Table of Contents
Advertisement
Advertisement
Table of Contents
Related Manuals for NIFTYLIFT Nifty Heightrider HR21 MK2 Series
Summary of Contents for NIFTYLIFT Nifty Heightrider HR21 MK2 Series
- Page 1 Heightrider Operating & Safety Instructions MODEL HR21 SERIES Manufactured by: Niftylift Limited Chalkdell Drive Shenley Wood Milton Keynes MK5 6GF England www.niftylift.com e-mail: info@niftylift.com Tel: +44 (0)1908 223456 Fax: +44 (0)1908 312733 M50541/03...
- Page 2 For further information on all controls refer to Sections 4.2 and 4.3. Emergency lowering instructions vary between different types of Mobile Elevating Work Platform. Niftylift recommend that operators, site-safety personnel, and ground workers are trained in and practise these machine-specific procedures.
-
Page 3: Table Of Contents
Height Rider/SP Series Operating & Safety Instructions Table of Contents Introduction and General Information ....................... 2 FOREWORD ......................3 SCOPE ......3 INTRODUCING THE HEIGHT RIDER SELF-PROPELLED (SP) SERIES ................... 4 GENERAL SPECIFICATION ................5 IDENTIFICATION (UK PLATE) ............7 EC DECLARATION OF CONFORMITY (Typical) Safety ................ -
Page 4: Introduction And General Information
Height Rider/SP Series Operating & Safety Instructions Introduction and General Information FOREWORD The purpose of these manuals is to provide the customer with appropriate safety operating and maintenance instructions essential for proper machine operation. All information in these manuals should be READ and fully UNDERSTOOD before any attempt is made to operate the machine. -
Page 5: Scope
These operating instructions contain all the necessary information required to allow the safe operation of any Niftylift Height Rider 21 (SP64 in the USA), powered by diesel (D) and DC electric (E). For further technical information, circuit diagrams and specific instructions for all maintenance which may need to be carried out by specialist trained personnel, see the associated Workshop and Parts manual for your model of Niftylift Height Rider. -
Page 6: General Specification
Height Rider/SP Series Operating & Safety Instructions GENERAL SPECIFICATION FEATURE HR21 4x4 MAXIMUM HEIGHT - WORKING 20.8m 68ft 2in MAXIMUM HEIGHT - PLATFORM 18.8m 61ft 8in MAXIMUM OUTREACH 13.0m 42ft 8in MAXIMUM HEIGHT – STOWED 2.18m 7ft 2in MAXIMUM WIDTH 2.27m 7ft 5in MAXIMUM LENGTH –... -
Page 7: Identification (Uk Plate)
Operating & Safety Instructions IDENTIFICATION (UK PLATE) This manufacturer’s plate is attached to the chassis on each machine at the time of manufacture on every Niftylift. Please ensure all sections have been stamped and are legible. English/USA – 07/17 Original instructions... - Page 8 Operating & Safety Instructions 1.5a IDENTIFICATION (USA PLATE) This manufacturer’s plate is attached to the chassis on each machine at the time of manufacture on every Niftylift. Please ensure all sections have been stamped and are legible. English/USA – 07/17 Original instructions...
-
Page 9: Ec Declaration Of Conformity (Typical)
Height Rider/SP Series Operating & Safety Instructions EC DECLARATION OF CONFORMITY (Typical) English/USA – 07/17 Original instructions... -
Page 10: Safety
Always operate the Niftylift in accordance with these model-specific Operating & Safety Instructions. 2.1.3 Before use each day and at the beginning of each shift the Niftylift shall be given a visual inspection and functional test including, but not limited to, operating and emergency controls, safety devices,... - Page 11 Only operate the Niftylift on a firm, level surface. 2.1.12 Never position any part of the Niftylift inside the Minimum approach distances (MAD) to above- ground electrical conductors as listed in the table below. (Reference ISO 18893:2014). Voltage range (kV) MAD (m) <0.7...
- Page 12 Any problems or malfunctions that affect the safety of operation shall be repaired prior to continued use. 2.1.30 The boom and platform of the Niftylift shall not be used to jack the wheels off the ground. 2.1.31 The Niftylift shall not be used as a crane.
- Page 13 EN61326-3-1:2008, EN61000-6-2:2005 and EN55012:2007 for emissions and immunity. Niftylift offer a generator option on this machine, but cannot control the device that is connected to the system or the resulting variation in the amplitude of electrical noise produced when operating the generator.
-
Page 14: Environmental Limitations
All standard Niftylift machines are rated for a wind speed of 12.5 m/s, which equates to 45kph / 28mph or force 6 on the Beaufort scale. No attempt should be made to operate a Niftylift in wind strengths above this limit and if the operator has any doubts over the wind speed they should cease operation immediately until it can be established that the wind speed has fallen to a safe level. -
Page 15: Test Report
Operating & Safety Instructions TEST REPORT All Niftylift machine models are subjected to a comprehensive ‘type test’ which examines the worst- case combination of safe working load (SWL), overload, windage, inertia and pull force to assess the various safe stability criteria. Self propelled machines are also subjected to kerb and braking tests at the SWL to satisfy additional dynamic stability requirements. -
Page 16: Preparation And Inspection
PREPARATION FOR USE Whilst every effort has been made at the Niftylift factory to ensure your machine arrives in a safe and operable condition it is necessary to carry out a systematic inspection prior to putting the aerial platform into service. -
Page 17: Pre-Operational Safety Check Schedules
Height Rider/SP Series Operating & Safety Instructions PRE-OPERATIONAL SAFETY CHECK SCHEDULES Before use each day and at the beginning of each shift the aerial platform shall be given a visual inspection and functional test including, but not limited to, the following: It is recommended that these be performed at regular intervals as indicated on each checklist. - Page 18 Check the bushes in the front wheel hubs for wear. Check that slew ring bolts are secure (torque 218ft lbs. 295Nm). Toughcage Niftylift toughcage is fully UV stabilised for outdoor use in the most demanding climates. However, the user and machine owner should consider the following; ...
- Page 19 Note: The date of manufacture of the toughcage floor is located on its underside. Niftylift recommends that the user and machine owner regularly inspect the toughcage floor for damage. If any significant damage is found then the floor must be replaced. For further guidance please contact Niftylift Limited.
-
Page 20: Placard, Decals & Installation (Uk Spec)
Height Rider/SP Series Operating & Safety Instructions PLACARD, DECALS & INSTALLATION (UK SPEC) ITEM DESCRIPTION NUMBER Serial Plate P15383 Clunk Click P19961 IPAF ‘Are you trained?’ P22055 Caution - ‘SiOPS’ P22820 “If E-Stop Disabled P14864 ‘Do not place objects on controls’ P21511 Danger Warning - Icons P29379... - Page 21 Operating & Safety Instructions SWL 250kg P28294 Footswitch P14884 Cage Tie-down Warning P21404 Logo HR21 P16998 SP64 P19070 P14697 “Niftylift.com” P14389 Travel Direction P29066 Hazard tape Power to Cage Socket 240V P26427 Power to Cage Socket 110V P26426 Generator to cage (Option) P28828...
- Page 22 Height Rider/SP Series Operating & Safety Instructions English/USA – 07/17 Original instructions...
-
Page 23: Torque Requirements
Height Rider/SP Series Operating & Safety Instructions TORQUE REQUIREMENTS Bolt quality/size Tightening torque in Nm (ft-lbs) Plated Unplated Grade 10.9 12.9 10.9 12.9 7 (5) 10 (8) 12 (9) 8 (6) 11 (8) 13 (10) 17 (13) 25 (18) 29 (22) 19 (14) 27 (20) 32 (23) -
Page 24: Operation
MULTI-TONE SOUNDER & BEACON The Niftylift will warn personnel that the machine is about to move when the green power button or footswitch is pressed. The machine’s default setting is to sound a beeper at the base control location and flash a beacon mounted on the top of the engine canopy. - Page 25 Height Rider/SP Series Operating & Safety Instructions 4.1.2 PLATFORM CAGE DISPLAY UNIT: - Mounted in the Platform Control Station, this screen receives signals from the PLC to provide a warning indication to the operator for a range of functions. Refer to Section 4.3.2 for further details.
-
Page 26: Ground Control Operation
Height Rider/SP Series Operating & Safety Instructions GROUND CONTROL OPERATION 4.2.1 GROUND CONTROL FUNCTIONS 1 Emergency Stop Push to Stop Operation Twist to Enable Operation 2 Green Power Button Push and hold for Power Release to Cease operation 3 Base/Platform Selector Clockwise for Platform, Centre for Base, 0 for all power off 4 Engine Glow &... - Page 27 Height Rider/SP Series Operating & Safety Instructions Base Levers 1 Operates Platform Levelling Forward for Up Backward for Down * 2 Operates the Flyboom Up for Up Down for Down * 3 Operates Telescoping Up for Out Down for In * 4 Operates the Link Booms Up for Up Down for Down...
- Page 28 Height Rider/SP Series Operating & Safety Instructions ALL MODELS Push and hold green power button on the base control panel. Select a function and operate the appropriate control lever(s) in full accordance with the manufacturers operating and safety manual. (Refer to Section 4.2.1) To return control to the platform, turn base control key-switch to the Platform position (fully clockwise).
-
Page 29: Platform Control Operation
Height Rider/SP Series Operating & Safety Instructions PLATFORM CONTROL OPERATION 4.3.1 PLATFORM CONTROL FUNCTIONS The platform controls are designed to prevent inadvertent operation of the machine and the user must be familiar with the following safety features. Footswitch timeout – If the footswitch or green button is pressed, but no function is activated within 15 seconds, the machine will not function until the footswitch or green button is released and re-pressed. - Page 30 Height Rider/SP Series Operating & Safety Instructions 9 Green Power Button Push and hold to activate machine 10 Joystick Grip the joystick and hold the trigger switch at the front. Machine movement is achieved by slowly moving the joystick away from the neutral position in the required direction.
- Page 31 Height Rider/SP Series Operating & Safety Instructions 4.3.3 INFORMATION ICONS Safety Critical (Main screen) MAX tilt angle exceeded:- The alarm sounds, the display shows this image and drive is disabled. Lower booms down into the stowed position and drive onto level ground to fully restore machine operation. Safe Working Load (SWL) exceeded:- The alarm sounds and the display will show this image.
- Page 32 Height Rider/SP Series Operating & Safety Instructions Advisory (Mode of operation) Boom Function Speed: Determined by the Speed Selector switch on the Cage Control Panel (Refer to Page 27). Drive Speed: Determined by the Speed Selector switch on the Platform Control Panel (Refer to Page 27).
- Page 33 Height Rider/SP Series Operating & Safety Instructions Cage Overload Warning Red: SWL exceeded. (Refer to ‘Safety Critical (Main screen)’ section on page 29). Cage Overload Override Evidence Amber: Cage overload has been overridden. This will remain until reset. Red: Malfunction. In order to reset overload override evidence, press Button 3 and follow on- screen instructions.
- Page 34 If any square is red, the engine should be switched off immediately. The engine coolant or oil level should be checked once the engine has cooled sufficiently. Refer to Niftylift Service Manual for further information. This screen can be accessed at any time to check Engine RPM, oil pressure and water temperature status.
- Page 35 To access this screen, press button 3. To reset either the Cage overload override evidence or the Chassis zero, contact Niftylift and quote the reference number displayed on the screen. Niftylift will supply a code which must be entered by using the arrow keys.
- Page 36 Height Rider/SP Series Operating & Safety Instructions Select Language This allows the operator to choose a language for the menu screens. Cage Rotate (Ground Controls Only) This allows the operator to rotate the cage from the Ground Controls. Push and hold green power button on the ground control panel. Press either the left or right arrow on the navigation button (Refer to Section 4.3.2) as required.
- Page 37 Operating & Safety Instructions 4.3.5 OPERATION NEVER START THE NIFTYLIFT IF YOU SMELL PETROL (GASOLINE), LIQUID PROPANE OR DIESEL. THESE FUELS ARE FLAMMABLE. BEFORE OPERATING THE NIFTYLIFT ENSURE THAT EACH OPERATOR HAS READ AND FULLY UNDERSTOOD THE OPERATING MANUAL. FAILURE TO DO SO MAY RESULT IN DEATH OR SERIOUS INJURY.
- Page 38 Height Rider/SP Series Operating & Safety Instructions EMERGENCY PROCEDURES Push in red emergency stop to shut down all machine movement. Release both emergency stops to restore normal controls. In the event that the controls fail or the cage overload is activated as described in Section 5.3, the booms can be operated from the cage location as described below: Press white override button situated on the cage console.
-
Page 39: Driving Controls
When driving with the booms fully stowed, the Tilt Sensor is bypassed to allow the Niftylift to be driven in areas where the slope exceeds the allowable inclination limit. In normal operation the drive is therefore unaffected when driven onto a slope in excess of this limit, until the booms are raised, whereupon the drive is disabled and the tilt alarm sounds continuously. -
Page 40: Cage Weigh System
4.5.1 LOAD CELL VERSION The Niftylift HR21 is fitted with an electronic load cell. This load cell is a moment-independent design. This means that independent of the load position inside the machine cage, the actual load is measured and if pre-calibrated limit values are exceeded, warnings will be activated. If load exceeds the safe working limit (SWL) of the machine, the machine will be disabled until the load is reduced to below 95% of the safe working limit. -
Page 41: Batteries And Charging
Height Rider/SP Series Operating & Safety Instructions BATTERIES AND CHARGING (Hybrid) BATTERIES MUST BE RECHARGED IN A WELL-VENTILATED AREA FREE OF FLAME, SPARKS OR OTHER HAZARDS THAT MAY CAUSE EXPLOSION. HIGHLY EXPLOSIVE HYDROGEN GAS IS PRODUCED DURING THE CHARGING PROCESS. Recharge batteries at the end of every working day or shift. - Page 42 Height Rider/SP Series Operating & Safety Instructions During normal machine usage with the engine running, the batteries are on continuous recharge, except when the control system decides that additional electric power is required in order to maintain drive/function speed. Should the operator ignore the onset of the battery discharge warning the "shut down" of the motors will continue, until the machine is rendered in-operative.
- Page 43 Note; this requirement does not apply if the battery isolating handle (Anderson connector) ONLY has been disconnected. The Battery Controller Unit has been calibrated to function correctly with Niftylift factory fitted batteries. If for any reason you suspect any of the batteries have been replaced with a non-factory fitted unit then please contact the Niftylift Service Department on (44) 01908 857899, Fax: 01908 227460.
-
Page 44: Transporting, Towing, Craneage, Storage And Setting To Work
Always ensure the truck or trailer you are loading or towing the Niftylift with can carry it legally. If loading by crane the use of shackles and an adequately rated spreader beam, with four leg slings, is MANDATORY. - Page 45 Operating & Safety Instructions 4.7.2 TOWING If the Niftylift needs to be towed in case of an emergency, it will be necessary to chock the wheels before starting any of the following actions. IDENTIFYING GEARBOX TYPE In order to safely tow the HR21, the drive mechanism will need to be bypassed. Identify the type of gearbox fitted to the machine then refer to the relevant procedure for disengagement of the gearboxes.
- Page 46 Height Rider/SP Series Operating & Safety Instructions GEARBOX DISENGAGEMENT (TYPE 2) The drive gearboxes located on the front and rear wheel hubs must be disengaged as follows; Remove both retaining bolts that secure the cover disc to the centre of the wheel hub. Partially screw one of the retaining bolts into the end of the central disengage pin and pull the pin out fully, ensuring the recess on the pin is visible.
- Page 47 If in doubt, contact our Service Department for further advice. Niftylift Limited is not liable for any third party damage caused during transport. Careful attention to correct procedures will prevent many of the small snags that can happen in transit. Re-work is both expensive and time consuming.
-
Page 48: Emergency Controls
BEFORE USING THE MACHINE. INCIDENT NOTIFICATION It is a mandatory requirement that any accident or incident involving a Niftylift, regardless of whether any party received injury or property was damaged is reported by telephone directly to Niftylift. Failure to do so may render any warranty on the machine void. -
Page 49: Responsibilities
CHANGES IN OWNERSHIP When a change of ownership of a Niftylift occurs, it shall be the responsibility of the seller to notify Niftylift directly of the unit, model and serial number and the name and address of the new owner within 60 days. -
Page 50: Inspection/Service/Pre-Hire Check List
Height Rider/SP Series Operating & Safety Instructions INSPECTION/SERVICE/PRE-HIRE CHECK LIST MACHINE SERIAL NO ADMINISTRATION PASS FAIL Daily, Weekly, Monthly checks carried out as outlined in manufacturers Operating and Safety Manual? Machine has valid LOLER Certificate? (UK only) TOWING PASS FAIL Check brakes are released or…... - Page 51 Height Rider/SP Series Operating & Safety Instructions PLATFORM PASS FAIL Operation of Emergency Stop button Operation of SiOPS (Refer to Section 4.3.5) Operation of control valve and control panel buttons/switches Operation of all booms over full range Operation of Footswitch Platform levelling over full range Slewing smooth over full range Condition of harness points...
- Page 52 Height Rider/SP Series Operating & Safety Instructions Comments, remedial work required etc; INSPECTED BY: DATE: English/USA – 07/17 Original instructions...
-
Page 53: Appendix A
Height Rider/SP Series Operating & Safety Instructions Appendix A Application specific error codes For more comprehensive error information please refer to the HR21 MK2 Service Manual. Description Error Code Action There is a problem with the signals Ensure contact blocks are securely in position. from the normally closed and 01A10000 Check Keyswitch wiring from the switch contacts to... - Page 54 Avoid sharp changes of direction. The drive pressure in elevated mode 01AD0000 is too high Contact a Niftylift approved service centre Return the Links Paddle to the neutral position and The Links Paddle was out of the release the Green Button and Footswitch.
- Page 55 Height Rider/SP Series Operating & Safety Instructions Description Error Code Action Return the Telescope Paddle to neutral and release the Green Button and Footswitch. The Telescope Paddle was out of the neutral position too long before the Press the Green Button or Footswitch and then move 01B40000 Green Button or Footswitch was the Telescope Paddle to operate Telescope.
- Page 56 Height Rider/SP Series Operating & Safety Instructions Description Error Code Action Ensure screen is plugged in. The Base Screen and PLC are not 01C90000 Check power supply and CAN Bus connections to the communicating Base Screen Ensure Chassis Inclination Sensor is plugged in. The Chassis Inclination Sensor and 01CF0000 Check power supply and CAN Bus connections to the...
- Page 57 Check the machine serial plate. The serial number of the machine 01F30000 is incorrect Contact a Niftylift approved service centre Move the Test Jumper in the Main Control Box to 0 V 01F40000 The PLC is set to download (Zero volts)
-
Page 58: Appendix B
Safety Related Parts of the Control System (SRP/CS) The Niftylift control system has been designed and validated according to the required standards. The table below lists the safety related parts of the control system and the level to which they have been approved. - Page 59 Maintenance must only be carried out by appropriately trained and competent persons. 3.The effects of deviations from the specified performance on the safety function(s); If the tilt interlock does not function as intended it is possible that the Niftylift may encounter slopes for which it is not rated.
- Page 60 Do not attempt to open the tilt sensor or replace components soldered to any PLC. Do not attempt maintenance of hydraulic components i.e. replace seals or internal component. Only Niftylift original and supplied parts shall be used. 12. Means for easy and safe trouble shooting;...
- Page 61 3. The effects of deviations from the specified performance on the safety function(s); If the elevated drive speed interlock does not function as intended it is possible that the Niftylift may experience dramatic dynamic effects which may adversely affect the stability of the product.
- Page 62 All components within the elevated drive speed are rated to the environmental conditions acceptable for the machine; refer to Section 2.2. 7. Indications and alarms; There are no indicators or alarms to show that the Niftylift is under the control of the elevated drive speed interlock. 8. Muting and suspension of safety functions;...
- Page 63 Height Rider/SP Series Operating & Safety Instructions 13. Information explaining the applications for use relevant to the category to which reference is made; Not applicable 14. Checking test intervals where relevant. Check the operation of the elevated drive system to be made at the beginning of every duty cycle. English/USA –...
- Page 64 3.The effects of deviations from the specified performance on the safety function(s); If the load sensing system does not function as intended it is possible that the Niftylift may encounter overloads for which it is not rated.
- Page 65 Height Rider/SP Series Operating & Safety Instructions 5. Response time; The Load sensing system is active all the time the green button or footswitch is depressed, the application of an overload will be detected within 4 seconds to cater for transient loads and acceleration forces.
- Page 66 12. Means for easy and safe trouble shooting; To check the operation of the load sensor system 1. Power on the Niftylift and select the base control location. 2. Allow the power circuits to cycle and ensure the machine is ready for the command signal.
- Page 67 Pass criteria - If the booms do not operate the system is functioning correctly. Fail criteria – If the booms move there is a previously undetected fault with the system and the Niftylift must not be used until this fault has been repaired.
- Page 68 Height Rider/SP Series Operating & Safety Instructions PLATFORM LEVELLING The Platform levelling system is PL c in accordance to with ISO 13849-1:2008 as required by BS EN 280:2013+A1 2015 1.The limits of the safety-related parts to the category selected and any fault exclusions; The Platform levelling system comprises of a load holding device mounted to the slave levelling cylinder.
- Page 69 Section 2.2. 7.Indications and alarms; There are no indicators or alarms to show that the Niftylift levelling system is functioning. 8.Muting and suspension of safety functions; It is not possible to suspend the operation of the levelling system.
- Page 70 3. The effects of deviations from the specified performance on the safety function(s); If the interlocking of the control positions does not function as intended it is possible that the Niftylift may allow modes of operation that render it potentially dangerous.
- Page 71 12. Means for easy and safe trouble shooting; To check the operation of the load sensor system. 1. Power on the Niftylift and select the base control location. 2. Allow the power circuits to cycle and ensure the machine is ready for the command signal.
- Page 72 Height Rider/SP Series Operating & Safety Instructions PREVENT MOVEMENTS OF LOAD HOLDING CYLINDERS IN CASE OF PIPE FAILURE The load holding system is PL c in accordance to with ISO 13849-1:2008 as required by BS EN 280:2013+A1 2015 1.The limits of the safety-related parts to the category selected and any fault exclusions; The load holding system comprises of a load holding device mounted to the cylinder.
- Page 73 Section 2.2. 7.Indications and alarms; There are no indicators or alarms to show that the Niftylift load holding system is functioning. 8.Muting and suspension of safety functions; It is not possible to suspend the operation of the load holding system.
- Page 74 3. The effects of deviations from the specified performance on the safety function(s); If the interlocking of the travel controls does not function as intended it is possible that the Niftylift may allow modes of operation that render it potentially dangerous.
- Page 75 12. Means for easy and safe trouble shooting; To check the operation of the travel control interlock. 1. Power on the Niftylift and select the cage control location. 2. Allow the power circuits to cycle and ensure the machine is ready for the command signal.
- Page 76 3.The effects of deviations from the specified performance on the safety function(s); If the Emergency stop system does not function as intended it is possible that the Niftylift may function when the E-stop is pressed.
- Page 77 12. Means for easy and safe trouble shooting; To check the operation of the emergency stop system 1. Power on the Niftylift and select the base control location. 2. Allow the power circuits to cycle and ensure the machine is ready for the command signal.
- Page 78 Pass criteria - If the booms do not operate the system is functioning correctly. Fail criteria – If the booms move there is a previously undetected fault with the system and the Niftylift must not be used until this fault has been repaired.