NIFTYLIFT HR12LE MK2 Manual
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NIFTYLIFT HR12LE MK2 Manual

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Heightrider
Operating & Safety Instructions
MODEL HR12 (SP34) SERIES
MK2
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
M50512/02

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Summary of Contents for NIFTYLIFT HR12LE MK2

  • Page 1 Heightrider Operating & Safety Instructions MODEL HR12 (SP34) 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 M50512/02...
  • 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 FOREWORD ..................... 2 SCOPE ......................3 INTRODUCING THE HEIGHT RIDER SELF-PROPELLED (SP) SERIES ....3 GENERAL SPECIFICATION ................4 IDENTIFICATION (UK PLATE) ................5 EC DECLARATION OF CONFORMITY (Typical) ..........7 Safety MANDATORY PRECAUTIONS ................

  • 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 12 MK2 (SP34 in the USA) powered by 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 HR12LE MK2 HR12NE MK2 MAXIMUM HEIGHT - WORKING 12.1m 39ft 6in MAXIMUM HEIGHT - PLATFORM 10.2m 33ft 4in MAXIMUM OUTREACH 6.34m 20ft 9in MAXIMUM HEIGHT – STOWED 1.98m 6ft 5in MAXIMUM WIDTH 1.49m...

  • 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 – 01/18 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 – 01/18 Original instructions...

  • Page 9: Ec Declaration Of Conformity (Typical)

    Height Rider/SP Series Operating & Safety Instructions EC DECLARATION OF CONFORMITY (Typical) English/USA – 01/18 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 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 205ft lbs. 279Nm). 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)

    Danger Warning - Icons P29379 Clunk Click P19961 Caution - ‘SiOPS’ P22820 “If E-Stop Disabled P14864 ‘Do not place objects on controls’ P21511 “Niftylift” P30187 Logo HR12 P14604 SP34 P14119 General crush hazard P14782 Hydraulic levers – Base (on canopy)
  • Page 21 Height Rider/SP Series Operating & Safety Instructions Do not jet wash P29665 No dust or water (LE) P31446 LED indicator P26934 Power to cage 110V P26426 230V P26862 Power to cage (tool) 110V P33012 230V P33011 English/USA – 01/18 Original instructions...

  • Page 22: 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 23: Operation

    MULTI-TONE SOUNDER AND 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 24 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 25: 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 Red flashing: Indicates safety critical problem.
  • Page 26 Height Rider/SP Series Operating & Safety Instructions Base Levers 1 Operates Platform Levelling Forward for Up Backward for Down * 2 Operates Telescoping Up for Out Down for In * 3 Operates the Lower Boom Up for Up Down for Down * 4 Operates the Upper Boom Up for Up Down for Down...
  • Page 27 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, the cage overload is activated due to contact with a fixed object or a cage operator is incapacitated, the booms can be operated from the base location as described below: If normal controls are available (fastest recovery time): Turn key switch to ground, press the green button and operate the desired function lever(s).

  • Page 28: 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 29 Height Rider/SP Series Operating & Safety Instructions 8 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. Steer by using the thumb rocker switch located on top of the joystick.
  • Page 30 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 31 Height Rider/SP Series Operating & Safety Instructions Anti-clash active:- to avoid potential machine damage, boom lowering and slew functions have been disabled due to minimum height from ground being reached. Raise boom until symbol disappears from screen to restore all control functions. SiOPS:- SiOPS has been activated, to restore normal machine controls refer to Section 4.3.6.
  • Page 32 Height Rider/SP Series Operating & Safety Instructions Cage Overload Warning Red: SWL exceeded. (Refer to ‘Safety Critical (Main screen)’ section on page 28). Cage Overload Override Evidence Amber: Cage overload has been overridden. This will remain until reset. In order to reset overload override evidence, press Button 3 and follow on- screen instructions.
  • Page 33 To access this screen, press button 3. To reset either the Cage overload override evidence or Chassis zero contact Niftylift using the details displayed and quote the reference number displayed on the screen. Niftylift will supply a code which must be entered by using the arrow keys.
  • Page 34 Height Rider/SP Series Operating & Safety Instructions SETTINGS To access this screen, press button 4. Beacon/Sounder and Machine Info options are displayed. Scroll up or down to the information required using the arrow keys and press the right arrow key or ok to open the screen. Press Left arrow key or button 4 to return to previous screen.
  • Page 35 Height Rider/SP Series Operating & Safety Instructions 4.3.5 OPERATION 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. ALL MODELS NEVER exceed the maximum platform capacity.
  • Page 36 Height Rider/SP Series Operating & Safety Instructions If normal controls are not available, continue using the override button to lower the machine using auxiliary power. Note: The override mode is for booms only and will not operate the drive function. 4.3.6 SiOPS - LOAD SENSING CONSOLE...

  • Page 37: 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 38: Cage Weigh System

    4.5.1 LOAD CELL VERSION The Niftylift HR12 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 39: Batteries And Charging

    Height Rider/SP Series Operating & Safety Instructions BATTERIES AND CHARGING 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. NEVER ATTEMPT TO CHARGE A FROZEN OR NON-RECHARGEABLE BATTERY. Recharge batteries at the end of every working day or shift.
  • Page 40 Height Rider/SP Series Operating & Safety Instructions CHARGING LIMITATIONS The capacity of the 110V supply must be capable of 3.5kVA (32A current); hence a small hand-tool transformer must not be used with the battery charger. A minimum size of 4.5kVA is highly recommended.
  • Page 41 Height Rider/SP Series Operating & Safety Instructions The charger requires a minimum battery voltage of 1.5 volts per battery (overall for two batteries 3 volts, for 4 batteries 6 volts for 8 batteries 12 volts and 18V for 72V). If the voltage is below these values then the charger will not function (Charger will not detect batteries to begin charge.) If the batteries have fallen to such a poor state they will have to be removed from the machine and charged individually with an independent charger until the optimum voltage has been reached.

  • Page 42: 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 43 HR15/17 4x4/Hybrid MK2 D81795 HR15N/17N D81996 HR12NE MK2 D82069 HR12LE MK2 4.7.4 STORAGE If being stored for any length of time without use, then the machine should be thoroughly inspected for the following:- Grease all bearings /slides, worm drives, etc.
  • Page 44 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 45: 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 46: 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 47: 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 48 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 49 Height Rider/SP Series Operating & Safety Instructions Comments, remedial work required etc; INSPECTED BY: DATE: English/USA – 01/18 Original instructions...
  • Page 50 Description Error Code Action 019F0000 The Steer Sensor is out of range Contact a Niftylift approved service centre There is a problem with the signals Ensure contact blocks are securely in position. from the normally closed and 01A00000 Check SiOPS wiring from the switch contacts to the...
  • Page 51 Height Rider/SP Series Operating & Safety Instructions Description Error Code Action Check the wiring to the Drive Joystick. The steer switch is sending a left 01AA0000 and right signal at the same time Replace the Drive Joystick There is a problem with the signals Ensure contact blocks are securely in position.
  • Page 52 Height Rider/SP Series Operating & Safety Instructions Description Error Code Action Return the Drive Joystick to the neutral position and The Drive Joystick was out of the release the Green Button and Footswitch. 01B60000 neutral position before the Green Press the Green Button or Footswitch and then move Button or Footswitch was pressed the Drive Joystick to operate drive Ensure Joystick is plugged in.
  • Page 53 Height Rider/SP Series Operating & Safety Instructions Description Error Code Action Ensure Boom 2 Inclination Sensor is plugged in. The Boom 2 Inclination Sensor and 01CC0000 Check power supply and CAN Bus connections to the PLC are not communicating Boom 2 Inclination Sensor Ensure Boom 3 Inclination Sensor is plugged in.
  • Page 54 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) English/USA –...
  • Page 55 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 56 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 57 Do not attempt to open the inclination sensor or replace components soldered to any PLC. Do not attempt maintenance of hydraulic components i.e. replace seals or internal components. Only Niftylift original and supplied parts shall be used. 12. Means for easy and safe trouble shooting;...
  • Page 58 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 59 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 60 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 61 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 62 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 63 Height Rider/SP Series Operating & Safety Instructions PLATFORM LEVELLING The Platform levelling system is PL c in accordance to with BS EN ISO 13849-1:2015 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 64 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 65 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 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 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 BS EN ISO 13849-1:2015 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 68 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 69 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 70 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 71 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 72 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 73 7. Release the cage emergency stop button, switch the controls to the base and repeat for the base emergency stop button. 8. Power off the Niftylift. 13. Information explaining the applications for use relevant to the category to which reference is made;...
  • Page 74 Height Rider/SP Series Operating & Safety Instructions SiOPS The Sustained Involuntary Operation Prevention System (SIOPS) is PL d in accordance to with BS EN ISO 13849-1:2015 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 SiOPS is always active.
  • Page 75 12. Means for easy and safe trouble shooting; To check the operation of the SiOPS system 1. Power on the Niftylift and select the cage control station. 2. Allow the power circuits to cycle and ensure the machine is ready for the command signal.
  • Page 76 9. Remove the pressure from the cage console and observe that the flashing green buttons, the klaxon and the blue warning light should stop. Normal operation will be returned. 10. Power off the Niftylift. 13. Information explaining the applications for use relevant to the category to which reference is made;...

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