- 0 - UT Series Product Manual

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2 Congratulations on your purchase of this Quality Up-Lift Product! Before operating, please read this manual thoroughly and follow the safety rules closely. CONTENTS A INTRODUCTION 1. Product Schematic Diagram 2 2. Product Introduction 3 3. Technical Specifications.. 3 B SAFETY 1. Safety Rules Safety Decal. 5 C USING THE MACHINE 1. Preparation the Machine Operation of the Machine 8 3. Manual Lowering of Platform from Ground Controls Emergency Lowering Machine Achieving Optimal Performance. 11 D TRANSPORT 1. Loading & Unloading E OPTIONS 1. Dual Power Source Laser position indicator Hour meter F MAINTENANCE 1. Electrical System Use and Maintenance of Battery Hydraulic System Trouble Shooting

3 A INTRODUCTION 1. Product Schematic Diagram Typical UT Series Machine Schematic - 2 -

4 A INTRODUCTION 2. Product Introduction Up-Lift UT series elevating work platforms employ advanced technology and material, powered by a high quality hydraulic system and incorporates various safety measures to provide a higher capacity, safe and reliable aerial working unit. The components which make up the UT product are derived from proven quality sources, with key components sourced from quality European suppliers. The product is equipped with a number of advanced features. Lower height models have a patented back-up power feature allowing lowering of the platform during power black-outs. As a consequence, operators feel a greater sense of safety comparing with many similar products. Up-Lift UT elevating work platforms are extensively used for cleaning, decorating, maintenance and aerial signage work in hotels, restaurants, department stores, emporiums, shopping centers, airport departure lounges, sports stadiums, convention centers and stadiums, as well as factories, hospitals, universities and colleges. The smaller models are designed to pass through standard doorways and elevator lifts and are especially suited to small confined working space applications. 3. Technical Specifications Model UT20 UT23 UT26 UT33 UT36 UT40 UT46 UT52 UT58 Working height m Platform height m Load capacity kg Number of persons Power Source V 230/12 230/12 230/12 230/12 230/12 230/12 230/12 230/ Weight (AC) kg Weight (DC) kg N/A Stowed Height m Stowed Length m Stowed Width m Guardrail Height m Outriggers Footprint (LxW) m 2.1x x x x x x x x X3.8 The company reserves the right to alter its design & specification without prior notification

5 B SAFETY 1. Safety Rules All personnel should carefully read this warning sign and the instruction manual and follow the operating rules. Failure to do so could result in serious safety hazard. NEVER try to move the machine while platform is loaded or with the outriggers installed. NEVER elevate the platform in windy environments. This machine is designed for non-wind conditions. NEVER operate the platform if the level indicator shows the machine is not on a level position. This machine is designed to be elevated when the chassis is level. ENSURE that the outriggers are on firm solid ground. NEVER sit on, stand on or climb over the platform top-rail or mid-rail to conduct aerial work. NEVER use ladders, planks or other devices to increase the height of the platform. NEVER exceed the load limit specified for the machine. NEVER use machine as a goods lift or a people mover. ENSURE that no person or object is placed beneath the platform before and during operation of the machine. NEVER move the machine into overhead beams or objects. NEVER operate the machine while under the influence of alcohol. NEVER operate the machine under poor lighting conditions. NEVER operate the machine within proximity of power lines, or use as an earth for welding. Electrical shock can kill you. This machine won't protect you from shock

6 B SAFETY 2. Safety Decal Warning decals form an important part in the safe operation of a machine. It is the responsibility of the operator to inform the owner if the decals are missing or are in poor condition

7 C USING THE MACHINE 1. Preparing To Use the Machine 1(A). For models UT20 to UT52 Main (Gound) Control Panel Platform Control Panel 1. Move the machine to the location where aerial working is required. 2. Connect power supply to the unit. Turn the key-switch to the "PLATFORM" position. Power supply indicator red light will light up. 3. Install the four outriggers and position these supporting legs on firm ground surface (Fig 1A). Before operating the unit, check that the bubble in the spirit level indicator is centered within the black circle (Fig 1B) and all four outrigger indicator lights on the base control box are lit up. If required adjust the outriggers until the bubble in the spirit level indicator is centered within the black circle, the machine is now leveled for use. 4. Preparing to use the Platform Cage from its stored position Follow the steps below to raise the cage from its stored position and secure for use. a. Open the ground control panel and switch the key switch to the PLATFORM position. Check that all 4 outrigger safety switches are lit. Refer Fig 2 For DC model, turn the Multi-function switch on the DC box to the ON position before proceeding to the next step. Refer Fig 3 b. Depress the Red ascending button on the left side of the ground control panel. Refer Fig 2 Allow the platform to ascend slowly JUST above the support brackets located on the two sides of the masts. Refer Figs 4 & 5. Fig 1A Fig 1B Fig 2 Fig 3 Fig 4 Fig 5-6 -

8 c. When the platform is JUST above the two support brackets, pull out each of these support brackets ready for the platform to sit on. Refer Fig 5 d. Once this is ready, depress the descend button on the ground control panel. This will lower the platform until it is sitting on the pin boss, allowing the pin to be inserted and secured in position with the split pin provided. Refer Figs 6 &7. e. The Platform is now ready for operator use. 1(B). For Model UT58 Main (Ground) Control Panel Fig 6 Fig 7 Platform Control Panel NOTE: Before moving the UT58 machine using the motorised drive wheel, check that the charge meter on top of the drive motor control cabinet is full (see Figure 1A). To charge the 2 x 12V batteries, (refer to Figure 1B), set the RED isolating switch ON. This connects the charger to the batteries. Using the power cord, connect the charger to an external V AC power supply. When the LED2 light turns green, the batteries are fully charged. Switch off the RED charging isolator switch. Remove the power cord and store securely. Fig 1A Isolating switch Charge meter First move the machine to the work location. A. Drive Wheel Operating Instructions CAUTION: TURN SLOWLY TO MOVE THE MACHINE. DO NOT SPEED. Fig 1B B. Engage on the drive motor power switch on the chassis of the machine (Fig2). From the motor control handle, turn the key Fig2-7 -

9 switch ON and gently twist the red knobs in the forward direction to move the machine forward and vice versa to more the machine backwards. To stop the machine in an emergency, press the centre red button. Once the machine is moved to the desired position (check using the laser position locator), ensure that the floor is flat and firm. C. Connect the machine to V AC external power using a 15 Amp supply and power cord of less than 20 metres. Switch 'ON' the key switch on the ground control panel. Release the emergency button so the power source red light is on. D. Set the 4 outriggers on the chassis first, one by one, checking the spirit level indicator and making sure that the wheels are detached from the ground. Next swing out the four (4) external outriggers until these are taking load and the four (4) outrigger lights are all lit up on the ground control panel. Refer Figs 3. WARNING: Check that the spirit level bubble is centred within the circle. (Refer page 6) E. Raise the cage from its stored position (refer Fig 4). With the cage in its stored position, release the four (4) locking pins to allow the cage to be raised. On the side of the ground control panel, depress the red ascending button until the cage is raised by at least 1.2 meters, then swing open the support brackets (on both ends). Lower the cage until it rests on the two support brackets (Fig 5). Insert the four (4) locking pins to lock the cage in position. Refer Fig 6. The machine is now ready to commence work. Red ascend button Fig3 Fig 4 Support bracket Fig5 2. OPERATION OF THE MACHINE 2 (A). For Models UT20 to UT52 1.The operator can now use the ladder provided to access the platform by lifting the mid-rail on the access side and drop close the mid-rail. 2. Once inside the platform, depress the "UP" and "POWER" buttons simultaneously to raise the platform. When the required height is reached, releasing pressure on both buttons will stop the platform. Operator can now commence aerial work. 3. After completion of work, check the space below the platform is clear before depressing both the "DOWN" and "POWER" buttons simultaneously to lower the platform to the minimum height position. Releasing the pressure on these buttons STOPS the platform. 4.To return the platform cage to the stored position, follow the instructions under 4 above in REVERSE order (from step 4 (d) (remove pin from boss), step (c), (b), back to step (a) switch off the multi-function switch to OFF). This is described as follows: Fig6-8 -

10 C USING THE MACHINE First, unlock and remove the pins from each of the sockets. Press the Up button on the ground control panel to lift the cage slightly until the base of the guide rails is separated from the support brackets. Fold back the two support brackets and lower the platform cage down to the lowest position. 5. Detach the outriggers and return to outrigger pockets provided. Finally move the machine to a dry storage area. WARNING 1. Never move the machine unless the platform has returned to the lowest position. 2. Never use the machine as a welding earth 3. After operator has completed work, return the outriggers to its stored position. 4. Return the key switch to the OFF position and remove the key for safe keeping. 5. If AC power supply is cut while the machine is in the elevated position, the electrical system will automatically switch over to the backup power supply allowing normal operation of the unit to reach the ground level position. 6. For DC system, always charge the battery when the charge level as shown on the battery charge meter, drops to 70%. To charge, set the Multi-function switch to the CHARGE position and connect to power supply. NB: As the machine is similar in design to single mast machines with the mast columns being held tightly in between by bearing blocks, new machines are expected to produce friction noises while the platform is raised. Overall noise is generally within 70 decibels. 2 (B). For Model UT58 A. The operator can now enter the platform cage by lifting the entry gate bar. To operate the platform controls, depress the UP & POWER buttons simultaneously to ascend. To descend, depress the DOWN & POWER buttons simultaneously. Use the Emergency stop button to cut the power supply in an emergency. B. The following procedure should be undertaken to return the cage to its stored position after completion of work. With the platform at its lowest position, release the four (4) locking pins. Depress the red ascending button located on the side of the ground control panel until the platform s cage is raised slightly above the two (2) support brackets. Fold back the two (2) support brackets and lower the platform s cage to its stored position by depressing the DOWN button on the ground control panel. Lock the four (4) locking pins. Raise the chassis outriggers off the ground and move the external outriggers to the sides of the chassis. Switch the ground control s key switch to the OFF position. Remove key. Move the machine to a dry storage area. Switch the key switch from the drive wheel motor to the OFF position. Remove key

11 C USING THE MACHINE NOTE: 1. WARNING Never move the machine unless the platform has returned to the lowest level. 2. WARNING Never use the machine as a welding earth. 3. The platform can be lowered during a power failure by opening the emergency down valve slowly. Once the platform reaches the stored position, retighten the emergency down valve. 4. If the drive motor s battery voltage is low, charge the battery immediately. Never allow the charge to fall below 70 %. 5. As the UT58 machine is similar in design to single mast machines with mast columns being held tightly in between bearing blocks, new machines are expected to produce friction noises while the platform is raised. Overall noise is generally within 70 decibels. 3. Manual Lowering of Platform from Ground Control Check that the key switch is in the "OFF" position. Twist the Emergency Stop button clockwise to release to on position. Switch and hold the key switch to "GROUND" position, press the Down button to lower the platform. For UT58S, switch the key switch to the ON position and press the Down button. 4. Emergency Lowering The emergency down valve is located between the masts on the hydraulic system. To lower the platform, the red dial is turned anti-clockwise. The lowering speed is dependent on the number of turns of the dial. Return the dial to the closed position prior to re-using the machine. Caution must be taken to control the speed of descent. Make sure that no one is beneath the platform

12 C USING THE MACHINE 5. Machine Achieving Optimal Performance 1) The standard unit is suitable for indoor operation and the operator should as far as possible operate the machine indoors. 2) If the machine is used outdoors, care should be taken to ensure that the ground is firm and solid to prevent instability. Avoid operation under any windy condition. 3) Always check that the outrigger position indicator lights are operating correctly. 4) Descent at full height: When the platform is loaded and raised to its highest point, momentarily press the platform control s POWER and DOWN buttons simultaneously. Then fully engage these two buttons to continue the descent. This minimizes the impact to the equipment of a change in hydraulic flow direction. 5) Before using the machine for aerial work, raise the platform slightly without load to ensure normal functioning of the machine. 6) Frequent checks should be made of the electricity leakage protection to ensure effectiveness. 7) For maintenance requirement of the hydraulic system, please refer to Section F3 (C.) 8) If the machine is used frequently, routine maintenance and safety checks should be carried out every 3 months. 9) Regular check of the chain-drive system for wear and tear at least on a quarterly basis. Apply N32 oil on chain friction points as well as wheels points as required. 10) Keep machine away from dust and rain. Never store the machine outdoors or in an area of high humidity or heat. During storage, keep the machine covered with a protective cover. 11) Only qualified professionals are allowed to dismantle any part of the machine or conduct maintenance on the machine. If unsure, please contact supplier

13 D TRANSPORT 1. Loading & Unloading Step1: Move the machine from the pallet to firm and level ground. Cut the steel bands which tie the machine onto the timber base. Remove any timber protective structure around the machine. Dismantle any timber blocks placed against the castor wheels of the machine for protection during transport. (Refer Fig.1). With a fork lift, lift the machine from its timber base using the machine s fork lift pockets and place it on the floor (Refer Fig 2). Alternatively, use a hoist or overhead crane to lift the machine with a sling. (Refer Fig 3). (Make sure that the machine s weight does not fall on the cage rail). Gently lower the machine to the floor. Step 2: Insert the outriggers onto the machine and adjust them to ensure the machine is level. (Check spirit level indicator). Study the product manual carefully before connecting to a power source. Switch the key switch on the main control panel to the PLATFORM position. For the UT58 machine switch the key switch on the main control panel to the ON position. The machine is now ready for a trail run. (Refer Section 4) WARNING: - To avoid damage when unpacking, extreme care should be taken with the Mast Cover and Cage. Also with the Upper and Lower Control Boxes. - The unloading procedure must be strictly followed. Incorrect handling may cause serious machine damage and personal injury. UT

14 E OPTIONS 1. Dual Power Source means either External AC supply source or AC source from DC battery & inverter pack. CHARGING PROCEDURE: Using the power cable supplied in the cable storage compartment, connect directly to a V AC external power source. Set CHANGE-OVER-SWITCH to CHARGE position. Charging is complete when charger LED indicator light is green. After charging, set the CHANGE-OVER-SWITCH to the OFF position. Store the power cable inside cable storage compartment.. (For battery maintenance, refer to section F2.) AC OPERATION FROM INVERTER OUTPUT: Connect AC power plug from the hydraulic motor to inverter V AC output socket. Set the CHANGE-OVER-SWITCH to the ON position. Commence normal operation. After completion of work, set the CHANGE-OVER-SWITCH to the OFF position. Disconnect the machine s AC power cable from the inverter Output Socket. Store the portable power trolley in a clean, dry and ventilated area. AC OPERATION FROM EXTERNAL V SUPPLY SOURCE Connect the hydraulic motor s AC power plug to a 220/240VAC power source. Commence normal operation. After completion of work disconnect the hydraulic motor s AC power plug from the power source

15 E OPTIONS 2. Laser Position Indicator Push the machine to the location beneath where aerial working is required. 2. Press the button on the side of the laser position indicator inside the platform. 3. Check the spot where the laser beam is directed to see if this is within the desired working area. 4. If the laser beam is outside the desired working area, adjust the machine position so that the laser beam shines within the working area. WARNING: NEVER LOOK INTO THE LASER BEAM, Remove cap on the outlet to check work position. Replace cap immediately after use to avoid harm to eyes. 3. Hour Meter An optional hour meter can be used to record the number of hours the machine has been used (based on the time the key switch is on). This usage record helps in determining the need for maintenance service. Hour Meter

16 F MAINTENANCE 1. Electrical System Note: Repairs by unauthorized personnel may result in serious personal injury or death. Any interference with and electrical the hydraulic system may also invalidate the product warranty

17 F MAINTENANCE 2. Use and Maintenance of Battery ( DC Models) When transporting the DC powered personnel lift, the battery casing and battery should be detached from the rear of the machine to prevent damage to the battery casing. To prepare the machine for use, install the outriggers, then load the battery box (including battery inside) onto To charge the battery, follow instructions located on the machine. When the charger indicator changes from red to green, the battery is fully charged. Continue charging for about an hour or more, this will ensure maximum performance of the battery. If the charged battery has been used or left unused for a period of time, recharging is required, as prolonged storage at low charge will result in reduced battery performance Store the battery in a cool and dry area to reduce the loss of power during storage period. An Absorbed Glass Matt (AGM) maintenance free battery is used. AGM batteries do not include fluid so unlike Lead Acid batteries they not require the battery s fluid level to be checked. Check the battery and the terminals regularly to ensure they are secured tightly in position. Inspect the insulation casing for worn spots, cracks or broken terminals and repair them immediately. To connect the battery and the charger, set the power switch to the "OFF" position. Ensure that the positive terminal on the battery is connected to the positive socket of the charger and vice versa. To commence charging set the power switch to the ON position. Charging must be carried out in a well-ventilated area, away from inflammable materials as charging may result in sparks or flames, which may result in an explosion. Ensure the connecting socket on the battery casing is properly maintained to avoid power disruption. Keep batteries fully charged when in storage. Prolonged storage at low charge will result in reduced battery performance. Disconnect the battery from the machine prior to long term storage. Store in a cool dry place. The battery casing carrying the charger contains an ammeter, which indicates the charge rate. All power usage should stop and the battery recharged, when the power discharge level indicated by the ammeter reaches 70%. This is strongly recommended to ensure maximum battery life. WARNING Do not charge batteries under direct sunlight or near heat generators. Battery should be charged immediately after use. If battery is stored without recharging, performance could deteriorate. Avoid operating the battery below - 5 C (5 F) or above 50 C (122 F). Batteries are heavy and should be handled accordingly. Never disassemble a battery. Clean with moist soft cloth. Never dispose of a battery into fire. Recycle all used batteries. Do not short the battery terminals

18 F MAINTENANCE 3. Hydraulic System (A) Operating Principle schematic diagram Legend: 1. Uni-directional Valve 2. Relief valve 3. Flow Restrictor 4. Solenoid Valve 5. Oil Cylinder 6. Hydraulic Pump 7. Filter 8. Motor 9. Explosion relief valve 10. Oil Reservoir Once the hydraulic pump s motor is switched on, the pump will deliver a high pressure oil flow into port P of the valve block (shown as dotted line). The unidirectional valve 1 allows the oil to flow out via Port A and into the hydraulic cylinder. This raises the platform slowly. The relief valve 2 is adjusted to by-pass oil when the rated capacity is reached. This prevents operation beyond the pre-set capacity rating. When the operator calls for the platform to descend, solenoid valve 4 is energized, oil from the hydraulic cylinder then flows back to the valve block via Port A (The unidirectional valve 1 prevents oil flow through port P). Oil flow can only pass through solenoid valve 4 onto the flow restrictor 3 and out of the valve block through Port 0 into the oil reservoir 10. This allows the platform to descend slowly. Due to the pressure balancing design of the valve block, the ascending and descending speed is not affected by the platform capacity changes. (Refer Fig 6.1) (B) UT58 Operating Principle schematic diagram UT58 comprise of two set of hydraulic systems powered by M1&M2 respectively and covers the two groups of masts. M1 is the hydraulic motor which drives the lower four (4) sets of masts, these 4 lower masts move in synchronism as the 4 hydraulic cylinders rise. M2 is the hydraulics motor which drives the upper (2) sets of masts powered by two hydraulic cylinders. Ascend control: Depressing the ascend and power button, starts the M1 motor driving the four (4) hydraulic cylinders and the corresponding masts to its maximum position governed by the limit switch. At this point, the M1 motor is de-energized, and the M2 motor is energized. The M2 motor drives the upper series of masts, until these reach their maximum position as defined by its limit switch. This stops the M2 motor and the maximum platform height is attained. Descend control: - Depressing the descend and power buttons, first energizes the lowering hyraulic solenoid allowing the upper series of masts to descend. When this upper series of masts reaches their lowest position as determined by the limit switch, the limit switch then energizes the hydraulic solenoid for the lower series of masts, allowing these lower set of masts to lower to their minimum position

19 F MAINTENANCE (C) Hydraulic System Maintenance 1. The specification of the hydraulic oil used is ISO VG32. Depending on the frequency of use, the oil may require a complete change once a year. Mixing of oil with other fluids and the introduction of any other fluids into the oil tank is strictly forbidden. Should the oil level fall below normal operating level, the platform will not reach its maximum height. In addition, the noise coming from the hydraulic system during lifting of the platform will increase and may sound abnormal. If this happens, top up the oil tank with ISO VG32 hydraulic oil. 2. After using the manual descending emergency valve to lower the platform to its stored position, please remember to turn the valve knob to its original closed position. The platform cannot be raised normally unless this is carried out. 3. Do not adjust the hydraulic pressure setting or change any original hydraulic system parts without obtaining the approval of the supplier of the machine. 4. If operating in continues cold store conditions (-35 degrees C), the use of a synthetic hydraulic fluid S.A.E.0W is recommended. NB: When the platform is loaded and raised to its highest point, momentarily press the platform control s POWER and DOWN buttons simultaneously to minimize the impact to the machine of a change in hydraulic oil flow direction. Thereafter, fully engage these two buttons to continue the descent

20 F MAINTENANCE 4. TROUBLE SHOOTING 1) Please ensure machine is on a firm and level ground. All four outriggers must be correctly inserted prior to commencing any repair works. 2) Please read the product manual and maintenance manual carefully before carrying out any repair work. 3) If problem persists after following the steps below, please cease using the equipment and contact the manufacturer or authorized representative immediately. Trouble Probable Cause Remedy Platform will not reach max height. Platform can not be raised although motor is running. Platform can not be raised; electric motor is not running. Platform descends gradually from raised position. Platform will not Descend. Oil leaking Insufficient hydraulic oil. 1. Excessive platform capacity. 2. Emergency down valve is left open. 3. Insufficient hydraulic oil. 4. Hydraulic oil is contaminated. 1. Key switch is in OFF position. 2.AC Power connection faulty. (DC model: battery level low). 3. Outriggers not installed properly. 4. Emergency stop button is depressed. 5. Electric motor faulty. 1. Emergency down valve is left partially open. 2. Oil contaminated, causing relief valve to remain open. 3. Hydraulic seal needs replacement. 1.AC power not connected and back-up battery is flat.(dc model: Battery level low). 2. Oil cylinder bypass causing explosion relief valve to block oil flow. 3. Pressure release valve damage, cannot open to release pressure. 4. Outriggers not installed correctly. 1. Hydraulic seal needs replacement 2. Oil leakage from fittings. Add hydraulic oil. 1. Keep to capacity specified. 2. Close the emergency down valve. 3. Add hydraulic oil. 4. Replace hydraulic oil. 1. Turn key switch to PLATFORM Position. UT58- Turn key switch to ON position. 2.Check AC power point (DC model: Recharge battery). 3. Adjust outriggers until all indicator lights are on. 4. Release emergency stop button. 5. Contact supplier for replacement motor. 1. Close emergency down valve fully. 2. Replace hydraulic oil, clean filter. 3. Contact supplier for replacement seal. 1.Check AC power connection Recharge or replace back-up battery as required. (DC Model: Recharge battery.) 2. Press Up & Power button to raise platform and slowly open the emergency down valve, repeat this cycle if required. 3. Contact supplier for replacement pressure relief valve. 4. Adjust outriggers until all indicator lights are on. NB. To lower the platform, open the emergency down valve. Stop using the equipment. Contact supplier for replacement seal/fittings

21 UT Series Elevated Work Platform ISO9001 Quality Management System Certification. Australian Standards AS CE Compliance The product is insured by CPPIC The Company reserves the right to alter its design & specification without prior notification. Version number: May