JLG Power Towers Nano Betriebsanleitung

Operating and

Maintenance Manual

www.powertowers.com

Courtesy of Crane.Market

CONTENTS

Introduction 2

Operating Speciﬁcations 3

Working Envelope Diagram 3

Do’s and Don’ts 4

Primary Components 5

Operating Procedures (Incl. Emergency Operation) 6-8

Maintenance Procedures

(Incl. Castor Safety and Maintenance) 9-13

Storage 14

Key Spare Parts 15-16

Electric Circuit Diagram 17

Hydraulic Circuit Diagram 18

Warranty Terms 19

CONTENTS

INTRODUCTION

The Power Tower Nano is designed to be a simple, quick and safe

powered alternative to a portable scaffold tower, podium or a step

ladder, for internal construction site and maintenance applications.

It can be used in applications where previously portable scaffolding

towers are erected on castors, and moved about on hard level

surfaces. These types of tower are open to incorrect assembly, and

are difﬁcult and time consuming to work from. The Nano eliminates

many of the risks associated with portable scaffold towers.

The Nano is suitable for any application provided it is used within

its speciﬁed operating parameters. If used for applications such as

sand blasting, welding, paint spraying or with any other hazardous

materials, then measures must be taken to ensure the Nano does not

become damaged in any way which may impair safety, or reliability.

Additional protection for the operator may be required in some cases,

which is the responsibility of the operator and/or the operator’s

employer.

The purpose of this manual is to provide essential basic information

required to operate and maintain the Nano.

This is not a workshop manual. Please contact the manufacturer or

their agent for specic operation or maintenance information if in

doubt.

The health and safety of the operator or maintenance technician is

the responsibility of the individual and/or their employer and not

Power Towers Ltd.

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OPERATING SPECIFICATIONS

Working Dimensions

Maximum working height: 4.50 m

Maximum platform height: 2.50 m

Platform dimensions: 1.00 m x 0.73 m

Working footprint: 1.19 m x 0.75 m

Safe working load: 200 kg (1 person plus tools)

Maximum manual force: 200 N

Max. gradient for operation: 0°

Max. wind force: Indoor use 0 mph

Manual push force on level ground: 9 kg

Maximum total weight Inc payload: 485 kg

Maximum castor point load: 180 kgs (1.77 kN)

Max. wheel force: 1.75 kN

Closed Dimensions

Length: 1.195 m

Width: 0.750 m

Height: 1.560 m

Weight: 285 kg

Power Source

Standard 12v DC Electric Motor

Or 240V AC Electric Motor 13A Supply

Or 110V AC Electric Motor 16A Supply

Battery Charger Speciﬁcation

Input Voltage:

If single voltage: 90-135V AC (UK)

180-265V AC (non-UK)

If dual voltage: 90-265V AC

Frequency: 45-65 Hz

Output: 12V DC, 7A

Power sound level: Less than 70dBA

Emission EN 55014N, EN 61000 – 3 – 2

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DO’S and DON’TS

DO’S

1. Read and adhere to the instructions both on the machine

and in this manual.

2. Ensure pre-operation checks and operations are carried

out in the manner described.

3. Use only on hard, level surfaces able to support the weight

of the machine (e.g. concrete oor, tiled oor, hard wood

oor).

4. Use the Nano internally only.

5. Ensure operator is t and does not suer from a fear of

heights.

6. Ensure the Nano is correctly positioned with castor brakes on.

7. Ensure guardrail gate is closed and latched before elevation.

8. Ensure work area around the machine is cordoned o

from pedestrians and other trac.

9. Ensure operator is wearing the correct safety equipment.

10. Ensure the platform is correctly positioned so as not to

come into contact with xed or moving objects.

11. Ensure that the safe working load is evenly distributed

on the platform.

12. Never leave the Nano unattended without the castor

brakes on.

DON’TS

1. Never exceed the safe working load (1 person, 200kg).

2. Never use the Nano on sloping or uneven ground.

3. Never use the Nano as a goods lift or crane.

4. Never exceed horizontal forces; never use in wind

(maximum horizontal force 200N).

5. Never use in the vicinity of live conductors.

6. Never try to move the Nano on its castors

when elevated.

7. Never extend the height of the platform by using boxes,

steps, ladders etc.

8. Never modify the Nano in any way without the

full approval of the manufacturer.

9. Never attempt to enter or exit the platform unless it is

fully lowered.

10. Never operate the Nano outside.

11. Never ax the pendant controller to the guardrails or toolbox

area of the platform; stow in its holster when not in use.

12. Never use the Nano in an explosive environment.

13. Never use the Nano if fatigued.

14. Never use the machine inappropriately or for‘horseplay.’

15. Never use the machine if under the inuence of drugs or alcohol.

16. Never use the machine if suering from poor health or using

medication which might impair the safe operation of the Nano.

17. Never use the Nano if vision impaired by bright lighting.

18. Never push the Nano on sloping surfaces without the use of a

safe method.

19. Never push or pull objects with the platform.

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PRIMARY COMPONENTS

PRIMARY COMPONENT LOCATIONS

Control

Box

Entrance

Gate Latch

Spirit

Level

Swivel

Castor

Auto-Lok

Braked Wheel

Emergency

Stop/Battery Isolator

Emergency

Lowering Valve

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OPERATING PROCEDURES

It is essential to be familiar with the correct operating procedures as outlined in this

manual

The operator must have adequate training for this type of platform.

The Nano is ﬁtted with a safety harness point as standard. If the operator chooses to

wear a safety harness, an approved ‘fall restraint’ type harness should be worn.

Operating procedures are divided into three key areas:

1. Pre-operation checks.

What to do before operating the Nano.

2. Normal operation.

How to use the Nano safely.

3. Emergency operation.

How to lower the Nano without power or in the event of

operator incapacity.

There is no speciﬁc legal requirement to wear a safety harness. However,

there is an employers’ requirement to ensure the correct equipment is

used for a task and that is used correctly and safely. For this requirement

to be met, a risk assessment should be conducted to assess the potential

risks and if an increase in operator safety can be achieved with a safety harness, then

use a ‘fall restraint’ type harness only.

It is the owners and/or the users responsibility to ensure that the machine is

maintained and operated in accordance with the operation and maintenance

procedures contained within this manual.

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PRE-OPERATION CHECKS

1. Ensure there are no obvious signs of mechanical damage to the handrails,

platform, lifting structure or chassis.

2. Check platform access gate closes when released and that the latch

engages correctly.

3. Check castors and wheels rotate freely and are undamaged.

4. Check castor wheel and castor xings. Check circlip (red ring) is correctly located

on end of stub axle and retained with hub cap (See pic A.)

5. Check emergency lowering is functioning correctly (refer to procedure on p.8).

6. Ensure the battery (where applicable) is fully charged, referring to the battery

condition dial indicator.

7. Ensure the hydraulic oil level is at the correct level. Do not overll.

8. Check there are no hydraulic oil leaks and that all hydraulic connections

are tight.

9. Cordon o area around machine in accordance with guidelines.

NORMAL OPERATION

Only use the Nano internally, on hard level surfaces. Ensure a person is available at

ground level to assist in case of emergency.

Position machine under application. Refer to working envelope

diagram if necessary.

1. Apply both castor brakes.

2. Check spirit level to ensure machine is level.

3. Ensure the emergency lowering valve is closed (push and twist 90º,

release - do not force).

4. Turn key switch in emergency stop button (located at the base of the

machine), then pull to release.

5. Battery condition dial indicator on control box will indicate battery charge.

6. Check there are no overhead obstructions.

7. Enter platform via step and gate and ensure the gate is closed

and latched correctly when in platform. Do not elevate if the access gate is

not closed and latched.

8. Press arrowed button to elevate. Press arrowed button to descend.

9. In case of uncontrolled platform elevation or descent, depress

red emergency stop button (on control box or at base of

machine - refer to pics 4 & 5).

The user shall obtain the guidance and approval of the manufacturer in

the event of any special working methods or conditions which are outside

those speciﬁed by the manufacturer.

OPERATING PROCEDURES

Locked

1Unlocked

Pic. A

Never ax the pendant controller to the guardrails or

toolbox area of the platform

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EMERGENCY LOWERING OPERATION

In case of platform control failure or operator incapacity:

To lower the platform:

1. Locate emergency lowering valve at base of machine (see, pic

right). Push, twist 90 degrees anti-clockwise and release

the knob. The platform will lower. Pushing and twisting the knob

clockwise will stop the descent at anytime.

2. Check the area below the platform is free from obstructions

when lowering.

3. Keep clear of descending structure.

4. Do not force the release knob.

BATTERY CHARGING

The battery charger is located under the checkerplate cover A.

The charging lead (usually tted with a yellow 110V plug) is on the

exterior of the machine base (this lead can be tted with 230V plug if

required) B. Dual voltage chargers are fully voltage sensitive, so there

is no voltage selection to do when connecting to dierent voltages. If

tted with a single voltage charger, the input voltages are 90-135V AC

for UK and 180-265V AC for non-UK.

Ensure the battery isolator is switched on when charging. Plug into

an available power supply and ensure the green LED (top of charger)

illuminates. The adjacent amber LED has three modes C. 1. Rapid

ash, indicates maximum charge rate. (Note, when switching charger

on, the amber light must rapid ash. If not, there is a fault, check

fuse* and connections). 2. Slow pulse, indicates slower charging. 3.

Continuous illumination indicates oat charge. Both lights go“o”

when fully charged. Additionally the battery charge indicator dial on

the control box will indicate charge level D.

The battery charger can be connected to the mains supply at any

time or left for extended periods.

The machine can be operated when the charger is connected, although

this is not recommended.

All mains supply should be protected with a suitable RCD.

Only charge in a well-ventilated area.

*Note: The charger is tted with a 15A automotive spade fuse (blue). If the

fuse has failed, the indicator lights will still operate. The fuse may have failed

if the battery is heavily discharged and the motor is run when the charger is

switched on. In such an event, the fuse is simple to replace; ensure battery

isolator is switched o and that the mains supply is disconnected before

attempting to check or change fuse.

OPERATING PROCEDURES

C D

Courtesy of Crane.Market

Please note that whilst the Nano is extremely simple to maintain,

all work must be carried out by a competent person.

When removing checkerplate cover for maintenance purposes,

ﬁrst switch off by depressing the emergency stop/battery isolator

button located at the base of the machine. Use appropriate

safety/personal protective equipment where necessary.

DAILY MAINTENANCE

Tilt cage by releasing gate latch on cage mount (see pic). Pull cage

frame from gate end and cage will lift and tilt assisted by gas strut.

Ensure gas strut is fully extended and that the safety chock is in place.

You can now access the powerpack housing. Unscrew the black

retaining knobs and lift out the checkerplate cover.

1. Check Battery Electrolyte Level:

Remove battery cover and battery caps. Ensure the electrolyte

covers the plates by no more than 1mm – 2mm. Replenish with

distilled water to this level, only if the electrolyte level is below

the top of the plates.

2. Check Hydraulic Oil Level:

Ensure the tank is not overﬁlled.The level must only be checked

when the machine is in the transport position.The correct level

in this condition is approximately 3/4 from the base of the tank,

as indicated by the line.

3. Ensure there is no obvious mechanical damage to the handrails,

entrance gate, post or structure of chassis. Also check the castors

and wheels are undamaged, rotate freely and are secured

to machine.

4. Check hydraulic connections around the pump and base of

cylinder are tight and undamaged.

5. Check the spirit level to ensure it is clearly legible and

undamaged.

6. Check all functions operate correctly including movement alarm

and emergency stops.

7. Ensure mast surfaces are clean and not greased.

WEEKLY MAINTENANCE

Check battery terminal connections are tight.

MONTHLY MAINTENANCE

Check Battery Speciﬁc Gravity:

On a monthly basis check the speciﬁc gravity in each of the

battery cells.When a battery is correctly fully charged the

speciﬁc gravity should be 1.27 - 1.3.The speciﬁc gravity

reading should be equal across the cells, if not repeat the full

charge cycle.

Check rollers and mast surfaces for damage. Ensure brushes are ﬁtted

correctly and brush against mast surface.

MAINTENANCE PROCEDURES

Cage mount

gate latch

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MAINTENANCE PROCEDURES

HYDRAULIC OIL

The hydraulic oil must be replaced on an annual basis. If the oil is not

replaced, then premature wear and failure of components will occur.

To drain the hydraulic tank, the mast must be in the transport

position, and the platform tilted to allow access to the motor/pump

unit.The only practical method to remove the oil from the tank is to

use a syringe suitable for hydraulic oil, which are easily obtainable,

or a vacuum system for hydraulic oil.The hydraulic steel pipe

connection 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.

Reﬁll with grade 32 mineral oil.

WHEELS AND CASTORS

It is absolutely essential that the wheels and castors are maintained in

good condition at all times, for two reasons:

The ﬁrst is that they act as the stabilisers, and whilst their load

capacity is over rated for the application, any failure could result in a

serious accident. Secondly, if the bearings become tight, then it will

make the machine difﬁcult to manoeuvre.

A measure of horizontal push force can simply be made to determine

the condition of the wheel bearings. On a ﬂat smooth surface the

machine should move with a force of 9 – 10 kg at the mid guard rail

height. The maximum allowance is 20 kg.

Obviously this force is dependant upon the surface and gradient, but

the above is the recognised method of measurement, in accordance

with HSE guidelines.

Check rear wheels to ensure retention circlip is securely ﬁtted to

end of stub axle and plastic cap is ﬁtted over it.

MOTOR CONTACTOR SOLENOIDS

When conducting the six monthly LOLER inspection, check the

correct functioning of the two motor contactors.

Fit new contactors after every three years.

When replacing components for any reason, only use OEM

speciﬁcation parts, either supplied from the manufacturer or

authorised in writing by the manufacturer.Warranties and design

approvals will be void if alternative components are ﬁtted.

It is essential to obtain manufacturer’s approval of any alteration

which might affect stability, strength or performance in writing

before proceeding.

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