.

The not following of these notices can lead to heavy unhealthy effects up to life threaten injuries.

We replace at existing danger the pictogram by a warning of for example

picto-gram

damage to ...

note

definition/ consequences

Per

son

s

Danger! There is immediate menacing hazard for the life and health of people. Danger imminent when non-observance.

Warning! There is a possible menacing hazard for the life and health of people.

Caution!

A situation that leads to an undesirable result. The measure of damages for health of people is low. For example at foreseeable faulty operation.

mat

eria

l

Attention! A material damage at the machine can happen when non-observance this danger note.

-- Information!

Application tips and especially useful information. Non-observance leads simply to malfunction of handling the machine. No danger for persons or material.

i

danger by crashing the foot. warning! general



230 V 10 AEinspeisung

Other pictograms

Rinse eyes with cold water! Call doctor !

Warning! Danger by crushing the foot Warning! Hazard by batteries

Warning! High explosive substances

Wear protection glasses!

Pay attention to environment protection

Warning of acidly substances Warning of floating load

1,5 t

Fire, open fire and smoking is forbidden!

Crane eyes

Place forklift truck here

Plug-in electric cable here

Recycle the parts professional

Put not into domestic waste!

Stay away from electric active overhead lines!

Not operate while thunderstorm!

Telephone number of contact person Not enter the danger zone !



User The user of the aerial work platform has to be:

18 years of age or older.

Lead in the instructions of the machine by the manufacturer or by the entrepreneur.

In possession of the carrying out order, for the usage of the machine, handwritten by the entrepreneur.

Provide a document that he/she is able to operate the machine.

If more than one person is working on the aerial work platform, an advisor has to be determined.

Only trained staff is allowed to operate the aerial work

platform ! Warning

Do not drive on public roads and alleys.

Warning



Danger

Not allowed working conditions It is not allowed to use the machine if the following conditions occur:

If the ground is soft and instable.

If the permissible tolerance of the soil inclination is exceeded.

If the wind speed exceeds the permissible value of 12.5 m/s (max. 6 after Beaufort). (s. attachment of Beaufort and wind speed).

Ambient temperature for storage the working platform: -5° to +50°.

Ambient temperature for operating the working platform: -5° to +50°.

Do not operate the machine in dangerously explosive areas.

The usage of the machine, in areas, which are not provided with sufficient ventilation, is not permissible.

The machine is not to use during a thunderstorm (lightening stroke).

Don´t drive with the machine on public roads.

During darkness it is only allowed to use the machine if the machine has headlights.

The insert of the machine close to strong magnetic fields (Radar, running wheels, heavy current) is not permissible.

The performance of work near electronically active overhead electric line is prohibited (observe the regulations).

It is not allowed to use the aerial work platform as a crane.



Danger

Inset of the aerial work platform The following clauses have to be heed during the inset of the machine:

The maximal permissible load capacity is not to be exceeded.

Not more than the admitted amount of people is allowed on the platform.

The permissible value of the wind speed (max.12.5 m/s) (6 after Beaufort) is not to be exceeded (s. attachment beau fort-scale and wind speed, respectively labels on the platform).

The user is reponsible for seeing that there are sufficiently lighting conditions to overlook the working aeria of the working platform.

It is not allowed to drive with high speed in narrow and no clear arranged places.

The permissible value of the handcraft on the aerial work platform is not to be exceeded.

It is not allowed to take on load on the platform (basket).

The lifting or stacking of load is forbidden.

The leaving and entering of the working tool is forbidden, if the platform (basket) is raised.

The maximal permissible Inclination of the machine in diagonal axis is not to be exceeded in transport position.

To bridge any safety device, protection device, limit switch or similarities are forbidden!

Warning



Danger

Danger

In order to prevent falling consider the following:

The user is responsible for seeing that the pothole protection has to be folded out if the platform is lifted.

While operating the working platform the user has to hold on to the handrail.

Do not use the working platform before shutting the entrance door. It ist not allowed to fix the door.

Access of the platform only through the main inspection entrance, res. to leaving.

The user is not allowed to climb on the handrail.

It is not allowed to scale-up the working height through a ladder or other scaffoldings.

Lubricant, oil and other liquids at the inspection entrance, on the platform and the handrail have to be removed immediately.

Carry out the wearing of protection clothes provided by the company, especially in dangerous areas.

Do not deactivate the final end stock switch of the safety device.

Do not drive fast in spots where you cannot watch over and tight areas.

Pay attention to that the obstacles will not be touched. In order to prevent falling of the aerial work platform consider the following:

The maximum load capacity is not to be exceeded.

Do not use the aerial work platform if it is overloaded.

It is not allowed to take on load on the platform (basket).

It is not allowed to operate the machine if objects are attached to the handrail.

The usage of the elevating working platform above the permissible wind speed of 12.5 m/s (max.6 after beau fort) is not permitted (s. attachment of beau fort-scale and wind speed, respectively labels on the platform). The operation must shut down.



Warning

Do not use the machine, if objects which increase the tendency to drift, are attached to the handrail of the aerial work platform.

Only the permitted number of persons are allowed on the platform.

Do not deactivate the final end switch of the safety devices.

The ground floatation of the underground has to be checked so it will not be exceeded.

Pay attention to that the obstacles will not be touched.

Do not drive with hight speed at blind and narrow aereas

Driving in reverse gear only at enough visibility.

Driving along kerbstones, edges or something like that, out of the transport position, is forbidden, except you made additional safety arrangements.

Maintenance practices on the machine are only allowed if suitable safety devices have been made (safety through crane or bridge crane).

Other people then the employees are not allowed around the machine.

The every-day-tests have to be carried out and the machine has to be watched while being operated.

The normal operating conditions movements of aerial work platforms are only allowed to be steered from the platform (basket).

For stability reasons do not use batteries that weigh less than the original equipment, refer to Technical Data. If used batteries stronger or with more weight, this must be considered in the overall weight of the machine.

Never use the aerial work platform as a crane, freight elevator or elevator!

Warning

Do not use the aerial work platform as motor tractor or for towing!



Gefahr

Aptitude of the machine

The company which is inserting the machine is in charge of using the working

tool correctly and that the works are completed without taking any risks.

Other hazards The danger that the machine will tilt or does movement jerky can happen in the following situation:

Abrupt activity of the joystick.

No hard underground. Especially during sudden thaw in the winter.

Working on train platform.

Driving along kerbs, curbs or the like.

Contact with an obstacle on the ground or in the height.

In addition pay attention to that there is enough safe distance round the aerial work platform. The maximum stopping distance is:

1m in transport position.

0,3 m at low speed.

Endangerment through electric current occurs especially in the following situations:

Contact with an alive electric line.

Inset during a thunderstorm.

Explosion and burning danger consists especially in the following situations:

Using the machine in dangerously explosive and combustible areas.

Use of an aerial work platform, which shows oil licks in the hydraulic area.

Contact with hot pieces of the motor.



Collision danger consists especially in the following situations:

If the persons are in the active area of the machine, the danger of getting run over may consist.

Before using the machine, the user has to make sure that there are not any dangers in the above active area.

Driving speed must be adapted to ground conditions, traffic conditions, incline, position of persons and other factors, where there are collision risks.

Drive wheels need to have constant ground contact. This must be assured before driving on inclines. Moreover a low speed must be chosen. At the beginning of drives on inclines (upwards or downwards) it needs to be proven if the brake action is sufficient.

As the lifting platform uplifts do not run it in the exercise area of a crane or other equipments except the case that it is locked or reasonable precautions are taken, in order to rule out collisions.

The machine is not isolated and it is forbidden to use it close to electric lines!

Danger

Only enter and leave the aerial work platform through the provided entrance!

Warning

It is not allowed to leave the machine unattended with extended lifting system!

Attention

TESTS SCH13119007505HBF00


Tests The working platform underlies, according to the jurisdictional conditions of the inset country, regular tests. According to § 3 article 3 of the regulations of industrial safety it is the obligation of the entrepreneur to ascertain the kind, scale and terms of tests of the work equipment. Safety defects should be systematically identified and removed at these tests. ( abridgement from BGG 945 part 2 „Tests on responsibility of the operator“)

Further the entrepreneur arranges the requirements the authorized persons have to meet. (Qualified persons „regulation of industrial safety“ § 2 (7)).

According to current view it is assumed that the tasks of the qualified persons for the given below tests were taken by the there named persons. Kind, scale and terms of the tests are previous practice and are up to the rules of technique. It is the obligation of the entrepreneur to meet the tests. The user who is in charge of the liability (for example in case of a leasing) has to make sure that the inspections and tests will be carried out (see test and inspect log book) and that the machine is in an operable condition.

Regular Tests Regular tests have to be done every 12 months. These tests have to be done by a technical expert.

The regular test is basically a visible and functional test and comprised the test of status of the components and constructions, completeness and effectivity of the safety devices and completeness of the test and inspect logbook. The time of the next test is given on top of the working platform.

Fundamentally is that the working platform, if used seldom, undergoes a daily visibility control, with which it is available for use.

The appointment would be, e.g. August 2018

TESTS SCH13119007505HBF00


The test through a surveyor can be carried out by (according to BGG 945 part 2 chapter 3.2):

technical service from the manufacurer,

plant engineer,

plant foreman

Extraordinary tests Aerial work platforms with a lift of more than 2 m as well as working platforms, which were designed to carry persons on the platform or standing under the platform or load, have to undergo after changes at the construction and after essential repairs at supporting parts before reconnection, a test through a surveyor. The test through a surveyor can be carried out by (according to BGG 945 part 2 chapter 3.1):

Surveyors of the technical control (i.e. technical control association, Dekra, also the employment protection office in Hamburg, and the technical control offices in Hessen),

skilled engineers of the manufacturers,

skilled engineers of the operators,

free-lance skilled engineers.

The scale of extraordinary test based upon kind and scale of change of the construction or repair (see chapter. 7.1.1.6 EN 280).

The exchange of parts as well as the test results must be recorded in the inspect and test logbook.

Changes at the control mode as well as changes at parts of the working platform, which defy the control of the manufacturer “PB Lifttechnik GmbH” are not permissible.

MACHINE DESCRIPTION SCH13119007505HBF00


ARBEITSBÜHNEN

Machine description The self-propelled aerial work platform PB S131-13 E is within the scope of its approval, considering the necessary safety, suitable to carry persons to their work places to perform operations from the aerial work platform It is a scissor lift with a prolongable platform. The aerial work platform will be delivered ready for use The control stand is on the platform. Operator facilities at the chassis resp. boogie serve solely for emergency operation and for service and maintenance.

Designation / Type plate

The necessary details for identification of the machine are stated on the type plate. If you need information, a technician or spare parts please give always the

machine type and the serial number.i

PB Lifttechnik GmbH Gewerbegebiet Gassenäcker D-89429 Oberbechingen

Telefon: +49-09077- 9500 - 0

Fax: +49-09077- 9500 – 40 Germany Type:

Model:

Year of manufacturing:

Serial-Number:

Gross vehicle weight (net): 7250 [kg]

Maximum payload: 750 [kg]

Persons / payload: 5 Per/ 350 [kg]

Max. permissible hand force:: 400 [N]

Max. allowable wind speed: 12,5 [m/s]

Max. allowable inclination of the underframe: with wind: 3 [°] no wind: 3 [°]

eMa i l : i n [email protected] - I n te rne t : h t tp : / /www.pbgmbh.de - Se rv i ce : +49 0700 95009600

Allow. working pressure: 220 [bar]

Control voltage (DC =): 48 [V]

Operating voltage (DC =): 48 [V]

Independent

connection (AC ): 230 [V] 16 [A]

PB S131-19E

**. 20**

19132.***

SCH13119007505HBF00-AB082B240725A2



Assembly groups

Functional principle

The revolution speed controlled inverse-speed motor with 8 kW activates a geared pump. This geared pump delivers the required oil volume for the steering, lift system and the driving motors.

The aggregate conveys the required oil volume for the steering, the lift system and the driving motors.

The dual-processor control provides for that the oil will be allocated to the respective 4/3 direction control valves of the different purviews.

1: underframe 5: Steerable front Drive wheels 9: railing fold-away

2: lift system 6: emergency operating 10: entrance platform

3: ladder 7: platform 11: rear wheels

4: battery tray left 8: platform extension

1

2

11

5

7

10

6

8

3

9

4



Technical Data Name PB S131-19 E Design Scissor Lift Serial-Number 19132.* Color RAL 3002 Transport dimensions

Gross vehicle weight 7250 kg Overall Length 4200 mm Overall width 1930 mm Overall height – Rails up 3050 mm Overall height – Rails down 2100 mm Work platform

Maximum platform capacity 750 kg equally shared max. 300 kg/m

2 allowed persons 5 (80 kg/person) maximum vehicle payload 350 kg Platform extension one-side 2250 mm Hand force 400 N Platform length 4110 mm Platform width 1880 mm Platform railing height 1230 mm Foot Protection Bar 190 mm Access heights 400 mm Platform height – extended 11000 mm Platform height - lowered 1900 mm Platform flooring 3450x1790x12 mm Finnish birch, screen printing Platform flooring extended 2835x1675x12 mm Finnish birch, screen printing Weight control hydraulic via pressure sensor Electric power supply on platform prepared Lifting gear

Lifting 9100 mm Horizontal outreach inexistent mm (outer edge basket) Maximum noise level 70 db(A) operable temperature range -5 to +50 Centigrade Emergency lowering Valve with hand pump Operating pressure max. (payload) Lifting cylinder scissor 225 bar Pressure relief 240 bar Max. current consumption lifting (payload from basic position) Lifting cylinder scissors 182 A Operating range: Maximum working height 13000 mm Maximum horizontal outreach inexistent mm at platform height inexistent mm Operating outside yes Maximum wind speed 12,5 m/s Lifting time 72 sec. Lowering time 54 sec.



Chassis

Length 3990 mm Width 1929 mm Shaft center distance 2820 mm Wheelbase 1607 mm Move by crane yes Attachment points 4 Piece Maximum load 25 KNewton/Piece Maximum drawbar load (wheel) 58 KNewton Permitted Inclination Longitudinal axis 3 degree Diagonal axis 3 degree Incline control Incline switch with audible and acoustic alarm Max. Speeds: retracted 2,4 km/h extended 0.4 km/h Grade ability fixated underground 20 % permissible inclination in diagonal axis at transport position 25 % Turning radius outside 3900 mm Ground clearance center chassis 326 mm Pothole protection Reduction ground clearance to mm Tires: Type of tires solid rubber Name SKS-900 Total Solution Manufacturer Trelleborg Size 31 x 10 x 20 Zoll Diameter / width 775x236 mm Rim 7,5x12 Zoll Actuation Power unit: electro hydraulic Manufacturer C.F.R. Type 2 x EP 8KW 48 V 1500 rpm Hydraulic pump 1 x 8+4 ccm / 1 x 8 ccm Front drive: traction motor + hub gear + brake Manufacturer Brevini Nature orbital motor Type HPRC 80 max. operating pressure 210 bar Steering hydraulic Driving hydraulic Differential lock hydraulic 100% Hub gear: Gear reduction i = 23,67:1 Gear rating 5500 Nm Brake: Manufacturer Brevini Nature Spring-operated brake Type RX 21-12 Static torque brake 250 Nm Brake torque 5917,50 Nm/driven wheel Cracking pressure brake 20 bar



Supply unit

Battery 5 PzS 24 Piece Battery voltage 2 V Capacity 625 Ah Type Single cell (IEC 254-2) Total weight 920,6 kg Manufacturer Banner Operating voltage 48 V Charger: Manufacturer ZIVAN Type NG3 Data 48V / 45A bufferable yes Control: Software version Manufacturer PB Lifttechnik GmbH Mode of operation proportional Nature dual processor controlling with safety control Control voltage 48 V IP protection 65



Floor Loads

PB S131-19 E

Own weight: 7250

Max. additional load: 750

Total weight: 8000

Width b: 1,93

Length l: 3,99

Retracted area chassis b x l : 7,70

Max. supporting force per Wheel: 58,00

Max. supporting force per Support:

Bearing area per wheel: 260

1039

10,39

Max. point load 223,08

Max. point load 2,23

2mm

N

2cm

kg

kg

kg

2m

kg

2m

KN

m

m

2m

KN

2cm

N

Traffic load areaRetracted

Total weight p

Traffic load areaRetracted

Total weight p

KN



1,9

m

11 m

13 m

1,93 m

2,1

m

3,1

m

6,19 m

3,99 m

Working diagram

FEATURES AERIAL WORK PLATFORM SCH13119007505HBF00


Features aerial work platform

Hydraulic The movements of the working platform are hydraulically operated. The hydraulic power unit conveys the therefore required oil volume. Except for the platform extension all movements driving, lifting and lowering can be operated proportional in their speed. In case of failure the hand-operated emergency pump enabled the lowering of the lift system. The RPM-regulated inverse-speed motor with 8 kW activates a geared pump, which conveys the required oil volume for steering, lift system and driving motors. The aggregate conveys the required oil volume for the steering, the lift system and the driving motors.

The dual-processor control provides for that the oil will be allocated to the respective 4/3 direction control valves of the different purviews.

A current regulating valve between the right and the left front wheel provides for a differential lock at the front axle. The lock effect is 100 %.

There is a negative multiple disc brake integrated inside the driving motors with wheel hub gear that opens up at a pressure of 20 bar.

Lifting – Lowering

Lifting of the aerial work platform occurs through a double-action differential cylinder, which is secured by a load holding valve. Lowering will be proportional lead in and controlled by the joystick. It is effected through the gross vehicle weight of the working platform. Additionally an emergency lowering can be done by pressing the switch on the ground operation.

FEATURES AERIAL WORK PLATFORM SCH13119007505HBF00


Driving

Driving occurs by hydraulic wheel hub gears (with overload safety device in both driving directions) with integrated negative multiple disc brake. The actuation is situated in the steering wheels.

While driving with power gear the driving wheels can be locked to each other by pressing the locking button.

Steering Steering occurs by a double action differential cylinder, which enabled a maximum angle of turn of 88 degrees.

Electronics

The machine is using a dual processor control proportionally controlled with security.

The power supply occurs by batteries, see the technical datas.

Inclines resp. ramps have to be driven with power gear by pressed locking button!

Warning

From a certain inclination of the chassis, the drive wheels are automatically locked hydraulically to one another!

Power gear

Fast motion

Locking button

SAFETY DEVICES SCH13119007505HBF00


Safety devices Please note additional to this handbook

the warning notes on the machine,

the applicable laws and ordinances,

the legal requirements for accident prevention

Keep the handbook always in the document box of the machine. The aerial work platform is equipped with the following safety devices:

EMERGENCY- STOP at the control panel

When pressing the emergency-stop the main circuit will be broken.

All valves become electroless and all movements will be stopped directly.

The main circuit will be closed again by pulling the emergency-stop and all operations can be reelected. (After approx. 5 sec.).

Battery master switch at the chassis

When push in the battery master switch the main circuit will be broken

The pulse contact control and motors will be separated from battery. Control is still working and it is even possible to lower SW.


A perfect function of the emergency-stop button has to be permissible in order to provide a safe operation of the working tool!

Warning



keypad

display

battery control unit

turn-switch

EMERGENCY STOP

dongle socket

SW - Lower

Ground operation electrical For activating the ground operation the turn-switch has to be thrown from „platform“ to „ground“. Operating the lift system with this control panel can only be done in case of an emergency and after consulting the operator on the platform, but only with reduced speed. Therefore the sidewise pushbutton and the respective button on the keypad have to be pressed. Machine parameters, motor operating time, operating time and service information can be recalled respectively set as well. (For this a dongle is essential).

Operating the working platform from the bottom should be acted with caution. There must be enough safety distance between the working platform and stationary obstacles.

Keep away hands and extremities from the scissor system! - crushing danger!

Keep away your feet from the safety system (pothole protection) – crushing danger!



Schwarz - Weiss (SW)-LOWER with the button on the ground operation

Besides the lowering via the foil keypad, in an emergency the lifting system can also be retracted by pressing the „SW-Lower button“ (see picture). When actuating the button, the lowering movement of the scissor mechanism in the bottom area is not interrupted by the safety stop!

During manual SW-Lower it must be ensured, that the admissible working load is not exceeded!

Attention

SW-LOWER

SW-SENKEN

Keep away your feet from the safety system (pothole protection) – crushing danger!



Display report ground operation

Report at connected dongle

**

**

dongle

Report at drive mode Report at lift mode

It can be switched between the displays` lines with the key „Menü +“ „Menü –„. Choose the corresponding menu item with the enter key. The numerical values can be set with the key „Menü +“ and „Menü –„.

***.* ***.*



Key switch at the control panel The key-/main switch centrally turns all functions of the working platform on and off. Is the key engaged in Position 0 the main- and control circuit is interrupted and any functions are disabled. Only in this position the pulling out of the key is possible. In order to operate the machine the key has to be engaged in Position 1. It is the purpose of the key to avoid unauthorized practice. For that reason please pull out the key when leaving the aerial work platform and store the key at a safe place.

Only if the key switch is engaged in “0” the control mode is turned off and the electric current environment is interrupted. This inhibits an unnecessary stress of the batteries.

In fact the aerial work platform is equipped with deep discharge protection, this means that the control switches off while operating when a certain minimum voltage has been reached.

If the machine will be left with activated control mode, this deep discharge protection is ineffective.

Start button

This button enables the desired function. That means the start button has to be pressed first (self-holding), than the joystick can be moved (within 5 sec.).

When operating again the start button has to be pressed again.

i Do not leave on the working platform for a long time!

i

i The self-holding will be deactivated by the „null-position“ of the joystick after approx. five seconds!



Incline control

There is an audible and visible signal if the chassis is more slanting than the allowed incline and if the aerial work platform is not in basic position. At the same time “lifting” is deactivated.

Speed regulation Driving with “fast motion” is only possible at retracted condition of the lift system. When lifting the platform the drive speed will be reduced to a minimum creep speed.

: Light emitting diode is on : Light emitting diode is off

T i l t i n g d a n g e r if there is an audible and visible signal!

Danger

Inclinometer for control the underframe



pressure sensor

ventilation fill

Load measuring equipment (weight control) There is equipment at the aerial work platform (pressure sensor) that controls the weight on the platform as well as the scissor system.

After achieving the nominal loading and before exceeding 120 % of the nominal loading the LED is blinking permanent and there is an audible signal. Any operational movement will be cut off.

Only by reducing the weight the operational movements will be activated again.

Lowering will be cut off if the extended platform hit an obstacle during the lowering procedure. (< 40 bar in the load cell).

Lifting will be automatically deactivated If the platform of lifting system snagged on anywhere during the lifting procedure. (>400 bar in the load cell)

: Light emitting diode off : Light emitting diode on

: Light emitting diode blinking

Load measuring equipments can not protect against overload that exceed suddenly the nominal loading in a great extent!

Warning

Danger will be bear if the machine is overloaded since the machine may tilting or the carrying system gets a damage. A damage by overloading has not directly been noticeable! Danger



Crushing protection at the lifting system To avoid crushing and sheering the fingers the lowering procedure will be automatically interrupted at the area below for approx three seconds. The light emitting diode of the weight control (double seizure) is glowing permanent. Meanwhile the operator has to satisfy himself that there is no other person near the working platform in the danger area who can get hurt. Afterwards if the light emitting diode is off the operator can complete the lowering procedure by pressing again the start button and moving the joystick.

Fastening eye for safety belt

The railing is equipped with six fastening eyes so that you can attach your personal protective equipment (antifall guard, belt) at the working platform.

: Light emitting diode off : Light emitting diode on

Other people then the employees are not allowed around the machine!

Warning

Fastening eye



Safety support for locking the scissor mechanism The safety supports on the left and on the right side of the scissor system need to be used for maintenance work. This safety supports relief the lifting cylinder and they hold the working platform safe. To put the safety supports into the retainer the working platform has to be lifted. Afterwards the knurled screws can be released so that the safety supports can be allinged downward.

When lowering the lifting system the safety supports will be engage into the retainers among. The lowering procedure will be interrupted automatically if the safety supports are on block.

Using these support is necessary during operations near the scissor system if the platform is lifted!

Danger

support

retainer

safety screw

OPERATION AERIAL WORK PLATFORM SCH13119007505HBF00


Danger

Operation aerial work platform

General In order to prevent accidents while using the machine and for proper inset of the working tool, pay attention to the operating instructions and recommendations of the handbook.

Especially pay attention to:

that the maximum useful load will not be exceeded

that the number of permissible people will not be exceeded

that the maximal permissible hand force will not be exceeded

that the underground storage is hard

that the environment is suitable for the inset

Since the working platform is suitable for inset in inside and outside areas:

Especially pay attention to: Do not operate the working platform at a wind speed of more than 12,5

km/h (6 after Beaufort). 6 nach Beaufort)

Do not work near electric active aerial lines.

Here pay extra attention to that the underground storage is hard.

Danger

Whoever does not know the operat ing instruct ions, is not al lowed to use the plat form!

Danger



Warning

First commissioning

Before delivery the aerial work platform had to undergo abroad function and end controls at the plant. After delivery you have to check for damages, which could have happened during the transport. If this is the case you have to file a written report of damage, which has to be certified by the forwarding agent. Damages need to be advised in written form.

Before commissioning for the first time the following points are to be controlled:

Check for possible damages, especially on the carried parts.

Check for spilled hydraulic oil or battery acid.

Randomly check for loose screws and bolts.

Visibility checks of the hydraulic and electrical device.

Verification of the hydraulic oil stand.

Verification of the state of charge of the batteries since the working platform is only serviceable with fully charged batteries.

Be familiar with the machine before the first inset. Read the instruction guide.

Pay attention to the signposting and amendment boards.

i The manufacturer, res. the dealer is not responsible for transport damages.

People who not know the operat ing instruct ion are not al lowed to operate the working plat form!

Attention



Daily commissioning

The aerial work platform has to be undergoing a visibility check daily. The following points have to be included:

Check the aerial work platform for possible damages especially on the carried parts, for example scissor tubings, lifting armes, traverse, basket holder, basket, basket arm, pull rod, or pull rod holder. The piston rod of the cylinder must not have any deflection.

Visibly check for possible damages on the machine, spilled hydraulic oil and battery acid.

Randomly check for loose screws and bolts.

Visibility checks on the hydraulic and electric device.

Inspection of the hydraulic oil stand. (only in transport position of the machine)

Inspection of the charge of batteries.

Control of the battery acid level. (10 mm above the battery plates)

Control the cables for damages or loose cable connections.

Control the wheel bolts for fix hub and existence

Check running wheels for damages and wear.

Check the steering angle for deformation.

Check the handrail and entrance door for deformation, cracks, missing parts and functions.

Inspection of the emergency-stop equipment and check the general machine functions.

Check the safety equipment especially the function of the creep speed and the pothole protection (s. chapter safety equipment).

Readability of the warnings and the type plate.

Underground has to be suitable for the inset (stability, smoothness, wheel load…)

Safety devices, e.g. fire distinguisher, in sufficient reach.

The working area has to be free of all obstacles, which can disturb and jeopardize the user and his environment.

Before inset check, that there are not any people engaged in the working area.

The inset of the aerial work platform is only allowed within the permissible temperature range.

Danger

Warning

Attention



Be sure that there is no endangerment through dirt or oil residue on the platform.

Entrance – Railing

Pay attention that the entrance mechanism is in good condition. It has to be able to move perfectly and close self-acting. The door must not be fixed in the open position.

The working platform is to be entered and leaved through the provided entrance. In order to do so the machine has to be in its transport position.

The entrance has to be shut during the inset of the machine. Damages on the entrance or on the working platform can lead to a wrong inset or overloading of carrying parts.

Because of that test the working tool, or let trained staff check the machine.

Damages on the working platform have to be removed immediately, this is the only way a safe and free from interference inset is possible.

Decommissioning and Disassembling

Warning

Warning

i PB Lifttechnik GmbH takes your aerial work platform back. We would recommend the professional decommissioning and disassembling trough us. We will recycle the parts. Please sort the parts on computer scrap, metal, plastics, liquids and hazardous waste when you dispose of the machine. Recycle the machine professional. Please note at disassembling the environment protection for disposal.

Attention



Working positions of the machine During the inset of the machine different valve element positions are used.

Basic- and transport position

If all lift systems (scissors, arms, etc) are inserted, the working platform is in basic position (transport position).

The extendable and movable platforms have to be interjectionaled as well.

The rear elevation of the handrail has to be parallel to the rear elevation of the underframe (chassis).

Drive position fast motion If the machine is in basic- and transport position it can be driven in fast motion gear maximum.

Drive position creep motion

When lifting the platform the drive speed will be reduced to a minimum creep motion.

When driving with creep motion the drive force is reduced and the differential lock as well as the 4-wheel, if existing, is without function.



Control panel (control equipment)

Toggle switch lifting / driving

EMERGENY STOP

Fast gear / power gear

Key switch

Horn

Differential lock

Start button Weight control / SafetyStop LED

Incline control LED

Display

JoystickToggle swing axle left / right



EMERGENCY STOP

When pressing the emergency-stop the main circuit will be broken.

All valves become electroless and all movements will be stopped directly.


Key switch The key switch centrally turns all functions of the aerial work platform on and off. Is the key engaged in Position 0 the main-and control circuit is interrupted and any functions are disabled. Only in this position the pulling out of the key is possible. The key has to be engaged in Position”1” in order to operate the machine. It is the purpose of the key to avoid unauthorized usage. For that reason please pull out the key when leaving the working platform and store the key at a safe place.

Only if the key switch is engaged on Position “0” the control unit is turned off and the electric current environment is interrupted. This prevented an unnecessary loading of the batteries.

A perfect function of the EMERGENCY STOP button has to be permissible in order to provide a safe operation of the working tool!

Warning

i Don’t leave on the Aerial working platform for a long time!



Kippschalter

Drucktaster

Drucktaster

Console By pressing the buttons and actuating the toggle switches the functions will be preselected and proportional implemented by deflecting the joystick. Miscellaneous warning notices will be advised by the light-emitting diodes (LED) on the control panel.

Flares

All LEDs are on + horn: Function control of the LED at switch on of the control panel

LED „> max. kg“ is blinking + horn:

The permissible loading capacity is overstepped. Any operational movements will be cut off. Only by reducing the weight they will be activated again.

LED„> max. kg“ on + horn:

To avoid crushing and sheering the fingers the lowering procedure will be automatically interrupted for a few seconds in the lower lifting band. If the light-emitting diode is off the operator can complete the lowering procedure by a new command. Meanwhile the LED is blinking the operator has to satisfy himself that there is no person in the danger aerea.

LED „Inclination > max. ° “ on + horn:

The aerial work platform is more slanting than the max permitted incline „Lifting“ is deactivated

Toggle switch Push button

Push button



Joystick

Movement of the Joystick

After pressing the start button the movement can be started.

The joystick controls all movements of the machine.

The preselection by the toggle switch “driving” or “lifting” can only be implemented if the joystick is in position „0“.

The displacement sag of the joystick can be ensued in every desired direction, so that the movements “driving” and “steering” can be operated at the same time.

Industry-Joystick MS-A2:

Biaxial; small, handy, compact and robust; protection class IP 65; Bearing by elastomer joint; double seal – water- and dust proof even if

the bellows is damaged; Protection by separate directional switches

for each direction; potentiometer steering standard.

steering right

steering left

driving forward

driving reverse

lifting

lowering



Platform extension

The extension of the platform (2.25 m to the rear) is extended and retracted by the control. This must be selected on the control panel with the toggle switch the "lifting ". Then the start button and the toggle switch for the alignment of the oscillating axis to the left for extension and to the right retraction.

platform extended platform not extended



NOT-AUS Schlüsselschalter Joystick

Control equipment on the platform

All movements which are possible with the working platform can be implemented stepless.

First the plug connection of the control panel has to be locked into the socket on the platform.

When actuating the control (the emergency stopp is pulled and the key switch is in position „1“) the light-ermitting diode of the incline control is on an and a signal is audible for one second.

Afterwards the start button can be pressed and a movement can be implemented with the joystick.

Note the order: First press the start button then move the joystick.

i

socket

Emergency Stop Key switch



Movement possibilities The following movements are possible:

Driving

Steering

Lowering

Lifting All movements are implemented step less and sensitive. The functions are activated through the control panel, which is located on the platform. By buttons and toggle switches (see chapter control panel) the functions can be selected and proportionally controlled with the joystick. The console can be disconnected from the machine through a connector. If the console is taken down, e.g. for transport or for safety against foreign use, you have to ensure that when connecting again, the connector will be connected safely with the provided interlock.

Driving – Steering After activating the “fast motion” and “driving” by the toggle switch the start button (self-holding) has to be pressed then the joystick can be moved (within 5 seconds). The movement of the joystick occurs stepless. Deflection forward (the machine is driving forward) or deflection backward (the machine is driving reverse). Driving in fast motion is only possible in basic position. The power gear can be selected by throwing the toggle switch to the elephant.

By selection of the driving function the control of the steering is automatically active. With the movement of the joystick rightwards (the machine will drive a right hand band) or to the left the working platform can be steered.

i The operator of the working platform is responsible that the working tool is safe against unauthorized usage!



80x4080x40

30x30x2

Masch.Schwerpunkt

1

2

30x30x2

2

15.6 kg

80x40x56.4 kg

St tzzylinder 704

/7 50/70 Hub 700

St tz

zylinder 704

/7 50/70

Hub 700

Lifting – Lowering After flipping the toggle switch to "lift", the Start button needs to be activated (within 5 sec) to enable the user to use the joystick. By a continuous step less either forward or backward movement of the joystick, the raising and lowering can be initiated.

on level surface:

on inclined surface:

If the aerial work platform is not in level position the lifting procedure will be interrupted at the area below and a signal is audible and visible. (See chapter „Incline control“)

EMERGENCY OPERATING WITH HAND PUMP SCH13119007505HBF00


Emergency operating with hand pump

Emergency lifting / Emergency lowering

lifting

lowering

14

3

2

(P)Lowering won`t be stopped automatically during

emergency lowering! -> Release valve for lowering! Attention

4. Operate the hand pump (P) in order to carry out the movement.

5. Reopen the valve (V) against the direction of the arrow.

Allocation of the valves:

Lowering: valve 1

Lifting: valve 2

1. Unplug the lever (H) and put it into the hand pump (P). 2. Turn the valve (V) in direction of the arrow. 3. For emergency operation actuate the corresponding valve manually.

(H)

(V)

(P)

3

1



Towing the aerial work platform Adjustment of the wheels:

1. Actuate valve 3 „steering left“ or valve 4 „steering

right“ and the emergency switchbar in valve 6 manually.

2. Close valve (V) of the hand pump in direction of the

arrow.

3. Unplug the lever (H) and put it into the hand pump (P).

4. Operate the hand pump with the lever (H) the wheels will be steered.

Deactivate the brake: 5. Lift the wheel off the ground.

6. Remove the circlip “A” (as shown in fig. 6), and pull off the disconnect plug “B”.

7. Turn the disconnect plug 180° (as shown in fig. 7), re-insert it into its seat and replace the circlip.

no more b rak ing e f fec t

Now towing is possible.

Reset steering: 8. Release valve 3 „steering left“ or 4 „steering right“ and bring the emergency

switchbar in valve 6 to its original position.

9. Open the valve (V) of the hand pump against the direction of the arrow.

10. Put the lever (H) back into the cranks.

Reactivate the brake: In order to couple again the gear to the motor, the above-described operations have to be executed in the reverse order.

For coupling start hydraulic motor and turn it slowly, so that the the toothing on the motor shaft correctly engages with the sun gear: therefore, carry out this operation very carefully, reversing the motor rotation direction, if necessary, to make the operation easier.

If the brake was loosen manual there is no more braking effect – the aerial work platform has to be protected against unintentional coasting!

Warning

Attention

5

13

6

4

(V) 3

1

(H)

(P)



Retract / extend Platform extension Retract / extend platform extension

1. Manually actuate valve 8 „retract platform extension“ or valve 9 „extend platform extension“ and the Emergency button at valve 7.

2. Close valve (V) of the hand pump in direction of the arrow.

3. Unplug the lever (H) and put it into the hand pump (P)

4. Operate the hand pump with the lever (H) the platform extension moves.

5. Reopen the valve (V) of the hand pump against the direction of the arrow and reset valve 8 or 9.

6. Put the lever (H) back into the cranks.

9

7

8

(V)

(H)

(P)

TRANSPORT SCH13119007505HBF00


Warning

Transportation of the aerial work platform

See after transportation of the working platform that there were no damages. Faulty handling can result in damages at the working platform and in serious accidents.

Notes for transportation The following points should always be considered prior to loading/transportation for the working platform:

The aerial work platform has to be in completely retracted position.

o Basic position of the aerial work platform

Just as every extendable and movable platforms have to be in interjectional position.

The rear elevation of the handrail has to be parallel to the rear elevation of the underframe (chassis).

If the handrail will be folded this must be carried out in prescribed order (s. chapter „handrail hinged“).

No people or loads are allowed on the platform

The control mode has to be switched off and the control panel has to be disconnected and removed from the platform.

Protect the working platform by the intended attachment points.

The protection of the platform may only occur against the machine.

Move the working tool by the control panel. The aerial work platform has its own acting brakes.

Attention



Handrail hinged

The rails can be fold-away with a few handgrips. Thereby the overall height of the working platform can be reduced for transportation.

After opening the latches in the corners the rails have to be folded in correct order of the numbering.

Operating the aerial work platform with folded rails is forbidden - verboten – fall danger!

Warning

closed latch open latch

If the handrail will not be folded in correct order the platform extension is not protected against unintended extend! Check the correct protection of the platform extension! Warning

6

5

4 31 2



Lashing eyes and lifting lugs

in the front:

rear:

Lashing eyes

Lifting eye

Lashing eyes

Lifting eye

Warning

Fasten the loads carefully! Don’t stay under floating loads!



Loading with a loading ramp If you have the opportunity to load with a loading ramp then do so. This is the preferable way because it is the easiest and fastest method to load the aerial work platform.

Pay attention in the maximal climbing ability of the aerial work platform (see the technical datas

Check the bearing capacity and the securing of the ramp.

In order to prevent slipping of the machine sufficient grip has to be provided.

Important! - Drive inclines always in power gear and with simultaneus pressed differential button (differential lock).

At bigger acclivities use a hauling winch. During inset always drive simultaneously otherwise the machine will pull against the brakes.

Loading with a crane To load with a crane you need a suspended tray conveyor and four separate lifting accessories, which were fastened at the crane eyes of the underframe.

Fold the rails (if possible).

Pay attention to the permissible bearing capacity !

Pay attention to that the separate lifting accessories are hanging free.

Danger of damaging the working platform and the stop chain!

Make sure that the elevators are in good condition.

Do not attempt a solo run. Make sure that there is enough trained and with the work familiar staff.

Attention

1,5

Check the separate lifting accessories for enough carrying capacity and good condition!

Attention



Loading with a forklift truck With the lift cradle of the forklift truck at the marked spots between the axis can be retracted. The lift cradles have to look out at the other side of the underframe.

Make sure that the forks are long enough.

Follow the load capacity of the forklift!

Use the full width of the recess.

Severe to fatal injuries trough topple down and fall off from the forklift truck!

Danger

SERVICE AND MAINTENANCE SCH13119007505HBF00


Service: 0700 95009600

www.pbgmbh.de

ARBEITSBÜHNEN

Service and Maintenance

General remarks

The aerial work platform is designed in such a way that service and maintenance work are limited to a minimum requirement.

Nevertheless, it is indispensable to carry out some smaller jobs, in order to achieve trouble free operation of the platform. The condition for an undisturbed operation of each machine or installation implies the professional start-up and regular maintenance.

As a matter of principle, the working platform shall undergo a daily visual check when using infrequent before commissioning whereas the following points shall be considered:

Check the aerial work platform for possible damages especially on the carried parts, for example scissor tubings, lifting armes, traverse, basket holder, basket, basket arm, pull rod, or pull rod holder. The piston rod of the cylinder must not have any deflection.

Spot-checking on unscrewed nuts and bolts.

Inspection of the hydraulic plant on leakage. or on un-tight hydraulic couplings.

Inspection of the hydraulic pipes on possible damages or loosened screw connections.

Inspection of the electric wires on damages or loosened cable connections.

Inspection of the wheel bolts on loosened or lacking screws and nuts

Inspection of the running wheels on damages or abrasion.

Danger

Shut down the machine immediately and call our technician if you have accessed damage, which can be a hazard for persons! Danger



Inspection of the wheel suspension on abrasion or deformation.

Inspection of the handrail and entrance door on deformation, elevation, missing parts and operativeness.

Inspection of the emergency stop function and general function control.

Inscpection of the safety devices such as the function of the creep gear , the flaps of the pothole protection etc.

Inspection of readability of the warning signs and notices, type plate and operating instructions. General function control.

Remarks for working at hydraulic equipment

For safeness reasons it is not allowed to dismantling guide bolted joints, connections and units while the equipment is pressurizing.

Before, there has to lower the loads, stop the pumps and release the hydraulic accumulator.

The external environment should be cleaned before dismantling screwing.

All openings have to be closed by protection valves.

As a matter of principle one has to observe utmost cleanliness when servicing and maintaining hydraulic plant!

Attention

Never open a hydraulic plant when the same is still under pressure!

Warning

Attention



Weekly maintenance

Inspection of the battery acid level (min. 1 cm above the lead plates) not required in case of maintenance free battery cells.

General check of the joints.

Grease all hinge points of the pothole trotection with dry-film lubricant like „HHS DRYLUBE“.

Inspection of the hydraulic oil level in the hydraulic tank (only to be checked when the platform is retracted).

Use hydraulic oil HLP-22 (ISO VB 22) or at systems with biodegradable oil PANOLIN HLP SYNTH 22.

Please deliver used oil to the respective collecting points!

Replace hose lines by original spare parts if the following criteria apply:

Damage of the outer layer to the intermediate layer (as chafe marks, rifts,

cuttings);

Embrittlement of the outer layer (fissuring of the line material);

Deformations which do not correspond to the natural mold of the hose or hose line both unpressurised and pressurised state or at bending for example layer abscission, vesication);

leakages;

Demage or deformations of the hose fitting (sealing function affected);

the hose discharges from the fitting;

corrosion of the fitting, that lessened function and stability;

demands on assembly have been ignored

If time of storage and/or time of usage of the hose or the hose line are exceeded. If the user has not details about the time of storage and time of usage, the standard values according to DIN 20066:2002-10 chapter.: 14.1.2 are recommended.

Reparing of the hose line using the inserted hose and / or the inserted fitting is not permissible.

Warning

The safety support has to be used when working at the scissor system ore lifting cylinder!

Danger



i

Service: 0700 95009600

www.pbgmbh.de

ARBEITSBÜHNEN

Yearly maintenance Aerial work platforms are to be tested by a technical expert after the first commissioning at intervals of not exceeding one year. (Subject to BGR 500 part 1 chapter. 2.10 article 2.9.1 and accordingly BGG 945 (5.4.1).

During operating deviations of the safety level, which had existed at the first commissioning are possible.

The operator has to make the necessary arrangements to maintain the safety level.

Variations can be caused by for example wear, corrosion, violence, alteration of environment, changing of occupancy. Quod vide guideline 89/655/EWG from 30th November 1989 about minimum regulations for safety and health protection at using work equipment by employees at work. (Put into national legalization by the Arbeitsmittelbenutzungsverordnung – AMBV).

At the recurrent test ascertained deficiencies are to be removed according to their safety importance in an adequate timeframe. The working platform has to be prepared for the test and if necessary cleaned so that the test can be duly done. The regular test is primarily a visual and functional test. The regular test shall extend to:

condition of the devices and equipment also to assess if modifications were made,

completeness and effectiveness of the safety devices ,

completeness of the inspect and test log book.

If a sufficient appraisal through this is not possible more test are to be made, for example nondestructive tests of material and welding seams. If necessary a disassembling has to be made.

We are for your disposal for the yearly maintenance of your aerial work platform.



The regular test has to contain:

Testing of the working platform on identity considering the details of the inspect and test log book.

Testing of the working platform in consideration of its documentation in compliance of the basic safety and health requirements of the guideline 98/37/EG, accident prevention regulation and the engeneering rules (according to BGR 500 part 1 chapter. 2.10 article 2.9.1) through a technical expert or surveyor.

Testing the condition of devices and equipment on damage, wear, corrosion or other changes on the basis of addendum of these BG-standard, the engeneering rules and inspection notes in the operating instructions of the manufacturer.

Testing on completeness and evectiveness of the safety devices and brakes. The inspection notes of the manufacturer should be considered for example overload protection, brakes.

Function and brake tests with load, whereas the test load has to be near by the maximum load capacity.

Inspection of completeness of the labeling and signage.

Furthermore the details of the weekly maintenance have to be taken in consideration.

Visibly inspection of bolts sleeves on wear.

Inspection and re-tightening (if necessary) of hydraulic couplings.

Inspection of joint connections on tightness.

Inspection of crew locking devices and nut locks.

Inspection of hydraulic cylinder on leakage.

Inspection of electric motor’s carbon brushes on wear.

Checking of the relay switches on burning losses and functional test of any limit switches.

Inspection of the mast routing and (if necessary) readjusting.

Visual inspection of the supporting structure on damages

Recording the result of the regular test in the Inspect and test logbook.

Damaged pipes, hoses and couplings have to be changed immediately!



Inspect and test log book The inspect and test log book must bear the reports about the test before the first commissioning as well as the reports about the regular and extraordinary tests – if need be the certificate of the (EG-) prototype test as well as EG-declaration of conformity. The documents required for the regular tests have to be attached. Inspection record: The inspection report must bear:

Date and scale of the test as well as indication of component testing still

outstanding,

result of the test with indication of asserted deficiencies,

judgment if there were doubts against commissioning or against continue the

operation,

indications about a necessary check-over as well as name, address and signature

of the inspector (surveyor).

Repairs and regulations

Experienced and skilled personnel should always execute repairs, especially of load-bearing parts. Our service personnel will be at your disposal for these workings.

Don’t by-pass safety and protection devices, limit switches or the like!

Warning

When servicing and maintaining the electric system, make sure to remove the main fuses form the fuse carrier! Damaged wires and circuit components have to be exchanged immediately! Warning

Experienced and skilled personnel should always execute repairs ! If not, or if not original spare parts were used the warranty will be void!

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Only original spare parts shall be used. If not, or if the aforementioned workings done by untrained people the warranty will be void and the manufacturer is released from his liability.

Do not change anything at the structure of the working platform. Changes are only authorized in case agreed by the manufacturer and need to undergo further acceptance inspection.

Any exchange of parts need to be noted within the inspect and test log book.

Changes in the control, whether hydraulic or electric, are only allowed if authorized by the manufacturer (i.e. cabling, hoisting, piping ...).

Changes of the reference values, whether hydraulic or electric are only allowed if authorized by the manufacturer (i.e. pressures, speeds ...).

Line connection from the aggregate to the machine should be vibration-free passed without knee or pinch point. The line cross-section has to be adapted to the line length, in doing so the shortest path has to be favored. The used lines and armatures have to be up to the respective pressure level. The pipelines may only be screwed or attached free of stresses. Please note that pipelines expand by thermal fluctuation.

One has to observe utmost cleanliness at each working. The pipelines are to be cleaned from dirt, scales, sand, and so on. Cotton waste may not be used for cleaning. It is advisable to rinse the line system thorough after assembly. Remove sealing plugs at the connectors only directly before connecting the corresponding pipeline. This is conductive to keep the hydraulic unit cleanly.

The hydraulic unit should be filled in with the prescribed hydraulic fluid. The correct hydraulic fluid particularly its viscosity is important for its trouble-free operation. Use hydraulic oil on mineral oil base unless otherwise specified. After consultation biodegradable hydraulic oils can be used, too. Check the hydraulic fluid on ingress of water. The basic pollution of the filled in hydraulic fluid may not exceed class 10 according to NAS 1638. Experiences have shown that new fluids already often exceed this value. In that case please use a filler apparatus with a filter mesh of maximum 10 micron. Check the fluid level in the oil tank permanently during the fill-up process.

Fill pistons and control pumps at the overflow oil line connection before the first starting.

The electrical wiring has to be up to the corresponding VDE-terms and is only to be made by an authorized technician.

Take notice at the electrical circuit points of the voltage and frequency specifications at the electrical units.



Ground operation for Service For activating the ground operation (Service) the control panel must be inserted into the socket at the chassis. So all movements for endurance testing can be executed beyond the platform.

If the turn-switch is thrown form „platform“ to „ground“.you can operate the aerial work platform from the bottom. Look at chapter “Ground operation electrical”

Socket at the chassis

display

battery control unit

turn switch

EMERGENCY STOP

dongle socket

SW-Lower

keypad



Filling the load cell of the weight control If the load cell is unpressurized (piston in the load cell completely retracted) the following steps have to be done.

Loosen the safety supports to place the scissor system in the supports → see chapter Safety devices - Safety support for locking the scissor mechanism.

Lift the scissor system a little.

Turn in the hand wheel of the hand pump clockwise (see chapter “emergency operation with hand pump”).

Put the lever into the hand pump and operate the hand pump with the lever until a counterpressure is sensible.

Actuate emergency lowering at the hydraulic manifold (valve 1 → see chapter “emergency operation with hand pump”).

Operate the hand pump to open emergency valve at the lift cylinder.

The scissor system will lower → supports engage into the retainer.

Open ventilation (sidewise at the load cell).

Open the connection for oil filling (below the pressure sensor).

Screw the hydraulic hose of a external hand pump (with oil tank) on the filler connection.

Replenish the load cell unpressurized until there won´t escape air from the ventilation.

Close ventilation.

Go on pressure with external hand pump (max. 130 bar).

Releave the connection of the external hand pump -> piston rod shouldn’t move.

Remove the hydraulic hose of the external hand pump.

Close the connection for oil filling.

pressure sensor

ventilation refill



Release valve 1 „emergency lowering.

Fasten the safety puports again.

Lower scissor system → display of ground operation (lifting mode) shows a pressure under 18 bar at a scissor angle of 4° → OK.

Maintenance of the hydraulic unit

Start the hydraulic unit

Take care that the hydraulic unit can start reliable and that there are no people in the danger zone.

Start the power unit at unpressurized circulation generally at first commissioning. If there is no valve for unpressurized circulation existent connect the pressure line with the return pipe directly behind the pump.

Start the drive motor shortly at inching operation and check the rotating direction (rotation arrow at the motor). If the pump run more than a few seconds to the false direction that will lead to serious damages due to dry run.

Make an unpressurized run for at least 10 minutes. Then make every movement in manual operation and check the several functions. Pay attention to possible mechanical collision.

Bleed the power unit at the supply pipe preferably at the highest point by opening the screwing.

Activate the directional valve and extend and retract the supplier several times. Ventilation is ensured if there is no foam inside the tank, no jerky movements at the supplier and no abnormal sounds occur. Check the fluid level after ventilation and replenish as necessary.

Inspect the line connections for leaks and retightening as necessary.

The maximum oil temperature must not exceed 80 degrees as accelerated oil ageing occur with increasing operating temperature.

***.*



Hydraulic oil level

Check the fluid level in the oil tank at regular intervals.

The oil level should be in the middle between the black and the red line.

In order to replenish oil the blind plug from the hand pump has to be unscrewed (see picture) to refill hydraulic oil HLP-22 (ISO VG 22). The scissor system has to be completely retracted.

One tankful is about 30 l.

If the first fuel-filling was made with biodegradable oil you must use for refill hydraulic oil PANOLIN HLP SYNTH 22.

Operating temperature

Gradual temperature rise beyond the normal operating temperature is a sign of possible impurity, metal wear or seal wear and should give reason to check the hydraulic unit.

Condition of the pressure liquid

report impurity possible reason

dark coloring oxidation points overheating, oil change neglect

milky haze water or foam water inleakage, ingress of air

water separation water water inleakage for example condensed water

air bubbles air ingress of air for example lack of oil, leaky suction pipe or tank pipe above oil level.

floating or settled particle solid contaminants abrasion, dirt, ageing product

smell for burned oil ageing product overheating

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replenish here



Change pressure liquid

After commissioning the hydraulic oil should be spring-cleaned with a filter station. For not laboratory checked hydraulic oil an oil change is necessary all 2000 to 4000 operating hours.

An oil temperature of maximum 70° and a regular oil filter change is a precondition. Use hydraulic oil HLP-22 (ISO VG 22) rather. biodegradable oil PANOLIN HLP SYNTH 22 The PANOLIN HLP SYNTH can remain in use for .22000 operating hours

Hoses and hose lines Replace hose lines by original spare parts if the following criteria apply:

Damage of the outer layer to the intermediate layer (as chafe marks, rifts, cuttings);

Embitterment of the outer layer (fissuring of the hose material);

Deformations which do not correspond to the natural mold of the hose or hose line both unpressurized and pressurized state or at bending for example layer abscission, vesication;

leakages;

damage or deformations of the hose fitting (sealing function affected);

the hose discharges from the fitting;

corrosion of the fitting, that lessened function and stability;

demands on assembly have been ignored.

If time of storage and/or time of usage of the hose or the hose line are exceeded. If the user has not details about the time of storage and time of usage, the standard values according to DIN 20066:2002-10 chapter: 14.1.2 are recommended.

Reparing of the hose line using the inserted hose and / or the inserted fitting is not permissible.



Filter change Change the filter elements (if existent) directly after the first commissioning. Further filter changes have to be made monthly to half-yearly depending on operating conditions.

Filter with clogging indicator have to be checked daily if the operating temperature is reached. During the warm up an error message is possible since the flow resistance can be still raised.

The breather cannot be checked and therefore has to be changed yearly.

Outer leakage Screw connections can be loosen by operating vibrations and should be checked at regular intervals.

Particularly within the first 20 operating hours screw connections have to be checked currently and retightened as necessary.

Screw connections may only be retightened at unpressurized hydraulic unit. Damaged pipes and hoses have to be replaced immediately.

Settings Pressure valves, flow-control valves, pump controls as well as signal links like press switches, limit switches, temperature regulators and so on will be preset at the first commissioning. Initially this values have to be checked frequently afterwards at periodic intervals.



Service: 0700 95009600

www.pbgmbh.de

ARBEITSBÜHNEN

Other checks Initially as well as longtime operation failures can be seen and avoided betimes. Attention should be paid to:

Leakages at valves and equipment

Soiling

All types of outer damages

Abnormal sounds form pumps, electric motors and other components.

Operability of the indicators.

Fault finding A successful faultfinding presupposes an exact knowledge of configuration and mode of operation of the hydraulic plant.

Particularly at electro-hydraulic controls the coaction of electric and hydraulic will make the fault finding difficult and presuppose a high degree of knowledge and experience.

Functional diagrams, circuit diagrams and appropriate measuring instruments are a pre-condition for a successful faultfinding. After solving the real defect it is necessary to clear the basic cause of the defect.

Fault clearance Please do not hesitate to contact us, if you need our assistance in fault clearance or for the yearly regular test at your aerial work platform.



The Batteries

The electrical power supply takes place with 24 solitary cells according to IEC 254-2 each with 2 V battery voltage. There will be a capacity of 625 Ah at an operating voltage of 48 V at 5 hours discharge. It is about wet-cell-batteries, which were filled with acid.

It is important to wear protective clothing while working with batteries.

The accident prevention regulations and the DIN VDE 0510 T.1 need to receive attention.

Smoking is forbidden!

No open fire, glow or spark close to the batteries because of explosion risk and fire hazard.

For stability reasons do not use batteries that weigh less than the original equipment, refer to Technical Data. If used batteries stronger or with more weight, this must be considered in the overall weight of the machine.

Attention

Right lateral bin Left lateral bin



If you get an acid splash in your eye or skin, it has to be rinsed, res. washed up with a lot of cold water. Immediately after that you have to go to a medical doctor. Clothes that were polluted with acid should be rinsed with water. Slopped acid inside the machine should be neutralized with sodium dicarbonate.

Explosion risk and fire hazard due to high explosive mixture of gases.

Leave the drawer with the batteries open during the charging.

Avoid short circuits – Deposit no tools on the batteries.

Do not open or destruct batteries. The released electrolyte is very dangerous for humans and environement (acid danger for eyes and skin, toxic). The electrolyte is hardly acidly.

See that the cable claps are fixed.

See that the battery terminals are clean. Do not tilt the batteries.

Use only permitted lifting and transport devices, according to VDI 3616. Lifting clamps must not cause damages at cells, connectors or connection cables.

Never put the batteries in domestic waste.

Defective Batteries have to be recycled according to environment.

Local recycling requirements have to be noted.

Acid level Once a week the batteries of the working platform have to be checked on their respective acid level (exception: maintenance free gel-batteries (optional). Make sure that the level is at all times in minimum 1 cm above the plates.

In case the acid level is too low, the same shall be tapped up with distilled water.

Never top up the acid level prior to recharging the battery. This may lead to overflowing of the battery during charging; the spilled acid could then badly damage the equipment.

Attention



Charging condition and battery control

Always take care of sufficiently charged batteries, since the aerial work platform will only work properly with enough charge. At an operating voltage of 33,6 V the operating mode “lifting” will be locked (this will protect the batteries against deep discharge).

If the operating voltage is lower than 33,6 V (under load for example when lifting) the control will cut off because of low voltage. If so, it is necessary to charge the batteries.

It is advisable to recharge partial discharged batteries, too, as the electronic battery charger adapts the charging current to the state of charge. Therefore overcharge is excluded (Take note of the battery charger’s manual.).

If the both lower bars are gleaming the batteries are 70 % discharged.

At a discharge of 80 % the both lower bars are blinking alternately and “lifting” will cut off by the control because of low voltage.

After recharging the batteries the aerial work platform can be operated again. battery control

Please charge empty batteries immediately! Attention

The charger can be attached permanent at the usual household-net. i



Fuse

charging plug

Charging batteries

The charging process is relatively simple:

Move the working platform near to a 230 V socket connect the same with an extension cord to the feeder socket at the heck of the chassis.

The batteries will be charged by a charger which adapts itself to the respective state of the batteries to ensure an optimal charging.

Kindly check after plugging in whether the battery charger has started charging.

(LEDs indicate the state of charge)

If this is not the case, check if the fuse is in position I.

Never top up the acid level prior to recharging the battery. This may lead to overflowing of the battery during charging.

Attention



Take note of the battery charger’s manual.

The 230V socket in which you plug the charger needs to be fused with a 16 A fuse.

Please check after insertion that the charger has began to load. You can check the state of charge by illuminated diodes.

In the case that during the operations of the lifting platform the charger was already plugged in the 230V (charging while working) the mains plug needs to be unplugged and plugged again.

Now the control mode of the battery charger is reset and the work platform can be fully loaded overnight.

Do not connect any more consumer load at a fuse protection of 16 ampere during the charging process; otherwise activating the fuse might interrupt the charging process.

Explosion risk due to high explosive hydrogen gas.

It is thus forbidden to manipulate with open flames or tools that might cause sparks within a range of 5 m.

Proper ventilation has to be ensured. Low-level battery acid may only be topped up by distillate water.

Always keep the batteries clean and neat. Spilled acid needs to be rinsed with lots of water.

The battery terminals shall be protected against pollution and need to be tight at all the time.

Avoid using a cable drum as an extension to the charging wire, since the charging current might be higher than the overload protection of the drum, which then might be activated.

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Make sure that the socket, which is used for charging, does not apply an overvoltage. Furthermore the socket needs to be fused with a 16 Ampere fuse. i

i

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Wind Speed Beaufort-Scale

Beaufort-Number

Description Observations Wind Speed

m/s km/h

0 Calm Tree leaves don’t move; smokes rises vertically

0 - 0,2 <1

1 Light Air Tree leaves don’t move; smoke drifts slowly

0,3 - 1,5 1 - 5

2 Slight Breeze Tree leaves rustle; flags wave slightly 1,6 - 3,3 6 - 11

3 Gentle Breeze Leaves and twigs in constant motion; small flags extended

3,4 - 5,4 12-19

4 Moderate Breeze Small branches move; flags flap 5,5 - 7,9 20 - 28

5 Fresh Breeze Small trees sway; flags flap and ripple 8 -10,7 29 - 38

6 Strong Breeze Large branches sway; flags beat and pop, umbrella difficult to use

10,8 - 13,8 39 - 49

7 Moderate Gale Whole trees sway 13,9 –17,1 50 -61

8 Fresh Gale Twigs break off trees 17,2 –20,7 62 -74

9 Strong Gale Branches break of trees 20,8 - 24,4 75 - 88

10 Whole Gale Some trees blow down; tiles blow from roofs

24,5 –28,4 89 -102

11 Storm Widespread damage to trees and to buildings

28,5 –32,6 103 -117

Beaufort-Number

Description Observations Wind

Speed >117

OPTIONS SCH13119007505HBF00


Options Optional the following special equipments are available on additional charge:

Working headlights:

For the best possible illumination of the working area, they are assembled on the platform.

Batteries: Maintenance-free gel batteries.

Current transformer:

The current transformer dissipates the batteries´ electric power of low voltage to alternating voltage 230 V.

In conjunction with a 230 V socket on the platform electric tools, lighting equipments up to 800 W (short term to 1400 W ) can be used without additional feed lines.

Mini - Dat (operating data entry):

The aerial work platform will be prepared for the installation of the hardware.

Mini - Dat RC (operating data entry): The aerial work platform will be prepared for the installation of the hardware.

Biodegradable hydraulik oil

PANOLIN HLP SYNTH 22

The biodegradability was proved in various tests and in several laboratories.

ASTM D-6046-98a: PW1, TW1, TS1

Biodegradability (average values): ca. 80 % by CEC-L-33-T-82/A93 ca. 70 % by OECD 301 B

Blauer Engel UZ 79, eco-label – because biodegradable

Environment Agency Standards (GB)

OPTIONS SCH13119007505HBF00


JEA (Japan Environment Association)

ÖNORM, Teil 5 (A)

Swedish Standards SS 15 54 34

VAMIL Regulations (NL)

water hazard class PANOLIN HLP SYNTH 15 – 32 nwg by VwVwS PANOLIN HLP SYNTH 46 – 68 WGK-1 by VwVwS

Tires:

rain tires:

For a better adhesion at wetness.

Vulkollan - tires: This special tires aid to provide abrasion on sensitive grounds. They are harder than the white solid rubber tires.

Special lines to the platform:

230 V socket on the platform

Compressed air supply

Hose as supply line for high-pressure cleaner

Special lacquering: Your company color by request. Choice within the safety regulations.

Warning device:

visible: signal lamp

audible: horn Different Employer’s liability insurance associations or safety administrators will regulate these additional safety devices for operating the working platform in areas in which stay many people.

LABELS SCH13119007505HBF00


Labels

Arrangement at the machine

Allocation general labels

Allocation special labels

1

3

21

4a

11

10

54c

13

19w 30d

8 7

3

9a

5

47

9b36f

40

18e

54f

6



General labels

2e 3

4a 5 6

1a

1

230 V / 16 A

10 11

9

1,5 t

7

8

9a 9414123



12,545

//

m

kms

h( )

0 //

m

kms

h(0 )

Special labels

13

19w

40

54c Me nü +M enü -

60

30d

55

47 18e

36f

120

47

66

80

66e

67

NOTES


ZIVAN

NG3 48 V

Operating Instructions

of Charger

Battery charger NG3

D01058-02 2

ATTENTION: To reduce the risk of electric shock, do not remove cover. Refer servicing to qualified service personnel. Disconnect the mains supply before connecting or disconnecting the links to the battery.

Read the Instruction Manual carefully before use. Verify that the selected charge curve is suitable for the type of battery You have to re-charge.

Explanation of Graphical Symbols

The lightning flash with arrowhead symbol, within an equilateral triangle, is intended to alert the user to the presence of uninsulated “dangerous voltage” within the equipment’s enclosure; that may be of sufficient magnitude to constitute a risk of electric shock to persons.

The exclamation point within an equilateral triangle is intended to alert the user to the presence of important operating and maintenance (servicing) instructions in the literature accompanying the equipment.

This product is covered by warranty. The relative warranty certificate is attached to the Instructions Manual. If the Manual is not provided with this certificate, please ask your retailer for a copy. For further references, please write the serial number in the proper space:

Serial No. _____________________

Information contained in this Manual relates to ZIVAN S.r.l. property which reserves the right to supply for the exclusive use of customers. No other use is allowed without a written authorization supplied by ZIVAN S.r.l.

ZIVAN S.r.l. will be not responsible for inaccuracies contained in this manual due to print or translation errors. ZIVAN S.r.l. has the right to make changes or improvements, also for the user interest, without prejudicing the essential characteristic of operation and safety.

Copyright © 2003 by ZIVAN S.r.l. Second Edition

Battery charger NG3

D01058-02 3

Installation and safety instructions

Battery charger NG3 has been designed to provide safety and reliable. It is necessary to observe the following precautions in order to avoid damage to persons and to the battery charger:

• Read the installation instructions contained in this Manual carefully. For further information put the Manual in a proper place.

• Fix the battery charger to a stable surface through the appropriate holes inserted on the fixing flanges. In case of installation on a vehicle it is advisable to use antivibration supports.

• Preferably the charger should be installed in the vertical position with fans facing up. The horizontal installation is allowed. Never install in the vertical position with fans facing down.

• Ensure all ventilation ports are not obstructed, to avoid the overheating. Do not put the battery charger near heat sources. Make sure that free space around the battery charger is sufficient to provide adequate ventilation and an easy access to cables sockets.

• Protect the battery charger from ingress of water. Do not pour liquids inside the case.

• Verify that the available supply voltage corresponds to the voltage that is stated on the battery charger name plate. In case of doubt, consult a retailer or local Electric Supply Authority.

• For safety and electromagnetic compatibility, the battery charger has a 3-prong plug as a safety feature, and it will only fit into an earthed outlet. If you can not plug it in, chances are you have an older, non-earthed outlet; contact an electrician to have the outlet replaced. Do not use an adapter to defeat the earthing.

• To avoid damaging the power cord, do not put anything on it or place it where it will be walked on. If the cord becomes damaged or frayed, replace it immediately.

• If you are using an extension cord or power strip, make sure that the total of the amperes required by all the equipment on the extension is less than the extension’s rating.

• Disconnect the mains supply before connecting or disconnecting the links to the battery.

• To recharge Lead Acid batteries: WARNING: Explosive Gas – Avoid flames and sparks. The battery must be positioned in a correctly cooled place.

• Do not use to charge batteries installed on board of thermal engine cars.

• Avoid recharging of non-rechargeable batteries.

• Verify that the nominal voltage of the battery to be re-charged corresponds to the voltage stated on the battery charger name plate.

• Verify that the selected charging curve is suitable for the type of battery to be re-charged. In case of doubt, consult Your retailer. ZIVAN S.r.l. will not accept any responsibility in case of mistaken choice of the charging curve that may cause irreversible damage to the battery.

• In order to avoid voltage drop, thereby assuring 100% charge at the battery, the output cables must be as short as possible, and the diameter must be adequate for the output current.

• In the case of thermal compensation of the battery voltage, it is necessary to place the thermal sensor in the area of highest battery temperature.

• Do not try to service the battery charger yourself. Opening the cover may expose you to shocks or other hazards.

• If the battery charger does not work correctly or if it has been damaged, unplugged it immediately from the supply socket and from the battery socket and contact a retailer.

Battery charger NG3

D01058-02 4

Operating principle

The battery charger considerably affects battery life and performances, which is the main part of every electric vehicle.

A non controlled traditional battery charger (rectifier) provides a simple direct AC/DC conversion.

Disadvantages of this solution are: • Low efficiency • Large physical size • Long charge times • Charge depends on changes in the mains supply (with

overcharge danger in the final charge phase) In modern battery chargers these disadvantages are solved with an indirect AC/DC conversion, by passing through an intermediate DC/DC conversion.

This is the usual method of operation for the SMPS (Switching Mode Power Supply) at high power. This solution gives a good performance for minimum costs and physical dimensions using switches more faster and powerful (modern technology).

The main advantages of this solution are: • High efficiency • Reduced dimensions • Short charge times • Charge independent from the changes of the mains supply • Electronic control that provides the desired charge curve

The advent of electrical problems (due to commutation) has imposed the introduction of adequate filtering to satisfy requirements of EMC 89/336/EEC directive for electromagnetic compatibility.

Block Diagram

STAGE

POWERE

L

N

F1 F2

LOGIC

CONTROL

FILTER

FILTER

FILTER

RECTIFIER

RECTIFIER

RECTIFIERAND

AND

ANDFILTER FILTER

EMI EMI

Battery

i

v DC

AC

Battery

i

vDC

DC

DC

AC

Battery charger NG3

D01058-02 5

LED Indicator

RED LED shows that the battery is in the initial charging phase. YELLOW LED shows that the battery charger has reached 80% of charge. GREEN LED shows that the battery has reached 100% of charge.

Further information can be found in the description of the Charging Curve. Example: RED LED on with brief blinks indicates a constant tension phase.

Alarms (Two-tone audible message) An two-tone audible message and the flashing LED shows that an Alarm situation has occurred:

Condition Alarm Type Description (Action)

Audible message +

RED flash

Battery Presence Battery disconnected or not in conformity. (Verify the connection and the nominal voltage).

Audible message +

YELLOW flash

Thermal Sensor The thermal sensor is disconnected during the re-charge or it is out working range. (Verify the connection of the sensor and measure the temperature of the battery).

Audible message +

GREEN flash

Timeout Phase 1 and/or Phase 2 have a duration in excess of the maximal allowed. (Verify the battery capacity).

Audible message +

RED-YELLOW flash

Battery Current Loss of output Current control. (Failure of the control logic).

Audible message +

RED-GREEN flash

Battery Voltage Loss of output Voltage control. (Battery disconnected or failure of the control logic).

Audible message +

YELLOW -GREEN flash

Selection An unavailable configuration has been selected (Verify the selector’s position)

Audible message +

RED-YELLOW-GREEN flash

Thermal Overheating of semiconductors. (Verify the fan operation).

When there is an alarm the battery charger stops supplying current.

Thermal Sensor and/or External Indicator

Thermal Sensor and External Indicator are Options that have to be connected to the 5 poles socket 180°.

Unless otherwise stated, the compensation of the Battery Voltage in function of the temperature of the Thermal Sensor is of -5mV/°C for battery cell. The control range of the Thermal Sensor goes from -20°C to +50°C.

The External Indicator reflects exactly the LED Indicator which is placed on the equipment. Further information can be found in the description of the Charging Curve.

100%

START

80%80%

Battery charger NG3

D01058-02 6

CURRENT

50%

100%

Auxiliary Contacts

Technical Features: changeovers contacts 0,3A 125VAC 0,3A 110VDC 1A 30VDC

Connector: faston 6,3 × 0,8 mm

Unless otherwise stated, the auxiliary contacts provide the following functions:

Section Function Description AUX1 Mains Presence When the equipment is switched on, the contact

Normally Open (NO) CLOSES and instead the contact Normally Closed (NC) OPENS.

AUX2 End of charge or Trickle Phase

When the Stop Phase or the No Stop Phase is reached, the contact Normally Open (NO) CLOSES and instead the contact Normally Closed (NC) OPENS.

LED Bar Graph

The LED Bar Graph is an Option that shows a percentage indication of output current in comparison with its max. value

Battery A battery is characterised by two sizes: tension and capacity.

Tension: Each element has a nominal tension, which depends on the type of battery (no matter what size). In order to reach higher tension, many elements are connected in series, so creating a “BATTERY” of elements. The number of elements is calculated by dividing the nominal tension of the battery for the tension of each single element in the table:

Capacity: It is the quantity of electric charge that the batteries can supply to an external circuit before the tension decreases under the final limit value and it is obtained by multiplying the intensity of the discharging current I, expressed in ampere (A), for the discharging time t expressed in hours (h): C = I x t The traction battery capacity is normally referred to the discharging system of 5h: C5 = I x 5h. The capacity values that can be recharged by the battery chargers can be found in the description of the Charging Curve (this value is not present in the curves able to charge any capacity).

: This device is in conformity with the Low Voltage directive 73/23/EEC

and EMC directive 89/336/EEC and their further modifications.

NOCNCNOCNC

AUX2AUX1

Type Nominal Tension

Pb 2 V/cell NiCd 1,2 V/cell NiMH 1,2 V/cell NiZn 1,714 V/cell

Battery charger NG3

D01058-02 7

Mechanical dimensions

90

220 370

430

78

6

N.B. All dimensions are expressed in mm.

Drilling details

UP

Advised Installation

N.B. All dimensions are expressed in mm.

= =

60 60

18

13

6

220

399 430

100

Battery charger NG3

D01058-02 8

TECHNICAL FEATURES

Ta=25°C unless otherwise specified

Mains side

Description Symbol Test Condition Value and/or Range

Unit

Supply Voltage Vin - 230 ± 10% Veff

Frequency f - 50 ÷ 60 Hz

Absorbed Maximum Current Iinmax P = Pmax 20 Aeff

Inrush Current - Vin = 230Veff < 1,35 A

Power Factor cosϕ P = Pmax 0,68 -

Absorbed Minimum Power Pinmin End of charge < 5 W

Absorbed Maximum Power Pinmax P = Pmax 3 kW

Battery side


Unit

Output current I - See curve -

Maximum output current I1 Phase 1 See curve A

Output current ripple - I = I1 < 5% -

Absorbed current Ia Equipment turned off < 0,5 mA

Output voltage U - See curve -

Constant output voltage U1 Phase 2 See curve V

Thermal compensation of output voltage

dU1/dT Phase 2 -5 mV / (°C·cell)

Operating range of Temperature Sensor

∆T - from -20

to +50

°C

Output voltage ripple - U = U1 < 1% -

Maximum power supplied Pmax U = U1, I = I1 2550 W

Output capacity C - Depend on the model (>0,2)

mF

Battery charger NG3

D01058-02 9

General


Unit

Operating range of temperature ∆T - from -20 to +50 °C

Maximum relative humidity RH - 90% -

Switching frequency fc - 30 ± 5% kHz

Efficiency η At each operation condition

> 85% -

Maximum size a×b×c Without connecting cable

430×220×90 mm

Weight - Without connecting cable

5,5 kg

Enclosure class - - IP20 -

Protection and Safety


Unit

Insulation - Mains to Battery side 1250 VAC

Insulation - Mains side to Earth 500 VDC

Insulation - Battery side to Earth 500 VDC

Leakage current IL Supplied equipment < 3 mA

Input fuse F1 Inside the equipment 20 A

Output fuse F2 Inside the equipment about 1,2×I1 A

Minimum output voltage of operation (Battery Detector)

- Equipment turn on 1,5 V/cell

Maximum output voltage Um Phase 3 (IUIa - IUIUo) See curve V

Reverse output polarity - At the connection to the Battery

Protection provided by

fuse F2

-

Thermal protection of semiconductors (Temperature of Thermal Alarm)

- Ta=55°C 100 °C

Safety Requirements (Rules) - EN60335-1, EN60335-2-29 - -

EMC Requirements (Rules) - EN55014-1, EN61000-3-3 EN55014-2, EN61000-4-2 EN61000-4-4, EN61000-4-5 EN61000-4-6, EN61000-4-11

- -


Hydraulic circuit diagram / Electric circuit diagram

operating- and maintenance instructions - mälarlift · 2017. 6. 22. · daily commissioning ... we...

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