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INSTRUCTION MANUAL
MAXI 75 V BOEING SATELLITE EDITION
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INSTRUCTION MANUALOperation and maintenance of MAXI 75V BSS edition
For power lift serial no. :
Instruction manual no.:
Date of publication: April 27, 2006
Supplier: MaxMove Industrier ABIndustrivägen 9916 31 BjurholmSWEDEN
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INTRODUCTION
TABLE OFCONTENTS:
Read this first! .......................................................................................................4
SAFETY REGULATIONS .................................................................................5
WARNING SIGNS ................................................................................................5PERSONNEL ........................................................................................................6ENVIRONMENT ..................................................................................................6MOVING ...............................................................................................................7DURING OPERATION ........................................................................................8AFTER OPERATION ...........................................................................................8TRANSPORTING THE LIFT ...............................................................................9HYDRAULICS................................................................................................... 10ELECTRICAL SYSTEM ................................................................................... 10
GENERAL SAFETY DURING REPAIRS ........................................................ 10
DESIGN AND FUNCTION .............................................................................. 11
TECHNICAL DATA MAXI 75V ....................................................................... 13OVER AND UNDERCARRIAGE ..................................................................... 14MOTOR AND DRIVE SYSTEM ...................................................................... 15ELECTRICAL SYSTEM ................................................................................... 17SENSOR SYSTEM ............................................................................................ 19BUMPER OVERRIDE BUTTON ..................................................................... 20HYDRAULIC SYSTEM .................................................................................... 21SCISSOR AND PLATFORM ............................................................................. 22SAFETY BRACE ............................................................................................... 22CONTROL BOX ................................................................................................ 23SELECTING MOVEMENT MODE.................................................................. 24RAISING/LOWERING THE PLATFORM ....................................................... 24
WARNING LIGHT AND SIGNAL ................................................................... 24
OPERATION .................................................................................................... 25
STARTING AND STOPPING ........................................................................... 25RESETTING THE WARNING LIGHT AND SIGNAL .................................... 25MOVING ............................................................................................................ 26LIFTING FUNCTION AND WORKING FROM THE PLATFORM ............... 27EMERGENCY LOWERING CONTROL ......................................................... 27EMERGENCY STOP ......................................................................................... 27SAFETY BRACE ............................................................................................... 27TRANSPORT, LIFT AND STORAGE .............................................................. 28
CHARGING THE BATTERIES ........................................................................ 29
MAINTENANCE.............................................................................................. 30IMPORTANT INFORMATION!........................................................................ 30DAILY INSPECTION ........................................................................................ 31BIANNUAL MAINTENANCE ......................................................................... 32MAINTENANCE AFTER STORAGE .............................................................. 33
REFILLING HYDRAULIC FLUID .................................................................. 35
TROUBLESHOOTING ................................................................................... 36
SCHEMATICS.................................................................................................. 37
DECLARATION OF CONFORMITY ......................................................... 46
CONTACT ........................................................................................................ 47
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INTRODUCTION
Read this first!Before using the lift it is crucial that you have read and understood the
instruction manual. It is important to follow all instructions on operationand maintenance to avoid endangering the safety of the operator and otherpeople in the vicinity and to avoid damage to buildings and the machine.
Supervisors and all those working with or from a machine should readthe instruction manual. In an emergency, it can be crucial for all thoseworking on the platform, and not just a specific operator, to have acommand of operating the lift.
Bear in mind that your employer is responsible for ensuring that youhave adequate knowledge of how to handle this equipment. Do not hesitateto contact your supervisor if you are in any way uncertain of how to workwith this machine.
Included in the instruction manualThe instruction manual consists of the following main sections:
• Safety regulations. Study these carefully!
Note the warning labels in the manual.
• A general description of the machine with technical data. This sectiontells you what kind of danger a warning light indicates and how thehydraulic system works.
• Step-by-step instructions on how to operate the lift.
• The maintenance schedule and relevant instructions.
• A troubleshooting guide.
• Schematics and Declaration of Conformity.
• Contact information.
MaxMove Industrier AB
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SAFETY REGULATIONS
Before using the lift, you must read these safety regulations andthe rest of the instruction manual.
Working with a scissors lift always involves certain risks since thework is often carried out at great heights. There is also the risk of beingcrushed between the lift and adjacent walls, striking your head on beamsor other hanging objects, or coming close to electrical cables. The risk ofaccidents is greatest when moving the lift with the platform raised.
Good judgment and extreme care are required of the operator. It isimportant to consider your safety and that of your co-workers and theequipment when performing work. Responsibility for operating the liftmay not be given to anyone lacking necessary knowledge or experience.
WARNING SIGNSThe instruction manual contains warnings about work situations that
may result in accidents if ignored. Because of the risk of accidents andthe possible consequences such an accident may have, warnings aredivided into four types.
DANGER! warns of accidents that may lead to seriousinjury or death.
CAUTION! indicates risks that can cause serious injury ifthe lift is operated incorrectly.
Attention! indicates risks that can cause injury if the liftis operated incorrectly.
Note! means that the instructions should be followed to avoid damagingthe equipment.
DANGER!
CAUTION!
Attention!
Note!
SAFETY REGULATIONS
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PERSONNEL
The operator is responsible for inspecting the lift regularly,conducting daily service and addressing any faults. In short,the operator is responsible for keeping the lift in such acondition that the safety of other people and the safety of theoperator are not put at risk.
Note!
CAUTION!
Only trained personnel may use the lift.Incorrect operation can lead to serious injury or damage to thesurroundings.
ENVIRONMENT
Note!
- The lift is intended for indoor use only.
- The lift may not be operated in water depths greater than5 cm (2 inches). Electrical equipment can be damaged ifwater comes into contact with it.
- The lift has no lighting of its own so the facility it is used inmust have good general lighting.
DANGER!
The machine may not be operated in premises where there isa risk of explosion.
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SAFETY REGULATIONS
MOVING
- Never move the lift without first inspecting the area in thedirection of travel. Check the condition of the surface tomake sure that there are no objects or people in thedirection of movement and that there are no objects neartheplatform.
- Make sure the surface is firm and flat before moving themachine.
- Objects may not protrude from the platform when it isbeing moved. Uneven loads can cause the lift to tip over.
Attention!
- If the ground inclines more than 3 degrees, the platformmust be in its lowest position while being moved.
- If the platform is heavily loaded, it must always be in itslowest position before being moved.
- The lift may not be used to tow or push trailers or anyother objects.
Note!
DANGER!
- The lift may not be moved while the power cable (to thebattery charger) is plugged in. The cable may be damagedand this could send a live current through the machine.
- It is essential to follow the instructions in the ”Operation”chapter when lowering the platform in an emergency.
- Check the surroundings when lowering the platform inemergencies.
- Check the bearing capacity of the surface before liftingthe platform.
Rotate carefully when the platform is extended. The slewradius is large and the rotational speed at the far end of theextension can be very fast.
CAUTION!
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DURING OPERATIONDANGER!
- Never stand on the platform’s rails. Disregarding thesesafety regulations may result in fatal injury!
- Climbing on the scissor structure is forbidden. There isconsiderable risk of being crushed.
- Never place objects between the scissor members. Neverstand in the vicinity of the scissors when lowering orraising the platform.
- No more than 4 people or a 400 kg (880 lbs) load is allowed onthe platform.
- Max 200 kg (440 lbs) load on extension.
- All protective covers are to be in position when the machine isin use.
Note!
- No objects may be suspended from the lift. Suspendedobjects can begin to swing and damage the scissors, otherobjects or people.
- The lift may never be left unattended when the platform israised.
Attention!
AFTER OPERATION
Always remove the key from the main power switch aftercompleting work. This will prevent unauthorized persons fromstarting the machine.
Note!
Always charge the batteries in premises where there is norisk of sparks. The oxyhydrogen gas that is formed duringcharging could ignite and explode.
DANGER!
CAUTION!
- No one may be under the platform during work.
- Always use a helmet when working at sites where there isrisk of objects falling onto the platform or where theplatform is in the vicinity of roofs, beams, telphers, orsimilar objects.
DANGER!
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SAFETY REGULATIONS
TRANSPORTING THE LIFT
Note!
- The lift must never be pulled, towed or pushed.
- The lift can be lifted with a fork lift truck of sufficientlifting capacity. The lifting forks must be inserted in thefork pockets under the chassis.
- Make sure that the forks are not inserted so far that thelift slides forward with the Maxwheel standing on the surface. This will damage the rotation frame and the wheel.
- The lift can also be lifted with a crane or telpher of sufficientlifting capacity. Follow the directions provided later in
this manual.
- The platform must be in its lowest position during all lifts.
- Always remove any tools and other objects from theplatform before lifting. Make sure no one is on or near thelift when it is being lifted.
- When transporting, such as on a truck, the lift must besecured using straps and wheel chocks. The lift must besecured so it cannot move during transport. The wheel unitand drive system can be damaged if external forces causethe lift to move.
- When transporting, such as on a truck, the lift must besecured using straps and wheel chocks. The scissors can bedamaged if the straps are too tight.
CAUTION!
The machine can be damaged or tip over if the forks areinserted outside the fork pockets or are too short.
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SAFETY REGULATIONS
GENERAL SAFETY DURING REPAIRS
HYDRAULICS
DANGER!
Never start servicing or repairs under the platform or on thescissors without first securing the scissors with the safetybrace.
- Repairs may only be performed by trained service personnel.
- Only trained service personnel may carry out repairs of the electricaland hydraulic system.
- Any faults or damage must be corrected immediately. Do notoperate the machine until any known faults have been corrected.
- Use only original spare parts for repairs and servicing.
Note!
Note the risks associated with working with the hydraulicsystem. Follow repair instructions thoroughly. Cleanliness isextremely important. When working on components, be awarethat some may still be under pressure even when the machinehas been turned off. Always secure moving parts whenworking on them.
DANGER!
- Never operate the lift if you suspect a problem with thehydraulic system.
- Never use your hand to attempt to stop a hydraulic fluidleak from a damaged hose. Atomized oil can penetrate theskin and cause serious injury.
CAUTION!
Note!
- Note that only persons with the necessary experience ofelectrical components may perform testing with instruments.
- Only authorized service engineers may open the electronicsbox and perform repairs. The batteries must be disconnected beforeworking on the electronics box in order to avoid damage to theelectronics.
- Note that a blown fuse means that there is a fault some where. Try tolocalize and rectify the fault before resetting the fuse.
- Check the function and condition of the control box regularly. Amalfunctioning control lever or button must be replaced immediately.
ELECTRICAL SYSTEM
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DESIGN AND FUNCTION
DESIGN AND FUNCTION
Maxi is an automatic electrically poweredscissors lift with unrivalled range of movementthanks to its unique drive wheel. The lift canmove in all directions and even around its owncenter point.
The chassis, scissors, and platform are madeof steel. This gives a stable and durable designwhile maintaining flexibility.
The platform has an extendable section whichgives a total work area of just over 5.0 m2 (53ft2). The approx. 4 meter long platform allowsfour people to work on a large area. The lift isavailable in 5.8 meter (19 feet) and 7.5 meter(24.6 ft) height models.
The lift has an advanced control system thatincludes sensors that register the platform’sheight and that adjust the movement speed basedon this. There are also sensors to measure the tiltof the lift.
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TECHNICAL DATA MAXI 75V
DimensionsA Maximum length 2700 mm (106 inches)
B Length with step folded in 2550 mm (100 inches)
C Maximum width 1425 mm (56 inches)
D Lowest overall height 2105 mm (83 inches)
E Work height 9400 mm (370 inches)
F Ground clearance 60 mm (2.4 inches)
PlatformG Width 1412 mm (55.6 inches)
H Platform inner length 2400 mm (94.5 inches)
I Platform extended length 4150 mm 163.4 inches)
J Minimum platform height 1145 mm (45 inches)
K Maximum platform height 7368 mm (290 inches)
L Height with lowered handrail 1755 mm (69 inches)
M Height with handrail removed 1367 mm (54 inches)
Important informationTotal weight 2145 kg (4728 lbs)
Maximum platform load 400 kg (880 lbs)
Maximum platform extension load 200 kg (440 lbs)
PerformanceMaximum drive speed (lowered) 3.24 km/h (1.8 mph)
Maximum drive speed (elevated) 0.54 km/h (0.35 mph)
Lift / Lower time 59 / 64 s
Turning radius (inside) 0 mm
Turning radius (outside) 0 mm
Maximum lateral incline 3°
Maximum longitudinal incline 3°
Hill climbing ability 15%, 7°
J
C
M
F
D
G
L
B
A
K
E
I
H
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DESIGN AND FUNCTION
Electrical systemDC system 24 V
Batteries nbw 6-240 4x 6V
Battery capacity 240 Ah
Connection to power system 230V, 10A
Battery charger 20A
Electrical motors
• Drive motor 24 V DC / 1500 W
• Control motor 24 V DC / 150 W
Main fuse
• Next to the batteries 200 A Maxifuse
Fuses on the logic circuit:
• Control logic circuit 5 A Autofuse
• Emergency stop circuit 1 A Autofuse
Hydraulic systemScissors raising/Swing:
Volume hydraulic system about 7 L (7.4 quarts)
Pump type Gear-driven pump
Hydraulic aggregate
Maximum operating pressure 195 bar
Lift cylinder 31492
Swing axle cylinder ESHL 633290OK-91081
OtherType approval CE
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OVER AND UNDERCARRIAGEThe chassis supports and connects the drive wheel, swing axle and
scissors. It includes batteries and the control system and their connections.The chassis is made of formed and welded steel plate. The cover plates aremade of aluminum and protect the drive motors, batteries and electrical box.
Two drive wheels and two link wheels are located diagonally under thechassis. The front wheels, a drive unit and a link wheel, are attached to acommon swing axle and form a tight turning wheel unit. Two swing axlecylinders are attached to the wheel unit. These allow the lift to drive overuneven surfaces without any of its wheels losing ground contact.
The scissors consist of several scissor members connected to thechassis and platform. The number of scissor pairs determines the workingheight of the platform.
The platform consists of an aluminum work floor, railings, and a steelextension. The surface is floor plating to reduce the risk of slipping on theplatform.
1. Maxwheel2. Drive unit3. Scissors4. Swing axle cylinder5. Caster wheels6. Swing axel
1
2
3
4
5
6
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DESIGN AND FUNCTION
Worm gear
Drive motorSteering motor
MaxWheel
MOTOR AND DRIVE SYSTEM
MOTOR AND WORM GEARSThe drive wheel is run by a 24 V electric motor for each wheel. Power
is transferred directly from the motors via the worm gears to the drivewheels. The wheels are controlled, i.e. rotated horizontally, by two steeringmotors underneath the chassis. Power from the steering motors is transfer-red in the same way as the drive motors.
LOW SPEED DRIVESThe machine is fitted with an lowspeed option for smooth operation.
Lowspeed drive mode is activated by setting an switch on the control box.
MAXWHEELThe two MaxWheels are used for both driving and steering the lift.
Unlike normal wheels that can only roll forward and backward, theMaxWheel can rotate around its own axis and therefore move the lift in alldirections. By running the wheels in opposite directions, the entire lift can berotated around its center point.
CASTER WHEELSThe rotating caster wheels follow the motion of the lift and adapt
themselves to the relevant direction of movement. The wheels are made ofsolid polyurethane rubber with casted steel hubs.
Low speed drive Brake
MaxWheel
Encoder
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1
2
3 4
31 2
LEFT SIDE1. Front worm gear+drive motor2. Swing axle cylinder3. Batteries4. Battery charger
RIGHT SIDE1. Back worm gear+drive motor2. Electronics box3. Swing axle cylinder
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DESIGN AND FUNCTION
1
2
ELECTRICAL SYSTEM
ELECTRICAL CABINETThe electronics cabinet is on the lift’s right side. The cabinet contains the
fuses and all the electronics needed to drive and steer the lift.
MAIN SWITCH / EMERGENCY STOPThe main switch disconnects all the lift functions and can be locked.
The main switch is by the step on the side of the machine.
There are two emergency stop buttons, one on the control box and oneon the chassis by the step. The emergency stop buttons disconnect allfunctions when pressed. Turn and pull out to reset the system.
BATTERIESFour 6V batteries are located on the lift’s left side under the middle
aluminum cover. The batteries are used in normal operation.
Under no circumstances may the lift be powered while connected by itspower cord.
If the batteries’ voltage drops below 20 V, the speed of the lift is reducedto compensate for the decrease in power. Note that the platform can belowered manually at any time to the ground level by following the instructionsfor emergency lowering in the ”Operation” chapter.
BATTERY CHARGER The battery charger is under the middle aluminum cover. Battery status
can be checked when the aluminum cover is on by looking in the inspectionhole.
Main switch
Electronics box
1 230V / 110V connection
2 LED
Emergency stop
Batteries
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SCISSORS HEIGHT SENSORA scissors height sensor that measures the height of the platform is
located on the outside of the back left support. The height affects how fastthe machine will move and whether the tilt protection feature is activated.The tilt protection turns off all functions except lowering if the lift tilts morethan 3° laterally or more than 3° longitudinally if the platform is over 3meters high.
TILT SENSORThe tilt sensor measures the machines tilt and sends a signal to the
steering system if the tilt is more than 3°. The sensor is in the electronic box. Scissors height sensor
110 VAC OUTLET ON PLATFORMOn the platform there is an outlet for 110V to drive electrical machines.
The intake for the outlet is located at the rear end of the machine by theladder.
WARNING BEACON / TRAVEL ALARMThe warning beacon is located on top of the right aluminum cover. The
beacon and travel alarm is active when the machine is moving or theplatform is raised or lowered.
Amber beacon
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DESIGN AND FUNCTION
SENSOR SYSTEM
SENSORSThe machine is equipped with an tuchless bumper system that consist of
18 photoelectric sensors. When an sensor is activated by an obstical ansignal goes to sensor plc and stops all machine functions as long as thaobstical is present.
The scanning distance can be simply and quickly adjusted by using theteach buttons or with the fine adjustment option.
Put an object in front of the sensor at the distance that you want to senson, press both yellow buttons in the back of the sensors for 2 sec.
The sensors yellow light should now light, until you remove the object infront of the sensor. For fine adjustment press either + or the - switch to getthe correct sensing distance. Make sure to keep the sensor head clean at alltime for best function.
Teach buttons
SENSOR CONNECTIONSThere are one connection box for the sensors locaded on the platform.
The box is located on the platforms rights side under the platform floor.Signals passing throuh the box are sent down to the main electrical cabinetwhere the connections for the chassi sensors are located. The signals fromthe sensors are processed in a PLC located in the main cabinet.
PLATFORM CONNECTION BOXIn the connection box are all of the eight platform sensors connected for
power to the sensors and signals down to the sensor plc. For future usethere is possible to connect one moore sensor on the platform, at connectionpoint 24 to 25 is an jumper when there is no extra sensor connected. Seinstructions below for how to connect an extra sensor.
1. Remove jumper on 24, 25
2. Connect the sensors cables according to the instruction below
24 = Brown cable + .
25 = White cable sense .
26 = Blue cable - .
3. Calibrate the new sensor at suitable scanning distanse.
4. Do an function test of the new sensor, put an object in front of thesensor, an alarm should now sound and stop when you remove the object.
Sensor Cables
SignalCable
Power on led(Green)
Sense led(Yellow)
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Bumper override buttonOn the control box there is and override button, this button can be
activated if one of the sensors is sensing an object and you still want tomanouvre the machine.
Press the button to activate machine functions (alarm will still be activeuntil the object is out of range)and drive away from the object.
- When override button is active the sensor bumber systemis out of function, only use it when nesessery
CAUTION!
Over ridebutton
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DESIGN AND FUNCTION
HYDRAULIC SYSTEMThe hydraulic system consists of a tank with an electric powered
hydraulic pump, a solenoid valve with emergency lowering, a pressuregauge outlet, a pressure sensor to avoid overloads in accordance with EN280, and a number of hydraulic cylinders for different functions.
HYDRAULIC AGGREGATE WITH PUMP (LIFT)The hydraulic system is filled with 7 liters (7.4 quarts) of hydraulic fluid
at the factory. The hydraulic fluid level must be topped-up at regularintervals. The hydraulic pump has an integrated strainer and since thesystem is completely self-contained, it is not necessary to change thestrainer provided thorough cleanliness is observed when changing fluid. Thehydraulic pump has an electric solenoid valve, emergency lowering valve, apressure sensor and a pressure gauge outlet.
HYDRAULIC CYLINDERS (LIFT)Lifting is accomplished by two cylinders, one on each side of the scissors
assembly. They are both single-action. The minus side is free and if there isan external leak, the oil will be returned to the tank.
Both lift cylinders have a valve plate that contains an electrical valvewith a manual bypass valve for emergency lowering. A broken hose valveis on the lower hose connection of both cylinders.
SWING AXLE CYLINDERThis is a cylinder with a piston rod that goes all the way through. The
chambers on each side of the cylinder are connected. There is a shutdownvalve in the connection pipe. When the valve is open, the swing axle canswing. When the valve is closed, the swing axle is locked in place. Thepressure accumulator is loaded with 100 bars of excessive pressure.
1 Pressure gauge outlet
2 Emergency lowering3 Solenoid valve
4 Pump
5 Top up cover
6 Tank 7 Pressure sensor
Swing axle cylinder
Pressure accumulator
BypassValve plate
1
34 5
2
6
7
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SCISSOR AND PLATFORMThe scissor and platform are made of a durable plate construction where
the platform is painted and the scissors have zinc plating both on the insideand out.
SCISSORSThe scissors consist of several pairs of scissors connected to the chassis
and platform with axle taps, sliding blocks, and cam rolls.
PLATFORMThe platform has an undercarriage, railing, and an extension that is
controlled from the control box.
SAFETY BRACEThe machine is equipped with a safety brace that can easily be lowered
between the scissor members and used to secure the platform in its raisedposition. For example, when performing maintenance work that requiresyou to be under the platform, the safety brace must be positioned inaccordance with the instructions in the ”Operation” chapter.
PlatformExtension
Railing
Safety brace
Control box
Scissors
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DESIGN AND FUNCTION
CONTROL BOXAll machine movements, i.e. moving, raising/lowering and maneuvering
of the extension, are controlled with the control box. The control box is onthe right-hand side of the platform.
The control box includes a steering control for direction of movement, anaccelerator, a number of buttons/function switches, and a warning light.
A rotary key switch and an emergency stop button are on the bottom of thecontrol box. Another emergency stop button is located next to the emergencylowering control on the right side of the chassis. The emergency stop buttoncan be reset by pulling it out.
The operator controls the speed of all movements with the accelerator.The selected movement begins when the accelerator is moved backward orforward. The more the accelerator is moved, the faster the lift movementwill be. The operator controls the speed of all movements with the accelera-tor. Above the steering control and accelerator there are a number offunction switches for work/transport mode, rotation and raising/loweringthe platform. The control box also has a warning light that uses differentflashes to indicate low battery voltage, lateral incline over 3°, longitudinalincline over 3°, and excessive loads.
The control box can easily be removed from its holder for safe storageor simple service.
1. Emergency stop2. Rotary key switch3. Accelerator4. Horn5. Bracket6. High / Lowspeed7. Transport/working mode - 3D8. Rotation9. Sensor Override10. Lift/Lower11. Extension12. Warning indicator13. Lift / Driving14. Battery indicator15. Steering wheel
13
1
2
11
3
4678 9
12
5
10 14 15
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DESIGN AND FUNCTION
SELECTING MOVEMENT MODEThanks to the design of the MaxWheel and the computerized control
system, the lift can be moved by selecting the 3D working mode, rotation ortransport mode. All movements are proportional to the lever movement.
3D WORKING MODEWhen in 3D working mode, it is possible to move the machine in any
direction. This mode of movement is preferable when the machine is beingpositioned and/or maneuvered in confined spaces.
ROTATIONThe lift will rotate around its own axis. This make it easier to change
transport direction.
TRANSPORT MODEUsing this mode, the lift will move as if it were a car. The front wheel
will turn and the rear wheel is locked straight ahead. This mode ofmovement is preferable when the machine is being transported to theworksite or for long distances under its own power.
RAISING/LOWERING THE PLATFORMThe platform can be raised or lowered continuously from the control
box. By pressing the lever forward the platform is raised to the desiredheight. The platform is lowered when the lever is pulled backwards.
WARNING LIGHT AND SIGNALThere is a warning light and signal on the control box which warn for
different events based on how it flashes.
1. The light flashes on and off with equal intervals =Overloaded platform ——___——___——___——___——___
2. Three short flashes followed by a long off period = Tilt protectionactivated.——___——___——____________——___——___
3. A short flash then off for a longer period =Emergency stop activated. ——___________——__________
4. Low battery voltage —————————————————--
5. Lamp flashing rapidly on and off for equally long periods =Bumper protection. ___----___----___----___----___----___----_
Restore following incidents, see chapter ”Handling”.
25
OPERATION
Read the safety instructions before using the machine.
If you have not used the machine before, practice operating it in a wideopen space first. It is essential that you can operate the machine in anemergency without having to think about how it works. Incorrect operationcan lead to bodily harm and damaged equipment.
STARTING AND STOPPINGBEFORE STARTING
The following must be done each morning and before work at a new sitebegins. Steps 1 and 2 only apply after transport.
1. Make sure there is no transit damage to the machine.
2. Inspect the premises in which the lift is to be used. Note any obstructions,changes in surface level, doors and other openings.
3. Carry out the daily inspection. See ”Maintenance”.
STARTING1. Remove the power cable if connected.
2. Turn on the main switch.
3. Insert the key into the rotary key switch on the control box and turn it.
4. Select the desired movement mode on the control box.
5. Move the accelerator forward/backward to start the selected function.
STOPPING1. Release the accelerator so that it returns to the neutral position.
2. Turn the rotary key switch on the control box.
3. Remove the key from the lock.
4. Turn off the main switch.
RESETTING THE WARNING LIGHT ANDSIGNAL- When lowering the platform and the scissors approach their lowestposition, the platform will stop and sound a warning, then continue loweringuntil it reaches its lowest point.
- The machine will stop and a warning sound will activate if the tilt ofthe machine exceeds 3° longitudinally or laterally. Lower the platform untilthe alarm ceases to sound.- If one of the two emergency stop buttons is pressed, all functions ofthe machine are turned off and a warning sound and light are activated. Thisis reset by rotating and pulling both of the emergency stop buttons.- If the machine is over loaded, all functions are stopped and a warninglight and sound are activated. This is reset by reducing the load on the ma-chine.
OPERATION
26
MOVINGNote that all movements are fully proportional to the movement of the
accelerator within respective speed ranges irrespective of which mode ofmovement is selected.
MOVING: 3D WORKING MODE1. Select ”Moving” and then ”3D” on the control box.
2. Check the direction of movement on the control box’s steering control.
3. Adjust the direction of movement if necessary by turning the steeringcontrol to the right or left.
4. Make sure there are no persons or objects in the direction of movement.Note that you must check the entire height of the lift, from the ground tothe platform!
5. Carefully move the accelerator forward.
6. Move the accelerator forward more to increase speed and towards theneutral position to reduce speed. Release the accelerator to stop.
MOVING: ROTATION POSITIONRotates the lift around its own center.
1. Select ”Moving” on the control box, and then hold down the button forthe ”Rotation” moving mode.
2. Make sure there are no persons or objects in the direction of movement
3. Move the accelerator forward to rotate to the left and backward torotate to the right. Move the accelerator backward/forward to increasespeed and towards neutral to reduce speed. Release the accelerator tostop rotation.
MOVING: TRANSPORT MODE1. Select ”Moving” and then ”Transport” on the control box.
2. Check the direction of movement on the control box’s steering control.
3. Adjust the direction of movement if necessary by turning the steeringcontrol to the right or left.
4. Make sure there are no persons or objects in the direction of movement.Note that you must check the entire height of the lift, from the ground tothe platform!
5. Carefully move the accelerator forward to move the lift forward andbackward to move the lift backward.
6. Move the accelerator further forward/backward to increase speed andtowards neutral position to reduce speed. Release the accelerator tostop. Note that the lift brakes automatically when the accelerator is inthe neutral position.
”Transport mode”
”3D WorkingMode”
”Moving”
”Moving”
”Rotation mode”
”Moving”
27
OPERATION
LIFTING FUNCTION AND WORKING FROM THEPLATFORM
RAISING - LOWERING1. Select the ”Platform” mode on the control box.
2. Press the ”Raising/lowering” button on the control box.
3. Move the accelerator carefully backward to raise the platform andcarefully forward to lower it.
4. Move the accelerator further back to increase speed and towards theneutral position to reduce speed. Release the accelerator to stop raising.
MOVING WITH RAISED PLATFORMThe lift can be moved with the platform raised, but the higher the
platform is, the slower the maximum speed will be. The platform should belowered completely for transporting long distances.
EXTEND IN/OUT1. Select the ”Platform” mode on the control box.
2. Press the ”Extend in/out” button on the control box.
3. Carefully move the accelerator forward to move the extension out andcarefully back to move the platform in.
4. Move the accelerator further back to increase speed and towards theneutral position to slow. Release the accelerator to stop the extension.
EMERGENCY LOWERING CONTROLThe lift can be lowered to the ground manually if a problem arises when
it is in the raised position.
1. Open the bypass valves on both lift cylinders.
2. Pull out the emergency lowering control to lower the lift.
EMERGENCY STOPBoth of the lift’s emergency stop controls will cut all power to the lift.
Emergency stop controls are located on the control box on the platform andon the chassis by the step. To operate the lift again, the emergency stopcontrol has to be turned counterclockwise until it comes out and then use thestart key to start the lift.
SAFETY BRACEThe scissors must be secured with the safety brace before maintenance orother work takes place under the scissors and platform.
1. Remove any loads on the platform.
2. Raise the platform.
3. Raise the safety brace.
4. Lower the platform until the safety brace touches the upper scissor.
Release the safety brace by repeating the process in reverse order.
”Platform raising/lowering”
”Platform”
Safety brace
Emergency lowering control
”Platform”
”EXTEND IN/OUT”
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2
3
4
(Principle picture)
TRANSPORT, LIFT AND STORAGELIFT WITH FORKS
The lift can be moved using a forklift truck or a fork-equipped wheelloader if it has sufficient lifting capacity. The lift forks must be inserted infrom the side of the machine into special purpose openings under themachine. The forks must be at least 1200 mm (47 inches) long.
1. Lower the platform to its lowest point.
2. Insert the forks in the lift pockets.
3. Make sure no one is nearby and then lift carefully.
LIFTING WITH STRAPSThe lift can also be lifted with straps.
1. Turn off the machine’s main switch.
2. Connect the lift straps to the four holes at the lower edge of the chassis.
3. Run the straps under the railing on the platform and join them in thecenter of the platform.
4. Attach the straps to any lifting device.
TRANSPORTING ON ANOTHER VEHICLEWhen transporting on a truck or trailer, the machine must be tightly
secured.
1. Secure the lift using straps that can be attached to the lift holes on thelower edge of the chassis.
2. Tighten so that the lift cannot move.
3. Place chocks in front of and behind the wheels.
STORAGEThe lift may only be stored in a dry, indoor environment. Remember todisconnect the batteries when stored for longer periods of time. Beforeany use of the lift after long-term storage, read the instructions under”Maintenance” on page 32.
Lift pocketLift hole
29
OPERATION
CHARGING THE BATTERIESThe batteries must be charged after each working period or at least
every eighth operating hour. The batteries can be charged either from themains or from a reserve power source.
CHARGING THE BATTERY FROM THE MAINS1. Turn off the lift with the main power switch.
2. Connect the machine to an earthed outlet with AC mains voltage. Theoutlet must be fused for 10 A.
The charging starts after a few seconds and the status indicator, Orangeled is lit up. Orange led remains on until the battery is fully charged. If thecharger is connected to a fully charged battery the charger will be chargingfor 1 hour. This is the minimum charging time. Green led, is lit up when thebattery is ready to be used. Maintenance charging will continue as long asthe battery is connected. The charger will be reset as soon as the charger isswitched off and then on or if the mains connector is disconnected and thenconnected again. The charging time depends on the size of battery and thedepth of discharge. Red flashing led may mean that the battery is notproperly connected. Check cables, connection terminals, plugs and otherconnections to the battery. Rectify if possible. Measure the voltage at thebattery and at the charger. If the connecting points and the voltage iscorrect.
OBS: Switch off the charger before the battery is disconnected. If thebattery is disconnected without switching of the charger, sparks may beproduced.
Refer to the separate instruction manual for more information onthe battery charger.
The power cord for the batterycharger
30
MAINTENANCEMaintenance instructions must be followed to insure the safety of the
operator and maximum operating life of the lift. Maintenance must beperformed by qualified personnel.
If the machine malfunctions or if it is damaged during operation, it mustbe repaired before is continued. Even minor damage and faults can causeserious damage or injury.
Remember to lock the scissors with the safety brace before performingany work under the scissors or platform.
IMPORTANT INFORMATION!The hydraulic system is extremely sensitive to impurities. Particles of
only a few µm (0.001 mm) in size can jam in a valve and cause seriousinterruptions and accidents. Impurities also increase the wear on componentsand can damage seals, valves and other moving parts.
Damaged piston rods will allow impurities to enter the hydraulic system.Impurities can also enter the hydraulic system during repairs unless sufficientcare is observed. Internal damage to pumps, cylinders and other movingparts can result in metal particles entering the system.
Be observant to unusual sounds or noise from the hydraulic system andabnormal heat radiating from hydraulic system components. Also be obser-vant to leaks and check the hydraulic fluid level in the tank when necessary.
Never fill the machine with used hydraulic fluid. Care for the environmentand avoid fluid spills. Always dispose of waste fluid with an authorizedcompany.
Always read the fluid manufacturer’s instructions for use. Avoid long-term skin contact with hydraulic fluid and be careful not to allow it to splashin your eyes.
31
MAINTENANCEMAINTENANCE
DAILY INSPECTIONCheck the following before starting work:
• Inspect the lift for any exterior damage.
• Make sure the control devices and signs are not damaged.
• Make sure there are no leaks in the hydraulic system. ”Oil stains un-der the machine”.
• Make sure the scissors height sensor is located correctly.See illustration.
• Test run the lift functions and make sure the emergency stop is working.
CLEANINGClean the lift as needed. The lift should be kept clean for reasons of both
safety and job satisfaction. Certain functions can be affected by extremecontamination, warning signs can become difficult to read, and it may bedifficult to detect oil leaks.
1. Remove any oxidation from around the battery terminals with a wirebrush. Use protective gloves and take care not to get acid on hands orclothes. Lubricate the terminals with petroleum jelly to avoid oxidation.
2. Check the fluid level in the batteries. The battery acid must cover theplates in the battery. Top up with distilled water as needed.
3. Check the hydraulic fluid level in the tank.
4. Inspect wheels and treads.
5. Check scissor mountings and joints, making sure all pins are securedwith circlips. See illustration.
6. Inspect the swing axle. Begin by turning off the machine. Raise themachine on one side of the swing alxe with a jack or other tool. The twowheels should be about 5 cm (2 inches) from the ground. The swing axleshould be completely fixed and maintain the same position as when it ison the ground. Turn on the power and move the accelerator in anydirection. Now the swing axle should turn so that one wheel is in contactwith the ground. If this works as it should, the swing axle and swing axlecylinder are performing properly.
7. Control of tilt sensor.
a. Drive the lift "lateral" up on a sloping surface over 3º.Raise the platform from its lowest position to 118 inches.The machine’s drive function will be inactivated and a warninglight will turn on.Lower the platform and the lift will reactivate and the warninglights will be reset.> 3º
> 3º
x2
x2
Longitudinally
Laterally
Longitudinally
Laterally
Circlip Axle tap
Scissors height sensor
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BIANNUAL MAINTENANCENote that a maintenance interval of 6 months assumes the lift is used
under normal conditions. Use in dirty environments or under difficultconditions may entail a shorter maintenance interval. Make sure to alsocheck the points for daily and weekly inspection.
CONTROL OF THE SCISSORS AND THE LIFT FUNCTION1. Remove the control box from its mounting.
2. Raise the lift to a suitable height while holding the control box.
3. Open the bypass valves.
4. Pull the emergency lowering control and make sure the platform dropsslowly.
INSPECTION OF THE UNDERCARRIAGE1. Secure the scissors with the safety brace.
2. Inspect the hydraulic cylinder mountings for fractures or other damage.
3. Inspect electrical connections and protectors on electric motors andhydraulic pump. Fix any problems.
4. Inspect all the cables in the undercarriage and on the scissors. Payattention to chafing, pinching and damaged clamps. Fix if needed.Immediately replace damaged cables.
5. Remove the covers on the drive wheel.
6. Check and retighten bolted joints on the worm gears above the drivewheel.
7. Check the wear on the drive wheel’s rubber wheel.
8. Remove the cover plate and inspect the tilt sensor under the chassis.
9. Reset the scissor lock.
7b.Drive the lift ”longitudinal” on a sloped surface over 3º.Raise the platform from its lowest position to 118 inches.The machine’s drive function will be inactivated and a warning light will turn on.
Lower the platform and the lift will reactivate and the warninglights will be reset.
Important! The same procedure must be carried out in all fourdirections.
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MAINTENANCEMAINTENANCE
> 3º
> 3º
x2
x2
MAINTENANCE AFTER STORAGE
CLEANING AND GENERAL MACHINE INSPECTIONS1. Clean the lift. Remember that water and damp can destroy the electrical
and drive system.
2. Inspect the lift for any exterior damage.
3. Make sure the control devices and signs are not damaged or illegiblebecause of dirt and other things.
HYDRAULIC AND ELECTRICAL SYSTEM1. Make sure there are no leaks in the hydraulic system. ”Oil stains un-
der the machine”.
2. Check the hydraulic fluid level in the tank.
3. Remove any oxidation from the battery terminals with a wire brush. Useprotective gloves and avpod gettomg acid on hands or clothes. Lubricatethe terminals with petroleum jelly to counteract oxidation.
4. Check the fluid level in the batteries. The battery acid must cover theplates in the battery. Top up with distilled water as needed.
5. Make sure that both emergency stops work.
INSPECTION OF THE SCISSORS AND THE LIFT FUNCTION1. Make sure the scissors height sensor is located correctly.
2. Remove the control box from its mounting.
3. Raise the lift to a suitable height while holding the control box.
4. Open the bypass valves.
5. Pull the emergency lowering control and make sure the platform dropsslowly.
INSPECTION OF TILT SENSOR1. Inspection of tilt sensor.
a. Drive the lift ”lateral” on a sloped surface over 3º.Raise the platform from its lowest position to 118 inches.The scissors and platform should nevilera until it isstanding vertically.
Lower the platform and the scissors will return to the defaultposition
. b. Drive the lift ”longitudinal” on a sloped surface over 3º.Raise the platform from its lowest position to 118 inches.The machine’s drive function will be inactivated and a warninglight will turn on.Lower the platform and the lift will reactivate and the warninglights will reset.
Important! The same procedure must be carried out in all fourdirections.
34
INSPECT THE SWING AXLE1. Begin by turning off the machine.
2. Raise the machine on one side of the swing axle with a jack or other tool.The two wheels should be about 5 cm (2 inches) from the ground. Theswing axle should be completely fixed and maintain the same position aswhen it is on the ground.
3. Turn on the power and move the accelerator in any direction. Now theswing axle should turn so that one wheel is in contact with the ground. Ifthis works as it should, the swing axle and swing axle cylinder areperforming properly.
35
MAINTENANCEMAINTENANCE
REFILLING HYDRAULIC FLUID
HYDRAULIC AGGREGATE (RAISING SCISSORS):Hydraulic fluid: Shell Tellus TX 32 or similar.
Consumption: 7 liters (7.4 quarts).
1. Lower the platform to its lowest point.
2. Clean around the filler cap on the hydraulic tank.
3. Remove the blue return hose from the pump before the oil is filled.
4. Unscrew the filler cap.
5. Fill with the right type of fluid to the max level indicated by the label.
Note: Hydraulic fluid is only changed when performing major repairs.
Fluid filling
Level indicator
36
TROUBLESHOOTING
TROUBLESHOOTINGThis troubleshooting section is in no way comprehensive but provides
tips on the components that should be checked for some of the mostcommon problems.
The lift must be returned to the supplier or authorized service companyfor more extensive troubleshooting and repair. Always get in touch with thesupplier or trained service personnel if you are not sure how to fix aproblem.
NOTHING HAPPENS WHEN KEY ON THE CONTROL BOX ISTURNED TO START.1. Make sure the emergency stops have been pulled out (2 pcs.).
2. Check for triggered fuses in the electronics box.
3. Make sure the batteries are charged.
4. Make sure the control cable running between the control box and theelectronics box is secure at both ends and that none of the pins aredamaged.
5. Call qualified service personnel.
BATTERIES NOT CHARGED DESPITE POWER CORD BEINGCONNECTED.1. Make sure the red LED on the charger is on when the cable is plugged
in. This indicates that power is being supplied to the charger.
2. Check that the power being supplied is the right voltage.
3. Check the battery connection and fluid level.
4. Call qualified service personnel.
CERTAIN FUNCTIONS ON CONTROL BOX NOT WORKING.1. Make sure the control cable running between the control box and the
electronics box is secure at both ends.
2. Make sure none of the connector pins are bent.
3. Call qualified service personnel.
37
SCHEMATICS
SCHEMATICS
38
39
SCHEMATICS
40
41
SCHEMATICSSCHEMATICS
42
43
SCHEMATICS
44
45
SCHEMATICS
46
DECLARATION OF CONFORMITY
DECLARATION OF CONFORMITY
MAXI 75V BSS
Peter BerntssonName
Signature
INDUSTRIV. 9 916 31 BJURHOLM +46-(0)932-405 60
Address Phone
Type
Serial number
CompanyMAXMOVE AB
Town Date
Declaration of responsibility for the product:
BJURHOLM
To which this declaration refers is manufactured to conform with the CouncilDirective 89/392/EEC dated June 14, 1989 as amended by Council Directive 91/368/EEC dated June 20, 1991.
Manufacturer:
47Copyright: MaxMove AB
CONTACT
Manufacturing / RepairsIndustrivägen 991631 BjurholmSwedenPhone: +46 932 405 60Fax: +46 932 105 60
MaxMove Business CenterAugustendalsvägen 46131 26 NackastrandSwedenPhone: +46 8 71 62 020Fax: +46 8 553 606 44E-mail: [email protected]: www.maxmove.com
