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Summary of Contents for Boughton Power-Reach PR12
- Page 1 Engineering Limited Operation & Maintenance Manual Power-Reach Skiploader Incorporating Optional Sheeting System Document – S1005-ML-029 Issue 01 - May 2016...
- Page 2 Notes on Using Electronic Copies of This Manual The electronic copy of this manual is distributed in .pdf format. The manual opens in single page view with a bookmark pane to the left. The user can navigate the manual by:- •...
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Page 3: Table Of Contents
Maintenance Procedure 8 – Remote Controller Maintenance……………… 38 12. Further Information……………………………………………………………..39 © All rights reserved. This document remains the property of the author. Nothing in this publication may be copied or distributed without the prior consent of Boughton Engineering Limited. -
Page 4: Introduction
Introduction This manual has been produced, by Boughton Engineering Limited, to ensure that users of the PR12 Skiploader have all the information required to operate the equipment safely. It is the responsibility of the operator’s management to ensure that all health and safety requirements relating to the use of this equipment are assessed, and that all personnel who use the equipment are aware of its functionality and limitations. -
Page 5: General Function And Limitations
1. General Function and Limitations The PR12 skiploader is designed for transporting materials contained in skips. The equipment allows the operator to lift and load empty and loaded skips onto the bed of the vehicle or lift and unload empty and loaded skips onto the ground. In addition this equipment can be used to tip skips, provided that they have been designed for this purpose. - Page 6 Serious injury or damage to the vehicle or skiploader equipment may result. This manual also includes operating instructions for the Boughton Engineering Limited’s Intacova sheeting system. This system is optional and may not be fitted to all vehicles.
- Page 7 Spare parts used during repair and maintenance procedures must be approved by Boughton Engineering Limited. Please refer to the equipment maintenance section of this manual, Section 10, and spare parts catalogue S1005-ML-032 for information on procedures for maintaining the equipment in a safe operational condition.
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Page 8: Skiploader General Arrangement
2. Skiploader General Arrangement Telescopic Lifting Arm Adjustable Skip Stops - Lateral Cab Guard Main Lifting Arm Main Lift Arm Hydraulic Main Control Cylinder Valve Block Access Ladder (Both Sides) Hydraulic Fluid Tank Intacova Sheeting System (Optional) Lift Chain Stowage Load Bed Tiphooks Access Cover... -
Page 9: Skiploader Weights & Dimensions
3. Skiploader Weights & Dimension Model: Power-Reach – PR12 (Standard Model Only) Bed Length (Standard equipment only) 3342 mm Height from top of chassis 1870 mm Arm extension 1370 mm Chassis cut-off to load centre 1966 mm Overall length 4510 mm Chassis cut-off to stabiliser (raised) 254 mm G Bed width... -
Page 10: Intacova Dimensions
4. Intacova Dimensions The information in this section relates to the Intacova sheeting system. This system is an optional fitment and may not be installed on all vehicles. IntaCova Dimensions A Height from top of chassis 2002 mm B Maximum width 2456 mm C Main arm maximum radius 3120 mm... -
Page 11: Main Control Valve Block Overview
5. Main Control Valve Block Overview Levers - A B D E F G The skiploader equipment is operated using the hydraulic control block situated on the vehicle offset behind the cab. Lever A – Hold to run lever - must be in either the up or down position when operating the equipment. - Page 12 Note: When extending or retracting the telescopic arms and stabiliser legs operate both levers at the same time to synchronise left and right sides. Fine tune to level off by operating one or other lever. Operate Levers Together To Synchronise. Standard Control Functions –...
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Page 13: Remote Operation Hand Held Controller Overview
The Boughton remote operation hand held controller is an optional system which may not be fitted to your vehicle. The Boughton remote operation hand held controller is a portable wireless unit which can be used to operate all skiploader functions with the exception of the tiphooks. - Page 14 All buttons operate the equipment at a single speed with the button depressed either halfway or fully. A summary of the skiploader functions, operated by the push buttons, are detailed below:- Main Telescopic Telescopic Telescopic Stabiliser Stabiliser Arms Arm - Arm - Left Arm - Right Right...
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Page 15: Adjustable Skip Stops
7. Adjustable Skip Stops This vehicle is fitted with sockets towards the front and along the sides of the load platform. Six skip stop blocks are supplied with the vehicle, two for positioning at the front of the platform and two pairs for positioning down the sides. Adjustable Front Skip Stops Adjustable Lateral Skip Stops The skip stops, when fitted, restrain any potential forward or sideways movement of... -
Page 16: Warning Lights
8. Warning Lights WARNING It is the drivers’ responsibility to always ensure that the vehicle is operated within overall heights specified on the vehicle height notice located in the cab. Failure to ensure that the vehicle height is within this limit may result in a collision which may cause damage to the vehicle and/or other structure. - Page 17 Location of Body Warning Light Module The driver should check the display to see which lights are illuminated, indicating an item out of position. Note: The pressure switch lamp is illuminated when a signal is sent to set auto revs when operating the equipment.
- Page 18 With the equipment in this state check the body warning light module display, located on the front of the skiploader bulkhead. All lights on the display must be illuminated indicating that the auto revs signal is active and all of the proximity sensors are detecting equipment is out of the minimum travel height position.
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Page 19: General Safety Checks Prior To Operating
9. General Safety Checks Prior To Operating WARNING NEVER operate the equipment if there is a known fault. Take the vehicle out of service and affect a repair before returning into service. Only qualified technicians should carry out repair of faulty equipment. - Page 20 4. Check the area above the vehicle and lifting equipment. DO NOT lift if there is any risk of a collision. 5. When unloading, ensure that there is adequate space to accommodate the skip. To reduce the risk of a crushing hazard it is recommended that there is space all around the skip when unloaded.
- Page 21 8.3. The vehicle and equipment must remain clearly visible to the operator when the system is active and during any load/unload and tipping sequences. 8.4. When operating the system the operator must remain outside of the clearance zone shown in figure below:- Return to Contents Previous Page –...
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Page 22: Operating The Skiploader Equipment
10. Operating The Skip Loader Equipment In these instructions the following symbols are used to indicate the correct levers to operate when completing an instruction:- Lever Up Lever Down Levers - A B C D E F G H I Note: Limit the operation of the hydraulic system to 30 minutes at a time where possible. - Page 23 2) Ensure that the emergency stop button is in the out (run) position. If the emergency stop is in the pushed in (stop) position pull the button fully out. Note: It is not necessary to turn the button to set it to the out (run) position 3) Depress the start button.
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Page 24: Loading A Skip
Slow Flash (1 Flash/Second) - Battery Has Less Than 1 Hour Run Time. Fast Flash - Battery Has A 10 Minute Run Time. LED Flashes 3 Times/Sec During Start Up - Battery is flat For problems indicated by any other LED sequence please contact Boughton Engineering Limited. 10.1. Loading a Skip Prior to starting operation read through the “General Safety Checks Prior To Operating”... - Page 25 Extend telescopic arms, necessary, to place the chain pivot centrally over the skip lifting lugs. Levers: Attach the four chain key plates to the lifting lugs. Ensure that the plates are fully over the lug and that the chains are not twisted or tangled. Lift the skip off the ground using the main arms.
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Page 26: Deploying Intacova Sheeting System
Prior to driving on the highway a check should be made to ensure that the vehicle and its load are safe. Check the in cab warning light(s). If light(s) are illuminated check:- Main arms. Telescopic arms Stabilisers Refer to section 8. If no sheeting system is fitted and the vehicle is ready to depart ensure that the PTO is disengaged. -
Page 27: Retracting Intacova Sheeting System
10.3. Retracting Intacova Sheeting System WARNING During transit, Intacova Sheeting System must be in either the Fully Stowed or Fully Deployed positions to avoid damage to sheeter equipment. Prior to unloading or tipping a skip ensure that, if fitted, the Intacova sheeting system has been retracted. -
Page 28: Unloading A Skip
10.4. Unloading a Skip Prior to starting operation read through the “General Safety Checks Prior To Operating” section 9, and assess the proposed unload location to ensure that it is suitable. Take particular note of the available space and stability of the ground and ensure that there is adequate clearance behind the vehicle to accommodate the skip when unloaded. - Page 29 Continue the off load using the main arms. Rotate the skip over the rear of the vehicle and onto the ground. Continue rotating the main arms until there is sufficient slack in the lift chains to allow them to be disconnected from the skip lifting lugs.
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Page 30: Tipping A Skip
10.5. Tipping a Skip WARNING During the tip cycle, in the event that the load does not discharge, under no circumstances should anyone attempt to dislodge the load manually with the skip in the tipped condition. Return the skip to the horizontal position and repeat the tip cycle. - Page 31 Raise the tip hooks. Levers: Rotate the main arms and lift the skip off the load platform. Note: It may be necessary to extend the telescopic arms, prior to lifting, to avoid the skip dragging back along the bed. Check that the chain pivot is central over the skip just as the chains tighten.
- Page 32 11. On completion of the tip rotate main arms forward to return the skip to the horizontal position. Levers: 12. Complete the loading sequence by resting the skip on the load bed. Ensure that the main arms are rotated to the fully down position and that the telescopic arm is fully retracted.
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Page 33: Maintenance
DO NOT carry out any modification or adjustment (not described in this manual) to the skiploader equipment without obtaining written consent from Boughton Engineering Ltd. Maintenance work should always be carried out with the vehicle unladen. In the event of emergency repairs, by the roadside, all efforts must be made to remove any load prior to commencing work. -
Page 34: Schedule
Schedule Safety, life expectancy and performance of the skiploader equipment are significantly enhanced if maintenance is carried out as prescribed. The vehicle and skiploader equipment should be washed regularly (recommend washing weekly and more frequently if the type of operation demands). A build up of tipped materials on the bed, or around all moveable parts, can cause damage. -
Page 35: Maintenance Procedure 1 - Check And Fill Hydraulic Tank
6 Weekly 6 Monthly Annually Procedure Daily Checks – See Above & Grease all grease points Grease stabiliser leg stanchions Check nut and bolt torque values Replace hydraulic fluid filter *See Note Renew hydraulic fluid *Note Due to initial component bedding in, the hydraulic fluid filter must be changed at the first 6 weekly maintenance check. -
Page 36: Maintenance Procedure 2 - Filter Check/Change
Maintenance Procedure 2 – Filter Check/Change To check to ensure that the hydraulic fluid filter is not blocked the PTO must first be engaged. View the filter housing, located on the top of the hydraulic fluid tank, from the vehicle offside. The gauge on the side of the housing indicates the line pressure in the return line. -
Page 37: Maintenance Procedure 3 - Chain Inspection
Maintenance Procedure 3 – Chain Inspection WARNING Lift chains are critical safety components. DO NOT attempt to modify the lift chains by changing their length. DO NOT attempt repair of chains by cutting or welding. If a chain is damaged or worn beyond usable limits it must be replaced. -
Page 38: Maintenance Procedure 4 - Grease Points
Maintenance Procedure 4 - Grease Points Grease points are located as shown in the diagram below. Use a grease gun to apply grease to the bearing surfaces at these locations. Tiphook Pivot Chain Mounting Main Hydraulic Bearings Pivot Cylinder Pivot Rear Main Arm Pivot Bearing Main Hydraulic... -
Page 39: Maintenance Procedure 6 - Check Nut & Bolt Torque Values
Maintenance Procedure 6 – Check Nut & Bolt Torque Values All nuts and bolts should be checked to ensure that they are at the correct torque. Use a calibrated torque wrench set to the required torque. Recommended tightening torque for the chassis mounting bolts – 126Nm. Recommended tightening torque for main arm pivot cap bolts –... -
Page 40: Maintenance Procedure 7 - Renew Hydraulic Fluid
Maintenance Procedure 7 – Renew Hydraulic Fluid Hydraulic fluid is hydroscopic and over time will absorb water. Contaminated fluid will reduce the performance of the hydraulic system. Frequent changes of the fluid, see schedule, are essential to maintain optimum performance. During the change procedure old fluid must be drained from the hydraulic fluid tank. - Page 41 Keep the controller in a location where immersion in liquids can be avoided. Controller Faults The Boughton remote operation hand held controller is not a serviceable part. If the unit fails for any reason contact Boughton Engineering Limited for replacement.
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Page 42: Further Information
Further Information For further information or assistance in operating the PR12 Skiploader and Intacova Sheeting System contact:- Boughton Engineering Ltd, Balliol Business Park, Wobaston Road, Wolverhampton. WV5 9EU. Tel: +44 (0) 1902 623430 Fax: +44 (0) 1902 787265 Email: enquiries@boughtonengineering.com...
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