User`s Manual - Northeast Mast Climbers

USER'S MANUAL
MS 5000
MAST CLIMBING WORK PLATFORM
This manual is assigned to:
Issue: 02-2000
9095-050A
© 2000, HEK Manufacturing BV., Middelbeers, The Netherlands
Nothing contained in this publication may be copied, and/or published by means of
printing, photocopying, microfilm or any other method without prior written permission
from HEK Manufacturing B.V.
Drawings are illustrative only and do not necessarily show the design of the product on the market at any
given point of time.
II
MS 5000 • 9095-050A
HEK Manufacturing B.V.
Westelbeersedijk 18
5091 SM Middelbeers
The Netherlands
Tel : +31 13 51 48 653
Fax : +31 13 51 48 630
P.O. box 2
5090 AA Middelbeers
The Netherlands
MS 5000 • 9095-050A
III
IV
MS 5000 • 9095-050A
FOREWORD
FOREWORD
For glazing, masonry or renovation work
at height, the MS 5000 can be matched
to any type of building. Heavy building
components and their installation crews
can be elevated and positioned exactly
with optimum safety and efficiency.
This manual describes the installation,
operation and maintenance of the mast
climbing work platform.
The mast climbing work platform is
provided with a rack and pinion drive.
The mast climbing work platform can be
quickly moved and is easy to transport.
The mast climbing work platform can be
freestanding or anchored.
The mast, which consists of separate
elements, can easily be adjusted in
height to match the height of the building
work. The mast is easy to assemble from
the platform.
The platform can be adjusted with regard
to length and width to the shape of the
façade.
The MS 5000 mast climbing work
platform has a hold to run control system
which makes it possible to stop at any
desired height.
Every care has been taken in the
construction of the mast climbing work
platform to ensure that all safety aspects
have been considered.
Depending on the application area, a
choice can be made from different
platform lengths, platform widths and
permissible loading.
This instruction manual describes only
the basic machine, in the standard
configuration supplied by HEK
Manufacturing BV.
Read this instruction manual carefully before using the
mast climbing work platform. Follow the safety
precautions!
This manual is valid in combination with, as 5 L resp. 5 R,
marked components only (chassis, platform, mast
elements and platform elements).
MS 5000 • 9095-050A
V
CONTENTS
CONTENTS
FOREWORD
V
CONTENTS
VI
SURVEY OF ILLUSTRATIONS
VII
EC DECLARATION OF CONFORMITY FOR
MACHINES
MEANING OF THE SYMBOLS USED
1.
6.
VIII
IX
6-1
6-2
6-3
6-4
6-5
6-7
6-10
6-12
6-13
TECHNICAL DETAILS
1.1 General
1.2 Electrical installation
1.3 Chassis
1.4 Platform construction and
loading diagram
1.4.1 Maximum loading
1.5 Anchor forces
1-6
1-6
1-7
2.
COMPONENT DESCRIPTION
2.1 General description
2-1
2-1
3
SAFETY
3.1 General
3.2 Safety prior to use
3.3 Safety in use
3.4 Safety after use
3.5 Built-in and additional safety
features
3.6 Personnel
3-3
3-3
3-3
3-3
3-4
TRANSPORT
4.1 Repositioning on the building site
4.2 Repositioning with a crane
4-1
4-2
4-3
CONTROL COMPONENTS
5.1 Power supply socket for
the platform
5.2 Single phase outlet
5.3 Platform control box
5-1
A.
5-1
5-1
5-2
CHECKLIST MAST CLIMBING
WORK PLATFORMS
TYPE B
APPENDICE-1
B.
CHECKLIST MAST CLIMBING
WORK PLATFORMS
TYPE C
APPENDICE-5
4
5
VI
1-1
1-1
1-4
1-5
ASSEMBLY AND ANCHORING
6.1 Preparation for assembly
6.2 Ground support
6.3 Positioning the mast climbing
work platform general
6.3.1 Positioning the mast climbing
work platform
6.4 Assembly of the mast
6.5 Anchoring the mast
6.6 Adjusting the platform width
6.7 Lightning protection
3-4
3-5
7.
OPERATION
7.1 General
7.2 Preparation
7.3 Testing
7.4 Brake test
7.5 Operation from the platform
7.6 Operation in an emergency
situation
7-1
7-1
7-1
7-3
7-3
7-4
8.
DISASSEMBLY AND TRANSPORT
8-1
9.
MAINTENANCE
9.1 General
9.2 Maintenance intervals
9.3 The motor brake
9.3.1 Operation
9.3.2 Maintenance
9-1
9-1
9-1
9-4
9-4
9-5
10. MALFUNCTION ANALYSIS
10-1
11. MACHINE DISPOSAL
11-1
12. LIST OF KEYWORDS
12-1
MS 5000 • 9095-050A
7-4
CONTENTS
SURVEY OF ILLUSTRATIONS
Fig.1
Fig.1-1
Fig.1-2
Fig.1-3
Fig.1-4
Fig.1-5
Fig.1-6
Fig.2-1
Fig.4-1
Fig.4-2
Fig.5-1
Fig.5-2
Fig.6-1
Fig.6-2
Fig.6-3
Fig.6-4
Fig.6-5
Fig.6-6
Fig.6-7
Fig.6-8
Fig.6-9
Fig.6-10
Fig.6-11
Fig.6-12
Fig.6-13
Fig.6-14
Fig.6-15
Fig.6-16
Fig.6-17
Fig.6-18
Fig.7-1
Fig.7-2
Fig.7-3
Fig.7-4
Fig.7-5
Fig.8-1
Fig.8-2
Fig.8-3
Fig.9-1
Fig.9-2
Dimensions
Platform components
Mast element
Fence posts
Chassis
Maximum load
Anchor forces
Basic set MS 5000
Transport MS 5000
Locking pin outrigger chassis
Platform power supply socket
Control box
Position machine
Ground support chassis
Distance to the facade
Locking pin outrigger chassis
Lower striker plate
Securing platform elements
Locking pin step
Securing platform posts
and fences
Power supply socket
Main switch
Control buttons
Proximity switch
Mast element with mechanical
end stop
Mast cover
Anchor
Outrigger platform extension
Anchor ramp
Lightning protection
Main switch
Emergency push-button
Brake lever platform
Push-buttons control box
Brake lever platform
Brake lever platform
Locking pin outrigger
Locking pin outrigger chassis
Motorbrake
Motorbrake
X
1-2
1-2
1-2
1-5
1-6
1-7
2-1
4-1
4-2
5-1
5-2
6-1
6-3
6-4
6-5
6-5
6-5
6-6
6-6
6-7
6-7
6-8
6-8
6-9
6-9
6-11
6-13
6-13
6-13
7-2
7-2
7-3
7-4
7-4
8-1
8-2
8-2
9-4
9-6
MS 5000 • 9095-050A
VII
EC DECLARATION OF CONFORMITY
EC declaration of conformity for machines
(pursuant to Annex IIa of the Machine Directives 89/392/EEC)
We,
HEK Manufacturing bv
Westelbeersedijk 18
5091 SM Middelbeers
The Netherlands
hereby declare that, on the basis of its design and construction, the mast climbing work
platform named below and brought into circulation by us conform to the relevant basic
safety and health requirements contained in the EC Machine Directives.
Changes made to the machine without our consent invalidate this declaration.
This declaration applies to the mast climbing work platform:
HEK MS 5000
In accordance with:
EC Machine Directives 89/392/EG, Annex IV,
including 91/368, 93/44
EC number:
08/205/A 16-99/PM07490, 02-06-1999
Certified by (‘Notified Body’):
TÜV HANNOVER/SACHSEN ANHALT E.V.
HANNOVER, GERMANY
Date/Manufacturer’s signature:
Middelbeers, the Netherlands,
November 1st 1999
Signatory:
P.M. Blom, deputy manager
VIII
MS 5000 • 9095-050A
SYMBOLS
MEANING OF THE SYMBOLS USED
WARNING
Failing to (exactly) comply with
the working or operating
instructions may lead to serious
injury, fatal accident, severe
mechanical damage or
operating losses.
During use, no person may
stand under the machine.
Danger: High voltage.
Danger of falling objects.
MS 5000 • 9095-050A
IX
Fig.1
X
Dimensions
MS 5000 • 9095-050A
TECHNICAL DETAILS
1.
TECHNICAL DETAILS
The details in this manual are based on standard applications. In special
situations, it may be possible to deviate from these. This may only be done with
the prior written approval of the supplier.
This manual is valid in combination with, as 5 L resp. 5 R, marked components
only (chassis, platform, mast elements and platform elements).
1.1
General
Description
MS 5000
Platform length (A)
8.5 - 15 m
27.9 - 42.2 ft
Platform width
1.5 - 2.5 m
4.9 - 8.2 ft
Min. platform height
1.25 m
4.1 ft
Distance between mast centres (B)
6.9 m
22.3 ft
Max. anchor distance
6-8m
19.7 - 26.2 ft
Height of first anchor
8m
26.2 ft
Distance between cable guides
6m
19.7 ft
Max. mastheight free-standing (C)
8m
26.2 ft
Max. mastheight anchored (C)
100 m
328 ft
Max. mastheight above last anchor
0m
0 ft
Mast type
DRK500
Max. number of persons
4
Platform speed 50 Hz machine
5.0 m/min
16.4 ft/min
Platform speed 60 Hz machine
5.2 m/min
17.1 ft/min
Loading capacity
see section 1.4
Noise level
< 70 dB
Maximum wind-force during erection
12,5 m/s (6 Beaufort)
41 ft/s (6 Beaufort)
Maximum wind-force during use freestanding
12,5 m/s (6 Beaufort)
41 ft/s (6 Beaufort)
Maximum wind-force during use anchored
15,7 m/s (7 Beaufort)
51.5 ft/s (7 Beaufort)
MS 5000 • 9095-050A
1-1
TECHNICAL DETAILS
Fig.1-1
Platform components
Fig.1-2
Mast element
1-2
Fig.1-3
Fence posts
MS 5000 • 9095-050A
TECHNICAL DETAILS
Part
weight
l x b x h [mm]
[kg]
Basic machine 8.5 m
8500 x 2350 x 1920
incl. chassis & fences
No. of bolt dim. & torque
other
bolts
quality
[Nm]
Max. platform
extension façade
side 1000 mm
4500
---
---
---
86
4
M16 x 150
qual. 8.8
150
Platform element 150 1500 x 1500 x 500
198
---
---
---
Max. platform
extension façade
side 1000 mm
Platform element 175 1750 x 1500 x 500
205
---
---
---
Max. platform
extension façade
side 1000 mm
Plug-in fence 150
1425 x 30 x 1080
16.2
---
---
---
---
Plug-in fence 175
1605 x 30 x 1080
18.2
---
---
---
---
End fence
3000 x 30 x 1080
32.0
---
---
---
---
Gate
1605 x 30 x 1080
17.1
---
---
---
---
Lengthwise post
1195 x 45 x 120
3.2
---
---
---
---
Gate side post
1210 x 110 x 120
3.4
---
---
---
---
End side post
1245 x 118 x 100
4.0
---
---
---
---
Part
l x b x h [in]
Mast element 150
1508 x 570 x 565
weight
[lb]
Module 8
No. of bolt dim. & torque
other
bolts
quality
[lb ft]
Max. platform
extension façade
side 39.4 inch
Basic machine 27.9 ft
334.6 x 92.5 x 75.6
incl. chassis & fences
9900
---
---
---
Mast element 150
59.4 x 22.4 x 22.2
189
4
M16 x 5.9
in qual. 8.8
111
Platform element 150 59.1 x 59.1 x 19.7
436
---
---
---
Max. platform
extension façade
side 39.4 inch
Platform element 175 68.9 x 59.1 x 19.7
451
---
---
---
Max. platform
extension façade
side 39.4 inch
Plug-in fence 150
56.1 x 1.2 x 42.5
35.6
---
---
---
---
Plug-in fence 175
63.2 x 1.2 x 42.5
40.0
---
---
---
---
End fence
118.1 x 1.2 x 42.5
70.4
---
---
---
---
Gate
63.2 x 1.2 x 42.5
37.6
---
---
---
---
Lengthwise post
47.0 x 1.8 x 4.7
7.0
---
---
---
---
Gate side post
47.6 x 4.3 x 4.7
7.5
---
---
---
---
End side post
49.0 x 4.6 x 3.9
8.8
---
---
---
---
Meaning of the letters page 2-1:
A = Platform element 150
B = Platform element 175
C = Plug-in fence 175
D = Plug-in fence 150
E
F
G
H
=
=
=
=
End fence
Gate
Lengthwise post
Gate side post
MS 5000 • 9095-050A
Module 8
I = End side post
J = Mast element 150
1-3
TECHNICAL DETAILS
1.2 Electrical installation
Platform type
MS5000
220V - 60 Hz
MS5000
220V - 50 Hz
MS5000
400V - 50 Hz
Supply voltage
208 - 240 V
208 - 240 V
380 - 420 V
2
2
2
2 x 4 kW
2 x 4 kW
2 x 4 kW
Maximum starting current
240 A
240 A
100 A
Nominal current
35 A
35 A
20 A
Nominal power consumption
16 kVA
16 kVA
16 kVA
Phases
3 + Pe
3 + Pe
3 + N + Pe
63 A
63 A
32 A
42 Vac
42 Vac
42 Vac
up to 40m /
131 ft
4 x 25 mm² / 4 x 0.039 in²
4 x 25 mm² / 4 x 0.039 in²
5 x 10 mm² / 5 x 0.016 in²
up to 60m /
197 ft
4 x 35 mm² / 4 x 0.054 in²
4 x 35 mm² / 4 x 0.054 in²
5 x 16 mm² / 5 x 0.025 in²
up to 90m /
295 ft
4 x 50 mm² / 4 x 0.078 in²
4 x 50 mm² / 4 x 0.078 in²
5 x 25 mm² / 5 x 0.039 in²
Power supply
cable,
up to 40m /
131 ft
4 x 16 mm² / 4 x 0.025 in²
4 x 16 mm² / 4 x 0.025 in²
----------
V > 230 Vac
(building site
to machine)
up to 60m /
197 ft
4 x 25 mm² / 4 x 0.039 in² 4 x 25 mm² / 4 x 0.039 in²
----------
up to 90m /
295 ft
4 x 35 mm² / 4 x 0.054 in²
4 x 35 mm² / 4 x 0.054 in²
----------
up to 60m /
197 ft
4 x 10 mm² / 4 x 0.016 in²
(0.90 kg/m / 0.60 lb/ft)
4 x 10 mm²/ 4 x 0.016 in²
(0.90 kg/m / 0.60 lb/ft)
5 x 6 mm² / 5 x 0.010 in²
(0.64 kg/m / 0.43 lb/ft)
up to 100m
/ 329ft
4 x 16 mm² / 4 x 0.025 in²
(1.25 kg/m / 0.84 lb/ft)
4 x 16 mm² / 4 x 0.025 in²
(1.25 kg/m / 0.84 lb/ft)
5 x 6 mm² / 5 x 0.010 in²
(0.64 kg/m / 0.43 lb/ft)
up to 150m
/ 492 ft
----------
----------
5 x 10 mm² / 5 x 0.016 in²
(1.11 kg/m / 0.74 lb/ft)
up to 60m /
197 ft
4 x 6 mm² / 4 x 0.010 in²
(0.51 kg/m / 0.34 lb/ft)
4 x 6 mm² / 4 x 0.010 in²
(0.51 kg/m / 0.34 lb/ft)
----------
up to 100m
/ 329ft
4 x 10 mm² / 4 x 0.016 in²
(0.90 kg/m / 0.60 lb/ft)
4 x 10 mm² / 4 x 0.016 in²
(0.90 kg/m / 0.60 lb/ft)
----------
up to 150m
/ 492 ft
4 x 16 mm² / 4 x 0.025 in²
(1.25 kg/m / 0.84 lb/ft)
4 x 16 mm² / 4 x 0.025 in²
(1.25 kg/m / 0.84 lb/ft)
----------
120 V / 16 A
230 V / 16 A
230 V / 16 A
Number of motors
Rated power
Fuse at building site (slow)
Control voltage
Power supply
cable, under
all conditions
(building site
to machine)
Machine
cable, under
all conditions
Machine
cable,
V > 230 Vac
Single phase outlet
1-4
MS 5000 • 9095-050A
TECHNICAL DETAILS
1.3 Chassis
Dimension A
6880 mm
270.9 in
Dimension B
5630 mm
221.7 in
Dimension C
6878 mm
270.8 in
Dimension D
1710 mm
67.3 in
Dimension E
2320 mm
91.3 in
Dimension F
2040 - 2810 mm
80.3 - 110.6 in
Dimension G
668 - 968 mm
26.3 - 38.1 in
Dimension H
490 - 605 mm
19.3 - 23.8 in
1480 kg
3256 lb
5 bar
72 psi
Weight
Tyre pressure
Fig.1-4
Chassis
MS 5000 • 9095-050A
1-5
TECHNICAL DETAILS
1.4 Platform construction and
loading diagram
On any platform element, no more than one platform element of 150 and one
platform element of 175 may be attached. The permitted loading situations is
described in sections 1.4.1
The payload must be equal distributed on the platform.
1.4.1 Maximum loading
Fig.1-5
1-6
Maximum load
MS 5000 • 9095-050A
TECHNICAL DETAILS
1.5 Anchor forces
Torque scaffold coupling: 50 Nm / 36.9 lb ft.
The anchor forces are given on page 1.8.
A = Distance mast to facade < 1 m / 3.3 ft
B = Distance between the anchor points on the facade
F1 = Anchor force to its fixation at the facade (perpendicular)
F2 = Anchor force to its fixation at the facade (parallel)
Fig.1-6
Anchor forces
MS 5000 • 9095-050A
1-7
TECHNICAL DETAILS
Ratio A/B*
0.5
Mastheight above
last anchor = 0m
Mastheight above
last anchor = 1/2
anchor distance
1
2
3
F1
[kN]
F2
[kN]
F1
[kN]
F2
[kN]
F1
[kN]
F2
[kN]
F1
[kN]
F2
[kN]
anchor distance = 6 m
6.1
6.1
7.1
3.6
9.2
2.3
12.2
2.0
anchor distance = 8 m
5.9
5.9
7.9
4.0
11.9
3.0
15.9
2.7
anchor distance = 6 m
7.2
7.2
8.7
4.3
11.8
2.9
14.9
2.5
anchor distance = 8 m
6.7
6.7
8.8
4.4
13.3
3.3
17.9
3.0
* Ratios may be linear interpolated.
Ratio A/B*
0.5
F1
[lbf]
1
F2
[lbf]
F1
[lbf]
2
3
F2
[lbf]
F1
[lbf]
F2
[lbf]
F1
[lbf]
F2
[lbf]
anchor distance = 19.7 ft 1375 1375 1600
810
2070
520
2745
450
anchor distance = 26.2 ft 1330 1330 1780
900
2680
675
3580
610
anchor distance = 19.7 ft 1620 1620 1960
970
2655
655
2255
565
anchor distance = 26.2 ft 1510 1510 1980
990
2995
745
4030
675
Mastheight above
last anchor = 0m
Mastheight above
last anchor = 1/2
anchor distance
* Ratios may be linear interpolated.
1-8
MS 5000 • 9095-050A
COMPONENTS
2.
COMPONENT DESCRIPTION
2.1
General description
The basic set of the mast climbing work
platform with rack and pinion drive consists
of the following 5 main parts:
*
*
*
*
*
drive
masts
platform fences
chassis
control system
The platform moves along the mast with
the aid of Nylontron rollers.
The motors are fitted with centrifugal
brakes which retard the platform if the
speed of descent is exceeded.
The platform is driven up and down the
mast by means of two electric motors
acting through a differential gearbox, each
motor having two pinions. The parallel
movement of the platform is controlled
automatically.
Much consideration has been given to
simple and safe assembly and
disassembly.
A crane on the platform (option) ensures
that the mast elements can be positioned
quickly and safely.
The platform can be adjusted to suit the
required working situation with the use of
separate platform elements. The width of
the platform can be adjusted by means of
outriggers.
Fig.2-1
Basic set MS 5000
MS 5000 • 9095-050A
2-1
COMPONENTS
All electrical connections, which must be
disconnected for transport purposes, are
be made by means of connectors.
The electrical installation is mounted inside
the control box on the platform.
The simple construction ensures that only a
minimum of maintenance is required.
The mast elements, the chassis, the
platform and various other components are
protected from corrosion by means of
galvanization or another appropriate
surface treatment.
2-2
MS 5000 • 9095-050A
SAFETY
3
SAFETY
During use, no person should
stand under the machine.
3.1 General
No changes or modifications
may be made to the machine.
The ground surface must be
stable to support the weight of
the machine and the mast.
The mast must ALWAYS be
anchored in accordance with
the instructions.
If during assembly and
disassembly, the fences do not
provide sufficient protection,
suitable safety harness must be
used at heights above 2 metres.
3.2 Safety prior to use
- The chassis must be effectively
supported.
- The working area around the machine
must be free from obstacles.
- The machine must be securely
anchored at the specified intervals.
3.3 Safety in use
At wind speeds above 12.5 m/s
(41 ft/s, 6 Beaufort) by a
freestanding machine or
15.7 m/s (51.5 ft/s, 7 Beaufort)
by an anchored machine, the
machine must not be used and
the platform must be set in the
lowest position.
While a mast element is being
mounted, an anchor is being
fitted or while maintenance
activities are being carried out,
the emergency stop must be
active.
Material must never extend
beyond the outer limits of the
platform. Items which may roll
must be properly secured.
Materials must never be
stacked against the fencing.
If work must be carried on close
to high voltage cables, a
minimum safety distance of
15 m (49.2 ft) must be
maintained.
When materials and/or tools
with a large surface area will be
used contact your mast
climbing work platform supplier
in connection with wind
sensitivity.
When electrical storms are
expected, work on the platform
must be stopped in time to
avoid the danger of lightening
strikes. The power supply must
be switched off and the
connector withdrawn from the
supply socket.
There must be no obstructions
in the path of the machine.
MS 5000 • 9095-050A
3-1
SAFETY
- If the machine is to be used during the
hours of darkness, the area must be
adequately lit, so that the user has a
good view in all conditions. A minimum
brightness of 50 lux at control box
height is required.
- The working area must be kept free
from obstacles (building materials, dirt,
snow, etc.).
- The machine may only be used for the
purpose for which it was designed, that
is, the vertical transportation of
persons and materials with a
maximum weight within the design
limits of the particular construction.
- Loads (materials, persons, etc.) must
be distributed in accordance with the
loading diagram.
- Inspection and maintenance must be
carried out as given in this instruction
manual.
- During assembly and maintenance,
the mast climbing work platform may
not be used for other purposes.
- Local safety laws and regulations must
always be followed.
- Fences must never be removed during
normal use.
- The platform must only be entered
from one parking position only. The
same rule applies to leaving the
platform.
- Keep hatches in the base of the
platform clear. From the platform it
must be possible to get to the
emergency descent controls via the
hatches.
- In order to ensure that no person
unintentionally walks under the
platform and to protect persons
against falling objects, the mast
climbing work platform must be
surrounded with suitable fencing and/
or a marking wire. The marking must
be placed at a distance of at least
0,5 m (19.7 inch) from the mast
climbing work platform.
3-2
- Platform extensions on outriggers may
only be used to carry personnel. Such
personnel may only stand on these
extensions when the machine is
stationary.
- It is not allowed to climb into the mast
of the mast climbing work platform.
- If erecting two adjacent platforms there
must be a clear gap between the ends
of the platforms of at least 0,5 meter
(17.5 inch).
3.4 Safety after use
- Transport on public roads must only be
done with a truck intended for the
purpose.
- The platform must be placed in its
parking position and the main switch
must be secured with a padlock to
avoid unauthorised use.
3.5 Built-in and additional safety
features
The MS 5000 mast climbing work
platform is provided with the following inbuilt and additional safety features:
- Phase control relay in the control box.
Controls the phase sequence of the
power supply.
- Emergency stop push button on the
control box. When this button is
pressed the platform is locked.
- Electrical access protection. When the
access gate is open the platform is
locked.
- Centrifugal brakes ensure a controlled
descent in the event of an emergency.
- In the event of a power failure the
motor brakes are operated
automatically to prevent the platform
from descending unexpectedly.
MS 5000 • 9095-050A
SAFETY
- In the event of a power failure it is
possible for the platform to make an
emergency descent by manually
releasing the motor brakes.
- Audio Visual Warning. During descent
of the platform, a buzzer will sound
and a light will flash underneath the
platform.
- If the TOP limit switch fails to operate,
so that the mast climbing work
platform continues to rise, an
additional emergency limit switch is
operated.
- If the LOWER limit switch fails to
operate, so that the mast climbing
work platform continues to descend,
an additional emergency limit switch is
operated.
- If the TOP limit switch and the
emergency limit switch fail and also
the red topmast is not mounted, so
that the mast climbing work platform
continuous to rise, the drive unit will
rest on the safety hooks.
- Two proximity switches are mounted
on the platform to prevent the platform
rising above the mast during assembly.
3.6 Personnel
- Operations on the mast climbing work
platform may only be carried out by
persons who have reached the age of
18 years.
- Operations on the mast climbing work
platform may only be carried out by
persons who have the approval of the
owner or the responsible person.
- Operations on the mast climbing work
platform may only be carried out by
persons with adequate knowledge and
qualifications to do so.
- The competence and sense of
responsibility of the operator or
engineer are essential to the efficient
and safe use of the platform.
- Technical personnel must be instructed
and be familiar with this manual.
- Technical personnel must be in a
position to deal with any difficulty
encountered in every possible situation
during assembly and disassembly. The
operating personnel must be familiar
with those situations which can occur
during use.
- There must always be two persons
present on the platform during use.
This is required in case it is necessary
to make an emergency descent.
- If operating or technical personnel
report errors or dangers or are not
aware of the safety regulations, the
owner or the person responsible must
be informed immediately.
- Work on the electrical systems may
only be carried out by a qualified
electrician.
- Personnel protective equipment such
as a hard hat, safety shoes, tight-fitting
clothes must be used.
MS 5000 • 9095-050A
3-3
SAFETY
3-4
MS 5000 • 9095-050A
TRANSPORT
4
TRANSPORT
Transportation on the chassis
over the public roads is not
permitted.
The national valid traffic
regulations must be observed.
Because of its limited dimensions, the
basic implementation of the machine can
be transported with a normal lorry.
Ensure that, during transport, all securing
devices are properly fitted and that the
machine is lowered onto the buffers.
Disassemble the machine before
transporting it as described in chapter 8.
For the transport dimensions, see
chapter 1.
Fig.4-1
For transport, all fences, steps and mast
protection must be removed. These
components may be lashed firmly to the
platform.
For transportation, secure the machine
carefully onto the loading platform of the
transport vehicle.
The machine can be loaded and
unloaded from the transport vehicle using
a crane mounted on the vehicle, a crane
on the building site or a fork-lift truck. See
figure 4-1 for loading and unloading
points.
Set the machine down carefully to avoid
damage.
See figure 4-1
A lifting point.
B Support points for the fork of a fork-lift
truck (under the platform, with the
forks placed as far apart as possible).
Transport MS 5000
MS 5000 • 9095-050A
4-1
TRANSPORT
4.1 Repositioning on the building site
Ensure that trees, power cables
etc., cannot be touched.
During movement there may be
no load on the platform.
Once on the building site, the mast
climbing work platform can be moved in
the lowest position on its chassis.
The plug of the power supply must be
removed.
On a hard flat horizontal surface and
when there is no wind, the mast may
have a maximum height of 8 m / 26.3 ft
during repositioning. The platform must
be on the buffers. The legs must be set
out and secured. The jack must be
screwed out until they are just clear the
ground.
When the circumstances are
unfavourable than the above mentioned
circumstances, contact your supplier.
The chassis can be moved behind a
vehicle.
Fig.4-2
Locking pin outrigger chassis
The maximum speed at which the
chassis may be towed behind a vehicle is
30 m/min / 98.4 ft/min.
4-2
MS 5000 • 9095-050A
TRANSPORT
4.2 Repositioning with a crane
During movement there may be
no load on the platform.
At the building site the mast climbing
work platform can be repositioned with a
crane under the following circumstances.
A maximum of 4 mast elements may be
mounted on the chassis or the ground
frame. The eye hooks of the crane can
be attached to lifting points of the
chassis.
The total transport weight can be
calculated on the undermentioned way.
No. of basic machines
No. of platform elements 150
No. of platform elements 175
No. of mast elements 150
No. of plug-in fences 150
No. of plug-in fences 175
No. of end fences
No. of gates
No. of lengthwise posts
No. of gate side posts
No. of end fence posts
x 4500 kg / 9713.0 lb =
x 198 kg / 435.6 lb =
x 205 kg / 451.0 lb =
x 86 kg / 189.2 lb
=
x 16.2 kg / 35.6 lb
=
x 18.2 kg / 40.0 lb
=
x 32 kg / 70.4 lb
=
x 17.1 kg / 37.6 lb
=
x 3.2 kg / 7.0 lb
=
x 3.4 kg / 7.5 lb
=
x 4.0 kg / 8.8 lb
=
+
Total transport weight
=
MS 5000 • 9095-050A
kg / lb
4-3
TRANSPORT
4-4
MS 5000 • 9095-050A
CONTROL COMPONENTS
5
CONTROL COMPONENTS
5.1
Power supply socket for the
platform
The power supply cable for the electrical
supply between the building site
connection and the mast climbing work
platform must be connected to the socket.
The connection socket is positioned in the
centre of the platform. See chapter 1 for
the cable specifications.
5.2
Single phase outlet
On the machine a single phase outlet is
fitted. This outlet can be used for electrical
tools, lightning etc.
Fig.5-1
Platform power supply socket
MS 5000 • 9095-050A
5-1
CONTROL COMPONENTS
5.3 Platform control box
The door of the control box is secured with
two quick-release fasteners.
The control box is provided with the
following control components:
1. Main switch.
This switch is used for activating power
supply. This switch may not be used for
stopping the machine.
The main switch shall be secured with a
padlock to prevent unauthorized use of
the platform.
2. Info panel.
This information panel consists of a
display on which error codes appear, if
an error is detected.
Fig.5-2
Control box
3. Push button UP.
When this push button is pressed, the
platform rises.
4. Blue control light.
This light will illuminate when the electric
safety circuit (gates etc.) is closed.
5. Push button DOWN.
When this push button is pressed, the
platform descends.
6. Emergency push-button.
If this push button is depressed, the
lifting platform is “locked” in position.
When the Emergency push-button is
pressed it is locked in the depressed
position. It can be unlocked by rotating
it.
5-2
MS 5000 • 9095-050A
CONTROL COMPONENTS
7. Keyswitch buffer.
In position 1 the platform can be raised
out of the buffer
8. Horn.
When this button is pressed a horn will
sound.
The following components are mounted in
the control box:
- the main switch
- the safety relay
- the control relay
- the transformer
- the automatic fuses
MS 5000 • 9095-050A
5-3
CONTROL COMPONENTS
5-4
MS 5000 • 9095-050A
ASSEMBLY AND ANCHORING
6.
ASSEMBLY AND ANCHORING
This chapter describes the assembling and anchoring of the mast climbing work
platform. The definition of left and right in relation to positioning is the following:
Left-hand: Viewed from the step side, the machine is fitted to the left-hand side.
Right-hand: Viewed from the step side, the machine is fitted to the right-hand side.
Fig.6-1
Position machine
If assembly work must be interrupted, this must be done in such a way that,
when the work is restarted it is clear what stage had been reached when work
was stopped. For this reason always complete a part of the assembly, for
example, assemble collect or secure all the components for a connection,
complete a ground support or completely assemble an anchor before stopping
work.
Only components marked, as 5 L resp. 5 R, may be mounted (chassis,
platform, mast elements and platform elements).
While the mast is being erected, no more than two persons may be on the platform, so
that no more than 75% of the lifting capacity is used.
The assembly must always be followed by a test run, as described in section 7.3. Until
the test has been performed, the platform may not be used for any purpose other than
transporting its own mast elements and anchoring components.
The loading of the mast climbing work platform must be planned so that when an
anchor must be fitted (the maximum distance between anchors is reached), the material
load on the platform is a minimum.
MS 5000 • 9095-050A
6-1
ASSEMBLY AND ANCHORING
6.1 Preparation for assembly
Ensure that the site where the
mast climbing work platform will
be assembled accords with the
national requirements and that
permission has been obtained
from the relevant authorities for
the assembly.
- Ensure that a suitable power supply,
good lighting, lifting equipment and
tools are available.
- Ensure that the building site is easily
accessible to the vehicle which will
deliver the mast climbing work
platform.
- Prepare the site with suitable support
and anchoring facilities.
- Ensure that the position where the
mast climbing work platform will stand
has good drainage.
- Plan the positioning of the mast
climbing work platform so that where
the mast needs to be anchored, it can
be so anchored with the standard
material.
- The components of the mast climbing
work platform mast should be placed
as close as possible to the place
where it will be assembled.
- The electrical power supply connection
must be placed as close to the mast
climbing work platform as possible so
as to reduce the voltage drop to a
minimum. If the voltage reduction is
too great the machine may not function
correctly.
6-2
MS 5000 • 9095-050A
ASSEMBLY AND ANCHORING
6.2 Ground support
The machine must always have
a support underneath the jacks.
The ground support and the soil must
meet the following requirements:
- Ensure that the forces are spread
over as large an area as possible.
- The soil must be able to withstand a
ground pressure of at least
2 kg/cm² / 30 lb/in². If this
requirement is not met, soil
improvement must be carried out such
that the ground satisfies this minimum
requirement.
- The ground support must be flat and
centrally loaded with a minimum
ground support of 400x400 mm
/ 15.7 x 15.7 in. See fig. 6-2.
- The ground support must be able to
withstand a pressure of at least
20 kg/cm² / 300 lb/in².
- The platform must be supported with
suitable ground support placed under
the extended outriggers on the chassis
(see fig.6-2). If the height of the mast
exceeds 20 metres / 65.6 ft, ground
support must also be placed under the
mast.
Fig.6-2
Ground support chassis
- The ground support must be durable
and of such a quality that the load can
be transferred without plastic
deformation.
- If the machine is installed on a
concrete foundation or on a hard road
surface, the installation must be
provided with wooden packing to
prevent slipping.
MS 5000 • 9095-050A
6-3
ASSEMBLY AND ANCHORING
6.3 Positioning the mast climbing
work platform general
A fence (height 1.10 m / 43.3 in)
completely surrounding the
platform is compulsory. If the
distance between the platform
and the facade is 0.3 m - 0.5 m
(11.8 in - 19.7) in a fence with a
height of 0.7 m (27.6 in) can be
used. If the distance between
the platform and the facade is
less than 0.3 m (11.8 in) a fence
is not compulsory but in this
case a kick board with an height
of 0,15m (5.9 in) must be fitted.
Wheels of the chassis should
not have a bearing function
while assembly and operating
the platform.
Distance to the facade with standard
anchoring.
A = 726 - 916 mm (28.6 - 36.1 in)
B = 526 - 716 mm (20.7 - 28.2 in)
C = 200 mm (7.9 in)
There are two ways in which the mast
climbing work platform can be placed:
Fig.6-3
Distance to the facade
- freestanding on chassis
- anchored on chassis
6-4
MS 5000 • 9095-050A
ASSEMBLY AND ANCHORING
6.3.1 Positioning the mast climbing
work platform
1.
Position the chassis parallel to the
wall.
2.
When the construction is to be freestanding, the outriggers must be
fully extended and secured in
position. For an anchored
construction, it is possible to leave
the outriggers in the retracted
position. In this situation the
outriggers must be properly secured
and the first anchor must be placed
at a height of four metres.
3.
Place the ground supports.
4.
Unscrew the jacks until the wheels
no longer contact the ground and
adjust the machine to level. The
measurement must be done on two
sides of the mast with a spirit level
with a minimum length of 1 meter
(40 inch).
5.
Check that the lower striker plate is
mounted. See fig.6-5.
6.
Assemble the platform components
sequentially on both sides until the
desired length is attained. The
platform may not exceed the
maximum length.
7.
Secure the platform pins by means
of "hairpins". See fig.6-6.
8.
Adjust the platform elements so that
they are horizontal with the aid of
the adjusting bolts on the underside
of the platform.
9.
Fig.6-4
Locking pin outrigger chassis
Fig.6-5
Lower striker plate
Fig.6-6
Securing platform elements
The width of the platform can be
adjusted to fit the form of the
façade. See section 6.6.
MS 5000 • 9095-050A
6-5
ASSEMBLY AND ANCHORING
10. Mount the steps and secure them
with locking pins. See fig.6-7.
11.
Mount the platform posts on the
upper side of the platform and
secure them with "hairpins".
12. Mount the posts for the gate on the
longer side of the platform and
secure them with "hairpins".
13. Mount the platform posts on the
longer side of the platform and
secure them with "hairpins".
14. Mount the fencing and secure it with
"hairpins".
15. Mount the gate and check that the
gate safety switch is present on the
underside of the platform.
6-6
Fig.6-7
Locking pin step
Fig.6-8
Securing platform posts and fences
MS 5000 • 9095-050A
ASSEMBLY AND ANCHORING
6.4 Assembly of the mast
If work has to be stopped,
always complete the phase
being worked on. Tighten all the
bolts used for the last
attachment and switch off and
secure the main switch so that
the machine cannot be
operated.
As the assembly proceeds,
place the anchor tubes and
anchors as described in section
6.5
Note that the power supply of
the building site is
corresponding with the electric
design of the machine.
The masts must always be
assembled vertically.
In winds of strengths above
6 Beaufort (12,5 m/s) (41 ft/s)
the machine may not be
assembled.
While a mast element is being
mounted, the emergency stop
switch must be activated.
1.
2.
Connect the power supply to the
machine. The power supply
connection is in the centre of the
platform.
Fig.6-9
Power supply socket
Set the main switch in position I or II
(the position depends on the
direction of phase rotation of the
power supply). If the display shows
code 02 set the main switch in the
other position. The display must
show code 00 and the phase light
will be burning.
Fig.6-10 Main switch
MS 5000 • 9095-050A
6-7
ASSEMBLY AND ANCHORING
3.
When the mast climbing work
platform is delivered it is in the
buffer. In order to remove the mobile
work platform out of the buffer, carry
out the following procedure:
1. Press the push-button "reset
positioning" (fig.6-11, A) and keep
it pushed in.
2. Press the push-button "UP"
(fig.6-11, B).
A
4.
5.
The mast climbing work platform is
raised and lowered by pressing the
UP and DOWN push buttons. When
the push-button is released, the
mast climbing work platform stops.
In addition, an emergency stop
push-button is provided. When this
button is pushed, the power of the
motors will be shut off.
Check that the proximity switch is
mounted. See fig.6-12.
6.
Load the platform with mast
elements. Using a fork-lift truck or
crane if neccesasary. Ensure that
the maximum loading permitted
during assembly is not exceeded.
7.
Stand on the platform and place a
mast element on the last element
assembled using the crane if
required. Secure the mast element
with four bolts, washers and nuts.
Tighten the bolts with a torque
wrench to the specified torque (See
chapter 1).
If a crane is available on the
building site, the mast can be more
quickly assembled. Up to four mast
elements can be assembled on the
ground and then raised into position
with the crane.
6-8
B
Fig.6-11 Control buttons
Fig.6-12 Proximity switch
MS 5000 • 9095-050A
ASSEMBLY AND ANCHORING
8.
Mount the first anchor. See section
6.5.
9.
Raise the platform towards the top
of the mast element and repeat the
procedure until another element
must be assembled. Plan the
procedure so that, when an anchor
must be fitted, the loading of
material and mast elements is a
minimum.
Ensure that anchors are placed
at the specified intervals.
10. Repeat this working method until
the mast has reached the required
height. Finally, the mechanical end
stop must be attached to the lefthand mast. The maximum specified
height must not be exceeded.
11.
Mount the mechanical endstop on
the mast.
12. The mast must not extend too far
above the uppermost anchor (See
chapter 1). To achieve good stability,
it is always better to place an
anchor as close to the top of the
mast as possible.
Fig.6-13 Mast element with mechanical end stop
13. Assemble the mast guards from the
platform and secure them.
14. The assembly is now complete. The
assembly must now be tested as
described in section 7.2 and 7.3.
Fig.6-14 Mast cover
MS 5000 • 9095-050A
6-9
ASSEMBLY AND ANCHORING
6.5 Anchoring the mast
If work must be stopped, always
complete the current phase
before stopping. Tighten all the
bolts for the latest fixture and
secure the main switch so that
the mast climbing work platform
cannot be operated.
Before starting to fix any
anchors, ensure that the
chassis is level.
The wall must be of such a
quality that it can accept the
forces applied to it via the
anchors.
The platform extensions and
the anchors must not come into
contact during raising and
lowering.
While a mast element is being
mounted, the emergency stop
switch must be activated.
The anchor forces must be
approved by the owner or the
person responsible for the
building to which the machine
will be anchored.
1.
Check that each mast is vertical
with a spirit level at least one metre
long. Recheck as each anchor is
secured.
2.
The mast must be anchored to the
building at the distances specified in
chapter 1.
3.
The anchors consist of horizontal
anchor tubes with a stretcher
arrangement, mast couplings and a
wall plate.
6-10
MS 5000 • 9095-050A
ASSEMBLY AND ANCHORING
4.
Fixing the anchors:
- If conditions make it necessary,
use may be made of other
approved attachment materials
which are suitable for the forces
present. (Consult your dealer).
- Cemented-in anchors must be
allowed to become fully secure
(the cement must have time to
harden) before the mast climbing
work platform is assembled. The
cement or concrete used must be
in accord with the specifications.
- If chemical anchors or expansion
bolts are used, these must be
approved and must be able to
withstand the forces involved.
- Specifications for these types of
bolts are available from the
supplier. Permission to use them
must be obtained from the local
authorities.
5.
Securing an anchor:
- Attach the coupling to the mast
(1). Do not tighten it fully yet.
- Attach the wall plate (2) to the
building.
- Secure the horizontal anchor
tubes with stretcher arrangement
(3) between the coupling on the
mast and the wall plate.
- Tighten the bolts securing the
coupling to the mast and all the
remaining bolts on the anchor
with the correct torque loading.
- Adjust the stretchers so that the
mast is vertical and equidistant
from the building.
- Tighten the locking nuts (4) on
the stretcher arrangement.
Fig.6-15 Anchor
MS 5000 • 9095-050A
6-11
ASSEMBLY AND ANCHORING
6.6 Adjusting the platform width
The width of the platform can be adjusted
to the shape of the building. As standard
an extension of 1 metre is possible. In
addition, there is a possibility to position
the extension 46 cm (18.1 in) lower.
Adaptor tubes must then be mounted at
the height of the motors and the mast.
In case work must carry out behind the
mast an anchor ramp must be mounted.
The planks used for adjusting
the platform must in every case
be secured in every direction.
The platform widening and the
mast anchors must not come
into contact when the platform
is raised and lowered.
A fence (height 1.10 m / 43.3 in)
completely surrounding the
platform is compulsory. If the
distance between the platform
and the facade is 0.3 m - 0.5 m
(11.8 in - 19.7 in) a fence with a
height of 0.7 m (27.6 in) can be
used. If the distance between
the platform and the facade is
less than 0.3 m (11.8 in) a fence
is not compulsory but in this
case a kick board with an height
of 0,15m (5.9 in) must be fitted.
6-12
MS 5000 • 9095-050A
ASSEMBLY AND ANCHORING
The platform extension must be
fabricated from a non-slip, easily cleaned
material. The extension must be self
draining.
The width of any openings or gaps in the
floor must be sufficiently narrow that a
ball with a diameter of 15mm / 0.6 in will
not pass through.
The platform extension must be able to
withstand a static load of 200kg (440 lb)
on an square area of 0,1x0,1m
(0.4x0.4 in) on the least favourable part
of the floor surface without causing any
permanent distortion.
Fig.6-16 Outrigger platform extension
1.
Pull out the outriggers to the
required height and secure them
with locking pins. See fig.6-16.
2.
Cover the outriggers with planks.
3.
Fix cross strips or a right-angle
profile to the underside of the
planking and secure them to the
outriggers.
4.
Mount the anchor ramp (fig.6-17) to
the outriggers.
Fig.6-17 Anchor ramp
6.7 Lightning protection
1.
Mount the connection between the
chassis and the earth. This
connection must satisfy the
following specification:
DIN VDE 0185, part II, §5.2
The cable supplied (25 mm² /
0.039 in² cross section, 25 m / 82ft
long) must be connected to the
terminal box on the building site.
Fig.6-18 Lightning protection
MS 5000 • 9095-050A
6-13
ASSEMBLY AND ANCHORING
6-14
MS 5000 • 9095-050A
OPERATION
7.
OPERATION
7.1
General
No person may stand under the
machine while it is in use.
Material may never extend
beyond the edges of the
platform. Items which can roll
must be properly secured. The
load may never be supported
against the fencing.
The maximum reaction force (for
instance caused by tools) of the
platform with regard to the
facade amounts 800 N
(180 lbf).
When work stops for any reason,
the main switch must be secured
with the padlock.
During raising or descending no
person may stand on the
platform extensions.
Do not step on the wheels.
7.2
Preparation
1.
Before the mast climbing work
platform is used it must be visually
inspected (daily if it is used every
day) for:
- anchors
- presence of all security devices
- connection between mast
elements
- position of the masts
- any loose components
MS 5000 • 9095-050A
7-1
OPERATION
- ground supports and the quality of
the ground
- electrical connections
- protective covers (presence and
securing)
- securing of the platform extension
- operation of the limit switches
- no obstacles in the path of the
platform
- oil leaking from the drive units
- functioning of the motor brakes
(section 7.4).
2.
Connect the electrical power supply.
3.
Close the gate.
4.
Remove the padlock from the main
switch.
5.
Place the main switch in position I or
II (the position depends on the
direction of phase rotation of the
power supply)
6.
Check that the EMERGENCY pushbutton on the control box is switched
off (the push-button must be pulled
out).
7.
If the display shows code 02 , the
main switch must be set in the other
position. The display will show code
00. If the electric safety circuit (gates,
etc.) is closed the blue light on the
control box will burn.
7-2
Fig.7-1
Main switch
Fig.7-2
Emergency push-button
MS 5000 • 9095-050A
OPERATION
7.3
Testing
1.
Test the platform and check the
following:
- all limit switches, striker plates and
safety devices and ensure that
everything is properly adjusted.
- that the path of the platform is not
obstructed.
- the functioning of all the push
buttons on the control box.
- the free movement of the power
supply cable.
Also test the platform brakes! (see
section 7.4)
2.
After erection or relocation perform
all inspections as described in the
appendix: Checklist mast climbing
work platform type C.
7.4
Brake test
The brake test must be carried out daily.
1.
Release the brake on one of the
motors by pulling the lever on the
motor. The platform should not
descend. Release the brake lever.
2.
Release the other brake. The
platform should not descend.
Release the brake lever.
If the platform descends, the
mast climbing work platform
must not be used. Consult the
service engineer.
Fig.7-3
Brake lever platform
MS 5000 • 9095-050A
7-3
OPERATION
7.5 Operation from the platform
UP:
If this push-button is
pressed, the platform is
raised. When the
push-button is released,
the platform stops
immediately.
DOWN:
If this push-button is
pressed, the platform is
lowered. When the
push-button is released,
the platform stops
immediately.
EMERGENCY: When this push-button is
pressed, the platform is
locked.
Fig.7-4
Push-buttons control box
Fig.7-5
Brake lever platform
7.6 Operation in an emergency
situation
In an emergency, for example in the event
of a power failure, the platform can always
be lowered.
- Using the malfunction analysis in
chapter 10, try to solve the problem. If
the problem can not be solved it is
possible to make a emergency descent
in the following way.
1.
Open the trap door in the platform.
2.
Each motor is provided with a lever
with which the motor brake can be
released (A, Fig.7-5).
3.
When these levers are operated, the
platform will begin to descend.
7-4
MS 5000 • 9095-050A
OPERATION
The speed of descent will be limited
by the centrifugal brake.
After a maximum descent of 5
metres (16.4 ft), stop the platform
for 2 minutes in order to avoid
the centrifugal brakes becoming
overheated, which will result in
their working less efficiently.
MS 5000 • 9095-050A
7-5
OPERATION
7-6
MS 5000 • 9095-050A
DISASSEMBLY AND TRANSPORT
8.
DISASSEMBLY AND TRANSPORT
Ensure that the maximum
loading allowed during assembly
is not exceeded.
In winds of strenghts above
6 Beaufort (12,5 m/s) (41 ft/s),
the machine may not be
disassembled.
Never remove any intermediate
anchor.
Never remove an uppermost
anchor unless the mast above
the anchor is disassembled and
the platform is unloaded.
1.
Remove the mast guards.
2.
Disconnect the uppermost anchor.
3.
Together with the disassembly of the
mast, the anchor tubes and the
anchors must be disassembled.
4.
If a crane is available on the building
site, the mast can be more quickly
disassembled. As many as four mast
elements can be removed together
and lowered to the ground with the
crane. The mast elements can further
disassembled on the ground.
5.
Repeat this procedure until the mast,
with the platform in its lowest
position, has been completely
disassembled.
6.
Release the brakes and allow the
platform to descend onto the buffers
(A, Fig 8-1).
Fig.8-1
Brake lever platform
MS 5000 • 9095-050A
8-1
DISASSEMBLY AND TRANSPORT
7.
Disconnect the electrical supplies.
8.
Raise the jacks and remove the
ground supports.
9.
Remove the control box.
10. Remove the step
There are two possible ways to transport
the basic machine. This can be done with
or without the platform elements being
attached. The transport method depends
on the dimensions of the platform and the
widths and lengths of vehicles permitted by
national regulations.
Fig.8-2
Locking pin outrigger
Fig.8-3
Locking pin outrigger chassis
If the basic machine is too large to be
transported in one piece, take the following
steps.
11.
Disassemble the fencing, the fence
posts, the access gate and the
gateposts.
12. Disassemble the platform
extensions. Slide in the outriggers
and secure them.
13. Disassemble the platform elements.
14. Slide in the outriggers of the chassis
and secure them.
8-2
MS 5000 • 9095-050A
MAINTENANCE
9.
MAINTENANCE
9.1 General
The simple robust construction of the machine ensures that maintenance can be kept to
a minimum. Sensible use of the machine, regular checks for correct functioning and
regular cleaning will result in a minimum requirement for maintenance. This will
guarantee a long working life for the mast climbing work platform.
Maintenance on the mast climbing work platform may only be carried out by
persons with adequate knowledge and qualifications to do so. Preferably by
qualified persons from the manufacturer or the dealer.
Parts must comply to the technical specification of Hek Manufacturing b.v.!
Use only original parts of Hek Manufacturing b.v.
Before maintenance is carried out:
- Switch off the main switch (The main switch having been switched off, there
still remains voltage on the parts marked with
).
- remove the power supply socket
- lower the platform onto the buffers.
9.2 Maintenance intervals
The following maintenance activities are essential:
After erection or relocation
- Perform all inspections as described in the appendix: Checklist mast climbing work
platform type C.
Daily inspection
- The daily inspection is described in chapter 7.2 & 7.3.
MS 5000 • 9095-050A
9-1
MAINTENANCE
A.
Weekly maintenance
- Grease the rack and pinion. If these are heavily contaminated with sand or grit they
must be cleaned first.
Specification for grease:
- HEK-rack and pinion grease
- Shell Rhodina 2
- Clean the platform and the drive units.
- Visually inspect the rack and pinion drive (pitting).
- Perform the activities listed at daily inspection.
B.
-
C.
-
D.
Monthly maintenance
Inspect the guide rollers (visual inspection of security devices, gaskets and bearings).
Check that all mast bolts are tightened with the correct torque. Use a torque wrench.
Check that all anchors are secure and re-secure any loose parts.
Check the functioning of all limit switches.
Grease the jacks and the king pins of the chassis.
Grease the drive unit pressure rollers.
Perform the activities listed at A.
Perform all inspections as described in the appendix: Checklist mast climbing work
platform type C.
Quarterly maintenance
Check the motor brake (see section 9.3.2)
Check the play in the guide rollers.
Check the rack and pinion (visual).
Perform the activities listed at B.
Annual maintenance
-
Check the rack fixing bolts.
Grease the universal joints on the drive mechanism for the differential gearbox.
Grease the sliding tube on the drive mechanism for the differential gearbox.
General inspection of paintwork, corrosion and welds.
Check all welds of the mast climbing work platform.
Check the oil level in the reduction box.
Perform the activities listed at C.
Perform all inspections as described in the appendix: Checklist mast climbing work
platform type B.
9-2
MS 5000 • 9095-050A
MAINTENANCE
E.
Biennial maintenance
- Change the oil in the platform reduction gearbox.
Lubricant specification for Stephan motors:
ISO Viscosity class: ISO VG 220
- Aral BMB
- Shell Macoma W71
- Esso Vartan 220
- Perform the activities listed at D.
F.
-
Maintenance during storage of the machine
Inspect the machine in its entirety.
Check all vital parts and replace any which have become damaged.
Clean and grease the rack and pinion drive.
Inspect the mast elements (with the racks) and check that all separate connection
pieces are in order.
Check the lowest mast bolts for corrosion and replace them if necessary.
Cover the basic machine with a tarpaulin; in every case, cover the control boxes and
the limit switches.
Screw out the jack of the chassis so that it does not rest on its wheels.
For long-term storage, consult your dealer.
MS 5000 • 9095-050A
9-3
MAINTENANCE
9.3 The motor brake
The motor has a built-in electromagnetic
brake. This brake functions according to
the "normally ON" principle, that is, when
the motor has no power supply the brake
is active and the motor shaft will be
braked. (n = 0 rev./min).
The braking effect is achieved by friction
between several discs and the brake
must be used "dry" (not greased).
9.3.1 Operation
The brake mechanism has a metal rotor
(3) with friction material on both sides.
Four pressure springs (7) in the stator
exert an axial force on an anchor plate
(4). This anchor plate is pressed by the
spring force against rotor. The rotor is
mounted on the motor shaft in such a
way that it can slide in an axial direction
along the shaft. Because the anchor plate
presses against the rotor, the rotor is
pressed against the friction plate (1). The
contact between the friction material on
either side of the rotor, the anchor plate
and the friction plate results in the
required braking effect.
The stator has a built-in braking coil (5)
which produces a strong magnetic field
when a DC current is applied to it.
Fig.9-1
Motorbrake
When the brake is to be released, a
current is made to flow through the
braking coil. The resulting magnetic field
"pulls" the anchor disc toward the stator,
9-4
MS 5000 • 9095-050A
MAINTENANCE
thus releasing the brake.
It is also possible to release the brake
manually. If the manual release lever is
pressed in the direction indicated by the
arrow on the cover, the anchor plate is
moved against the spring pressure with
the aid of two ball bolts, so that it is
pressed towards the stator, releasing the
brake.
9.3.2 Maintenance
In normal use the motor brake is more or
less maintenance free. However, after
frequent raising and lowering of the
platform it may be necessary to adjust the
air gap between the anchor disk and the
stator, and if necessary, to replace the
rotor.
In order to check the condition of the
brake, the width of the air gap "a" and the
thickness of the friction material on the
rotor must be measured every three
months.
The air gap "a" is adjusted by the
manufacturer to 0.3 mm / 0.012 in and
must never be more than 1.1 mm
/ 0.043 in.
To check:
1.
Switch off the mast climbing work
platform at the mainswitch and
secure the switch with the padlock.
2.
Remove the brake release lever
using an open ended spanner.
MS 5000 • 9095-050A
9-5
MAINTENANCE
3.
4.
Remove the fan cover (9) from the
motor.
Use a feeler gauge to check the
width of the air gap "a" adjacent to
the hollow threaded collars (2).
The width of the air gap "a" must be
adjusted as follows:
6.
Remove the device securing the fan
and remove the fan from the shaft.
7.
Unscrew the hexagonal bolts (6) by
a ½ turn.
8.
Screw all the threaded collars (2)
equally far into the stator (8).
9.
Turn the hexagonal bolts (6) equally
until the air gap "a" has the correct
width.
Fig.9-2
Motorbrake
10. Screw the threaded collars (2) out of
the stator until they are in contact
with the fixed part.
11.
Check that the width if the air gap is
the same over the whole of its
length.
12. Tighten the hexagonal bolts (6) with
a torque loading of 25 Nm / 18 lb ft.
The adjustment of the hand
release may not be changed,
not even when air gap "a" is
readjusted, as security can be
adversely affected.
13. Re-fit the fan and secure it to the
shaft.
14. Mount the fan cover and the brake
release mechanism.
9-6
MS 5000 • 9095-050A
MALFUNCTION ANALYSIS
10.
MALFUNCTION ANALYSIS
The control box on the platform has an "information panel". This "information panel"
consists of a display on which fault codes appear in the event of a malfunction. An
explanatory list of fault codes is attached to the control box as an aid to rapid and efficient
fault repair. The following table gives an indication of the methods to be employed in the
event of a malfunction.
Code
01
Description
Motor M1 & M2
thermal overload
Malfunction
Solution
- Platform loading too high
- Reduce loading
- Voltage too low
- Consult an electrician
- Motor stalled
- Consult an electrician
02
Phaseguard relay
- Main switch incorrect position
- Set main switch in the other
position; if the malfunction is
not corrected, consult an
electrician.
03
Emergency stop
pushbutton
- Pushbutton depressed
- Rotate pushbutton to release
04
Limiting switch bottom
- The machine has run too far
downward
- Consult an electrician
06
Limiting switch top
- The machine has run too far
upwards
- Consult an electrician
07
Others
- Depending of erection, others
- Consult an engineer
- Gate is open
- Close the gate
- Connector not in socket
- Plug connector into socket
- Switch defective or "sticking"
- Check the switch
- Machine run too far during
assembly phase
- Switch defective
- Move the machine downward;
if the malfunction is not
corrected, consult an
electrician
- Fuse F104 deactivated
- Consult an electrician
05
08
12
13
Gate/other
Mast detection sensor
Control voltage
In all cases not covered by the above malfunction tables an electrician must be
consulted.
MS 5000 • 9095-050A
10-1
MALFUNCTION ANALYSIS
- D e fe c tiv e fu s e s in b u ild in g s ite s u p p ly
- D a m a g e d c a b le
N o p o w e r s u p p ly
- M o to r s a fe ty re la is s w itc h e d o ff
- M a in s w itc h d e fe c tiv e
M o to r d o e s n o t ru n
- In c o rre c t c a b le ty p e
V o lta g e to o lo w
- C a b le is to o lo n g
4 2 V a c c o n tro l v o lta g e n o t
p re s e n t
V o lta g e p re s e n t b u t
p la tfo rm c a n n o t b e ra is e d
o r lo w e re d
O th e r m a lfu n c tio n s
- A u to m a tic fu s e s o p e ra te d
R e la y s K 1 0 2 e n K 1 0 3 a re
e n e rg iz e d b u t p la tfo rm d o e s n o t
m ove up or dow n
- M o to r b ra k e lo c k e d
B ra k e d is ta n c e to o lo n g
- A d ju s t b ra k e
T h e p la tfo rm d o e s n o t d e v e lo p
s u ffic ie n t p o w e r
- In fo rm y o u r te c h n ic a l s e rv ic e o r d e a le r
- A d ju s t b ra k e
In all cases not covered by the above malfunction tables an electrician must be
consulted.
10-2
MS 5000 • 9095-050A
MACHINE DISPOSAL
11.
MACHINE DISPOSAL
General
After a number of years of reliable service the life of every machine inevitably comes to
an end. The machine must then be disposed of in an as environmentally friendly
manner as possible.
Amongst others, the following possibilities present themselves:
- Part exchange for a new machine.
- Disposal by a recycling facility.
- Demolition.
Discarding the machine
- Drain the oil out of the reduction gearbox and dispose of this via an authorized
facility.
- Remove any usable parts.
- Dispose of the remainder via waste disposal facility.
MS 5000 • 9095-050A
11-1
MACHINE DISPOSAL
11-2
MS 5000 • 9095-050A
LIST OF KEYWORDS
12. LIST OF KEYWORDS
A
Air gap
Anchor forces
Anchor ramp
Anchoring
Applications
Assembly
L
9-5
1-7, 6-10
6-12
6-1, 6-10
1-1
6-1
B
Brake test
Buffer
7-3
5-3, 6-8
C
Centrifugal brakes
Chassis
Component description
Contents
Control box
Control components
Control light
2-1
1-5
2-1
VI
5-2
5-1
5-2
D
Dimensions
Disassembly
Down
X
8-1
5-2
E
EC Declaration of Conformity
Electrical connections
Electrical installation
Emergency push-button
Emergency situation
VIII
2-2
1-4
5-2
7-4
F
Fence posts
Fencing
Foreword
1-2
6-4, 6-12
V
G
Gate safety switch
Ground pressure
Ground support
6-6
6-3
6-3
H
Horn
5-3
I
Illustrations
Info panel
VII
5-2, 10-1
Lifting point
Lightning protection
Loading diagrams
Lower striker plate
4-1
6-13
1-6
6-5
M
Machine disposal
Main switch
Maintenance
Malfunction analysis
Mast cover panels
Mast element
Maximum speed
Motor brake
11-1
5-2
9-1
10-1
6-9
1-2
4-2
9-4
N
National requirements
Nylontron rollers
6-2
2-1
O
Operation
Original parts
Outriggers
7-1, 7-4
9-1
6-13
P
Personnel
Phase rotation
Platform
Platform construction
Platform elements
Platform width
Positioning
Power supply
Power supply socket
Proximity switch
3-3
6-7
1-2
1-6
6-5
6-12
6-1, 6-4
6-7
5-1
6-8
R
Reaction force
Repositioning on the building site
Repositioning with a crane
7-1
4-2
4-3
S
Safety
Safety after use
Safety features
Safety in use
Safety prior to use
Scaffold coupling
Steps
Storage
Symbols
MS 5000 • 9095-050A
3-1
3-2
3-2
3-1
3-1
1-7
6-6
9-3
IX
12-1
LIST OF KEYWORDS
T
Technical details
Testing
Transport
1-1
7-3
4-1, 8-1
U
Up
5-2
W
Weight
12-2
4-3
MS 5000 • 9095-050A
APPENDICES
A.
CHECKLIST MAST CLIMBING WORK PLATFORMS TYPE B
At least once a year, or sooner if circumstances require, for the benefit of the periodic
inspection the installation should be checked against all the points on this list by an expert
such as: a) your own technical department; b) the manufacturer/supplier; c) an independent
authority.
Mast climbing work platform
description
Manufacturer
Type
Factory or serial number(s)
Year of manufacture of the drives
................................................................
................................................................
................................................................
................................................................
Nominal load
Platform length
Platform width
Maximum free-standing mast height
Erection set up
............................. kg
............................. m
............................. m
............................. m
............................. m
mobile / stationary
Owner
Established in
Test date (day/month/year)
................................................................
................................................................
................................................................
Following a successful inspection the day, month and year (in figures) are applied
on the drive.
Date
Location
Inspected by (name person)
................................................................
................................................................
................................................................
this list consists of 10 items
Mast climbing work platform B
column 1: x = in order
column 2: x = not in order
column 3: x = not applicable
1
1
General
1.1 user manual
1.2 electrical circuit diagram
2
Operation
2.1 unobstructed view of lift path
3
Mast
3.1 construction
3.2 mounting to chassis/base frame
3.3 bolt connection, locking
3.4 top mast present
MS 5000 • 9095-050A
2
3
1
APPENDICES
Mast climbing work platform B continued (1)
4
Chassis
4.1 outriggers, jacks
4.2 bolt and pen connection, locking
4.3 axles, wheels
4.4 tyres
4.5 steering gear
4.6 electrical operation and emergency stop chassis drive
4.7 brake operation
5
Drive unit
5.1 bolt and pen connection, locking
5.2 fail safe brake or speed limiter
5.3 guide wheels
5.4 platform condition
5.4.1 railings
5.4.2 connection pieces and accompanying railings
5.4.3 floors
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
6
2
column 1: x = in order
column 2: x = not in order
column 3: x = not applicable
1
2
run-out safety
autolevel safety electric
autolevel safety mechanical
eccentric overload device
overload safety device
drive unit not out of mast guide
rack and pinion wear
guide wheels
Set up/erection
6.1
stability
6.2
struts, ground support
6.3
free passage platform
6.4
free space erection site, fencing
6.5
space between platform and object
max. 0.3 m
: kick board 0.15 high
0.3 - 0.5 m
: kick board + railing at 0.7 m
greater than 0.5 m : kick board + knee rail + railing at 1.1m
MS 5000 • 9095-050A
3
APPENDICES
Mast climbing work platform B continued (2)
column 1: x = in order
column 2: x = not in order
column 3: x = not applicable
1
2
7
Electrical installation
7.1 main switch blockable/lockable
7.2 electric cables, wiring
7.3 relay operation
7.4 thermal protection
7.5 phase protection (380V model)
7.6 safety earth
7.7 cable strain
7.8 hold to run buttons
7.9 emergency stops
7.10 eccentric overload protection
7.11 overload safety device
7.12 condition power supply cables
7.13 drive unit mounting
7.14 emergency limit switch
7.15 lower limit switches
7.16 upper limit switches
7.17 gate switch
7.18 transport switch
7.19 anchor ramp switch
8
Signs
The presence of all signs in accordance with both the user
manual and the applicable standards.
9
Various
9.1 general state of maintenance
9.2 lubrication
9.3 panelling, mesh
9.4 paintwork (no rust formation)
10
Tests
10.1 functional testing of safety components in accordance
with manufacturers specifications.
Note:
3
An administrative record of the results of this checklist/inspection should
be kept, it is recommended that the administration book be used for that
purpose.
MS 5000 • 9095-050A
3
APPENDICES
4
MS 5000 • 9095-050A
APPENDICES
B.
CHECKLIST MAST CLIMBING WORK PLATFORMS TYPE C
To be completed following the erection or relocation of the mast climbing work platform,
preferably once per month for the benefit of erection set up inspections, special inspections
and periodic inspections.
Mast climbing work platform
description
Manufacturer
Type
Factory or serial number(s)
Year of manufacture of the drives
................................................................
................................................................
................................................................
................................................................
Nominal load
Platform length
Platform width
Maximum free-standing mast height
Drive
Erection set up
Owner
Established in
Test date (day/month/year)
............................. kg
............................. m
............................. m
............................. m
............................. m
mobile / stationary
................................................................
................................................................
................................................................
Following a successful inspection the day, month and year (in figures) are applied
on the drive.
Date
Location
Inspected by (name person)
................................................................
................................................................
................................................................
column 1: x = in order
column 2: x = not in order
column 3: x = not applicable
this list consists of 26 items
Mast climbing work platform type C
1
1
Is the stability of the mast climbing work platform guaranteed, on
a hard and level surface ?
2
Have the outriggers been deployed responsibly and in
accordance with the user manual ?
3
Has the ground support of the mast climbing work platform and
jacks been implemented in accordance with specifications ?
4
Has only slip-free material (preferably wood) been used for
ground support the mast climbing work platform and jacks ?
5
Following strut deployment are any wheels present free from the
ground ?
6
Have all anchors been fitted in accordance with the
manufacturers regulations ?
MS 5000 • 9095-050A
2
3
5
APPENDICES
Mast climbing work platform C continued (1)
6
column 1: x = in order
column 2: x = not in order
column 3: x = not applicable
1
2
7
Have all wall mounting anchors been fitted in accordance with
the instructions of an expert ?
8
Are all prescribed bolt connections present and tightened in the
prescribed manner ?
9
If a platform extension is present has it been fitted and fixed
firmly in position in accordance with specifications ?
10
Is the general state of the machine in order and free from
mechanical deformities and shortcomings ?
11
Have measures been taken to prevent users on the platform and
non-users around –especially underneath- the platform from
becoming trapped or crushed ?
Has the machine not been erected in front of openings or in
gangways where people continually pass by ?
In case multiple mast climbing work platforms have been erected
adjacently, is the minimum spacing between them at least 0.5 m
in order to prevent the danger of crushing ?
12
Have the railings been fitted and fixed firmly onto the platform:
• at a distance between wall and platform smaller than or equal
to 0.3 m: at least one kick board 0.15 high.
• distance smaller than or equal to 0.5: kick board + railing at
0.7 m
• distance greater than 0.5 m: kick board + railing at 1.1m +
knee rail.
13
Are all other railings present and fixed firmly in position ?
14
Is the mast guard with a minimum height of 2 m present and fixed
in position ?
15
Is the mast climbing work platform fitted with a run-out safety at
the end of the mast ?
16
Is the mast climbing work platform eccentric overload protection
functional (see user manual) ?
17
Does each motor brake function independently when in a
stationary condition (at least 2 independent brakes present, see
user manual) ?
18
Is the mechanical platform autolevel safety functional ?
(only applicable with 2 masts)
19
Is the emergency lowering system functional (see user manual) ?
MS 5000 • 9095-050A
3
APPENDICES
Mast climbing work platform C continued (2)
column 1: x = in order
column 2: x = not in order
column 3: x = not applicable
1
2
20
Are the following functional:
a Emergency switch
b Lower limit switch
c Lower emergency limit switch
d Upper limit switch
e Upper emergency limit switch
f Gate switch
g Electrical autolevel system (if applicable)
h Anchor ramp switch (if applicable)
i Transport locking switch
j Phase guard relay
21
Does the power supply cable run completely free ?
22
Are there no damaged power supply cables, connector plugs or
other electrical components ?
23
Is the main switch blockable/lockable ?
24
Is the user manual at least available in the national language ?
25
Are the type plates, correct load signs, the warning signs and
operating instructions: UP, DOWN, and EMERGENCY STOP
present ?
26
Are the operating buttons located in such a manner that the
operator has a clear view over the entire platform ?
3
Seen by the foreman / supervising person
Note:
An administrative record of the results of this checklist/inspection should
be kept, it is recommended that the administration book be used for that
purpose.
MS 5000 • 9095-050A
7
APPENDICES
8
MS 5000 • 9095-050A
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