Pop Up Users Inspection Guide
Transcription
Pop Up Users Inspection Guide
Pop Up & Pop Up+ 2 Contents Essential Inspection Guidance Contents 2 Part 1 - Users Introduction 3 Structure 4 Platform 5 Platform 6 Castors 7 Brakes 8 Hydraulic Oil & Leaks 9 Battery Condition 10 Raise & Lower Functions 11 Emergency Stop & Lowering Functions 12 Limit Switches 13 Safety Decals 14 15 16 Stabilisers 17 Hydraulic Bypass Kit (HBK) 18 Inspection Checklist 19 3 Introduction Introduction An Inspection Guide for Pop-Up users Pop-Up and Pop-Up+ products have been in service now since 2005 and through our experience in the inspection, maintenance and repair of these machines we thought it necessary to produce a guide to enable both the operators of the machines and the personnel involved in the inspection and maintenance of the machines, to carry out pre-use and thorough inspection of the Pop-Up machines. This guide has been provided to ensure that your machines continue to be safe to use and have trouble free operation for many years to come. The importance of regular inspection and maintenance is essential to ensure that any defects are detected at an early stage and that the equipment being used is safe. Once in service, the responsibility for using your machine safely lies with the end users of the machines, their employers, owners as well as technicians/engineers servicing the equipment. All the information contained within the guide applies to all Pop-Up machines but particularly to those machines that have been in service for over 4 years or machines that have had heavy usage over a shorter period of time. Thorough Examination and Inspection The Lifting Operations and Lifting Equipment Regulations 1998 (often referred to as the ‘LOLER regs.’) require that equipment for lifting persons must be thoroughly examined by a competent person at least every six months. Examining a machine once only every six months is usually not sufficient, especially if it is used on a daily basis. LOLER requires that, if appropriate, intermediate inspections should also be undertaken – this means daily pre-use checks by the operator and possibly additional inspections by a competent person should there be a need (e.g. if the machine is subject to high usage, or used in a harsh environment). Ensuring that daily/pre-use checks are undertaken satisfactorily prior to the machine being used is vital to identify faulty or damaged equipment at an early stage. As such, the operator is often seen as the first line of defence in detecting problems with the machine as a result of daily wear and tear. It is equally important should defects be identified, that they are reported and rectified within a reasonable timescale. UNDER NO CIRCUMSTANCES SHOULD FAULTY EQUIPMENT CONTINUE TO BE USED OTHERWISE DEATH OR SERIOUS INJURY MAY RESULT. The Health & Safety Commission publication L113 is an extremely useful interpretation to the Lifting Operations and Lifting Equipment Regulations 1998 and a copy should be available wherever a Pop-Up is being used – you can download it from http://www.hse.gov.uk You may also find British Standard BS 8460:2005 Safe use of MEWPS a useful document if using or maintaining a Pop-Up. 4 Structure Structure The Pop-Up structure supports the operator when the work platform is elevated. Needless to say, the structure is a vital part of your Pop-Up if work at height is to be undertaken safely. This is the reason why ‘structure’ appears first in the list of daily/pre-use checks – it should be thoroughly checked on a daily basis as you don’t know what may have happened since you last used the machine. 1. Damage – can occur, for example, if the Pop-Up collides with a fixed obstacle or something collides or falls onto the Pop-Up. Certain damage may be readily visible – the guard rails may be bent, for instance, or there may be scrapes along the side of the machine. Whilst scrapes may be superficial and may affect the integrity of the structure, significant distortion of the structure may weaken it to the point where it can no longer support a load. 2. Cracks – may occur as a result of a collision or overload, either in structural components or in the welded joints. If the structure is cracked in any way remove the machine from service and seek advice from your employer. 3. Corrosion – rust may occur if the Pop-Up is used and/or stored outdoors. Whilst the majority of corrosion may detract from the appearance of the machine, you should pay attention to rust around welds and connections (pins, bolts, etc.) 4. Abrasion - results from moving parts rubbing together, perhaps because they are out of alignment. Abrasion may indicate that parts of the structure need to be adjusted or tightened up. 5. Welds – are an important part of the structure and should be visually inspected on a daily basis. If your check reveals damage or corrosion in the area of a weld, seek advice from your employer. 6. Connections - pins serve as pivots in moving parts of the structure and nuts, bolts, etc. act as fasteners. Ensure that all moving joints move freely, and that all fasteners are tight and in place. What to look for? This guide is in two parts. Part 1 is for users of Pop-Up machines and those who undertake daily/pre-use checks. It expands on those items that require regular checks and those which you will find in your Pop-Up Operator’s Safety and Maintenance Handbook. Part 2 is intended for service engineers, technicians and competent persons undertaking periodic checks and maintenance. It is recommended that Pop-Up users read at least Part 1 of this guide. Service personnel should read both Part 1 and Part 2. Each page identifies items to look for, whether it is damage or faults to the equipment or missing parts, plus when repair or further assistance may be required. NOTE - This guide is not a comprehensive maintenance manual and should not be used as a substitute for training in either operation or maintenance of your Pop-Up product. It is recommended that you keep this guide alongside your Pop-Up Operator’s Safety and Maintenance Handbook. The final page of this guide takes the form of a check-list which may be photocopied for use when undertaking daily/preuse checks and other periodic examinations. It is good practice to complete these and file them as a record that the checks have been undertaken. Your Pop-Up Operator’s Safety and Maintenance Handbook also contains a similar check-list – the daily/pre-use checks are the same, you can decide which one to use. There are several references to the Pop-Up Operator’s Safety and Maintenance Handbook in this guide – you should ensure that the handbook remains with the machine at all times and is readily available to both operators and service personnel. If the handbook is missing you can download a copy from http://www.popupproducts.co.uk. REMEMBER - If you suspect at any time that the machine may be unsafe, remove it from service immediately and seek advice, either from your employer, the appointed competent person or the manufacturer. DO NOT USE THE MACHINE until the fault or faults have been rectified. 1. 2. 4. 3. 5. 5 Platform Platform 6 Platform Platform The work platform of the Pop-Up serves as the workspace for the operator whilst work is undertaken at height. As such it should provide a safe environment for the user to work from and above all prevent falls from height. 1. Floor – the floor of the work platform should be kept clean and clear of loose materials that may cause a trip or slip. Regular cleaning with a brush and dust pan may be all that’s needed to keep it a safe area to work in. 2. Guard rails – provide a barrier around the top edge of the work platform. These should be securely fastened and undamaged. If fasteners are loose, ensure they are adequately tightened. If the guard-rails are bent or cracked they should be replaced. 3. Mid rails – run around the platform at about knee height and are to prevent operators falling under the top guard-rail. As with the guard rails, ensure that they are not damaged, bent or cracked paying special attention to where they are welded to the uprights. Any cracked welds should be repaired before the machine is used. 1. 2&3. 4.Kick plate – this is the 6 inch (15cm) plate that round the edge of the floor and is intended to prevent tools/materials from being kicked out the work platform. It is fairly sturdy however check for damage and cracked welds. Even a sharp edge caused by a collision or dropped object could result in a nasty injury. 5. Handrail sockets – check the handrail sockets are in good condition, undamaged and adequately secure the uprights. 6. Access gate – the access gate opens inwards in order to prevent the operator falling out if it is leaned against whilst in the work platform. Make sure that the gate is not damaged in any way and that it returns automatically to the closed position. If it does not, the spring may need to be replaced. Pay close attention to the stop, which prevents the gate swinging outwards. If this is damaged it could allow the gate to open when leant against at height. It is often common to see access gates tied in the open position, in order to easily enter and exit the work platform. This practice is particularly dangerous since there will be no protection to the operator at the rear of the work platform and the risk of falling is increased. 4. 6. 5. 7 Castors 8 Brakes Castors Brakes Four castors are fitted to the Pop-Up – the two front ones are fixed whereas the ones at the rear can swivel for ease in manoeuvring the machine. As well as being important for the mobility of the machine, the castors also provide part of the supporting structure whilst the work platform is elevated. The brakes prevent any inadvertent movement whilst the machine is parked or whilst work is being undertaken at height. Although the machine is intended for use of flat level surfaces it may need to be manoeuvred and/or stored on surfaces with a slight incline. In these instances correct operation of the brakes will ensure the safety of personnel. Design – other than the front castors being fixed and the rears being swivelled, all four castor wheels should look identical. If one looks as if it may have been replaced by an incorrect size or type, then don’t use the machine. If in doubt, refer to the Operator’s Safety and Maintenance Handbook or seek advice from the manufacturer. 1. Rear manual brakes – begin your check with both brakes released (disengaged) – both levers should be up. Next, push down on the left hand brake with your foot to engage it. Attempt to move the machine. If the brake is working correctly you should not be able to move the machine. Release the left hand brake by pulling up the lever. Repeat the process with the right hand brake. If the machine can be moved with either brake engaged then isolate the machine and seek advice. With both brakes released the machine should be able to be manoeuvred with little difficulty. If either lever appears to be damaged or will not remain in the engaged/disengaged positions then the castor will need to be replaced – do not use the machine until this is done. 1. Fixing – visually inspect the castors and their mounting. In particular the fasteners used to secure the castor to the chassis should be tight and complete. If any of the fasteners are missing or are loose, then do not use the machine. Isolate it and seek further advice. 2. Damage – may have occurred as a result of a collision or careless manoeuvring. This may result in the castor wheel or mounting being deformed (e.g. bent) which may make moving the Pop-Up difficult. If there is any sign of distortion in the areas of the castor or mounting the structure may have become weakened and the machine should not be used until it is repaired. Check for non original components especially 3. Smooth movement – with the brakes on the rear castors released, push and pull the Pop-Up over as smooth a surface as you can find. The machine should be able to be moved easily, without too much effort, and all castors should rotate freely. If any castors are turning properly then look closer to identify whether any debris is caught in the area of the pivot. There may also be debris stuck to or embedded in the rubber part of the castor or the condition of the tyres may have deteriorated. If the problem cannot easily be identified or rectified then isolate the machine and seek further advice. 2. Front auto brakes – to check the operation of these brakes first make sure they are released. Next elevate the work platform approximately 150mm (6 inches). Once this height is achieved attempt to move the machine. If the auto brakes are functioning correctly you should not be able to manoeuvre the machine, indicating that the brakes have engaged. If the machine can be easily moved in this position the brakes may not be working and you should seek advice before using the machine. Regardless of whether your machine has front auto brakes or not, you should always ensure that the rear manual brakes are engaged before elevating the work platform. 4. Non original components - Check the adjuster bolt on the brake mechanism hasn't been replaced with a non original part such as a M10 coach bolt. 1. 2. 1. 2. 3. 4. 9 Hydraulic Oil & Leaks Battery Condition Hydraulic oil & leaks Battery condition Your Pop-Up has a self-contained hydraulic system which is what raises and lowers the work platform. Leaking oil from this system is an indication of a fault on the machine and, as well as causing a mess, should be a reason for concern. Daily checks in the following areas will ensure that any leaks from the system are detected at an early stage. Your Pop-Up or Pop-Up+ is fitted with a 12 volt battery and either a dedicated external or internally mounted battery charger. Electrical faults on the machine can not only degrade machine performance but can lead to risk of electrocution to the operator and/or bystanders and may even be a fire risk. NOTE – when checking areas within the chassis of the machine, ensure that both maintenance props have been engaged. NOTE – when checking areas within the chassis of the machine, ensure that both maintenance props have been engaged. 1. Hydraulic pack – this is located at the centre of the chassis and the work platform will need to be elevated in order to inspect it. Check the area of the hydraulic pack for any signs of oil, especially lying in the bottom of the chassis frame. 2. Hose – a short rubber hose runs from the hydraulic pack to the main lift cylinder. Check this hose to ensure it has not been damaged and the connections at either end are tight. Check also if there appears to be any oil around the areas of the connections at each end of the hose. 3. Main lift cylinder – this cylinder supports the work platform once it is elevated therefore it is vital it operates correctly. Again, check for any visible signs of oil leaking from it. Whilst checking the cylinder make sure that the connections at each end are secure. 1. 1. Battery Condition – a battery condition meter is fitted to the Pop-Up and Pop-Up+ on the side of the chassis. The battery condition needs to be checked whilst the machine is elevating. Stand a few steps away from the machine with the control pendant and press the UP button, whilst checking the bars on the charging indicator. The Pop-Up differs slightly and has a button that needs to depressed to enable the battery meter to function. You will need to depress this button and hold it whilst elevating the machine. This can only be achieved if you stand closer to the machine. Ensure your head and body are clear of the platform and scissor pack before attempting to test the battery condition. If when testing the battery condition on a Pop-Up or Pop-Up+ less than 4 bars are shown, then the battery requires charging. Refer to the Operator’s Safety and Maintenance Handbook for instructions on how to charge the Pop-Up or Pop-Up+. 2. Battery charger – a dedicated battery charger is supplied with your Pop-Up or Pop-Up+. No other type of battery charger is to be used to charge the machine. 2. 1. 3. 10 11 Raise & Lower Functions Emergency Stop & Lowering Functions Raise & lower functions Emergency Stop & lowering functions Correct operation of the raising and lowering functions on the Pop-Up is fundamental to its safe operation. An emergency stop button is provided on the control pendant. This is the red button with a yellow background which, when pressed, isolates the machine. The button is also has a key to protect it from unauthorised operation. An emergency lowering system enables the work platform to be lowered if the platform cannot be lowered using the DOWN button on the control pendant (e.g. in the event of the operator being unable to do so). 1. Buttons –inspect the UP and Down buttons on the control pendant for any damage. Make sure they are secure in the housing and that the buttons don’t stick in the ‘on’ position when they are pressed. The words ‘UP’ and ‘DOWN’ and the symbols alongside the buttons should be clearly legible – if they are not new decals will be required. 2. Cables – visually check the condition of the electrical cables in the chassis. If there is any sign of them having been trapped or kinked or if you can see any of the exposed wire you should not use the machine until it has been repaired. Notify your employer immediately. The connections at the ends of the electrical cables should also be checked. If any appear to be loose or damaged, again these should be rectified – seek advice from your employer. 3. Function test - the raise and lower functions can be tested by removing the upper control pendant from its holder in the work platform and using the controls whilst at ground level. (NOTE: unless in an emergency situation, this practice must not be employed when a person is in the work platform). Press the UP button until the work platform is fully elevated, and then press the DOWN button to lower the platform. Ensure that the raise and lowering movements are smooth in operation. If the movement is not smooth or very slow then seek advice from your employer. 4. Descent delay– the Pop-Up+ incorporates a system which stops the lowering motion momentarily whilst descending. This is to avoid persons from becoming trapped in the scissor mechanism. To test this system elevate the work platform to full height by pressing the UP button, then press the DOWN button on the control panel. The work platform should descend and will automatically stop BEFORE it reaches the fully lowered position. Check to make sure there is a time delay before the platform can be lowered further to the fully down position. If no time delay is present or the platform does not stop whilst descending, isolate the machine and seek advice. 1&3 1. Emergency stop – First remove the control pendant from the work platform and stand alongside the machine. With the emergency stop button pushed in remove the key. Press the UP and DOWN button each in turn. The electric motor should not start and the work platform should not move. If the motor does start the machine has a fault and should not be used until it is rectified. Insert the key into the button and turn it clockwise, which should release the emergency stop. Check no cable ties have been placed around the base of the emergency stop button or the key slot damaged by screwdrivers etc. Raise the work platform approximately 30cm (1 foot). Push in the emergency stop button. Press the UP and DOWN button each in turn. The work platform should not move. If it does the machine has a fault and should not be used until it is rectified – seek advice from your employer. 2. Emergency lowering – Again, standing alongside the machine with the control pendant raise the work platform to full height. The Pop-Up and the Pop-Up+, use the different emergency lowering systems, as follows Pop-Up – there is a control knob at the side of the chassis with a decal marked ’Emergency lowering’. Turning this knob in an ANTICLOCKWISE direction opens the lift valve. Once fully open the work platform should lower. Please stand back to ensure your safety. The control knob should always be fully turned CLOCKWISE after use. If the control knob cannot be turned or if the work platform does lower once it is turned the system is faulty and the machine should not be used. Pop-Up+ - the emergency lowering system on the Pop-Up+ requires the operation of two separate controls – one at the main lift cylinder and one at the chassis. Since resetting of both of these controls is essential to safe use of the machine reference should be made to the Operator’s Safety and Maintenance handbook. If either control is damaged, cannot be operated or the work platform does lower once it is turned the system is faulty and the machine should not be used. 1a. 4. 2. 1b. 2. 12 13 Limit Switches 14 Safety Decals Limit switches Safety decals The number of limit switches depends on which type of Pop-Up you have – • Pop-Up has one limit switch • Pop-Up+ (without stabilisers) has two limit switches • Pop-Up+ (with stabilisers) has six limit switches Use the following checks appropriate to the type of machine you have – NOTE – when checking areas within the chassis of the machine, ensure that both maintenance props have been engaged. The safety decals (e.g. labels, s ckers) fi ed to the Pop-Up form part of the overall opera ng instruc ons. If decals are missing, removed or are no longer legible then vital opera ng informa on may be lost, which can lead to unsafe opera on. Pop-Up & Pop-Up+ – a limit switch is fitted to the chassis which actuates once the work platform reaches its maximum height. To check the operation of the switch, stand alongside the machine with the control pendant and raise the work platform to full height. At full height the scissor pack should push against the switch actuator (sometimes called a ‘cat’s whisker’). If the scissor pack DOES NOT hit the switch actuator then the switch needs to be re-adjusted. If the scissor pack DOES hit the switch actuator and stop, then lower the platform to a position where the maintenance props can be inserted. Check the switch is securely mounted. If it is loose it will need securing. If you are in doubt as to the operation of the switch do not use the machine and seek further advice. Pop-Up+ (with and without stabilisers) – a limit switch is fitted to operate the descent delay system. You should check the correct operation of this system as described in the Raise & lower functions section of this guide (Page 10). With the work platform elevated and the maintenance props in place, check to make sure the switch is secure. Pop-Up+ (with stabilisers) – limit switches are fitted to each stabiliser leg to ensure it is correctly set. Four yellow indicator lights on the side of the chassis indicate that each stabiliser is correctly set and that the work platform can be raised. Set all stabilisers per the instructions in the Operator’s Safety and Maintenance Handbook and confirm that the yellow lights are illuminated. If they aren’t, check the setting of the stabilisers. If all lights cannot be illuminated and the work platform cannot be raised then there may be a problem with the switches. Also, if the work platform can be elevated when some of the lights are not illuminated there is a fault with the machine. The machine should not be used – seek further advice. Safety decals – refer to the list and Pop-Up Decal Loca on Sheet on the following page to familiarise yourself with the decals that are fi ed to the Pop-Up. Once you are familiar with the meaning and loca on of each decal on your machine you should be able to iden fy if any decals are missing. If the Pop-Up has had paint spilled onto it which obscures any words or symbols on the decals these should be replaced as soon as possible. Whilst you may be familiar with the opera on of the Pop-Up, the machine may be used by someone who may need to rely on the instruc ons provided by the decals. If safety decals are no longer legible or missing, please contact the manufacturer for replacements. List of safety decals fi ed to Pop-Up 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Maintenance isolator switch Indoor use only Check ba ery condi on Ensure brakes are locked CE mark Maximum chassis inclina on Emergency lowering Maintenance isolator on/off/charge OFF/ON Forking li point Maximum wheel load Work pla orm informa on Maintenance props Operators safety handbook Chassis plate Qty 1 1 1 1 1 1 1 1 1 4 4 1 2 1 List of safety decals fi ed to Pop-Up+ 'Cats Whisker' type Descent Delay Stabiliser 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Maintenance isolator switch Indoor use only Check ba ery condi on Ensure brakes are locked CE mark Maximum chassis inclina on Emergency lowering Maintenance isolator on/off/charge OFF/ON Forking li point Maximum wheel load Work pla orm informa on Maintenance props Operators safety handbook Stabiliser deployment Chassis plate Qty 1 1 1 1 1 1 1 1 1 4 4 1 2 1 1 15 Pop Up Decal Identification & Location Pop Up+ Decal Identification & Location 16 17 Stabilisers Hydraulic Bypass Kit (HBK) Stabilisers Hydraulic Bypass Kit (HBK) Stabilisers are only available on the Pop-Up+ and not the Pop-Up. They are optional on the Pop-Up+ and can be fitted on machines with or without auto brakes, if the machines are required to be used in internal exposed situations such as open sided buildings. The correct procedure for setting the stabilisers is described in the Operator’s Safety and Maintenance Handbook. You should check the operation of each of the limit switches and whether the platform can be elevated by following the steps in the Limit switches section of this guide (Page 12). The checks below should be undertaken on each stabiliser in turn. The Hydraulic Bypass Kit is an after-sales modification which applies to Pop-Up machines from Serial No. 001 to 4518 and Pop-Up+ machines from Serial No. 001 to 1438. To determine whether your machine has been fitted with this kit, first check to see whether a sticker such as the one shown below has been fixed to the work platform. The sticker should indicate the date on which it was fitted. If no sticker is present or if the one fitted cannot be read or has not been completed then contact your employer or Pop-Up Products. If you cannot find this sticker on the machine contact PopUp Products for information on the kit. Red knob – this knob secures the stabiliser beams in the fully closed (transport) and fully deployed positions. You should check the knob for damage and that it does indeed lock the beam at the two extreme positions. If it doesn’t lock correctly, then it should be replaced. Stabiliser beam – inspect the beam for any structural damage and/or distortion, which may have been caused by a collision or impact. Inspect also the weld between the beam and end tube for any cracks which could weaken the beam. If in doubt seek advice from your employer. Blue plunger – this plunger secures the stabiliser leg in the fully raised and lowered positions. Check the plunger for damage and that it does lock the stabiliser leg in the upper and lower positions. If there is any upward or downward movement of the leg in either of these positions then the plunger may need to be replaced. Stabiliser leg – inspect the leg and foot for any structural damage and/or distortion, which may have been caused by a collision or impact. If the stabiliser foot is damaged or missing then the machine should not be used. The kit comprises additional parts that should be included as part of the daily/pre-use checks. Handle – check the handle first for signs of damage. Turn the handle clockwise then anti-clockwise – the movement should be smooth, however if it is difficult to turn the handle or the stabiliser leg does not extend/retract when the handle is turned the problem should be rectified before the machine is used. Visually check the condition of all of the electrical cables in the chassis. If there is any sign of them having been trapped or kinked or if you can see any of the exposed wire you should not use the machine until it has been repaired. Notify your employer immediately. The connections at the ends of the electrical cables should also be checked. If any appear to be loose or damaged, again these should be rectified – seek advice from your employer. The additional hydraulic kit parts are shown below. As with the Hydraulic oil & leaks section of this guide, this area should be checked for damage and any signs of oil leakage. Make sure all the connections are tight. Do not use the machine if you notice oil around these parts or if any of the connections are loose – seek advice from your employer. HBK fitted to machine Note – later build machines with serial numbers higher than those above have these parts fitted as standard, however similar checks should be made to ensure the good condition of all electrical and hydraulic parts on the machine. 18 19 Inspection Checklist Inspection checklist Pop-Up serial number …………………… Make photocopies of this page and use the checklists to record daily/pre-use and other periodic checks. Ensure completed checklists are filed as a record of inspection. Refer to the Pop-Up & PopUp+ document Essential Inspection Guidance and the Operator’s and Maintenance Handbook for further information. Daily/Pre-use Checklist Structure Platform Castors Brakes Hydraulic oil & leaks Battery condition OK? Raise & lower functions Emergency stop and lowering Limit switches Safety decals Stabilisers OK? PRODUCTS LIMITED Additional Monthly Checks Check hydraulic oil level Inspect limit switches Inspect wiring OK? Check electrical connectors Lubricate roller guides Lubricate grease nipples OK? Lubricate pivot pins Additional 12 Monthly Checks Replace hydraulic oil OK? Name ……………………………………….. Signed ……………………………………….. Date ……………………………………….. popupproducts.co.uk +44 (0)1244 833 933 [email protected] Additional 6 Monthly Checks OK? ® Lubricate castor mounts OK?