PowerPicker Manual
PowerPicker Manual
Operating and
Maintenance Manual
CONTENTS
CONTENTS INTRODUCTION
The PowerPicker (referred to as “the Machine” in this manual) is designed to
Operating Specifications 3 be a simple, safe and efficient powered alternative to traditional platform
(airport type) steps, podium steps or small scaffold towers. Designed to be
Do’s and Don’ts 4 used in retail, warehousing, stores and order picking applications, the machine
provides a safe working platform to working heights of up to 4.4m. Its robust
Primary Components 5 heavy duty construction and innovative operating and safety features, will
provide the operator with many years of reliable, trouble free service.
Platform Access Gates, Manoeuvring and Load Tray Operation 6
The purpose of this manual is to provide essential basic information required
Operating Procedures 7 to operate and maintain the machine.
Emergency Lowering Procedure 8 This is not a workshop manual. Please contact the manufacturer or their
agent for specific operation or maintenance information if in doubt.
Battery Charging 9-11
The health and safety of the operator or maintenance technician is the
Maintenance Procedures 12-15 responsibility of the individual and/or their employer and not
Power Towers Ltd.
Storage 16
It is essential to be familiar with the operating, maintenance and safety
guidelines contained within the manual prior to operating the machine.
Warranty 17
Key Spare Parts 18-22
2
OPERATING SPECIFICATIONS
Working Dimensions
Maximum working height: 4.40 m
Maximum platform height: 2.40 m
Platform dimensions: 0.56 m x 0.65 m 4.0m
Working footprint: 1.28 m x 0.77 m
Closed platform height: 0.35 m
Safe working load: 200 kg, 1 person
Load distribution: 130 kg max. platform + 70 kg max. load tray
Maximum manual force: 200 N
Max. gradient for operation: 0°
Max. wind force: Indoor use 0 mph
Manual push force on level ground: 5-7 kg 3.0m
Maximum total weight Inc payload: 505 kg
Maximum castor point load: 180 kg (1.77 kN)
Max. wheel force: 180 kg (1.77 kN)
Closed Dimensions
Length: 1.28 m
Width: 0.77 m 2.0m
Height: 1.50 m
Weight: 305 kg
3
DO’S and DON’TS
DO’S DON’TS
1. Read and adhere to the instructions both on the machine 1. Never exceed the safe working load 200 kg, 1 person (130 kg maximum on
and in this manual. platform, 70 kg maximum on load tray).
2. Ensure pre-operation checks and operations are carried 2. Never use the machine on sloping or uneven ground.
out in the manner described. 3. Never use the machine as a crane.
3. Use only on hard, level surfaces able to support the weight 4. Never exceed horizontal forces (maximum horizontal force 200 N), and
of the machine (e.g. concrete floor, tiled floor, hard wood floor). never work in a way to create a swaying motion of the platform.
4. Use the machine internally only. 5. Never use in wind.
5. Ensure operator is fit and does not suffer from a fear of heights. 6. Never use in the vicinity of live conductors.
6. Ensure that both castor brakes are applied before operating 7. Never try to move the machine when elevated.
the machine. 8. Never extend the height of the platform by using boxes,
7. Ensure entrance gate is fully closed before elevation. steps, ladders etc.
8. Ensure work area around the machine is cordoned off 9. Never modify the machine in any way without the
from pedestrians and other traffic. full approval of the manufacturer.
9. Ensure operator is wearing the correct safety equipment. 10. Never attempt to enter or exit the platform unless it is
10. Ensure the platform is correctly positioned for the task, so as fully lowered.
not to come into contact with fixed or moving objects. 11. Never operate the machine outside.
11. Ensure that the safe working load is evenly distributed 12. Never use the machine in an explosive environment.
on the platform and load tray. 13. Never use the machine if fatigued.
12. Ensure the machine is switched off when it is left unattended. 14. Never use the machine inappropriately or for “horseplay”.
13. Ensure all parts of your body are within the guard rail when 15. Never use the machine if under the influence of drugs or alcohol.
elevating and lowering. 16. Never use the machine if suffering from poor health or using
medication which might impair the safe operation of
the machine.
17. Never use the machine if vision is impaired by bright lighting.
18. Never push the machine on sloping surfaces without the use
of a safe method.
19. Never push or pull objects with the platform.
4
PRIMARY COMPONENTS
Load Tray
Load Tray
Adjustment Lever
Platform
Control Panel
Keypad
Battery Charger
Battery Condition Lead Socket
Meter (On Rear Panel)
Emergency Stop /
Battery Charger Lights
Battery Isolator
(On Rear Panel)
(On Rear Panel)
Load Deck
5
PLATFORM ACCESS GATES, MANOEUVRING AND LOAD TRAY OPERATION
6
OPERATING PROCEDURES
PRE-OPERATION CHECKS 6. Ensure all parts of the body are within the platform guard rails when raising
1. Ensure that there are no obvious signs of mechanical damage to the or lowering.
handrails, platform, lifting structure or chassis. 7. Press the RAISE button to elevate. Press the LOWER button to descend (Pic D).
2. Release the isolator / emergency stop button at the rear of the chassis 8. In case of uncontrolled platform elevation or descent, depress the red
(Pic A). emergency stop button on the control panel (Pic D) or at the rear of the
3. Press and hold the parking brake button (Pic B) and manoeuvre the chassis (Pic A).
machine. Check castors and wheels rotate freely and are undamaged (Pic C). 9. If the keypad is fitted then the controls for lifting and lowering will remain
Release the parking brake button and check the parking brakes operate active for a period of 5 minutes after the last button press. After this time the
correctly. Check the castor brakes operate correctly. controls will cut-out. Re-enter the security code to re-activate the controls.
4. Ensure the battery is fully charged (at the start of the day) by referring to
the battery condition meter located on the platform control panel (Pic D). The user shall obtain the guidance and approval of the manufacturer in the
5. Check that the platform gates fully close automatically when released. event of any special working methods or conditions which are outside those
6. Step into the platform and use the lift controls on the contol panel (Pic D) to specified by the manufacturer.
raise and lower the machine 500 - 600mm. Check that the gate interlocks
prevent the gates from being opened when the machine is elevated.
7. Check the emergency lowering is functioning correctly (refer to
“Emergency Lowering Operation” on page 8).
8. Conduct a visual inspection of the Suzie cable. Ensure it is undamaged and
there are no kinks or splits. If there are, seek technical help.
9. Check the mast surfaces are clean and not greased.
NORMAL OPERATION
Only use the machine internally, on hard level surfaces. Ensure a person is
available at ground level to assist in case of emergency.
1. Release the isolator / emergency stop button located at the rear of the
chassis (Pic A). The keypad (fitted as an optional extra) located on the
platform control panel will illuminate, along with a red LED on the keypad A B
and the battery charge indicator (Pic D).
2. Depress and hold the parking brake button (Pic B) and manoeuvre the
machine to the desired location. Release the parking brake button to
activate the parking brakes. Press the foot pedals to apply both castor
brakes. Ensure the machine is on level ground. Cordon off the area around
machine in accordance with the operating guidelines. Refer to the working
envelope diagram if necessary.
3. Enter the platform, always using 3 points of contact. Ensure the gate is
fully closed. Enter the security code into the keypad (fitted as an optional
extra). A green LED will illuminate on the keypad.
4. The tilt sensor (fitted as an optional extra) will sound an alarm if the machine
is on uneven ground, and the machine will not elevate. Ensure the machine
is on level ground.
C D
5. Check there are no overhead obstructions.
7
EMERGENCY LOWERING PROCEDURE
8
BATTERY CHARGING
Remove the mains charger lead from the storage tube located at the rear of the
platform tray (B). Plug the charger lead into the socket at the rear of the chassis
(C). The lead is fitted with a 3 pin 230V AC plug.
Ensure the charger lead is in good condition and not split or damaged.
2. The left hand LED will illuminate. If flashing, a fault is indicated. Disconnect
and reconnect to the mains supply. If flashing continues seek technical help.
B
3. The LEDs will illuminate from left to right. When the far right “FULL” LED is
illuminated the charge is complete.
4. Disconnect the lead from the mains supply, then disconnect the lead from
the chassis socket, and place the lead back into the storage tube. Refit the
storage tube cap.
The battery charger can be connected to the mains supply anytime the
machine is not in use and left connected to the mains supply for extended
periods. The battery charger will automatically maintain the battery condition.
Do not operate the machine with the battery charger connected to the
mains supply.
9
BATTERY CHARGING
Remove the mains charger lead from the storage tube located at the rear of the
platform tray (B). Plug the charger lead into the socket at the rear of the chassis
(C). The lead is fitted with a 110V plug.
Ensure the charger lead is in good condition and not split or damaged.
4. Disconnect the lead from the AC supply, then disconnect the lead from the
chassis socket, and place the lead back into the storage tube. Refit the
storage tube cap.
The battery charger can be connected to the mains supply anytime the
machine is not in use and left connected to the mains supply for extended
periods. The battery charger will automatically maintain the battery condition.
Do not operate the machine with the battery charger connected to the
mains supply.
10
BATTERY CHARGING
Remove the mains charger lead from the storage tube located at the rear of the
platform tray (B). Plug the charger lead into the socket at the rear of the chassis
(C). The lead is fitted with a 110V plug.
Ensure the charger lead is in good condition and not split or damaged.
3. The Amber LED indicates the battery is charging. The charge is complete B
when the Amber LED stops flashing and becomes solid.
4. Disconnect the lead from the AC supply, then disconnect the lead from the
chassis socket, and place the lead back into the storage tube. Refit the
storage tube cap.
The battery charger can be connected to the mains supply anytime the
machine is not in use and left connected to the mains supply for extended
periods. The battery charger will automatically maintain the battery condition.
Do not operate the machine with the battery charger connected to the
mains supply.
11
MAINTENANCE PROCEDURES
Please note that whilst the machine is simple to maintain, all work must be
carried out by a competent person.
DAILY MAINTENANCE
See pre-operation checks on page 7.
6 MONTHLY MAINTENANCE
1. Check that the castor fixing bolts are secure.
2. Elevate the platform so that the gate interlocks are clear of the chassis.
3. Switch off the machine by depressing the isolator / emergency stop
button located on the chassis.
4. Release the two cage latches and tilt up the platform. This is assisted by a
gas strut, which should be fully extended until the gas strut is locked in
the centre.
5. Remove the front and rear chassis covers by undoing the 8 x M6 dome Cage latch
head screws to gain access to the front and rear compartments. Gas Strut
Lock
6. In the front compartment, check the powerpack hydraulic oil level and
that all of the hydraulic and electrical connections are tight and secure.
7. In the rear compartment, check the battery electrical connections are
tight and secure and that the top face of the battery is clean. Check the
electrical connections to all of the solenoids are tight and secure.
8. Replace the covers and lower the platform (releasing the gas strut lock
first) and re-lock the cage latches.
9. Switch on the machine by pulling the isolator / emergency stop button on
the chassis.
10. Lower the platform fully so it rests on the buffers on the chassis.
11. Ensure the machine moves freely, and there are no squeaks or rattles
coming from the machine.
12. Check the brakes function correctly. Powerpack
Battery And
Solenoids
12
MAINTENANCE PROCEDURES
Inspect the castors, looking for damage and distortion. Check the securing The mast is raised and lowered with a multistage hydraulic piston, which
bolts are tight and fully engaged. Check the castors swivel and rotate freely. raises the outer mast section first, followed by the middle mast section. When
the mast is lowered, the sections close in the reverse sequence, ie the middle
The rear wheels are hidden behind the side covers and a visual inspection is section and outer section close together until the bottom of the middle
limited, but check that the tyres are not damaged. section contacts the stop on the inner section, and the outer section continues
to close over the middle section. It is essential that the mast closes in this
The wheels and axles are extremely robust and are fitted in such a way that it sequence.
is practically impossible for them to become loose or detached.
The only maintenance required is to ensure that the mast surface is clean from
Check that there are no squeaks or rattles when the machine is pushed grease and debris and that it operates as described above. If not seek technical
around. help. Never grease the mast surface.
TILT SENSOR (FITTED AS AN OPTIONAL EXTRA) When replacing components for any reason, only use OEM specification
If the machine is on uneven ground and is switched on, then the tilt sensor parts, either supplied from the manufacturer or authorised in writing by the
stops the lift function and sounds an alarm. manufacturer. Warranties and design approvals will be void if alternative
components are fitted.
A test of the tilt sensor function can be made by switching the machine on
and tilting the chassis to approximately 1.5 - 2 degrees from level ground It is essential to obtain manufacturer’s approval of any alteration
(20 - 25 mm under the rear wheels). The alarm will sound. which might affect stability, strength or performance in writing before
proceeding.
If the machine is on level ground and the alarm sounds with no lift function,
then seek technical help.
13
MAINTENANCE PROCEDURES
ANNUAL MAINTENANCE
HYDRAULIC OIL
Gain access to the hydraulic reservoir, and use a syphon to replace the
hydraulic oil with a grade 32 biodegradeable hydraulic oil.
Premature machine wear and failure will occur if the oil is not replaced on an
annual basis.
The hydraulic steel pipe connections to the cylinder must not be disconnected
unless by a competent person. If the connection has been disconnected, then
a full pressure test of the system must be conducted, prior to placing the
machine back into service. No leaks must be evident when the pressure test is
conducted.
14
MAINTENANCE PROCEDURES
MAINTENANCE FREQUENCY
The machine must have a thorough (LOLER) examination by a
competent person at six monthly intervals.
Thorough examination must include checking:
All electrical connections, including battery Load tray operation and lock
All hydraulic connections Condition of swivel castors
Cylinder and powerpack Condition of wheel axles and wheels
Handrails are undamaged and secure Condition of battery terminal covers
Platform tray condition Condition of chassis covers
Mechanical condition of lifting structure and chassis Condition of all decals
Operation of gate interlocks Full operation check and load test of platform and load tray
15
STORAGE
STORAGE
If the machine is to be taken out of operation for a period longer than one
month, the following precautions should be taken:
Ideally, the battery charger should be switched on. The charger has an in built
maintenance mode, and will maintain the battery condition indefinitely. If this
is not practical, then the charger should be switched on once a week for half
an hour. This is especially important in cold conditions.
If the storage period is for an undetermined period then it is advisable that the
battery is removed and stored in a secure battery storage container. It is also
advised that all external electrical and hydraulic connections be wax coated to
prevent corrosion.
16
WARRANTY
WARRANTY IMPORTANT
Your PowerPicker (the Machine) is covered by a parts and components Warranty may, at the sole discretion of the Manufacturer, be voided if the
warranty as stated in the purchase terms and conditions (excluding battery scheduled service/inspections are not carried out in accordance with this
and battery charger). manual.
The Manufacturer, Power Towers Ltd (the Company), undertakes to replace or The Manufacturer and/or their recognised agents, directors, employees or
repair, free of charge, any defective part or component which the company insurers will not be held liable for consequential or other damages, losses
considers to be due to faulty workmanship or material, within the warranty or expenses in connection with or by reason of or the inability to use the
period, except for: machine for any purpose.
17
KEY SPARE PARTS
G H I
Notes
J K L
18
KEY SPARE PARTS
D E F
Notes
19
KEY SPARE PARTS
D E F
Notes
20
KEY SPARE PARTS
G H I
Notes
J K L
21
KEY SPARE PARTS
D E F
G H
Notes
22
CIRCUIT DIAGRAM - HYDRAULIC
KEY
1 Reservoir
2 Pressure compensated flow control
3 Directional control valve
4 Check valve
5 Motor pump unit
6 Relief valve
7 2 stage cylinder with flow control
23
CIRCUIT DIAGRAM - ELECTRICAL (BASIC)
24
CIRCUIT DIAGRAM - ELECTRICAL (OPTIONS)
25
TEST RESULTS & NOTES
Description Work Carried Out Date
ALTERATIONS & REPAIRS
Description Work Carried Out Date
POWERPICKER-OP | UK | 07:20