1. Manuals
  2. Brands
  3. SolarCity Manuals
  4. Lifting Systems
  5. ZepSolar
  6. Operation manual

SolarCity ZepSolar Operation Manual

Material hoist
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Material Hoist
Operations Manual
! WARNING: This product is exclusively for use by SolarCity employees
and SolarCity-authorized personnel who have been fully trained and
certified under SolarCity's Field Safety Program, and who have read
and understood the contents of this manual.
Load Capacity: 100 lbs
Complies with:
OSHA 1926.552
ANSI/ASSE A10.5
Lightweight material hoist
Not for lifting people
Document #800-1668-001
Date last exported: June 15, 2015 9:13 AM
Rev B

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the ZepSolar and is the answer not in the manual?

Questions and answers

Summary of Contents for SolarCity ZepSolar

  • Page 1 ANSI/ASSE A10.5 Lightweight material hoist Not for lifting people ! WARNING: This product is exclusively for use by SolarCity employees and SolarCity-authorized personnel who have been fully trained and certified under SolarCity’s Field Safety Program, and who have read and understood the contents of this manual.

  • Page 2: Dangers, Warnings, Cautions, And Notices

    Never climb the Material Hoist Ladder while the Material Hoist is in use. • Maximum load is 100 lbs. DO NOT EXCEED THE 100 LBS. WEIGHT LIMIT. Page 2 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 3 During each project’s initial site safety meeting, the crew should confirm verbal signals to be used when operating the Material Hoist and the physical location for setting it up. Page 3 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 4 Lightweight Material Hoist for Residential PV Installations User Notes Material Hoist operators, crews, or other field users may use this page to add their own notes if needed. Page 4 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 5: Table Of Contents

    ......Page 5 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 6 Inspection Checklist: Pulley Braking System Function ....Page 6 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 7: About The Material Hoist

    The Material Hoist is rated to lift a maximum of 100 lbs. Ladder Requirements The Material Hoist is designed to work with the 1-section, 2-section, or 3-section ladders approved by SolarCity’s Safety and Quality teams specifically for use with the Material Hoist.

  • Page 8: Major Assemblies

    Lightweight Material Hoist for Residential PV Installations Major Assemblies Ladder Stand- Upper Assembly Sled Assembly Pulley Assembly Ladder Stability Anchor (Underside view) Ladder (Exclusion Zone) Page 8 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 9: Safety Stickers

    (2) PV modules at a time. • “No Riders Allowed” • System Specified Load Rating: 100 lbs • For use by SolarCity employees ONLY Safety Sticker Part No. 850-1538-001 Page 9 of 63 Document # 800-1668-001 Rev B zepsolar.com...
  • Page 10 TO AVOID FREE FALLS, ALWAYS MAINTAIN GRIP ALWAYS MAINTAIN GRIP ON HOISTING ROPE WHEN PULLING ON HOISTING ROPE RELEASE CORD WHEN PULLING RELEASE CORD Page 10 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 11: Detail Assemblies

    Part No. 850-1534-001 Release Pin to rotate Leg Rung Bracket Telescoping Quick Release Pins Rung Hook Spring Button Legs Velcro Rung Straps Feet Rotation Page 11 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 12: Sled Assembly, Front View

    (Rubber Shock Absorber, behind Pulley Bottom Tray Hook bracket) Non-Friction Plastic Sheeting Stop Edge Haul Bag Hangers Non-Friction Plastic Sheathing Pulley Cover Detail Page 12 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 13: Sled Assembly, Side And Back Views

    Carry Handle Bottom Strap Ledge Ladder Ladder Strap Strap Side Brace Right Left Module Lock Carry Main Plate Handle Ladder Strap Back Page 13 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 14: Upper Assembly

    Lightweight Material Hoist for Residential PV Installations Upper Assembly Part No. 850-1531-001 Top Loop Slot Staging Tray Top Plate Ladder Connect Strap Rung Slots Front Roller Bar Page 14 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 15: Ladder Stability Anchor

    • If the Clamp is not operating properly, remove the Ladder Stability Anchor from service and do not use. Page 15 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 16: Pulley Assembly

    Rope Corner Loops Thimble Lower Pulley Rope Bag Hoisting Carabiner The Pulley Assembly ships with its own set of user instructions. Spool Page 16 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 17: Ladder Usage Notes

    6” clearance 18-24” clearance Ladder clearance from gutter Roof gutter Recommended Best Practices No Climbing Exclusion Zone Check Stability Engage Rung Locks Page 17 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 18: Parapets

    Shallow pitch: Both Legs on roof Rotating and telescoping legs Steep pitch: One Leg braced on side eave, one Leg on roof Page 18 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 19: Adjusting For Roof Pitch

    Hoist is under load, or the Ladder Stand-Off may be subjected to undue stress at the Leg joint. Use your own best judgment. using the following illustrations as an approximate visual guide. Flat 4th hole 15 Degrees 3rd hole 45 Degrees 2nd hole Page 19 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 20: Summary Of Operation

    Release Cord to prevent unintentional free-fall when Sled Assembly is loaded! Never pull the Release Cord without holding the Hoisting Rope. Page 20 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 21: Braking

    Sled Assembly Feet should never travel below this line Sled Assembly Feet Ladder Traction Example showing use of a Feet ladder leveling attachment Page 21 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 22: Loading

    Load a maximum of 2 modules in landscape orientation. Center the load First module rests here Second module rests here Side Brace Detail Page 22 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 23: Loading Haul Bags

    Top Strap Trims at once Balance the load Up to 3 Triangle Array Trims fit onto the Ledge Front View Side View Page 23 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 24: Loading Array Skirts And Spanner Bars

    Place longer items in appropriately sized haul Maximum 100 lbs Secure with Top and Bottom Straps Array Skirt 1x Spanner Bar Only Page 24 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 25: Module Lock Positions

    Storage (Packout) Double Lock (2 modules) Single Lock (1 module) Open (Non-module loads or lowering empty) Top View (Shown in Storage position) Page 25 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 26 Single Lock Single Module Hook fits in the Zep Groove of PV module frame Front View Top View Front Back Double Lock Open Page 26 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 27: Off-Loading On Roof

    Rotate the Module Lock another 90 degrees clockwise to the Open position, and then lift off the second module. Page 27 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 28: Setting Up The Material Hoist

    Velcro Straps Wrap the Velcro straps around the upper rung. Page 28 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 29: Attach The Upper Assembly

    This can also be done safely by someone on the roof, provided that the person is fully harnessed using appropriate Fall Protection PPE. Page 29 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 30: Unpack The Pulley Assembly

    Pulley Pulley Minimize rope slack between Upper and Lower Pulleys when packing for storage Hoisting Carabiner clips to fabric loop for storage Page 30 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 31: Job Site Setup

    If not already attached, the Upper Assembly can be attached to the Ladder from the roof. Ladder Stand-Off Ladder Stability Anchor Ladder Traction Feet: Leveled, on stable surface Page 31 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 32: Step 2. Attach Pulley Assembly

    Tarp, with the bulk of the Hoisting Rope left coiled and resting on the Tarp. Rope Bag Tarp Un-clip Un-clip Release Cord in Spool Upper Pulley Lower Pulley Page 32 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 33 ! WARNING: If Pulley Assembly appears to be broken or damaged, or the Hoisting Rope is frayed, do not use. Page 33 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 34 Material Hoist: Lightweight Material Hoist for Residential PV Installations Attach Pulley Assembly, continued Climb up to the Upper Assembly Page 34 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 35 At the top of the Ladder, unhook the Upper Pulley from your tool belt while still maintaining 3 points of contact with the Ladder. Page 35 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 36 The yellow side has text indicating that it should be facing outwards. Page 36 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 37 Anchor Carabiner to secure the Upper Pulley in place. Loop Lay the Anchor Carabiner flat The Hoisting Rope tail end reaches all the way to the ground Page 37 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 38 Release Cord to fall all the way to the ground. Roller Bar The Hoisting Rope weaves in front of the Roller Bar, while the Release Cord passes behind Page 38 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 39 Clip Lower Pulley to your safety harness To prepare for descent climbing down the Ladder, use the Hoist Carabiner to clip the Lower Pulley to your safety harness. Page 39 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 40 Maintain 3 points of contact on the Ladder while descending Reach around the back of the Ladder and take the Release Cord in one hand Page 40 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 41 Descend the Ladder one step at a time, pulling steadily on the Release Cord to release the Upper Pulley. You may need to use your body weight helps to pull the Upper Pulley down the Ladder. Page 41 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 42 Spool to secure it. This helps prevent crew members from accidentally stepping on the Release Cord while working at the job site. Page 42 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 43: Step 3. Attach Sled Assembly

    Ladder itself off the ground entirely, the Sled Assembly may not rest fully on the ground. If the Sled Assembly appears to be broken or damaged, do not use. Page 43 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 44 Main Plate. Use the Hoist Carabiner to clip the Lower Pulley to the Pulley Hook on the Sled Assembly. Lower Pulley Pulley Hook Hoist Carabiner Ensure that Hoisting Rope slides freely Page 44 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 45 Attach Sled Assembly, continued Secure Ladder Strap Always secure Ladder Strap when using the Material Hoist. The Ladder Strap metal attachments rotates down for storage. Page 45 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 46: Testing At Job Site Prior To Use

    Tray of the Sled Assembly to aid in lowering an empty load if needed. Top Plate Stop Edge Sled Assembly should reach Top Plate without interference Use Lowering Hole if needed Page 46 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 47: Job Site Packout

    Step 1. Sled Assembly Packout Disconnect Release Unbuckle Ladder Strap Carry Remove Move Module Use the Carry Lock to Storage Handle position Page 47 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 48: Step 2. Pulley Assembly Packout

    Climb with Lower Pulley on tool belt Climb Clip the Lower Pulley to your safety harness Take slack out of the Hoisting Rope as you climb up Page 48 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 49 Lightweight Material Hoist for Residential PV Installations Pulley Assembly Packout, continued Pack up Release Cord at top of Ladder Release Cord Spool Page 49 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 50 Lightweight Material Hoist for Residential PV Installations Pulley Assembly Packout, continued Disengage Upper Pulley Top Loop Anchor Carabiner Un-Clip Upper Pulley Re-Clip to safety harness Lower Pulley Page 50 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 51 Clip the Upper Pulley Anchor Carabiner to your safety harness. The Hoisting Rope tail end is still on the ground. Page 51 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 52 Tarp as you would a Loop sleeping bag. Release Cord The Tarp is sewn to the Rope Bag. Rolling Up the Tarp Page 52 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 53: Step 3. Ladder Packout

    Step 3. Ladder Packout Collapse Ladder Detach from roof The Upper Assembly remains attached Remove the Ladder Stability Anchor Detach Ladder Standoff Lower to ground Page 53 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 54: Inspection And Maintenance

    (Pulley Assembly, Sled Assembly, Upper Assembly, Ladder, Ladder Stand-Off, and Ladder Stability Anchor). To request replacement of any portion of the Material Hoist, please notify your immediate supervisor. To report any out-of-the-box defects, please notify Zep Solar Support. Zep Solar Support support@zepsolar.com +1 (415) 230-2096 Page 54 of 63 Document # 800-1668-001 Rev B zepsolar.com...

  • Page 55: Periodic Inspections

    Main header shows who, where, when Each major assembly has its own checklist Reason for failing grade Note any actions taken. Page 55 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 56: Material Hoist Periodic Inspection Checklist

    Ladder traction feet are in good working condition If any item is marked “FAIL” remove the Ladder from service immediately. Page 56 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 57: Inspection Checklist: Ladder Stand-Off

    Fasteners are securely tightened and intact Quick-release Ring Pins are uncompromised If any item is marked “FAIL” remove the Ladder Stand-Off from service immediately. Page 57 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 58: Inspection Checklist: Ladder Stability Anchor

    If any item is marked “FAIL” remove the Ladder Stability Anchor from service immediately. Page 58 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 59: Inspection Checklist: Sled Assembly

    Bottom Tray is not bent or deformed Non-Friction Plastic Sheeting is intact and uncompromised If any item is marked “FAIL” remove the Sled Assembly from service immediately. Page 59 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 60: Inspection Checklist: Upper Assembly

    Upper Assembly is free from any significant bends or deformities If any item is marked “FAIL” remove the Ladder Stability Anchor from service immediately. Page 60 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 61: Inspection Checklist: Pulley Assembly

    Etched Serial Number All pulleys rotate freely If any item is marked “FAIL” remove the Pulley Assembly from service immediately. Page 61 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...
  • Page 62 Pulley Assembly is free from any modifications Carabiner Hole If any item is marked “FAIL” remove the Pulley Assembly from service immediately. Page 62 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

  • Page 63: Inspection Checklist: Pulley Braking System Function

    Brake engages IMMEDIATELY under load, when the Release Cord is NOT being actively pulled. If this item is marked “FAIL” remove the Pulley Assembly from service immediately. Page 63 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM...

Table of Contents