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nifty TrackDrive TD120T Series Operating/Safety Instructions Manual

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TrackDrive
Operating & Safety Instructions
MODEL TD120T/TD34T 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
M50261/06

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  • Page 1 TrackDrive Operating & Safety Instructions MODEL TD120T/TD34T 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 M50261/06...

  • Page 3: Table Of Contents

    TrackDrive (TD) Series Operating & Safety Instructions Table of Contents INTRODUCTION AND GENERAL INFORMATION PAGE 1.1 Foreword 1.2 Scope 1.3 Introducing the Track Drive 120T (TD) Series 1.4 General Specification 1.5 Identification 1.6 EC Declaration of Conformity SAFETY 2.1 Mandatory Precautions 7-10 2.2 Environmental Limitations 2.3 Noise &...

  • Page 4: Introduction And General Information Page

    TrackDrive (TD) 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

    Niftylift Inc, 1525 S. Buncombe Road, Greer, SC 29651 USA Tel: +01 864 968 8881 Fax: +01 864 968 8836 Nifty Pty Ltd, 11 Kennington Drive, Tomago, NSW 2322, Australia Tel: +61 (0) 2 4964 9765 Fax: +61 (0) 2 4964 9714 The Niftylift TD120T (Track Drive) is an extremely versatile articulated boom platform of unique and simple design.

  • Page 6: General Specification

    TrackDrive (TD) Series Operating & Safety Instructions GENERAL SPECIFICATION FEATURE TD120T (TD34T) MAXIMUM HEIGHT - WORKING 12.2m 40ft 10.2m MAXIMUM HEIGHT - PLATFORM 34ft MAXIMUM HEIGHT - STOWED 1.9m 6ft 3in MAXIMUM OUTREACH 6.1m 20ft 1in MAXIMUM WIDTH - TRANSIT 1.1m 3ft 7in MAXIMUM WIDTH –...

  • Page 7: Identification

    TrackDrive (TD) Series Operating & Safety Instructions IDENTIFICATION (UK PLATE) This manufacturer’s plate is attached to Boom 1 on each machine at the time of manufacture on every Niftylift. Please ensure all sections have been stamped and are legible. English/USA – 02/17...

  • Page 8: Ec Declaration Of Conformity

    TrackDrive (TD) Series Operating & Safety Instructions EC DECLARATION OF CONFORMITY (Typical) English/USA – 02/17...

  • Page 9: Safety

    TrackDrive (TD) Series Operating & Safety Instructions Safety MANDATORY PRECAUTIONS When operating your Niftylift, your safety is of utmost concern. In order to fully appreciate all aspects of the machines operation it should be ensured that each operator has READ and fully UNDERSTOOD the relevant manual covering machine use, maintenance and servicing.
  • Page 10 TrackDrive (TD) Series Operating & Safety Instructions 2.1.8 Never exceed the maximum platform capacity, as indicated on the decals and machine serial plate. 2.1.9 Only operate the Niftylift on a firm level surface. 2.1.10 Never position any part of the Niftylift inside the Minimum approach distances (MAD) to above- ground electrical conductors as listed in the table below.
  • Page 11 TrackDrive (TD) Series Operating & Safety Instructions 2.1.18 Stunt driving and horseplay, on or around the Niftylift, shall not be permitted 2.1.19 The aerial platform is not equipped for, or intended for use on a public highway. 2.1.20 When other moving equipment and vehicles are present, special precautions shall be taken to comply with local ordinances or safety standards established for the work place.

  • Page 12: Environmental Limitations

    TrackDrive (TD) Series Operating & Safety Instructions 2.1.34 The engine must be shut down while fuel tanks are being filled. Fuelling must be done in a well- ventilated area free of flame, sparks or any other hazard that may cause fire or explosion. PETROL (GASOLINE), LIQUID PROPANE AND DIESEL FUELS ARE FLAMMABLE.

  • Page 13: Noise & Vibration

    TrackDrive (TD) Series Operating & Safety Instructions Extended operation in dusty environments is not recommended and frequent cleaning will be necessary. All dust, dirt, salt encrustation, excess oil or grease should be removed. Deposits of paint or bitumen, particularly on legends or labels should also be removed. 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.

  • Page 14: Preparation And Inspection

    TrackDrive (TD) Series Operating & Safety Instructions Preparation and Inspection UNPACKING Since the manufacturer has no direct control over the shipping or carriage of any Niftylift it is the responsibility of the dealer and/or owner and/or hirer to ensure the Niftylift has not been damaged in transit and a Pre-operational Report has been carried out by a qualified engineer before the aerial platform is put into service.

  • Page 15: Pre-Operational Safety Check Schedules

    TrackDrive (TD) Series Operating & Safety Instructions PRE-OPERATIONAL SAFETY CHECK SCHEDULES Before use at the beginning of the work shift, the aerial platform shall be given a visual inspection and functional tests including, but not limited to the following. It is recommended that these be performed at regular intervals as indicated on each checklist.
  • Page 16 TrackDrive (TD) Series Operating & Safety Instructions 3.3.3 MONTHLY SAFETY CHECKS Check the engine oil level (if applicable). Check outriggers for condition, security and operation. Check that the slew gearbox is secure and correctly in mesh. Clean and re-grease. Grease the slew ring. Inspect the engine fuel tank for damage or leaks.

  • Page 17: Placard, Decals And Installation

    Overload Warning P18848 Outrigger P16363 Track Drive - Controls P16364 Harness Points P14883 No Step P14785 Outriggers P14841 General Notice P21941 Power to Cage Socket P24787 Nifty TD120T P29881 Niftylift.com P14390 Emergency Controls P22877 Tank Pressure P16365 English/USA – 02/17...
  • Page 18 TrackDrive (TD) Series Operating & Safety Instructions Black/Yellow Warning Stripes Cage Levelling P10853 Base Controls P15881 Cage controls Standard P12832 Cage weigh P18961 E-Stop background (USA) P24893 Operating Instructions P14892 Safe Cage Entry (USA) P18192 Noise Warning – 85dB P17124 Daily Safety Check List P14908 Tie Down Point...
  • Page 19 TrackDrive (TD) Series Operating & Safety Instructions English/USA – 02/17...

  • Page 20: Torque Requirements

    TrackDrive (TD) Series Operating & Safety Instructions TORQUE REQUIREMENTS BOLT QUALITY/SIZE Tightening torque in lbs ft (Nm) Plated Unplated Grade 10.9 12.9 10.9 12.9 5 (7) 8 (10) 9 (12) 6 (8) 8 (11) 10 (13) 13 (17) 18 (25) 22 (29) 14 (19) 20 (27)

  • Page 21: Operation

    TrackDrive (TD) Series Operating & Safety Instructions Operation OVERVIEW 4.1.1 CONTROL CIRCUIT COMPONENTS CONTROL BOARD: - Situated under the canopy, the control board comprises a PCB (printed circuit board) design which incorporates all of the relays to control the machine operation. The control board is common between models with the same power source, and will contain, where appropriate, discrete fuses for the circuits concerned.
  • Page 22 TrackDrive (TD) Series Operating & Safety Instructions LPG OPERATION: - On machines equipped for LPG operation (propane), the Honda engine will also have an LPG vaporiser, valve lock and micro-vac switch. The vapour take-off system requires a vaporiser to convert the liquid gas into an airborne mixture. This is then held by the micro-vac switch and valve lock until the engine turns over, creating a vacuum on the inlet to the engine carburettor.
  • Page 23 TrackDrive (TD) Series Operating & Safety Instructions 4.1.3 MANOEUVRING Once the engine is running, the operator can manoeuvre the machine from the platform. On entering the platform and selecting 'drive' on the duty selector switch, the operator can now reach forward and grasp the two drive handles to enable the drive function.
  • Page 24 TrackDrive (TD) Series Operating & Safety Instructions When climbing steps, a further judgement will be needed as to whether the weight of the machine, or the traction required to climb or descend would cause damage. Many domestic installations feature soft edge strips or boards to provide the front edge of the step. These edging strips are unlikely to tolerate the action of climbing and might detach causing degradation of the steps themselves.
  • Page 25 TrackDrive (TD) Series Operating & Safety Instructions Minimum width – Selector in line. Maximum width – Selector sideways. Minimum width – Track in. Maximum width – Track extended. 4.1.6 OUTRIGGERS The four outriggers are deployed using the individual levers behind the main turret. Each lever controls the movement of an outrigger leg, their relative positions being indicated by the lever spacing.
  • Page 26 TrackDrive (TD) Series Operating & Safety Instructions 4.1.7 BOOM CONTROLS As soon as all four outriggers are making contact with the ground, the four sensing switches will activate allowing the Booms to be elevated. Turning the Hydraulic Duty Selector switch to 'Booms' re-sets the circuit to permit this.
  • Page 27 TrackDrive (TD) Series Operating & Safety Instructions 4.1.8 EMERGENCY CONTROLS Emergency descent and/or machine recovery is achieved by the use of the standby hand pump, mounted on the base of Boom 1. This can accommodate all functions, with the exception of the drive system.

  • Page 28: Setting Up Procedures

    TrackDrive (TD) Series Operating & Safety Instructions SETTING UP PROCEDURES FAILURE TO DEPLOY THE OUTRIGGERS CORRECTLY COULD RESULT IN DEATH OR SERIOUS INJURY. TRACK DRIVE MODELS ONLY Read and fully comply with all safety precautions and operating instructions in the Operating and Safety manual and the warning decals on the machine.

  • Page 29: Ground Control Operation

    TrackDrive (TD) Series Operating & Safety Instructions GROUND CONTROL OPERATION ALWAYS ALLOW THE ENGINE TO WARM UP BEFORE OPERATING 4.3.1 GROUND CONTROL INSTRUCTIONS ALL MODELS Check below, above and around the platform for any obstructions or hazards before operating any function. Ensure all red emergency stops are out.
  • Page 30 TrackDrive (TD) Series Operating & Safety Instructions EMERGENCY PROCEDURES Push in red emergency stop to shut down all functions. Use manual hand pump to provide motive power and manoeuvre the machine as normal using the hand levers (Platform or Base). 4.3.2 BOOM FUNCTIONS Push and hold green power button.

  • Page 31: Platform Control Operation

    TrackDrive (TD) Series Operating & Safety Instructions PLATFORM CONTROL OPERATION NEVER START THE NIFTYLIFT IF YOU SMELL PETROL (GASOLINE), LIQUID PROPANE OR DIESEL. THESE FUELS ARE FLAMMABLE. 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.
  • Page 32 TrackDrive (TD) Series Operating & Safety Instructions ALL MODELS Push and hold green Power Control button (if fitted), or depress footswitch. Select the boom function required and operate hand levers in full accordance with manufacturers Operating and Safety manual. When not in use return machine to stowed position, fully raise and stow all outriggers, turn the key to the “OFF”...
  • Page 33 TrackDrive (TD) Series Operating & Safety Instructions 4.4.2 BOOM FUNCTIONS Push and hold green "Power Control" button (if fitted) or depress footswitch Select lever 1, 2, 3, 4 or 5 for desired function 1 Operates Platform Lev. FWD for forward BACK for back 2 Operates Telescope UP for out...

  • Page 34: Cage Weigh System (If Fitted)

    TrackDrive (TD) Series Operating & Safety Instructions CAGE WEIGH SYSTEM (If fitted) 4.5.1 LOAD CELL The Niftylift TD120T 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.

  • Page 35: Transporting, Craneage, Storage And Setting To Work

    TrackDrive (TD) Series Operating & Safety Instructions TRANSPORTING, CRANEAGE, STORAGE AND SETTING TO WORK 4.6.1 TRANSPORTING If a work platform is to be moved over a longer distance, whether the machine is trailer mounted, vehicle mounted, self propelled or tracked, the following procedure should be read before restraints are attached to the machine.
  • Page 36 TrackDrive (TD) Series Operating & Safety Instructions 4.6.2 CRANEAGE Observe all of the limitations relating to straps and chains stated above under ‘Transporting’. (Section 4.6.1) When utilising the designated lifting points never apply a ‘snatch’ load, i.e. lift slowly to take up the load before raising.
  • Page 37 TrackDrive (TD) Series Operating & Safety Instructions On completion of an extended period of road transport, the machine might need additional inspection to identify any transit degradation, which could render the machine unsafe. Perform a P.D.I. inspection on the unit before it enters service. Record any faults found and rectify them immediately.

  • Page 38: Emergency Controls

    TrackDrive (TD) Series Operating & Safety Instructions Emergency Controls GENERAL CHECKING THE OPERATION OF THE EMERGENCY CONTROLS EVERY DAY AND/OR BEFORE EACH SHIFT IS AN ESSENTIAL PART OF THE OPERATOR'S DUTIES The operator and all ground personnel must be thoroughly familiar with the location and operation of the EMERGENCY CONTROLS.

  • Page 39: Responsibilities

    TrackDrive (TD) Series Operating & Safety Instructions Responsibilities CHANGES IN OWNERSHIP When a change of ownership of a Niftylift occurs, it shall be the responsibility of the seller to notify Niftylift direct of the unit, model and serial number and the name and address of the new owner within 60 days.

  • Page 40: Inspection/ Service Check List

    TrackDrive (TD) Series Operating & Safety Instructions Inspection/Service/Pre-Hire Check list MACHINE SERIAL NO TOWING PASS FAIL Machine secured on trailer Straps correctly positioned and tightened Machine chocked if necessary TRACK ASSEMBLY Tracks are complete and engaged with drive sprockets Track tension correct – grease in tensioner. Machine climbs slope Brakes hold machine on slope BASE...
  • Page 41 TrackDrive (TD) Series Operating & Safety Instructions TILT ALARM PASS FAIL Machine driven on to excessive slope - drive disabled, siren tone constant Hi drive operation affected Return to level ground – Hi drive restored INTERNAL (POWER PACK) Power pack and all components secure All cables and terminals secure All hose connections secure Hoses not kinked or fouled...

  • Page 42: Safety Related Parts Of The Control System (Srp/Cs)

    TrackDrive (TD) Series Operating & Safety Instructions Appendix A 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 43 TrackDrive (TD) Series Operating & Safety Instructions 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 monitoring of the stabilisers does not function as intended it is possible that the Niftylift may encounter slopes for which it is not rated.
  • Page 44 TrackDrive (TD) Series Operating & Safety Instructions  Check of the equipment correct operation, by simulating a fault condition and correspondent resetting. See “Means for easy and safe trouble shooting”  Check correct operation of the boom switch. Should special maintenance be required please observe the following precautions. ...
  • Page 45 TrackDrive (TD) Series Operating & Safety Instructions 5. In order to verify only the operation of the alarm circuit whilst the booms are elevated, it is possible to again manually depress each jack foot switch plunger in turn by reaching inside the outrigger housing and finding the safety switch.
  • Page 46 TrackDrive (TD) Series Operating & Safety Instructions 4. Clear descriptions of the interfaces to the SRP/CS and protective devices; The monitoring of the booms is primarily the circuit through the booms elevated switch, operated via a cam on Boom 2/3. The initial ‘proving’ circuit that permits the stabilisers to move has to pass through the safety relay module which provides a two channel output for safety.
  • Page 47 TrackDrive (TD) Series Operating & Safety Instructions  Do not touch directly boards, transducers and boxes with flushing or degreaser fluids under pressure.  Do not pierce the board box.  Seal the box and/or the panel which contains the electronic board, to reveal any unauthorized access or tampering.
  • Page 48 TrackDrive (TD) Series Operating & Safety Instructions 5. Repeat steps 1 to 4 for channel 2. Pass criteria – If the jack legs do not operate the system is functioning correctly. Fail criteria – If the jack legs move there is a previously undetected fault with the system and the Niftylift must not be used until this fault has been repaired.
  • Page 49 TrackDrive (TD) Series Operating & Safety Instructions PLATFORM LEVELLING The Platform levelling system is PL c in accordance with ISO 13849-1:2008 as required by BS EN 280:2013+A1 2015. 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 50 TrackDrive (TD) Series Operating & Safety Instructions Operating limits (including environmental conditions); All components within the tilt interlock are rated to the environmental conditions acceptable for the machine; see Section 2.2. Indications and alarms; There are no indicators or alarms to show that the Niftylift levelling system is or is not functioning. Muting and suspension of safety functions;...
  • Page 51 TrackDrive (TD) Series Operating & Safety Instructions INTERLOCKING OF CONTROL POSITIONS The interlocking of the control positions is PL c in accordance with ISO 13849-1:2008 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 physical interlocks between the multiple control positions are controlled through primarily electrical means such that neither position takes sole command unless selected.
  • Page 52 TrackDrive (TD) Series Operating & Safety Instructions 9. Control modes; The standard EU control circuit will permit independent operation of either control position, working through a series Emergency Stop control circuit. In some countries (e.g France and Australia) the alternate control interlock permits the cage system to be isolated by the ground control key switch and will ignore the use of the Cage Emergency Stop.
  • Page 53 TrackDrive (TD) Series Operating & Safety Instructions PREVENT MOVEMENTS OF LOAD HOLDING CYLINDERS IN CASE OF PIPE FAILURE The load holding system is PL c in accordance with ISO 13849-1:2008 as required by BS EN 280:2013+A1 2015. 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 54 TrackDrive (TD) Series Operating & Safety Instructions Operating limits (including environmental conditions); All components within the load holding system are rated to the environmental conditions acceptable for the machine; see Section 2.2. Indications and alarms; There are no indicators or alarms to show that the Niftylift load holding system is or is not functioning. Muting and suspension of safety functions;...

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