Thank you for choosing Hydralada® as your Elevating Work Platform supplier.
The team at Hydralada Company will be working hard to ensure that supplying your new machine is only the beginning of our ongoing commitment to provide service and support. An ever increasing circle of owners rely on our products to provide long and efficient service in many different applications and in various international markets.
Hydralada Company have been building this type of machine since 1975, accumulating a wealth of experience. Your new machine has been engineered, using the best available components to ensure it gives a long and trouble free life.
The Occupational Safety and Health Regulations impose a duty on manufacturers and owners to take all reasonable steps to ensure that operators are made aware of potential hazards and the correct operating procedures. We have prepared this manual carefully to provide the information you need to meet your obligations. “Ignorance” is not a defence to legal actions in respect of this law so please ensure that you, and your operators study and understand this information before using your Elevating Work Platform (MEWP).
The Hydralada Elevating Work Platform has been manufactured specifically for a particular country and complies with the regulations that applied in that country at the time of production. Hydralada Company cannot be held responsible if the Hydralada MEWP does not comply with or only partly complies with the relevant legal requirements in other countries and continents.
To ensure the best possible performance, it is important your MEWP is serviced and maintained in good working condition. The service section of this manual has been prepared to give those persons responsible for this work the information they require to perform this work effectively. Our Service Department is always available to provide advice of a more detailed nature should this be required.
Finally, DO NOT file this manual away in a dusty corner. This manual should be in regular use, especially with regard to the Daily Inspection and Maintenance section. Should you have any problems or require any further advice please contact your local dealer or Hydralada Company - we will be pleased to assist you.
HYDRALADA® is a registered trademark of AJ & JP Smith Ltd
THE HYDRALADA STANDARD WARRANTY
Hydralada Company warrants the new machine referred to on the ‘Delivery and Warranty Registration’ form against faulty parts or workmanship for a period of 12 months from delivery to the original purchaser. Notwithstanding the date of delivery, this Warranty will cease to apply 24 months following departure from the factory of the guaranteed equipment.
Where a customer believes a Warranty Claim may be involved, the machine must be returned to the authorised dealers’ workshop for assessment. If the owner requires a serviceman to travel to a machine for diagnosis or repairs, any labour or travelling cost incurred must be met in full by the owner. Hydralada Company is not responsible for updating or upgrading completed machines with design changes that occur after production of the machine.
Any work whatsoever carried out during the warranty period shall mandatorily be performed by Hydralada Company or by a Hydralada® authorised dealer, under penalty of forfeiture of the Warranty.
Any components deemed in the opinion of Hydralada Company to be defective will be repaired or a replacement supplied at no charge to the purchaser, such action being entirely at the discretion of Hydralada Company or its authorised representative. For any claim to be considered, evidence that the scheduled servicing has been maintained may be required.
Hydralada Company and the authorised dealer shall not be liable in the following cases:
• Malfunctions due to faulty servicing, user inexperience or abnormal use
• Failure to perform overhauls, oil changes and checks in accordance with manufacturer’s instructions
• Replacement of genuine parts or accessories with parts or accessories of another origin, or when the machine sold has been transformed or modified
• Trouble resulting from use of an oil other than that recommended or sold by the manufacturer
Hydralada Company retain the right to require any part claimed defective to be returned for inspection before any decision or action if any will be undertaken. In any case where Hydralada Company or its dealer may agree that it is impracticable to return any defective components, all failed parts must be tagged and held by the dealer until any decisions are confirmed. Replacement parts provided under the terms of this Warranty are covered for the remainder of the Warranty period applicable to the product in which they are installed as if such part were original components of that product.
Where a claim is to be made for labour of any kind, detailed instructions and approval to carry them out must be first obtained from an authorised representative of Hydralada Company before any repair or replacement is effected
This Warranty does not extend to cover normal maintenance, the replacement of normally wearing expendable parts, or custom-built variations. Fuel related failures, failures which result from poor lubrication of any kind, faults due to misuse, neglect, accident, or unauthorised modification, incorrect repair or the incorrect fitment of attachments to the machine will not be considered.
This Warranty may include an extended drive train warranty. Such extended warranty applies specifically to the Engine, Hydraulic Pump, Valves and Wheel Motors which are covered against major structural failure, excluding Seals and Gaskets. As concerns parts or equipment that are not manufactured by Hydralada Company, in particular internal combustion engines, pumps and motors, hydraulic distributors and accessories, etc, the warranty is limited to that of the suppliers to Hydralada Company if over the above 12 months.
In purchasing this Hydralada® equipment with this Warranty provided by Hydralada Company the purchaser accepts full responsibility to pay for mileage, transport or any other consequential cost, damages or losses incurred. Hydralada Company does not furnish loaner machines while the unit is being repaired.
To validate this Warranty, it is necessary to
• Register the machine by completing a ‘Delivery and Warranty Registration’ form at the time of purchase, a copy of this form must be returned to Hydralada Company within 30 days,
• Ensure the 250 Hour/6 month free service is carried out and the completed coupon is returned to Hydralada Company.
This Warranty is explicitly limited to the terms defined above. Hydralada Company shall not be liable, under any circumstances, for payment of any indemnity for any reason whatsoever. This Warranty is transferable to a new owner at the discretion of Hydralada Company provided the details of the new owner are advised in writing within seven days of the transaction.
THE HYDRALADA ELEVATING WORK PLATFORM IS NOT ELECTRICALLY INSULATED
If the Work Platform, booms, or any other conductive part of a Hydralada Elevating Work Platform (MEWP) contacts a high-voltage electrical conductor, the result can be SERIOUS INJURY or DEATH for persons on or near the MEWP.
STOP DAN G E R
GO NO CLOSER THAN MINIMUM SAFE APPROACH DISTANCES (M.S.A.D).
The M.S.A.D. in most areas of New Zealand is 4.00 Metres for overhead power lines on poles and 8.00 Metres for overhead power lines on towers.
You must check with your local power authority to obtain the correct M.S.A.D. for your area.
Be sure to allow for sag and sway in the wires and the Work Platform, and regard all conductors as energised at all times.
If a Hydralada MEWP comes in contact with a live electrical conductor, the entire machine can be charged. If that happens, you should remain on the MEWP and not contact any other structure or object within reach. That includes the ground, adjacent buildings, poles, and any object not a part of the Hydralada MEWP. Such contact could make your body a conductor to the other object creating an electrical shock hazard resulting in SERIOUS INJURY or DEATH.
DO NOT attempt to enter or leave the Hydralada MEWP until you are sure the electricity has been turned off.
If a Hydralada MEWP is in contact with a live conductor, the platform operator MUST warn others on the ground in the vicinity of the Hydralada MEWP to STAY AWAY from the machine, since their bodies can also form a path for electricity to ground thus creating an electrical shock hazard with possible ELECTROCUTION and DEATH.
DO NOT attempt to operate the Hydralada ground controls when the platform, booms, or any other conducting part of a Hydralada MEWP is in contact with electrical wires or if there is an immediate danger of such contact.
Personnel working on or near a Hydralada MEWP must be continuously aware of electrical hazards, recognising that SERIOUS INJURY or DEATH can result if contact with an electrical wire does occur.
Table of Contents
Introduction
n
n
n
n
n
n
n
n
n
n
n
n Identifying the
n
1. Specifications
n
4. Controls
2. Safety
n
3.
5. Daily Inspection and Maintenance
Table of Contents
o Hour Meter 5-2
o Fuel Level 5-2
o Fuel Leaks 5-2
o Hydraulic Oil Level 5-2
o Checking the Engine Oil Level 5-3
o Engine Air Cleaner 5-3
o Wiring 5-3
o Battery Terminals 5-3
o Battery Electrolyte Level 5-3
o Hydraulic Oil leaks 5-4
o Structural Damage 5-4
o Wheel Nuts 5-4
o Wheels and Tyres 5-4
o Lanyards and Safety Harnesses 5-5
o Bolts and Fasteners 5-5
o Electrical System Fuses 5-5
o Inclinometer 5-6
o Rotating Beacon (option) 5-6
o Switched Mid-rail 5-6
o Steel Tracks (option) 5-7
o Irrigated Pick Bag 5-8
6. Operation
n Operating Procedures 6-1
o Preparing for Operation 6-1
o Starting the Engine 6-2
o Starting a Warm Engine 6-3
o Starting a Fuel Injected Engine 6-3
o Operating the Throttle 6-4
o To Operate the MEWP 6-4
o Turning Techniques - Pedals 6-5
o Other Control Options 6-5
n Common Problems Encountered by New Operators 6-6
o Not Driving Straight 6-6
o Rough or Jerky Operation 6-6
o Lack of Traction 6-6
n
o
o
o Working Up or Down a Slope
n Boom Support
n Transport 6-9
8. Picking Bag Operation o Operation
9. Options
10. Troubleshooting
o Troubleshooting 10-1
o Engine Fault Diagnosis Flow Chart 10-1
o Electrical Fault Diagnostic Flow Chart (Kohler Engine) 10-2
Table of Contents
o
11. Servicing
o
12. Firefighting
o
o
o
o
o
o
13. Alphabetical Index
o
n
o
o
o
Introduction
The most important chapter in this manual is “Safety” chapter 2.
Take time, now, to study it closely. The information in chapter 2 may save your life, or prevent serious injury to yourself or others.
n
Signs
The following six conventions are used throughout this manual.
The Danger sign shown below.
DAN G E R
The signal word Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
The Warning sign shown below.
WARNING
The signal word Warning indicates a Hazard which has the potential to result in death or serious injury.
The Caution sign shown below.
CAUTION
The signal word Caution indicates;
1. A potentially hazardous situation which, if not avoided, may result in minor or moderate injury
2. An action, about to be performed, can harm the MEWP if not done correctly.
The Note sign shown below.
This NOTE sign means that the information following is to assist you in either the proper steps to take for an action or as additional information concerning your present situation, but does not indicate a dangerous condition to either you or the MEWP.
The Hot Tip sign shown below.
This HOT TIP sign is provided to give you helpful information on various aspects of operating the Hydralada MEWP. This information is based on actual operator experiences over many years of operational use and will make operation of your Hydralada MEWP more efficient.
The Important sign shown below.
This IMPORTANT sign is similar to the note sign but implies a greater emphasis on the importance of the information following. The information is to assist you in either the proper steps to take for an action or as additional information concerning your present situation, but does not indicate a dangerous condition to either you or the Hydralada MEWP.
n Other Publications
1. This Operators Manual contains the generic information you require to operate your MEWP efficiently and safely, and is one of three Manuals delivered with each Hydralada MEWP.
2. Delivery Manual (PN 64-5014-00)
This Manual contains the information unique to each individual MEWP and includes:
• Certificate of Stability
• Warranty Registration form
• Acknowledgement of Safety Responsibility form
• Dealer Pre-Delivery check
• 250 Hour Service form
3. Log Book (PN 64-5015-00)
This Book provides a convenient format for Owners and Operators to record relevant information regarding the Elevating Work Platform’s operation and servicing.
n Qualified Operators
The Hydralada Mobile Elevating Work Platform (MEWP) has built in safety features and has been factory tested for compliance with Hydralada specifications and Industry standards. However, any MEWP has the potential to be dangerous in the hands of untrained or careless operators.
Introduction
Training is vitally important and MUST be done under the direction of a QUALIFIED person.
The operator must display a sound understanding of the safe operating parameters of the Hydralada MEWP as well as displaying proficiency in handling and operating the Hydralada MEWP.
Before beginning operation of the Hydralada MEWP the operator must read and understand the operating instructions in this manual, as well as the decals, warnings, and instructions on the MEWP itself.
Before operating the Hydralada MEWP you must be AUTHORISED by the person in charge to do so.
n Operational Rules
The following rules will help ensure the safety of personnel and help prevent needless downtime and damaged equipment.
1. Only TRAINED and AUTHORISED operators shall be permitted to operate the equipment.
2. All manufacturer‘s operating instructions and safety rules, must be strictly adhered to.
3. All employers‘ safety rules along with all OSHA and other Government safety rules must be strictly adhered to.
4. Repairs and adjustments shall be made only by QUALIFIED TRAINED maintenance personnel.
5. No modification shall be made to the equipment without prior written consent of the Hydralada Engineering Department.
6. You must make a pre-start inspection of the Hydralada MEWP at the beginning of each shift. A malfunctioning MEWP must not be used.
7. You must make an inspection of the work place to locate possible hazards before operating the Hydralada MEWP.
WARNING
DO NOT operate this equipment unless you are TRAINED and AUTHORISED and have read and thoroughly understand all of the information given in this Operator‘s Manual and on all DANGER and CAUTION signs on the MEWP. Misuse of this MEWP can result in DEATH or SERIOUS INJURY.
n Maintenance
Every person who maintains, inspects, tests, or repairs these Elevating Work Platforms, and every person supervising any of these functions, MUST be properly trained. This Operator‘s Manual provides a daily inspection procedure and rountine maintenance that will help you keep your Hydralada MEWP in good operating condition.
DO NOT perform other maintenance unless you are a TRAINED mechanic, QUALIFIED to work on the Hydralada MEWP. Call QUALIFIED maintenance personnel if you find problems or malfunctions. Information contained in this manual concerns only current Hydralada Elevating Work Platforms, and Hydralada Company reserve the right to make changes at any time without obligation.
n Handing
When describing locations on the MEWP, it is always considered the operator is standing in the Work Platform with their back to the engine and the castor wheel behind. See chapter 1 page 1-4 to 1-9.
n Responsibilities of Parties
This Operators Manual has been prepared to enable the Operator to operate and carry out routine service of the MEWP in a competent manner. While aspects of safety are covered throughout the text in this manual, owners and operators also incur responsibilities under Industry and State Standards and Legislation.
Some of these documents are:
New Zealand
• Health and Safety at Work Act 2015
• Best Practice Guidelines: Mobile Elevating Work Platforms
• Best Practice Guidelines: Safe Use of Elevating Work Platforms in the Horticultural Industry
• AS/NZS 1418.10: 2011
Mobile Work Platforms
• AS 2550 Part 10
Safe Use of Mobile Work Platforms
• NZ Health and Safety in Employment Act 1992 Australia
• Commonwealth HSE Legislation.
• Individual State HSE Legislation.
• AS/NZS 1418 Part 10.
Mobile Work Platforms
Introduction
• AS 2550 Part 10.
Safe use of Mobile Work Platforms.
International Standards
• ISO 16368
Mobile Work Platforms
• ISO 16653 Part 3
Mobile Work Platforms for Orchard operations.
• ISO 18893
Safe use of Mobile Work Platforms.
It is imperative that all owners and users of the Hydralada MEWP read, understand, and confirm to all applicable regulations. Compliance to OSHA regulations remains the ultimate responsibility of the employer and operator using the equipment.
n Options
The use of optional equipment is discussed throughout the manual as it applies to a particular aspect of operations or controls. However not all optional equipment is covered in this way.
A summary discussion of all the optional equipment is provided in the ‘Options’ Chapter.
—IMPORTANT—
Use only the standard pickbag or Hydralada™ attachments.
The options you will find discussed there are:
1. Free Wheel Hubs
2. Twin Castors
3. Dual Castors
4. Tandem Drive
5. Hydraulic Slew Work Platform
6. Crate Magazine
7. Picking Bag
8. Hydrafork
9. Two Man Platform
10. Rotating Beacon
11. Auxiliary Oil Outlets
12. Adjustable Tracks
13. Rubber Track Drive System
14. Dual Power
NOTE
If you have any optional equipment installed on your MEWP you should read the Options chapter.
n Other HYDRALADA Equipment ¨ Power Pruning Equipment
A wide range of Hydralada Power Pruning equipment, both hydraulic and pneumatic, fully compatible with Hydralada Elevating Work Platforms is available.
This includes Hydraloppa power pruners and hydraulic pruning chainsaws.
Introduction
n HYDRALADA Model Code Key
These numbers are located on the Serial Number decals placed behind the Work Platform and on the left hand tail area of the MEWP.
Record your MEWP identification numbers on the identification label below for future reference.
MODEL NUMBER:
SERIAL NUMBER:
n Identifying the MEWP (Elevating Work Platform)
When ordering parts or servicing your MEWP it will be necessary to refer to the:
1. Serial Number
This identifies the individual MEWP.
Record your Model and Serial Numbers on the identification label below for future reference.
Note: There is an additional factory production number stamped on the extreme rear of the tail of the MEWP. This is only used as an internal purposes during the manufacture of the MEWP.
2. Model Number
This is a composite set of numbers which enables the identification of particular features and options on the MEWP.
n Identifying the Engine
When ordering parts, or in any communication involving an engine always give the Model, Specification, and Serial Numbers of the engine. The engine identification numbers appear on the decal (or decals) affixed to the engine shrouding. Include letter suffixes, if there are any.
Record your engine identification numbers on the identification label below for future reference.
MODEL NUMBER:
SPEC NUMBER:
DISPL (CC):
SERIAL NUMBER:
Introduction
n Additional Information
For additional information, on any Hydralada® Elevating Work Platforms or products contact your local dealer or the manufacturer.
HYDRALADA COMPANY LTD
702 Omahu Road Hastings 4120 New Zealand
Postal Address: PO Box 352 Hastings 4156 New Zealand
The design, text, photography and illustrations in this publication remain the sole property of Hydralada Company. All rights are reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical including photocopying, recording or by any information storage and retrieval system, without the written permission of Hydralada Company.
1. Specifications
n Specifications of the Hydralada MEWP (Elevating Work Platform)
This Chapter provides the basic technical characteristics of the Hydralada work platform. The Hydralada MEWP is a boom type Work Platform built to conform to all applicable Standards. All dimensions, weights, and specifications are nominal only. Due to a policy of continual development some specifications may change without prior notice or obligation.
SPECIFICATIONS
Maximum Rated Platform Capacity 1751 kg (385lbs)
Standard Colour Yellow
Maximum Towing Speed (free wheel hubs released) 30kph (20mph)
Maximum Manual Force @ 1.1 Mts above the Platform Floor 200 Newton’s / 20kgs (50 lbs)
Max Permissable Wind Speed 12.50 mts/sec (30mph)
Maximum Wheel Loading
Maximum Chassis Inclination
(1102lbs)
(2204lbs)
Refer to Stability Certificate (See Delivery Manual - Page 5)
Insulation Rating of Standard MEWP Non Insulated
Required Tare Weight of Water Filled Wheel Assembly (minimum) 23x10.50x12
Litres Hydraulic Oil Viscosity @ Ambient Temperature2 -10C to +25C = 10W +10C to +40C = 20W/40
1 Two Man Work Platform, Maxi Model - max rated Platform capacity 220 kgs (485lbs).
2 The Hydraulic Oil must contain a Minimum Zinc content of 0.125% by weight (125ppm).
1For best results, fill to “F” mark on the dipstick as opposed to adding a given quantity of oil. Always check the level on the dipstick before adding more.
1. Specifications
n Nomenclature and Serial Numbers
Left side view of MEWP
Pick Bag Drive Wheels
Serial Number
Castor Wheels Fuel Tank
Right side view of MEWP
Platform
Platform Controls Boom
Drawbar Mount Battery
Engine Cover
Pedal Controls
Hydraulic Oil Tank
1. Specifications
n Overall Dimensions - Compact 300
The dimensions shown below are for the Compact 300 in standard configuration. See ‘Specifications of the Hydralada MEWP’ table on page 1 - 1 for detailed dimensions.
All dimensions are nominal only.
COMPACT 300
Base Model
300 GIII 2WD Single castor Kgs 825
Plus add the following amount for the relevant options fitted
Dual Castor 20
Twin Castor 100
Tandem (4WD) 300/360 300
Hydrafork 150
Slew Cage 80
Pick Bag 30
Weights stated are nominal and may vary depending on combinations of options specified. Refer to serial number decal on machine for machine mass
1. Specifications
n Overall Dimensions - Hi Lift 360
The dimensions shown below are for the Hi Lift 360 in standard configuration. See ‘Specifications of the Hydralada MEWP’ table on page 1 - 1 for detailed dimensions.
All dimensions are nominal only.
HI LIFT 360
Plus add the following amount for the relevant options fitted
Weights stated are nominal and may vary depending on combinations of options specified. Refer to serial number decal on machine for machine mass
FORK WIDTH
1. Specifications
n Overall Dimensions - Maxi 440
The dimensions shown below are for the Maxi 440 in standard configuration. See ‘Specifications of the Hydralada MEWP’ table on page 1 - 1 for detailed dimensions.
All dimensions are nominal only.
MAXI 440
Base Model 440 Maxi 2WD Single castor Kgs 1100 Plus add the following amount for the relevant options fitted
Weights stated are nominal and may vary depending on combinations of options specified. Refer to serial number decal on machine for machine mass
TANDEM & 2WD WIDTH TANDEM
1. Specifications
n Overall Dimensions - Maxi 540
MAXI 540
The dimensions shown below are for the Maxi 540 in standard configuration. See ‘Specifications of the Hydralada MEWP’ table on page 1 - 1 for detailed dimensions. All dimensions are nominal only.
Base Model 540 Maxi 2WD Single castor Kgs 1385 Plus add the following amount for the relevant options fitted Dual Castor
Weights stated are nominal and may vary depending on combinations of options specified. Refer to serial number decal on machine for machine mass
TANDEM & 2WD WIDTH
1. Specifications
n Overall Dimensions - Maxi 640
640
The dimensions shown below are for the Maxi 640 in standard configuration. See ‘Specifications of the Hydralada MEWP’ table on page 1 - 1 for detailed dimensions.
All dimensions are nominal only.
1. Specifications
n Overall Dimensions - Venture 600
The dimensions shown below are for the Venture 600 in standard configuration. See ‘Specifications of the Hydralada MEWP’ table on page 1 - 1 for detailed dimensions. All dimensions are nominal only.
Plus add the following amount for he relevant options fitted Pick Bag
Weights stated are nominal and may vary depending on combinations of options specified. Refer to serial number decal on machine for machine mass
1. Specifications
n Overall Dimensions - Maxi 802
MAXI 802
The dimensions shown below are for the Maxi 802 in standard configuration. See ‘Specifications of the Hydralada MEWP’ table on page 1 - 1 for detailed dimensions. All dimensions are nominal only.
Base Model 802 Maxi 2WD Twin castor Kgs 1850 Plus add the following amount for the relevant options fitted Tandem (4WD) Maxi 640/802 50 Rubber Tracks
Weights stated are nominal and may vary depending on combinations of options specified. Refer to serial number decal on machine for machine mass
2. Safety
n Operating the Hydralada Elevating Work Platform Safely
This Chapter discusses potential hazards which need to be considered when operating the Hydralada MEWP. This Safety information is vitally important for the safe operation of a Hydralada MEWP.
As with all machinery, the persons working on this platform can be exposed to a certain degree of hazard if these recommendations are disregarded.
The Elevating Work Platforms design is based on recognised International standards which set the parameters of structural strength and stability. Your Hydralada MEWP will perform reliably and safely if it is serviced and operated as recommended.
Reading and understanding these safety instructions are an important element of the owners and operators responsibility.
Using the MEWP with care, and respecting the safety cautions, will reduce the risk of personal injury and damage to property considerably.
Failure to follow these instructions can result in personal injury or DEATH.
n Workplace Safety Hazards
A Hydralada MEWP is an all metal boom, NON-INSULATED Elevating Work Platform (MEWP).
Electrocution is likely to occur from the MEWP or its operator coming into contact with Electric Power lines.
NEVER operate any MEWP near any ELECTRICAL conductors.
Regard all conductors as being energized at all times.
NEVER operate outside during a thunderstorm.
DRIVE carefully to avoid branches protruding into operators platform cage.
Clearance Requirements for Operating NonInsulated Elevating Work Platforms
For Operating Elevating Work Platforms Seeking to Operate in the No GO Zone
1. Notify the power authority before commencing work.
2. Obtain written permission from the power authority.
3. Do NOT commence wrk until a pre-start site/ job meeting and a risk assessment have been completed.
The term “Spotter” is defined as a safety observer who is a person competent for the sole task of observing and warning against unsafe approach to overhead power lines and other electrical apparatus.
Note: These special provisions are not applicable to works in or engaged by compaines in the electricity supply industry.
If the boom is insulated and has a current test certificate issued by a Certified Authority no Spotter is required in the yellow area.
The minimum clearance for overhead power lines on poles is 4.0 metres and for overhead power lines on towers is 8.0 metres. Refer to the below safety decal and before operating the MEWP first check with your local power authority.
2. Safety
A suggested safety practice is to have personnel that are familiar with the operation of the emergency controls working in the immediate area of the MEWP to assist the platform operator in the event of an emergency.
DAN G E R
Maintain a minimum safe distance to energized power lines. See the “Electrical Hazard” section at the front of this manual for a complete explanation of the hazards concerning electricity.
DAN G E R
READ AND UNDERSTAND ALL OF THESE WARNINGS. MAINTAINING THE STABILITY OF THE MEWP IS ABSOLUTELY ESSENTIAL.
Unauthorised Persons in the workplace are a hazard to everyone.
Keep children out of any areas where the MEWP is being operated.
Keep ground personnel away from underneath or anywhere near the MEWP when the platform is raised.
NEVER permit riders on the MEWP at any time.
Watch for bystanders or spectators in the vicinity.
Never allow anyone to be under, or to reach through, the MEWP and its equipment while it is in operation.
Hazardous Areas in the Workplace.
Remove all loose objects stored in or on the MEWP, particularly in the Work Platform.
Always park the MEWP on level ground.
Never operate the MEWP while the lighting is inadequate.
Only operate the MEWP in areas defined by the supervisor.
Never operate the MEWP indoors or in enclosed areas.
It is the responsibility of the operator to ensure that no part of the lifting mechanism comes in contact with branches or other structures which could
potentially destabilise the machine.
Eye Injury from flying objects or hazardous materials.
Always wear safety glasses when servicing the MEWP.
Always wear appropriate Personal Protective Equipment (PPE) when using saws or pruners.
Keep batteries out of reach of children.
Windy Conditions when operating at elevated sites in exposed conditions.
NEVER operate the Hydralada MEWP at high elevations in windy conditions.
NEVER operate the Hydralada MEWP in winds or wind gusts of 28mph (12.5 metres per second) or more.
NEVER add anything to the Hydralada MEWP that will increase the wind loading (banners, flags, etc).
Flammable Materials or gases associated with fuel and batteries.
DO NOT smoke or permit open flames while fuelling or near fuelling operations.
Store fuel only in approved containers, in well ventilated, unoccupied buildings away from sparks and flames.
Never remove the fuel cap or refuel a gasoline engine while the engine is running or hot.
Never allow fuel to spill on hot machine components.
Maintain control of the fuel filler nozzle when filling the tank.
DO NOT fill the tank to maximum capacity. Allow room for expansion.
Tighten the fuel tank cap securely.
If the fuel cap is lost, replace it with an approved cap from Hydralada Company.
Use of a non-approved cap without proper venting may result in pressurisation of the tank.
Clean up spilled fuel immediately.
DAN G E R
Gasoline is extremely flammable and its vapours can explode if ignited.
2. Safety
Never use fuel for cleaning purposes.
Mechanical Failures as the result of poor or incorrect repair/maintenance/operational procedures.
NEVER operate an MEWP that is not functioning properly, or has been damaged, until the MEWP has been repaired by a qualified person.
NEVER operate an MEWP that does not have all its decals and placards attached and legible.
DO NOT override any of the safety features of the Hydralada MEWP.
DO NOT modify the MEWP in any way.
NEVER use the MEWP as a crane, hoist, or jack.
Never replace electrical fuses with fuses which have a higher rating.
NEVER use the boom for any purpose other than to position personnel, their tools, and materials.
Only attach safety belt lanyard to the lanyard anchor point provided on the platform.
When parts or components are replaced, use only genuine Hydralada replacement parts or components.
DO NOT attempt repairs unless you are a trained and qualified service technician.
Refer to manuals and call experienced repair personnel for help.
Hot Surfaces can cause serious burns. Beware
DAN G E R
Batteries produce explosive hydrogen gas while being charged. To prevent a fire or explosion, charge batteries only in well ventilated areas. Keep sparks, open flames, and other sources of ignition away from the battery at all times.
Remove all jewellery and wear Personal Protective Equipment (PPE) when servicing or charging batteries.
WARNING
Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odourless, colourless, and can cause death if inhaled. Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area.
of Hot Exhaust.
Overhead Obstructions such as branches and other structures.
Be aware of, and avoid overhead obstructions. Always look in the direction of travel when driving. NEVER operate under roofs or in enclosed areas. Always be careful when the Work Platform is elevated.
It is the responsibility of the operator to ensure that no part of the lifting mechanism comes in contact with branches or other structures which could potentially destabilise the machine.
Falling from Heights
Always use a suitable Approved Safety Harness with a short lanyard, connected to the certified anchor point which is provided under the top rail of the Hydralada Work Platform.
The lanyard anchor point is provided for the operator to connect a safety harness to the MEWP, and must not be used for any other purpose.
All Work Platform occupants MUST wear and use an Approved Safety Harness.
NEVER permit riders on the Hydralada MEWP at any time.
NEVER operate the Hydralada MEWP from a position on trucks, trailers, scaffolds, or similar equipment.
NEVER allow the Work Platform to come in contact with another moving, or stationary, Work Platform or any other object.
NEVER use the Work Platform or any part of the extending structure as a crane.
NEVER steady the Work Platform by positioning it against another platform or tree.
NEVER climb onto the Work Platform rail to reach further.
NEVER use ladders, planks, or other devices to extend or increase your work position from the Work Platform.
NEVER jerk the controls. Move the controls slowly and deliberately to avoid jerky and erratic operation. Ensure the MEWP is ballasted as described in the stability certificate at all times.
Avoid travelling at speed at higher elevations. Never engage in any procedure which imposes
2. Safety
additional side or wind loads to the work platform. NEVER exceed the Platform Rated Capacity as indicated on the capacity placard at the entrance to the Work Platform.
NEVER operate the MEWP when the COMBINED LOAD of the operator, picking bag and its contents, and/or any other items in the Work Platform exceeds the Platform Rated Capacity.
NEVER attempt to enter or leave the Work Platform when it is in an elevated position.
NEVER attempt to transfer from the Work Platform to another structure or vice versa.
Collisions with stationary objects must be avoided.
Always comply with local traffic regulations as they may require.
Take special precautions to avoid any risk of collision when other mobile equipment is in the area.
Check the ground conditions and clearance when moving the MEWP, to avoid contact with structures or other hazards.
Reduce speed any time the MEWP is approaching a stationary object.
Before towing the MEWP check that it is securely coupled to the towing vehicle.
Always make sure the MEWP is on level ground and restrained before unhitching from the towing vehicle.
NEVER exceed 30kph when towing the MEWP.
High Speeds and inappropriately high engine RPM‘s.
NEVER engage in any form of “horseplay” or “stunt driving” while operating the MEWP.
NEVER use high engine rpm with the Work Platform at full elevation.
Avoid travelling at speed at higher elevations.
CAUTION
DO NOT operate the Hydralada MEWP unless you are trained and authorised, understand the operation characteristics of the MEWP, and have inspected and tested all functions to be sure they are in proper working order.
Steep Terrain is always dangerous. Use a proper slope gauge to measure the angle
of any inclines before beginning work, and ensure these are within the allowable incline ratings of your MEWP.
NEVER operate the Hydralada MEWP on slopes exceeding 5 degrees in either direction unless you have measured the incline and checked the individual MEWP Stability Certificate which is included in the machines Delivery Manual.
NEVER move the MEWP on steep terrain with the Work Platform at maximum elevation.
Always park on level ground.
Slippery Surfaces or ground conditions can upset the operation of the MEWP.
Never operate the MEWP on slippery ground.
It is IMPORTANT to ALWAYS keep the platform clean and clear of slippery materials.
Clear away any organic material which accumulates on or within the MEWP.
Always maintain a firm footing on the Work Platform floor.
Use a slope meter to establish the gradient of any slopes in the work area, and check that they do not exceed the maximum allowable slopes the Hydralada MEWP can work on. This slope angle is listed in the Stability Certificate included in the Delivery Manual.
Instability as the outcome of incorrect loading, or operating procedures.
NEVER operate the MEWP when the COMBINED LOAD of the operator, picking bag and its contents, and/or any other items in the Work Platform exceeds the Rated Capacity.
NEVER exceed the platform Rated Capacity as indicated on the placard behind the Work Platform.
NEVER carry loads from any point outside of the Work Platform other than those attachments approved by Hydralada Company.
Ensure the MEWP is ballasted as described in the stability certificate at all times.
The tires on this MEWP must be water-filled to ensure the Elevating Work Platforms stability.
The Inclinometer and its warning system must be fully operational at all times.
Never allow more than one person in the Single man Platform.
2. Safety
Slewing the Work Platform downhill can result in instability.
NEVER engage in any procedure which imposes side loads on the Work Platform at higher elevations.
NEVER move the MEWP on steep terrain with the Work Platform at maximum elevation.
Always park on level ground.
It is the responsibility of the operator to ensure that no part of the lifting mechanism comes in contact with branches or other structures which could potentially destabilise the machine.
DAN G E R
DO NOT perform service work under a raised boom unless it is supported by the boom support or an approved Hydralada service tool. Refer page 6-9 Failure to comply with this requirement is one of the major hazards of servicing the MEWP and can result in SERIOUS INJURY or DEATH.
DAN G E R
The incorrect choice of safety harnesses, belts, and lanyards can be extremely dangerous.
Operators MUST have the appropriate training in the use of such equipment.
General
Take care to prevent rope, electric cords, and hoses, etc., from becoming entangled in the Work Platform. Remove all loose objects stored in or on the MEWP, particularly in the Work Platform
WARNING
Hydralada recommend that Operators in a single man platform use an ‘Approved Safety Harness‘ system with a short lanyard.
WARNING
Although the design of the MEWP is inherently stable the final overall safety of the operation remains dependent on the operator observing all operation instructions and placards. If there is any doubt, always err on the side of caution.
In Diesel engines, use the correct fuel grade for the operating season.
Make sure the area below the platform is clear of any personnel before lowering.
CAUTION
Be sure that all the safety decals and placards on the Hydralada MEWP are legible. Clean or replace them if you cannot read the words or see the pictures. Clean with soap & water and a soft cloth. Do not use solvents.
You MUST replace a decal or placard if it is damaged, missing, or cannot be read. If it is on a part that is replaced, make sure a new decal or placard is installed on the replaced part. See your Hydralada dealer for new decals and placards.
2. Safety
o Work Place Inspection
Before the Hydralada MEWP is used, and during use, check the area in which it is to be used for possible hazards such as, but not limited to:
1. Drop-offs or pot holes.
2. Side slopes and downgrades.
3. Bumps and floor obstructions.
4. Debris.
5. Overhead obstructions including power and telephone lines.
6. Hazardous locations.
7. Inadequate surface and support to withstand all load forces imposed by the elevating Work Platform in all operating configurations.
8. Wind and weather conditions.
9. Presence of unauthorised persons.
10. Other possible unsafe conditions.
3. Safety Devices
n Safety Device Information
This Chapter discusses the Safety Devices of the Hydralada MEWP and gives some information on their functions.
The Safety devices listed in this Chapter are fitted to the Hydralada MEWP to increase safety in the work place for both the operator and other people near the Hydralada MEWP.
For detailed information on the use of these devices, see the ‘Operation’ Chapter of this manual.
WARNING
DO NOT bypass, disable, modify, or ignore any of these devices. Check them carefully at the start of each work shift to see that they are in working order (see “Daily Inspection and Maintenance” chapter 5). If any are found to be defective, remove the MEWP from service immediately until a qualified service technician can make repairs.
o
Emergency Stop Controls
There are two emergency stop buttons located on the MEWP
1. Ground station control panel under the lefthand bonnet
2. Work Platform Control panel on the rear of the platform.
The emergency stop is a red two-position push button switch.
• Pushing the stop inward disconnects all power to the MEWP and shuts down the engine.
• Twisting the button clockwise resets the button and restores power.
o Platform Height Control
While not a ‘Safety Device’ in the strictest term, the Work Platform lift control provides a Hydralada Operator with a very powerful manner of controlling instability while the MEWP is operating. Lowering the working height by even only a small distance can vastly improve the stability of the MEWP. Operators should form the practice of always lowering the Work Platform as soon as possible after working at height, before moving the MEWP away from its position.
The Work Platform on this MEWP lowers by gravity only to avoid the possibility of applying download onto a surface and take weight and traction away from the drive wheels.
WARNING
The option to use the Ground Station Emergency controls should only be exercised in an emergency situation after consideration has been given to the possibility that this action could bring the Work Platform into contact with live wires or adversely affect the stability of the MEWP.
3. Safety Devices
o Ground Station Emergency Controls
Hydraulic Movement Controls
A manual control lever is mounted to the front of each control section. The decal on the front of the Hydraulic reservoir sets out the function of each lever.
MANUAL MOVEMENT CONTROLS
OPERATING MACHINE MOVEMENTS
o Emergency Engine Crank
If the engine will not run for any reason, the machine can still be moved by operating the respective hydraulic movement control while simultaneously cranking the engine using this push button. This button is coloured black and is positioned by red emergency stop button under the left-hand bonnet.
WARNING
Emergency stop button at the chassis base must be in the ON reset position for this emergency crank to operate.
o Quick Release Pins
The clevis pins which connect the control cables to the valve spool can be removed to enable persons at the ground station to manipulate the movements using the manual control levers. This action is only necessary if something is jamming the platform controls or is required to isolate the platform controls to ensure safe retrieval.
REMOVING THE QUICK RELEASE CLEVIS PIN
3. Safety Devices
o Ground Station Function Enable Control
The function enable control is fitted to Hydralada Industrial model MEWP and must be activated for the ground station emergency controls to be operational. This button is coloured blue and is positioned by red emergency stop button under the left hand bonnet.
o Platform Locking System
A flow control cartridge and locking Solenoid is built into the base of the Work Platform Hydraulic lifting cylinder. This controls the flow of oil from the lift cylinder, limiting the maximum speed the Platform can be lowered. In the unlikely event of a hydraulic hose failure, this control system will prevent the Platform from lowering uncontrollably.
o Emergency Platform Lowering
A lift control lever is provided under the right hand bonnet to enable persons on the ground to lower the Platform in the event of an Emergency.
o Horn
A button on the Rear of the Work Platform sounds the horn which can be used to attract attention in an Emergency.
o Switched Mid-rail
An opening mid-rail is provided to allow convenient access of the Operator into the Platform. As soon as this mid-rail is opened, the engine is shut down, and the starter motor deactivated. If the engine shuts down as a result of the mid-rail being raised, the ignition switch must be activated to the OFF position before leaving the MEWP. This is intended to avoid the possibility of any inadvertent operation of any controls in the Work Platform.
PLATFORM SWITCHED MID-RAIL
o Lanyard Anchor Point
A Certified Anchor Point is provided on the Work Platform of every Hydralada MEWP. This point is intended for the operator to connect a safety harness to the MEWP at all times when the machine is being operated. This anchor point should not be used for any other purpose. Hydralada Company recommend that operators use an ‘Approved Safety Harness’ which is available from the Hydralada Spare Parts Department.
3. Safety Devices
o Battery Isolating Switch
A red key switch is located on the control panel in the right hand engine bay. On Elevating Work Platforms fitted with Diesel engines these are located under the left hand bonnet. Turning this fully in the anti clockwise direction isolates the battery and deactivates the elevating work platform’s electrical circuits. By turning this key anti-clockwise past the off position, the key can be removed to immobilise the MEWP.
CAUTION
Do not use a higher rated fuse or in any way attempt to modify the fuse connection. If replacement fuses fail refer the problem to a qualified service technician.
o Electrical Fuses
These are located behind the fuel tank under the left hand bonnet. These fuses protect all the electrical circuits in the event of an electrical overload or short circuit.
Not all fuses are required. This is dependant on the Model and the options of the machine.
o Inclinometer
The Inclinometer monitors the angle of the machine. Its function is to warn the operator should the machine reach its maximum slope rating. Each unit has a pre-set degree rating that if exceeded in the elevated travel position activates an audible alarm to warn the operator.
The inclinometer is mounted in the centre of the MEWP inboard of the engine.
Note: refer Chapter 6 for measuring and assessing slopes.
Industrial model machines with function enable have an additional safety feature when the MEWP reaches its stability limit, and the alarm is activated. The inclinometer will disable the functions of the machine with only the boom lower function available to the operator.
This safety feature is only active when the boom is raised in the elevated travel position. Once the boom is returned to the lowered travel position the functions become available to allow movement of the machine to a more stable position.
The machine will not allow the boom to be lifted above the lowered travel position if it is outside its stability rating.
3. Safety Devices
WARNING
nclinometers are factory calibrated for each individual MEWP. Never tamper with or move the inclinometer off the MEWP or between MEWP’s.
The slope rating information that the machine is rated to is located on the serial number decal on the chassis.
o Drive Wheel Brakes
Elevating Work Platforms with mechanical brakes have them mounted in the drive wheels of at least one drive axis.
These provide a failsafe brake whenever the machine is stationary. The brake systems which are fitted to the Hydralada MEWP are completely automatic in their operation meaning they require no special operating procedures.
o Water-filled Tyres
The tyres on the Hydralada MEWP are water filled to provide stability for the machine.
It is important that the weights of the wheel assemblies are maintained to the values listed in the Specifications charts on Page 1-1 of this Manual.
DAN G E R
Never operate the MEWP fitted with non standard wheel assemblies, or with wheel assemblies which weigh less than the specified weight (refer to Stability Certificate in Delivery Manual or decals on MEWP).
n Optional Safety Devices
o Rotating Beacon
Rotating beacon options are fitted where an MEWP will be used near vehicular traffic. This is an orange beacon mounted on the tail of the machine.
o Auxiliary Hydraulic Oil Outlet
A control module operating the auxiliary hydraulic oil outlet shuts down the oil supply automatically whenever the engine of the MEWP is shut down.
This means, to restart the flow of oil, the switch must be activated again once the engine is running.
3. Safety Devices
o Malfunction Indicator Lamp (MIL)
Light located on the engine indicates that there is a fault within the Kohler Electronic Fuel Injection (EFI) system. Fuel injected engines only.
o Hydraulic lock solenoid
Mounted to the base of the lift ram a hydraulic block with solnoid valve. This valve is designed to lock the cylinder and avoid the uncontrolled decent in the event of a hydraulic hose failure.
o Platform control panel warning lights
Diesel engine models include low oil pressure and high-water temperature warning lights on the work platform control panel. Illumination of either of these lights indicate that there is an issue with the engine and should be shut down immediately. The light also includes the sounding of an audible alarm.
3. Safety Devices
o Safety Decals and Placards for Compact 300 and Hilift 360
Look to see that all placards and decals are in place and legible. Replace any missing or illegible placards or decals before placing the Hydralada MEWP into service for the daily work shift. Decal and placard kits for the Hydralada MEWP are available from Hydralada dealers.
3. Safety Devices
3. Safety Devices
o Safety Decals and Placards for Maxi 440/540/640/802
Look to see that all placards and decals are in place and legible. Replace any missing or illegible placards or decals before placing the Hydralada MEWP into service for the daily work shift.
Decal and placard kits for the Hydralada MEWP are available from Hydralada dealers.
3. Safety Devices
3. Safety Devices
3. Safety Devices
3. Safety Devices
N
G O Z O N E
4. Controls
n Description of the Controls
This Chapter locates and explains what each control does, but DOES NOT explain how to use the controls to produce useful work. For that information, refer to the ‘Operation’ section after you have read this section. If you have optional equipment installed on your Hydralada EWP, that is not explained here, then refer to the ‘Options’ section.
Hydralada Company offer a wide range of options for the Hydralada EWP. This section covers all the available control options, but you will need to refer to the sections that specifically apply to your MEWP and its configuration.
n Work Platform Control panel
o Emergency Stop Button
Pushing the emergency stop inward disconnects all power to the MEWP and shuts down the engine. The button is a two-position push switch. Twisting the button clockwise resets the button and restores power.
o Ignition Switch
Operation of the ignition switch will provide electrical power to the machine. Moving the switch to engine crank will energise the engine starter motor. The switch is a three position ON/OFF with the ENGINE CRANK being spring loaded return to ON.
o Horn Button
The operation of the horn button sounds the horn which can be used to attract attention in an emergency.
o Auxiliary Oil Switch
The operation of auxiliary oil switch controls the supply of hydraulic oil to the platform. Rotating the ‘self-centring’ switch to ON begins the flow of hydraulic oil from the outlet port in the work platform. Rotating to OFF will discontinue the oil flow.
DAN G E R
Activation of the aux oil switch with a Hydraloppa connected will close the jaws of the pruner and load up the hydraulic system.
o Fork Switch
The operation of the fork switch controls the operation of the bin fork. Rotate the ‘self-centring’ switch to raise and lower the bin forks.
DAN G E R
Raising of the forks with a Hydraloppa connected will close the jaws of the pruner and load up the hydraulic system.
NOTE
The Hydrafork hydraulic system uses gravity to lower the bin forks. If the forks are not fitted to the chassis the ram will not extend.
o Fork Switch
The operation of the fork switch controls the operation of the bin fork. Rotate the ‘self-centring’ switch to raise and lower the bin forks.
o Water Pump Switch
The operation of the water pump switch controls the water pump on mango model machines. Switching to ON provides water to the irrigated picking bag in the front of the platform.
o Two Speed / Dual Power Switch
The operation of the speed switch changes the speed the machine operates.
o Oil pressure Switch
The illumination of the oil pressure light indicates the engine oil pressure is below allowable limit and the engine should be shut down. This option is used on Diesel engines only.
4. Controls
o Water Temperature Light
The illumination of the water temp light indicates the water temperature in the engine is above its allowable limit and the engine should be shut down. This option is used on diesel engines only.
o Glow Button
The operation of the glow button allows the glow plugs in the engine to redden prior to starting. If ambient temperature is above 10 Degrees Celsius, operation of the glow plugs is not required. This option is used on diesel engines only.
n Engine throttle control
This control controls the Governor setting and engine speed. See Chapter 6-4 for detailed instructions for the correct operation of this control.
n Drive Pedal Controls
The standard Hydralada configuration for the control of the machines movements is by foot operated pedals as shown in the illustrations The operation of these controls is as follows:
The Drive motors are controlled by the two outer pedals. Each pedal controls the drive wheel on the respective side of the EWP as shown below. The operation these pedals are shown on the floor mat of the MEWP.
n Platform Lift Pedal Control
Pressing the centre pedal forward lifts the Work Platform. Pressing the centre pedal back lowers the Work Platform.
n Controls For Optional Equipment
The controls in this Work Platform are similar to the standard Work Platform pedals, excepting for the layout. The operation of these pedals are shown on the floor mat of the EWP.
This control system has a locking device on the pedal that needs to be activated before the control can be depressed for operation.
THROTTLE CONTROL SIX
4. Controls
n Two Pedal Control
This system uses a single pedal to control the drive. Pressing either the toe or heel determines the direction of the EWP, while rotating the pedal determines the direction of travel.
n Tiller Lever Hand Operated Controls
This system is mounted at the front of the Work Platform and provides hand support grips for the operator. This allows the operator to grip the supports whilst utilising the thumb and fingers to activate the controls.
n Work Platform Slew Control
This controls the slewing of the Work Platform through a total arc of 90 degrees. The control lever is mounted in the front of the operators Work Platform. Moving this control lever to the left or right results in the respective movement of the Work Platform.
n Function Enable
Function enable button must be activated to allow operation of the ground station manual movement controls. This button is coloured blue and is fitted to Industrial model machines.
Hand operated function enable has two blue buttons mounted to each side of the upper rail of the work platform.
Foot operated function enable is available on tiller lever hand operated control option. It is mounted to the work platform floor.
n Ground Station Controls
Located under the LH bonnet and controls the following functions.
n Ground Station control panel
• Emergency Stop Button
• Engine Crank Button
• Function Enable Button
TWO PEDAL CONTROL
TILLER LEVER HAND OPERATED CONTROLS
CENTRE MOUNTED PLATFORM SLEW CONTROL
4. Controls
o Emergency Stop
Pushing the emergency stop inward disconnects all power to the MEWP and shuts down the engine. The button is a two-position push switch. Twisting the button clockwise resets the button and restores power.
o Engine Crank
Operation of the engine crank will energise the engine starter motor. The Black button and is used to start the engine and for emergency operation of hydraulic functions.
o Function Enable
Function enable button must be activated to allow operation of the ground station manual movement controls. This button is coloured blue and is fitted to Industrial model machines.
o Manual Movements levers
These levers are located under the ground station control panel behind the hydraulic oil tank. A manual control lever is mounted to the front of each hydraulic control section. Operating any of these control levers with the engine running will activate the respective movement, overriding any other device on the MEWP. When operating the boom control lever, the boom can be lowered, even when the engine is not running.
DAN G E R
Operating the manual control levers will result is movement of the selected function of the machine. Make sure all personnel are clear before activating any of the functions. If the engine is running at high RPM settings it will result in sudden movements, caution is advised when making control inputs.
n Ground Station Controls
Located under the RH bonnet
n Engine Bay Controls
Located under the RH bonnet
• Battery Isolator switch
• Hour Meter
• Malfunction light
• Choke control
o Battery Isolating Switch
A red plastic key battery isolating switch is mounted At the left hand end of the small control panel. It Is under right hand bonnet. Releasing this plastic key in an anticlockwise direction isolates the battery from the entire electrical system.
4. Controls
• This means that this switch must be in the ‘ON’ Position before the EWP can be started.
• This switch can be used as a security device to Immobile the MEWP by turning it past the ‘Off’ position and removing the plastic key. Technicians can use this switch to isolate the battery from the electrical system when they are carrying out maintenance.
o Hour Meter
While not strictly a control, the Hour Meter is a necessary tool for scheduling the servicing and maintenance of the EWP. It is located under the bonnet and records the total operating hours the Elevating Work Platform engine has run.
o Malfunction Indicator Light MIL
The light illuminates if a fault is present within the fuel injection system, engine light is illuminated with engine running indicates the presence of active fault. The light will remain on as long as the fault is current. If the light turns on the Off a code will be stored in the ECU memory.
A technician can access stored fault code using a blink code diagnosis flashed out through MIL or with Kohler software diagnostic program.
o Engine Choke Control
The choke control is mounted on the front of the Kohler Command CH23S twin cylinder engine. It may be necessary to use this when the engine is being started from cold. There is no Choke on the Fuel Injected engines.
5. Daily Inspection and Maintenance
n Daily Inspection
At the start of each work day (or 8 hour shift), a qualified Hydralada MEWP operator must perform the Daily Inspection and Maintenance as listed in the table below.
NOTE
Further information on items such as engine oil, hydraulic oil, oil filters, air cleaner elements, engine adjustments etc. can be found in “Servicing” chapter 11.
The purpose of this procedure is to keep the Hydralada MEWP in proper working condition and to detect any signs of malfunction at the earliest possible time. Defective parts and/or equipment malfunctions jeopardise the safety of the operator
Item
Emergency lower - ground
Engine fuel level
Fuel tank cap
Fuel leaks
Engine oil level
Engine cooling
Wiring
Battery terminals
Battery fluid level
Hydraulic oil level
Hydraulic oil leaks
Bolts and fasteners
Wheels and tyres
Structural damage and condition
Lanyard anchor point
Lanyards and safety harnesses
Drop down Work Platform midrail
Rotating beacon (option)
Emergency stop switches - ground
Inclinometer
Air filter
Work Platform controls
Hour meter
Placards and decals
Wheel nuts
Hub nuts
Pin Brake disc wear
and other personnel, and can cause damage to the MEWP. Do not attempt to make repairs unless you are authorised to do so.
The rest of this chapter shows how to perform the Inspection and Maintenance required for each item in the Daily Inspection and Maintenance Table.
DAN G E R
DO NOT operate a Hydralada MEWP that is known to be damaged or malfunctioning.
Repair all equipment damage or malfunctions before placing the MEWP into service.
Once your inspection is completed, fill in the MEWP Log Book, taking care to record any matters which may need further attention.
Service Required
Check operation (causes correct motion)
Check the fuel level in the tank is sufficient
Check to see that the cap is tight
Visually inspect (hoses and connections)
Check oil level (between dipstick lines)
Check that grills and intakes are not blocked
Visually inspect (installation, condition)
Visually inspect (no corrosion)
Check fluid level (just covering the separator plates)
Check the operating hours to confirm the current service period. If the MEWP has turned into another 100 hour period it must be serviced as shown on the serviceman‘s check sheet.
o
Fuel Level
Check the fuel gauge to see that the fuel tank is full. Check to see that the tank cap is in place and is tight. Visually inspect that there are no defects in the sealing surfaces of the Fuel Tank Cap
o Fuel Leaks
Visually inspect the fuel tank and any visible fuel line for damage and leaks.
• Inspect the in line filter which lies on the floor of the MEWP. If there is any visual indication of contamination the filter assembly should be replaced.
o Hydraulic Oil Level
To check the hydraulic oil level the boom must be completely lowered and the engine turned off. Oil must be added to the system if the level is not clearly visible in the filler neck.
The minimum hydraulic oil level is 70mm from the top of the internal screen and the maximum is 50mm from the top of the internal screen.
If it is necessary to add hydraulic oil, refer to the ‘Specifications’ chapter of this manual for type and grade of hydraulic oil. Remove the quarter turn filler cap, and add oil until the reservoir reaches the correct level.
Always use good quality regular unleaded gasoline. Using fuels containing lead may result in the failure of the spark plug and excessive carbon deposits in the combustion chamber. See ‘Specifications’ chapter 1 for fuel octane and grade.
FUEL TANK
HYDRAULIC RESERVOIR AND FILLER CAP
FUEL FILTER
Cap
Cap
Label showing the oil which is in the reservoir
5. Daily Inspection and Maintenance
o Checking the Engine Oil Level
With the engine turned off, remove the dipstick located on the top rear of the engine, and wipe the oil off. Re-insert the dipstick into the tube, and remove again to check the level. If the level is low, fill to the “F” mark with the recommended oil. Ensure that the level always remains within the operating range on the dipstick. Replace the dipstick before starting the engine. See ‘Specifications’ chapter 3, for the correct engine oil grade and weight.
Add engine oil through the cap beside the engines fuel pump as necessary.
o Wiring
Inspect all visible wiring harnesses on the MEWP, for loose connections, broken wires, and frayed insulation.
If the MEWP is operating in some fruit growing operations, particularly Avocados, rodents can be a problem. They will chew wiring looms and hydraulic hoses, often inside the boom, where these are not so accessible. This results in electrical and hydraulic problems.
o Battery Terminals
Battery terminals should be tight, clean and free of dirt and corrosion. Any acidic buildup should be washed away with hot water and the terminals coated in a protective coating or grease.
o Battery Electrolyte Level
Remove the caps from the battery and visually check to see that the battery fluid is just covering the separator plates in the cells. The cells can be topped up with distilled water, or a tap with very clean water.
“F Mark
Range
DO NOT smoke or permit open flames or sparks when checking batteries. Batteries emit hydrogen and oxygen, elements that can combine explosively.
o Engine Air Cleaner
Check for build up of dirt and debris on the filter elements, as well as on the grass screen on the front of the crankshaft.
See “Servicing” chapter 11 for correct cleaning/ replacement procedures.
CAUTION
• Always wear safety glasses when checking or adding to battery fluid level.
• Do not overfill the cells – the water should only just cover the plates.
Filler Cap
5. Daily Inspection and Maintenance
o Hydraulic Oil leaks
Hydraulic oil leaks are easily visible and can show up any place.
Visually inspect the entire MEWP for hydraulic oil leaks. Check the ground under the MEWP for leaked oil.
Carefully inspect the exposed hydraulic hoses for signs of leaking hydraulic oil or obviously loose fittings.
DAN G E R
Never search for Hydraulic leaks with your hand - use a piece of board.
High pressure oil will puncture your skin and enter your bloodstream, resulting in death or amputation in a very short time.
DAN G E R
Leaking hydraulic oil can cause burns, fires, falls (slipping), cuts, and puncture wounds (if under high pressure). Have a qualified trained maintenance person repair all hydraulic fluid leaks before you operate a Hydralada MEWP.
o Structural Damage
Visually inspect the entire MEWP for deformity, cracks, dents or anything unusual.
Inspect for cracks or damage.
Clean the Work Platform daily before beginning operations.
Check all retaining fasteners are fitted and tight.
o
Wheel Nuts
Pay particular attention to all of the wheel nuts/bolts. None should be visibly loose, missing, or deformed.
Tension five stud and six stud rims to 60 ft/lbs. DO NOT over-tension as this can distort the wheel rim.
Problems with wheel nuts continually coming loose are usually the result of damage to the tapers in the rim, as well as the nuts. This damage can only be caused by running the MEWP with the nuts loose.
When checking the wheels, visually inspect the hub nut for any indication of movement. If there are any concerns with this item, it will be necessary to call a qualified Hydralada service technician as these require special equipment to service.
DAN G E R
Never use an MEWP unless any problems with wheel nuts are properly resolved as the stability of the MEWP relies entirely on the wheels.
o Wheels and Tyres
The tyres on the Hydralada MEWP are water-filled to provide ballast and form vital part of the Elevating Work Platforms stability.
If the MEWP is being operated in areas where the day time temperatures are less than 1C, the ballast
HUB AND WHEEL NUTS
Hub Nut
Six Wheel Nuts
5. Daily Inspection and Maintenance
liquid will need to include antifreeze. Alternatively, the wheels can be foam filled. Call a local tyre specialist, or call the Hydralada Service department free-phone for advice.
• Check each tyre for obvious damage that could cause a blowout.
• Ensure they are filled to the required level with a suitable liquid.
• Check the pressures using a suitable tyre gauge. The wheel must be positioned with the valve at its highest position.
• The recommended pressures are set out in the ‘Specifications’ chapter 1 and the ‘Servicing’ chapter 11 of this manual.
• If the tires are repaired or serviced in any way, they must be ballasted to reach the tare weight as set out in the ‘Specifications’ chapter 1 of this manual.
o Bolts and Fasteners
Visually inspect all bolts and fasteners to see that none are missing or obviously loose.
Wheel motor mounts bolts, rear pivot block bolts.
Boom, levelling bar and lift ram pivot pin have retaining Bolts and circlips to prevent the pin from walking out from the machine. Check bolts are fitted and tight.
The tyre pressures on the Hydralada MEWP must be maintained at the correct level. Uneven pressures will cause the MEWP to drive to one side, instead of in a straight line. High inflation pressures deliver poor traction, and impair the tyres ability to clear the treads. Low inflation pressures result in damage to the tyre side walls, and affect the stability of the MEWP on slopes.
o Lanyards and Safety Harnesses
Check with your local regulatory authority for their specific requirements concerning lanyards and safety harnesses.
Visually check the lanyard anchor points to see that they are not deformed, damaged or cut off.
Visually inspect the condition of lanyards and safety harnesses being used for cuts or damage.
o Electrical System Fuses
These are located behind the fuel tank under the left hand bonnet. These fuses protect all the electrical circuits in the event of an electrical overload or short circuit.
Not all fuses are required. This is dependant on the Model and the options of the machine.
5. Daily Inspection and Maintenance
It is important that only the correct fuses as shown on the chart are used in the respective positions.
Relay Description Application Rating
Platfrom Mid-Rail Standard Start Standard Glow Plug Option - Diesel Engine Water Pump Option - Mango Oil Cooler Option
Fuse Description Inclinometer #1 Standard 4a
Enable Coils Industrial Model 4a
Beacon Industrial Model 2a Water Pump Relay Option - Mango 10a Oil Cooler Fan Option 10a
Inclinometer #2 Option 4a Travel Recovery Fuse Industrial Model 4a
o Inclinometer
Hydralada Elevating Work Platforms are fitted with Alarms which become active once the EWP reaches its maximum slope rating.
To check the operation, proceed as follows;
• Turn system power on. The inclinometer will do a self test and sound a audible beep indicating the system is active and ready. If no beep is heard investigate.
• If the Inclinometer in any way does not perform or respond as stated above, the MEWP must not be operated. The MEWP must be immobilised by removing the Battery Isolator switch key until the issue is rectified by a Qualified Hydralada Service Technician.
o Rotating Beacon (option)
Visually check the optional rotating beacon, to see that it is functioning when the MEWP is turned on.
o Rubber Tracks
Check rubber track condition, check sprockets and track rollers are enaged in the track.
RUBBER TRACKS
6. Operation
n Operating Procedures
This Chapter explains how to properly start and operate a Hydralada MEWP. Read and understand all the previous chapters in this manual before you begin to operate a Hydralada MEWP.
NOTE
Be especially sure that you are familiar with the ‘Safety’ Chapter. Review it now if it is some time since you read it. It may save you from serious injury or death.
DAN G E R
The Hydralada MEWP is NOT ELECTRICALLY INSULATED. Never approach to within 4 Metres of any Overhead Power cable or line. Death or Serious Injury to operating personnel, can occur if the MEWP should come into contact with energised electrical wires during the operation. DO NOT attempt to operate the MEWP controls if the platform, boom, or any other conducting part of the machine is in contact with energised electrical wires or if there is an immediate danger of such contact.
DAN G E R
The Operator, or any of the people involved with the operation of the Hydralada MEWP, must not be under the influence of alcohol or drugs of any kind.
n Safety Harnesses and Lanyards
DAN G E R
n Restraint Harnesses
A suitable Restraint harness must be worn by any person operating a Hydralada machine at all times. With even the best designed machine with all modern safety systems, an operator cannot be safe at height without using proper Personal Protective Equipment (PPE).
o Preparing for Operation
Before beginning to operate the Hydralada MEWP the Operator must:
• Perform the ‘Daily Inspection’ as described in chapter 5 of this manual, and arrange to have any maintenance as described in chapter 11 of this manual carried out as necessary.
• Before beginning to operate the MEWP, the Operator must check the work area, and identify any hazards such as uneven ground, overhead wires, or other obstructions.
• If the MEWP is to be operated on any slope, the gradient must be measured before operating the machine on the area. Refer to Page 6-7. The safe working angle is different for every MEWP depending on it‘s specification. Check the decal on the rear of the Work Platform for the maximum incline rating of the MEWP. Alternatively, this information is shown on the stability certificate belonging to the MEWP you are operating which is included in the delivery manual of the machine. If in doubt contact Hydralada Company quoting the serial number of your MEWP for the appropriate information and advice.
• Check the Maximum Rated Capacity for the platform, and ensure this weight is not exceeded.
• The Operator must wear appropriate clothing and PPE. To be able to operate the pedals effectively, it is particularly important to wear sturdy footwear.
• Before starting the engine, the Operator/s must connect their safety harness to the certified anchor point provided under the top rail of the Hydralada work platform.
6. Operation
o Starting the Engine
To start the engine from cold proceed as follows:
1. Check that the Switched Mid-rail on the platform is fully closed.
2. Reset Emergency stop switch on the platform control panel and turn the ignition switch in the platform control panel to the On position.
3. Set Throttle Control down the gate approximately 25mm (1”).
4. Turn the Battery Isolating switch fully clockwise to the ON position.
5. Check that the emergency stop switch on the ground station control panel. there until the engine starts or for a maximum time of 10 seconds.
6.
Note: EFI engines do not have a choke lever fitted.
7. Press the engine bay Starter Button. Hold it
8. When the engine starts release engine crank button (7) and open the choke control (6) as the engine begins to run smoothly.
9. When starting the engine in ambient temperatures of less than 12C avoid running the engine at maximum RPM‘s until the temperature of the hydraulic oil has reached approximately 50C.
The engine should now be running, and the Hydralada EWP is ready to begin work. The engine must be shut down using the Ignition switch on the platform control panel, before entering the Work Platform and restarting the engine.
o Starting a Warm Engine
Once the engine is already warm it can be started from the operators position in the Work Platform without needing to use the choke.
Operation of the Ignition Switch on the Platform Dash. Rotate the switch to Crank and Hold it there until the engine starts or for a maximum time of 10 seconds. Release once the engine starts.
Move the Choke Control to the closed position (CH23S Engine).
MOVING THE CHOKE CONTROL TO THE START POSITION ON THE CH23S ENGINE
EFI LABEL
‘Electronic Fuel Injection’
6. Operation
o Starting a Fuel Injected Engine
These engines have no choke control as described on the previous page, but otherwise the start-up procedure remains the same.
A Warning light is mounted near the top of EFI engines to alert the operator of any malfunctions in the electronic systems.
Normally this light will not activate. If it does, shut down the engine and call a Service technician.
MALFUNCTION INDICATOR LIGHT (MIL)
CAUTION
If the engine develops sufficient speed to disengage the starter but does not keep running (a false start), the engine rotation must be allowed to come to a COMPLETE STOP before attempting to restart the engine.
If the starter is engaged while the flywheel is rotating, the starter pinion and flywheel ring gear may clash resulting in damage to the starter.
To enter the Work Platform stand beside it, and raise your head and shoulders up into the Work Platform until you are standing upright. Now raise your feet into the Work Platform, taking care to only step onto the outer areas of the Work Platform floor.
CAUTION
If the engine does not start in 10 seconds release the starter button. Wait 60 seconds for the starter motor to cool down before trying to restart the engine again. Continual cranking of the starter motor will only result in its damage and may burn out the starter motor.
NOTE
The engine should already be running (as described earlier in this chapter) before you start this section. Hydralada Company offers a wide range of controls and combinations of those controls. You may have foot controls, hand controls or a combination of foot and hand controls. To simplify the process this part of the chapter describes driving with Foot Controls first, then describes driving with Hand Controls.
Driving the Hydralada MEWP
Enter the platform, close the mid-rail, and attach the lanyard of your safety harness to the anchor point provided.
o Operating the Throttle
There are three main positions for the Throttle Control:
THROTTLE CONTROL – FULLY RAISED IN THE IDLE POSITION
1st. Fully Raised To Top Of Gate:
If the starter does not turn the engine over, release the starter button IMMEDIATELY. DO NOT make further attempts to start the engine until the condition is corrected.
This is the idle position and does not provide any governor response. As any load on the engine causes the rpm to drop, this position is sometimes used to raise the Work Platform very gently.
This light will not activate unless there is a problem with the EFI system.
6. Operation
2nd. Partially Down The Gate: (Approximately 1” - 25mm)
When the control is in this position, the governor springs are tensioned without increasing the engine RPM appreciably. On this setting the governor provides a quick response to any increased load, making this the preferred working setting.
Running the engine too slow causes the compression release to activate and generate a loud ticking noise. Running the engine at this speed will cause serious damage to the engine.
3rd. Lower Down The Gate:
This provides a range of higher speeds and is used when driving the MEWP, between jobs, with the Work Platform down.
NOTE
The controls are progressive which allows the operator to ease the MEWP slowly in any direction by “feathering” the pedals.
o To Operate the MEWP
1. Move the throttle control partially down the gate until the engine just begins to increase in speed as described in the previous paragraph.
2. Facing forward, with the machine behind you, operate both drive controls in the forward direction to drive forward .
3. To reverse operate both controls in the reverse direction.
4. Operate the lift control to lift the Work Platform, which can be elevated safely until it reaches full elevation. Operating the lift control in the opposite direction will lower the Work Platform.
If the lift pedal stops are set correctly, lowering will require a slight force on the control. The descent speed is easily controlled by varying the pressure you apply to this control.
CAUTION
Be certain that the space into which you are about to move the platform, boom and/or chassis is free of obstructions. ALWAYS look in the direction of movement. Be sure that the lanyard of your fall restraint is attached to the anchor point on the platform mount.
o Turning Techniques - Pedals
1. When driving at LOW ENGINE SPEEDS turns are made by using a double wheel turn. Because it is not necessary to ‘feather’ these turns, the operator is able to stand on the pedals or the surrounding platform. Operating one wheel forward and the other backwards simultaneously turns the MEWP ‘on the spot’.
Using both wheels to make a turn doubles the speed of the turn, meaning that good productivity can be achieved, even at low engine rpm‘s.
CAUTION
Do not attempt to make a high speed turn when standing on the pedals.
6. Operation
2. When driving at HIGH ENGINE SPEEDS turns are made by slowing a single wheel. By standing on the side plate beside the control pedal the operator is able to use the side of his/her foot to ‘feather’ the control and make a smooth turn.
Because the speed of only one wheel is being changed, these turns, even at high engine rpm‘s can be quite gentle. However, single wheel turns are not very productive when the MEWP is working.
3. Now practice driving the MEWP using both turning techniques until you are totally comfortable with both turning concepts.
4. Finally, begin to drive the MEWP using various combinations of lift and driving functions. Take particular note of the effect of setting the throttle in the correct position to ensure good governor response without increasing engine rpm‘s.
CAUTION
The stops on the Drive Controls are preset and MUST NOT be altered by the operator.
o Other Control Options
While these instructions are for the operation of a standard Hydralada MEWP which is fitted with three pedal controls, they also apply to Elevating Work Platforms supplied with other control options. The two most important are T Bar hand controls and Six Pedal controls which are shown in the illustrations below.
To make a smooth turn at higher speeds when driving a machine fitted with the hand control option, use the grab handle to steady your hand. Use your fingers to operate the drive levers.
n Common Problems Encountered by New Operators
o Not Driving Straight
This is caused by one of two basic reasons:
1. The wheels are not rotating at the same speed. 2. The rolling radius of the wheels is not even.
• Drive the MEWP in the opposite direction on the same ground and see that it still veers off to the same side.
• Remember that when driving across a gentle slope, the weight transfer to the downside drive wheel changes the rolling radius and will naturally cause the MEWP to track down the slope.
• On steeper slopes the increased load improves the traction of the downside wheel, and can make the MEWP tend to turn uphill.
HAND CONTROLS
SIX PEDAL WORK PLATFORM
OPERATOR USING THE HANDREST TO STEADY THE HAND
6. Operation
• With a slew Work Platform machine the slew must always be in the straight ahead position when checking the tracking.
• Have a Hydralada technician check the settings of the pedal stops.
• Check the tyres on each drive wheel are equal. Odd size wheels mean the MEWP will always track off in one direction.
• Check the tyre pressures with a gauge. Tyre pressures affect the rolling radius of the wheel assembly
o Rough or Jerky Operation
• Using too high engine rpm‘s. Using double wheel turns at low engine rpm‘s is often smoother.
• Incorrectly adjusted pedal stops.
• Using double wheel turns at high engine speeds.
• Be positive about where you want to take the Work Platform and operate the pedals confidently. This will probably need lower engine rpm‘s, but will often make the overall result smoother. This tends to come only with practice.
• The machine is easier to drive with the Work
The advantage of using a double wheel turn technique when working is:
• The machine turns faster, and require less rpm‘s - less noise and fuel - to do so.
• Double wheel turns impose less mechanical stress on the machine
• Double wheel turns create less disturbance to the ground surface - this is especially important when using a Tandem Drive model.
Platform elevated as this moves the Work Platform above the axis of the turn, thus reducing the effect of throwing the operator sideways.
o Lack of Traction
If the tyre pressures are too high, the drive tyres will not deliver good traction. This can be particularly frustrating when working on slopes or in damp mconditions.
In extreme conditions, it may be necessary to run these at their minimum pressure.
Keep both wheels driving whenever possible. Keeping both wheels driving provides the power and traction to operate in these conditions with minimal loss of traction
WARNING
Beware of loose mulch under the driving wheels of the machine. The drive wheels can bury into this material quite quickly and cause potentially hazardous instability. This is particularly important when working in sloping areas.
This improves traction, as well as the tires ability to discard dirt from the tread. However there can be a risk of damaging the side walls of the tyres if the EWP is to be operated on a side slope, or for prolonged periods.
Refer to the ‘Service’ chapter 11 of this manual for guidance on this matter.
n Tips for Experienced Operators
Once you begin operating your Hydralada MEWP in different operating environments, you will notice various characteristics which require a degree of understanding and skill to manage safely.
SLOPE GAUGE
Keep both wheels driving whenever possible. Keeping both wheels driving provides the power and traction to operate in these conditions with minimal loss of traction
6. Operation
o Hillside Restraint Model
This applies to Models Compact 300 and Hilift 360. For flat land operations (up to 5 degree slopes) these models are fitted standard with the Hillside Restraint system. This is hydraulic retardation (dynamic) brakes only. This prevents the wheel drive motors from losing barking effect during overrun traveling down a slope. When parked the machine may creep. If parked on a slope the drive wheels are required to be chocked to prevent the MMEWP from creeping. Where the slopes exceed 5 degrees, the optional Hydrabrake failsafe brake system must be fitted. In no circumstances should the machine be operated on slopes greater than the Stability Rating specified in the Hydralada Delivery Manual.
o Assessing the Workplace
Before using the Hydralada MEWP in any workplace it is important to check the area for hazards of any kind.
If the area includes sloping ground, it will be necessary to measure the degree of slope using an appropriate gauge, and comparing the result with the rated angle of your machine. The maximum slope your Hydralada MEWP can be safely operated on in any direction is listed in degrees on the MEWP serial number plate and also on the ‘stability chart’ which forms part of the delivery manual supplied with the machine.
o Measuring a Slope
CONVERSION CHART - % INTO DEGREES
Any slopes on areas where the Hydralada MEWP is to be used should be measured carefully using a suitable slope meter to ensure no slopes exceed the rated capability of the MEWP. In the case of twin castor models, neither the castor or the main driving wheels must be operated over this rating. Where a slope meter is not available, slopes can be measured using a standard level and a suitable measuring device.
Taking a vertical measurement one metre horizontally out from the slope gives the percentage of the slope. Using the chart below, this can be converted into degrees which is the scale used by Hydralada Company.
o Working on Side Slopes
Even experienced operators need to be completely familiar with the MEWP they are operating before beginning to work on sloping areas.
• Remember to always keep the tail of the MEWP up the slope as much as possible.
• It is better to access the majority of the tree from the uphill side, leaving only a minimal amount to be accessed from
MEASURING A SLOPE WITH A LEVEL
6. Operation
DAN G E R
Never operate a machine fitted with Twin Castors with a wheel off the ground. The machines stability rating is void in this condition.
the downhill side. This practice minimises the amount the MEWP needs to be maneuvered in a tail down situation, where traction and control can be compromised.
• Remember that once an MEWP is already positioned and stationary on a slope, simply lifting the platform height could bring the MEWP into an unstable position.
o Working Up or Down a Slope
• Never exceed the maximum rated capacity of the MEWP.
• Always KEEP THE CASTOR WHEEL UP THE SLOPE. This keeps the machines weight over the driving wheels, and maintains traction and control at all times, even when operating in elevated positions.
• Drive the MEWP up/down the row at low engine rpm‘s, using double wheel turns to move into the tree.
• Keeping both wheels driving provides the power and traction to operate in these conditions with minimal loss of traction.
• Sometimes when working from the lower end of the slope, the operator will need to move up the row in the Elevating Work Platforms reverse direction.
WARNING
Never over-fill the picking bag. This practice invariably means the Manufacturers rated capacity specifications have been exceeded which will make the machine unstable.
DAN G E R
When operating the Hydralada machine at high elevations on slopes, never use the machine with the Work Platform facing uphill.
DAN G E R
Maintain a minimum safe distance to energised power lines. See the “Electrical Hazard” section at the front of this manual for a complete explanation of the hazards concerning electricity.
DAN G E R
Never operated a Hydralada MEWP when the combined weight of the Operator, the Picking bag, and its contents exceeds the machines rated maximum capacity
WARNING
If the inclinometer alarm begins to sound, lower the boom immediately before moving the MEWP towards an area of reduced incline
n Boom Support
This boom stand can be set to support the boom when the MEWP is being serviced or transported. It is not necessary to set this if the MEWP is being transported with the boom fully lowered. This stand is available for purchase from Hydralada Company.
6. Operation
The boom support for Compact and Hi Lift models utilises the Drawbar Pin placed through the hole provided in the Chassis, as shown. Raise the Boom, insert the pin and then gently lower the Boom to rest on the pin.
The Pin is stowed in the Castor Leg assembly.
DAN G E R
DO NOT perform service work under a raised boom unless it is supported by the boom support or an approved Hydralada service tool. Failure to comply with this requirement is one of the major hazards of servicing the MEWP and can result in SERIOUS INJURY or DEATH.
n Towing
Hydralada MEWP fitted with Free Wheeling hubs are able to be towed over short distances between orchards or job sites at a maximum speed of 30 kph.
CAUTION Do not tow the MEWP on public roadways, unless you have written approval of compliance to meet the legal regulations for agricultural equipment in your country.
For Hydralada MEWP operating within New Zealand the following regulations apply.
Hydralada machines are not considered trailers and are exempt from road use registration under New Zealand law (refer New Zealand Transport Agency Fact Sheet number 27). Therefore they can be towed behind a vehicle on their own wheels at low speed.
These self-propelled orchard work platforms are classified as: ‘a motor vehicle normally propelled by mechanical power that is being temporarily towed without use of its own power’.
Towing requirements on public roads
• Maximum towing speed 30 kph
• Use manufacturer approved drawbar with an approved safety chain and shackle attached to the towing vehicle
• The drawbar must be attached to the orchard work platform with the manufacturer approved towing pin and safety clip.
• Can only be carried out in daylight hours only.
Ensure before transport or towing, all attachments or loose items are removed or securely fastened to machine.
n Transport
The Hydralada MEWP is fitted with tie down points for when the machine is required to be transported.
The position of these are labelled on the machines as per the below diagram. One is under the tail and one each on a chassis leg.
When transporting the Hydralada EWP, it must be securely fastened to the transport deck. It must be restrained in two opposite directions on both sides of the chassis to prevent it from moving.
BOOM SUPPORT FOR MAXI MODELS
BOOM SUPPORT FOR COMPACT AND HI LIFT MODELS
6. Operation
Compact and Hi Lift Models
NOTE: Twin castor model, the wheels can be aligned together to allow better access for the tiedowns.
Ensure before transport or towing, all attachments or loose items are removed or securely fastened to machine.
n Storage
When the Hydralada MEWP is not in use, or is in storage, the Battery Isolating Switch must be turned off.
If the machine is to remain in storage for six months or longer:
1. The battery should be removed from the machine and its charge maintained by a monthly top up charge.
2. The fuel should be drained from the fuel tank. Hydralada Company have a weather proof Work Platform cover available to purchase for single man Work Platforms (Part Number 67-2763-00).
Maxi Models
7. Emergency Operation
n Emergency Controls
O Emergency Stop Controls
There are two red emergency stop buttons located on the MEWP
1. Ground station control panel under the left-hand bonnet
2. Work platform control panel on the rear of the platform.
In case of an emergency and the engine is required to be shut down, push on the emergency stop button. This will remove power from the engine and the Hydralada MEWP.
If the Battery Isolating Switch is turned off or the ground station control panel emergency stop is pushed in the emergency crank function described on Page 7-2 will also be disabled.
EMERGENCY RETRIEVAL INSTRUCTIONS
n Emergency Operation
o Electrical Hazards
The Industry Best Practice Guides in New Zealand, and the AS2550.10 Standard used in most States of Australia require operators working within 6.40 Metres of live overhead lines to be assisted by a dedicated spotter on the ground who is to warn the operator of any danger. Under no circumstances are any uninsulated Elevating Work Platforms allowed closer than 4 Metres of live overhead power lines.
The section on procedures to be followed in the vicinity of power lines in the Horticultural Industry Best Practice Document reads as follows:
3.2. Emergency procedures
If an H/MMEWP comes into contact with overhead power lines or equipment, anyone in the H/MMEWP at the time should remain there and warn any others in the vicinity to stay clear. If it is safe to do so, operate the controls to break contact.
If it is not safe to break contact, the safest course of action is to:
• call for assistance, warning all persons to keep well clear of the machine
• do nothing until the line is de-energised. If assistance is unavailable and electrical contact cannot be broken then leave the H/MMEWP and:
• switch off the motor and, where applicable apply brakes
• remove any loose clothing
• climb to a point about one metre above the ground
7. Emergency Operation
from where you can safely jump to the ground
• jump so that you clear the platform before any part of you touches the ground
• fall away from the H/MMEWP and not towards it
• do not touch the H/MMEWP until the lines are deenergised.
3.3. Electrical industry safety information
Additional guidance on safe use of mobile plant in the vicinity of power lines is available at the Electricity Engineers Association’s (EEA) website at www.eea.co.nz.
H/MMEWP = Horticultural/Mobile Elevating Work Platforms
o Instability and Loss of Control
In an Emergency situation, arising as the result of instability or loss of control, the first reaction of the Operator should always be to reduce the elevation of the Work Platform. Any reduction of the Work Platform elevation will immediately make a substantial improvement to the stability of the MEWP.
o Incapacitated Operator
If the operator becomes incapacitated, the machine can be shut down from the ground by turning off either the Emergency Stop Switch, or the Elevating Work Platforms Master Switch. In this condition, the Work Platform can be lowered by operating the emergency lowering control situated under the Left Hand Bonnet.
o Mechanical Failure
In the event of a mechanical failure, leave the engine running, and lower the Work Platform to the ground. If the failure is of systems to support the Work Platform, this descent will still be controllable, providing the ignition switch is still in the run position. If the failure is of the drive system, the brakes will continue to be applied.
o Rescue of Other Persons
Any operation of this nature must always be done within the design parameters of the MEWP. The maximum rated capacity is particularly important as the normal Hydralada MEWP is not designed to carry more than one person in the platform.
All Hydralada Elevating Work Platforms are designed and constructed to very exacting standards of technical excellence. Provided it is used by fully trained operators who are familiar with all safety procedures, and operate the machine within its design specifications, the procedures outlined in this chapter are unlikely to be needed.
o Ground Station Emergency Controls
Hydraulic Movement Controls
A manual control lever is mounted to the front of each Hydraulic control section. Operating any of these control levers with the engine running will activate the respective movement, overriding any other device on the MEWP. When operating the boom control lever, the boom can be lowered, even when the engine is not running.
MANUAL MOVEMENT CONTROLS
o Emergency Engine Crank
If the engine will not run for any reason, the MEWP can still be moved by operating the respective manual movement control while simultaneously cranking the engine using this button.
The Emergency Engine Crank button remains active even when the work platform emergency stop button and the ignition switch are in their respective Off position.
• To crank the engine, the Plastic Key under the Engine bonnet must be in the ‘On’ position and the Base control Emergency stop is reset.
7. Emergency Operation
CAUTION: Industrial model machines when operating the any of the manual controls (except lower) the blue function enable button must be pushed and held while the function is operated
o Quick Release Pins
If the Work Platform control is jammed for any reason the clevis pins, which connect the control cables to the spool, can be removed by pulling the ring which is attached to each of them. This will enable persons at the Ground Station to manipulate the movements using the Manual Movement Control Levers.
REMOVING THE QUICK RELEASE CLEVIS PIN
8. Picking Bag Operation
—IMPORTANT—
o Setup
Before using the bag it is important to ensure the following.
1. Check the condition of the liner and the foam lining of the steel case. These MUST be free of rips and damage.
2. Check the condition of the Draw-cords and Jam Cleats. The rope MUST NOT be frayed and MUST engage the teeth in the cleat securely. It is IMPORTANT to use only genuine rope as the “Lay” of these ropes must match the shape of the cleats properly to avoid slippage.
3. Check the condition of the Main-cord. The same factors apply as described above. The knot on the liner MUST be positioned so that when the door is fully closed the liner is pulled up to the level of the eye on the front of the bag.
o Operation
1. Straighten the liner before using the Main-cord at the front of the bag to pull the door closed, bringing the lip of the liner up to the small main-cord eye. Loop this cord around the top of the bag to secure it in case it is inadvertently released it from the Jam cleat.
2. Pull the top Draw cord to close the bag. This must be pulled very firmly to tension the liner. It is sometimes helpful to pull the cord between the bag and the top bar of the Work Platform to gain a more direct pull.
3. Close the bottom Draw-cord in the same manner. The bag is now closed and ready for picking. These procedures ensure that the liner is taught with no loose tucks which obstruct the flow of fruit through the bag. Having the fruit flow easily through the bag is necessary to avoid bruising.
8. Picking Bag Operation
4. Pick the top section full. Release the top Drawcord slowly, allowing the fruit to flow to the level of the second Draw-cord. Pull the rope through the cleat to the knot to avoid forming a choke point.
5. Pick the bag full and repeat the process again, allowing the fruit to flow to the bottom of the bag.
6. Finally pick the bag full.
DAN G E R
IN ANY CIRCUMSTANCES NEVER overfill the picking bag by releasing the Main-cord to increase the capacity of the bag. This practice results in damage to fruit, and usually means the maximum rated capacity is exceeded which comprises many safety factors.
7. Bring the MEWP over the bin. Release the Main-cord slowly lowering the chute laden with fruit down to the floor level of the bin. It may be necessary to adjust the height of the boom to avoid free falling the product, or crushing it where the height is too low.
8. Picking Bag Operation
8. Once the Main-cord is fully released the liner can be pulled up through the bag to release the fruit into the bin.
9. With the throttle at the low idle position the Work Platform can be lifted slowly to help complete the operation.
o Irrigated Pick Bag
This is used following exactly the same procedures as the standard pick bag.
The watering system must be kept operating at all times to avoid sap damage to susceptible fruits. The system operating pressure should be adjusted to 1.0 Bar. Using excessive pressure increases the amount of product being used without improving the performance of the system in any way.
If there are problems with maintaining the pressure, check the condition of the filter. The service interval for the filter maintenance will need to be determined at each location as this depends mainly on the condition of the water being used.
Never over-fill the picking bag. This practice invariably means the Manufacturers rated capacity specifications have been exceeded which will make the machine unstable.
If you have any problems contact your local Hydralada dealer or Hydralada Company for assistance!
Drive carefully to avoid branches protruding into operators platform cage.
8. Picking Bag Operation
o Maintaining the Filter
The filter bowl should be flushed regularly by removing the cap from the bottom of the bowl. To clean the filter properly, remove the filter element, the complete filter bowl assembly can be unscrewed, and the element removed for proper cleaning. If the element is damaged in any way, it should be replaced.
o Irrigated Pick Bag
Product System Filter
This filter should be removed and checked at least once a day. If the product includes an excessive volume of solid matter, it may need to be cleaned at more frequent intervals.
The filter can be flushed by removing the cap at the base of the bowl while the tank level is above the filter. However this may not be completely effective if the filter is plugged, meaning the element will need to be removed and cleaned.
To do this, the level in the product tank should be below the level of the filter. Proceed by unscrewing the plastic filter bowl assembly off of the base. This enables you to remove the plastic filter element for cleaning.
The element should be cleaned using a standard water hose. Never use hard brushes or high pressure washing systems on this component. If the gauze is punctured in any way, it must be replaced with a new part.
Nozzle Assembly
The operation of this should be checked daily to ensure the nozzles are spraying correctly and are not blocked in any way.
It is also important to ensure the mounting has not been bent in any way which could result in the spray pattern not covering the entire surface of the picking bag.
Pressure Regulator
With the system operating normally, the regulator should be set to 1.0 Bar. Operating at higher pressures will overload the Electric Product Pump, as well as using too much product.
Continuing to operate the system with a blocked filter will result in serious damage to the electric pump.
PRODUCT FILTER
Filter bowl assembly
9. Options
o Free Wheel Hubs
These allow the operator to disconnect the drive to the wheels to allow the MEWP to be towed between jobs.
All drive wheels must be latched out before the MEWP can be towed. To latch the drive pins out, first connect the MEWP to the towing vehicle by using the approved drawbar, then withdraw each pin, and latch them out by turning each pin a ¼ turn.
To re-engage the drive, reverse the procedure and operate the wheel motors gently until the pins engage. Ensure all drive pins are securely engaged before operating the MEWP.
CAUTION
When towing, always ensure the Hydralada MEWP is connected securely to the towing vehicle using the approved draw bar. Never exceed 30 kph when towing.
DAN G E R
Never operate an MEWP, fitted with Twin Castors, with a wheel off the ground. The machines stability rating is void in this condition.
o Twin Castors
These are 185 x 14 wheels mounted on an oscillating beam and increase the machines stability.
o Tandem Drive
The condition of the Brake Disc and its operating pin should be inspected regularly for excessive wear. If these components become worn, they should be replaced with new parts from your Hydralada Dealer.
This drive is supplied standard with Hydrabrake and is designed for maximum traction and extra stability. The MEWP is operated in the same manner as a standard MEWP.
Any scuffing effect on loose surfaces can be minimised by using double wheel turns wherever possible.
FREE WHEEL HUB PIN
TWIN CASTOR OPTION
o Dual Castors
DUAL CASTOR OPTION
9. Options
TANDEM DRIVE WHEELS
o Rubber Tracks
Check the condition of the track belts and rollers. The track belts should be tensioned so that the track deflection is 70-90mm in the position of the arrow as shown in the below drawing
RUBBER TRACKS
DAN G E R
Use care when the machine is on slopes that the offsetting effect of the Slew Work Platform is appropriate for the slope.
o Slew Work Platform
Hydralada Company offer the slew option which makes it easier to manoeuvre the work platform amongst branches.
o Picking Bag
o Slope Gauge
A hand held instrument for measuring the degree of slope to assist in the safe operation of MEWP. This is available from the Hydralada Company Spare Parts Department (PN 60-2797-00).
SLEW WORK PLATFORM MODEL
9. Options
o Hydrafork
o Two Man Platform
o Rotating Beacon
This orange beacon is mounted on the tail of the MEWP. Rotating beacons are fitted where the MEWP will be used near vehicular traffic.
o Auxiliary Hydraulic Outlet Option
Two Aux oil systems are used on Hydralada MEWP to supply oil to the work platform for use of hydraulic pruners and tools.
1. Momentary supply. Single hydraulic pressure hose supplies oil and holds the pressure when the tool is activated. Hydraloppa pruners use this system. Activation of the system is done though the Hydraloppa electrical plug.
2. Constant supply. Dual hydraulic hoses, pressure and a return hose to the hydraulic reservoir. This system constantly supplies oil to the platform with a Hydraulic tool fitted.
The control switch is mounted on the work platform control panel. Switching to On energies a latching relay which provides power to the auxiliary oil coil on the control valve.
CAUTION: The hydraulic tool must be connected to the machine before activating the auxiliary oil system.
DANGER: Activation of the auxiliary oil switch with a Hydraloppa connected will close the jaws of the pruner and load up the system.
Once the MEWP is restarted its electrical system will automatically discontinue the oil supply. To restart the flow of oil, the switch must be operated again once the engine is running.
The standard hydraulic tool flow and pressure (20 L/pm at 2000 psi) is delivered at around 2000 engine rpm. Increasing the engine rpm will not increase this flow or pressure. The pressure from the auxiliary oil port is limited to 2000psi with the standard hydraulic tool flow being delivered around 2000 engine rpm.
For further details contact Hydralada technical division.
HYDRAFORK
TWO MAN PLATFORM
SLOPE GAUGE
9. Options
Be aware of the dangers of working with high pressure oil. It can be almost invisible escaping from a pinhole, and penetrate the skin into the body. If fluid penetrates the skin, even if no pain is felt, a serious emergency already exists.
DAN G E R
If the Constant Pumping switch is activated while a Series II Loppa is connected, the jaws will close and the system will be overloaded. This could result in serious injury or death.
o Dual Power
The Dual Power option uses a triple hydraulic pump which provides an individual pump for each function, LH wheel drive, RH wheel drive and boom lift. A selector switch located on the work platform control panel allows the operator to turn this system on or off.
When the boom is in the lowered travel position, the Dual Power system is activated, this increases the hydraulic oil flow to the wheel drive motors providing a faster travel speed for transport.
When the boom is lifted above a pre-set height set in the factory the system is deactivated returning the machine to normal operating speed.
The boom cannot be raised simultaneously with the drive wheels whilst in high-speed travel mode.
The pressure provided from this outlet is controlled by the machines main system relief settings to deliver 2000 psi. Check the pressure rating of your equipment before connecting to these outlets.
o Two Speed
The Two Speed system uses a standard double hydraulic pump with an additional hydraulic block that when activated restricts the amount of oil available for the machines functions.
A switch located on the work platform control panel allows the operator to select the speed the machine operates. Moving this switch to the ‘Low’ position halves the speed of all hydraulic functions. Moving the switch to the ‘High’ position brings the speed to normal operating speed.
The system is useful for applications where the MEWP is to be operated at slow ground speeds and can operate at all boom heights.
9. Options
o Auxiliary Oil Cooler
The oil cooler radiator and fan decreases the temperature of the hydraulic oil being returned from the platform.
o Adjusta Trac
How to decrease and increase the width of the adjustable track option on a Hydralada MEWP:
1. Park the machine on level ground and on a firm surface. Dismount the jack from it’s storage position on the inside of the right hand chassis leg.
2. Position the jack on the mount bracket on the side of the machine to be adjusted and insert the locator pin. Carefully jack one side of the machine so the wheels are clear of the ground.
3. Loosen the four chassis bolts to half undone using a 3/4 inch socket and strong bar. Disengage the quick release positioning pin (you may have to adjust the leg extension fore and aft to release tension on the quick release locking pin).
Chassis Bolts
Chassis Bolts
Quick Release Locking Pin
9. Options
4. Fit a strong bar with a 3/4 inch socket and adjust the leg out until the quick release locating pin locks in to the outer position. Ensure pin locks fully. Check that the hydraulic hoses are lying in the correct position and are not snagged.
5. Ensure the quick release locking pin is fully engaged. Re-tighten the clamp bolts to 80ft/lbs torque. Lower machine and re-stow the lifting jack. Repeat process on the opposite side of the machine.
6. Carry out the above procedure to retract the leg extension. When retracting the leg watch the hydraulic hoses closely to ensure that they track correctly to their normal position and do not snag. Ensure clamp bolts are done up to the specified torque and the locating pins are fully engaged.
o Steel Tracks (option)
Fitting Tracks
1. Check the tyres are inflated to the maximum pressure (12psi).
2. Unroll the track in front of the wheels so the side plates are touching the ground. Lift the end up onto the tyre.
3. Connect a rope onto the end and lead this across the top of the wheels and down the back, and tuck it under the rear tyre.
4. Carefullly reverse the machine, pulling the track across the top of the wheels and into position.
5. Once the two ends of the track come close, chain or tie the two ends together, and continue to move the machine until the two ends are positioned centrally over the top of the two wheels.
6. An installation tool is provided with every set of tracks. Mount this as shown in the illustration, and pull the two ends together. It may be necessary to carefully move the machine back and forward a little to settle the tracks into position.
Chassis Bolts
Chassis Bolts Quick Release Locking Pin
9. Options
CAUTION
Do not use a lever longer than 400mm to pull the track ends together. Excessive force can damage the installation tool, and result in personal injury.
7. Install the Duro-pins to join the track, and torque the Duro-pin nuts to 80ft/lbs.
8. Drive the machine a little and check the tension of the tracks. They should operate with around a 75mm sag between the two wheels. Operating the tracks too tight uses a significant amount of driving power as well as overloading the bearings in the hydraulic wheel motors.
Adjusting the Track Tension
Each link has two holes which can be used to connect to the next link. If the tension becomes too loose, a link can be released and the track pulled up to the next hole. Once all the links are pulled up to the second hole, it will be necessary to inspect and replace the Duro-pins which are worn.
1. Track Pad
2. Track Link
3. Dura Pin
4. Jam Nut
10. Troubleshooting
o Troubleshooting
A number of the actions described in this chapter may be performed by a Hydralada MEWP operator. A trained and qualified service technician is not necessarily required.
o Engine Fault
• No fuel in tank
• Fuel filter blocked
Start fault
-Engine Cranks but will not start
Start fault
- Starter Cranks slowly
Start fault
-No reaction from starter
Start fault
-Starter does no disengage
Start fault
-Engine cranks from Ground station panel only
Engine starts but runs rough/ backfires
Engine runs but vibrates
Engine knocking on shut down
Engine smoking
CAUTION
Any problem that cannot be fixed by actions listed below should be referred to a trained and qualified Hydralada MEWP service technician.
• Running on 1 cylinder. (Pour water on exhaust manifold and observe evaporation). One colder than the other confirms cylinder is not firing. Sparkplug or ignition coil pack failure.
• Flywheel key sheared
• EFI – Battery voltage minimum 12V
• EFI – Fuel pump venting fuel through breather. Remove small vent hose from top of pump. If fuel coming from vent with engine running. Replace pump.
• EFI – Oxygen sensor failure. Check resistance
• EFI – Check fault code through MIL or contact local Kohler agent.
• Check torque Engine mount bolts
• Pump coupling spider worn / missing
• Engine oil level to high
• Blocked air filter
• Fuel contaminated.
10. Troubleshooting
o Electrical Fault
No power to system
-Ignition switch Platform dash ‘On’ (No audible beep)
-No starter engagement
-No Horn
Battery flat
-EFI Battery goes flat when machine is in use.
Inclinometer does not alarm during daily check
• Check Emergency stop buttons reset
• Midrail /drop gate down
• Battery isolator
• System fuse
• Gate relay
• Midrail drop gate switch
• Fully charge battery. Recommended not to jumpstart the machine as engine requires 12V to operate.
• Battery voltage 12V minimum
• Run engine and set half to three-quarter throttle. Battery voltage 13-14V
• If charging re-check in 15-20 min
• If still not charging
• Check Battery terminals are tight, not broken or deformed
• Check 30amp charge fuse behind engine.
• Check Electrical plug is connected to regulator
• Carry out Kohler engine charge circuit troubleshooting.
• Audible beep when system power turned on
• Inclinometer not pushed over enough
• Boom raised to operating height
• Tail switch contacting levelling bar cam
• Tail switch roller stuck in. Test internal N/C contact
• No audible beep when system power turned on, but engine starts
• Inclinometer fuse
• Buzzer failure.
10. Troubleshooting
o Hydraulic Fault
No Drive LH & RH, or lift
No drive in both directions single side (LH or RH)
• Pump drive coupling
• Pump Industrial models
• Function enable switch failure
• Function enable relay
• Function enable fuse
• FWH pin
• Cable clamps
• Broken cable – Confirm with manual lever operation
• Swap pump hoses top on pump. If fault changes sides pump is faulting.
• Relief valve setting
• Brake shuttle cartridge leaking internally
• Park brake cylinder leaking internally
• Wheel motor
• Tyre pressures, different tyre sizes fitted
• Pedal stops not adjusted
• Cable adjustment – check full travel of spool
• Rear castor pivots not greased
Weak drive on one side
Machine not driving straight
No lift
-Engine loads up when lifting
No Lift
-No change to engine
Boom drops in use
Dual power not working
• Auxiliary oil turned on or failed on with No tool fitted. Disconnect aux oil coil on control valve.
• Swap pump hoses top on pump. If fault changes sides pump is faulting
• Relief valve pressure
• Brake shuttle cartridge leaking internally
• Park brake cylinder leaking internally
• Wheel motor
• Lift switch
• Lift fuse
• Lift coil on base of lift ram
• Pedal stop
• Lift cable - Confirm with Manual lever operation
• Brake shuttle cartridge
• Boom drops in use
• Lift ram leaking internally
• Dual power switch On
• Boom in lowered travel position
• Tail switch contacting cam – Confirm N/C switch
• Dual power coil fuse
• Coil on Dual power hydraulic block
11. Servicing
o Engine Identification Numbers
KOHLER ENGINE
o Engine Oil
When ordering parts, or in any communication involving an engine always give the Model, Specification, and Serial Numbers of the engine. The engine identification numbers appear on the decal (or decals) affixed to the engine shrouding. Include letter suffixes, if there are any.
Record your engine identification numbers on the identification label below for future reference.
For details of machine/identification numbers and codes see the “Introduction”.
The engine is covered by a Kohler warranty for the first two years. Engine warranty service under the terms of the standard Kohler warranty can be obtained by presenting the engine to any authorised Kohler Service Centre.
MODEL NUMBER:
SPEC NUMBER:
DISPL (CC):
SERIAL NUMBER:
REFER TO OWNERS MANUAL FOR SAFETY, MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS
o Boom Support
DAN G E R
Working below the raised boom of a Hydralada MEWP is extremely hazardous and must NEVER be undertaken without proper measures being put in place to support the boom.
A special tool to support a raised boom is available from Hydralada® Company.
o Recommended Lubricants
o Grease
We recommend the use of good quality standard multipurpose grease. The pivot points of the Hydralada MEWP are not heavily stressed and do not require the use of high performance grease. Regular multipurpose grease is ideal for all greasing points on your MEWP.
Using the proper type and weight of oil in the crankcase is extremely important. So is checking the oil daily and changing the oil regularly.
Failure to use the correct oil, or using dirty oil, will cause premature engine wear and failure.
—IMPORTANT—
Neither Hydralada® Company or our component suppliers endorse any products or additives which claim to extend the service periods listed in this manual.
—IMPORTANT—
Because the engine of your Hydralada MEWP often runs under very light loads it is VERY IMPORTANT to use suitable oils to control sludge and gum deposits in the engine.
o Engine Oil Type
Use high quality detergent oil of API (American Petroleum Institute) series class SJ in KOHLER COMMAND engines. Select the viscosity based on the air temperature at the time of operation as shown in the following table.
RECOMMENDED SAE VISCOSITY GRADES FOR COMMAND ENGINES
*Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable up to 4˚C
Using other than service class SJ oil in a COMMAND engine or extending oil change intervals to longer than recommended can cause engine damage which is not covered by the engine warranty.
11. Servicing
A logo or symbol on oil containers identifies the API service class and SAE viscosity grade.
APISERVICESJ
The example above shows an API SERVICE CLASS SJ. Sometimes the symbol may show additional categories such as SF, CC, CD.
The centre portion shows the viscosity grade such as SAE 10W30 in the example.
The bottom portion shows “Energy Conserving”, it means that oil is intended to improve fuel economy in passenger car engines.
o Checking the Engine Oil Level
The importance of checking and maintaining the proper oil level in the crankcase cannot be over emphasised.
Check oil BEFORE EACH USE as follows:
1. Make sure the engine is stopped, level, and is cool so that the oil has had time to drain into the sump.
WARNING
Before servicing the engine or equipment, always disconnect the spark plug lead to prevent the engine from starting accidentally.
Ground the lead to prevent sparks that could cause fires. It is also a good idea to disengage the battery isolate switch.
2. To keep dirt out of the engine, clean the area around the oil level dipstick before removing it.
3. Remove the oil level dipstick, wipe the oil off, and re-insert the dipstick into the tube.
4. Remove the dipstick again and check the oil level. The oil level should be up to, but not over, the “F” mark on the dipstick.
5. If the level is low, add oil of the proper type, up to the “F” mark on the dipstick. Always check the level with the dipstick before adding more oil.
o Changing the Engine Oil
Change the oil while the engine is still warm. The oil will flow freely and carry away more impurities. Make sure the engine is level when filling, checking or changing the oil.
1. To keep dirt out of the engine, clean the area around the fill cap/dipstick before removing it.
2. Remove the oil drain plug and oil fill cap/ dipstick. Be sure to allow ample time for complete drainage.
3. Reinstall the drain plug. Make sure it is tightened to 13.6 N-m (10ft.lb) torque.
4. Fill the crankcase, with new oil of the proper type, to the “F” mark on the dip-stick.
5. Refer to “Oil Type” on page of this chapter.
6. Always check the level with the dipstick before adding more oil.
7. Reinstall the oil filling cap.
CH23SV-TWIN ENGINE
Add engine oil through the cap beside the engines fuel pump as necessary.
The first engine oil change must be within the first 8 operating hours.
11. Servicing
o Changing the Engine Oil Filter
KOHLER ENGINE
The Kohler Command is a full pressure lubricated engine which features a replaceable spin on cartridge.
A filter removing tool (#47-800-56) will probably be needed to remove the old filter.
Replace the oil filter at least every other oil change (every 200 hours of operation)
Always use a genuine Kohler oil filter, Part number 52 050 02-S
1. Drain the oil from the engine crankcase.
2. Allow the oil filter to drain
3. Remove the old filter and wipe off the filter adaptor.
4. Apply a thin coating of new oil to the rubber gasket on the replacement oil filter.
CAUTION
To prevent extensive engine wear or damage, ALWAYS maintain the proper oil level in the crankcase. NEVER operate the engine with the oil level below the “L” mark or over the “F” mark on the dipstick.
5. Install the replacement oil filter to the filter adaptor. Turn the oil filter clockwise until the rubber gasket contacts the filter adaptor, then tighten the filter an additional half turn.
6. Reinstall the drain plug.
7. Fill the crankcase with new oil as instructed under ‘Changing the Engine Oil’. Add an additional 0.24 litres (half pint) of oil for the filter capacity.
8. Start the engine and check for oil leaks. Correct any leaks before placing the engine into service. Check the oil level to be sure it is up to but not over the “F” mark.
Operating Range
o Air Cleaner and Pre-cleaner Element
This engine is equipped with a replaceable, high density paper air cleaner element. Some engines are also equipped with an oiled, foam pre-cleaner which surrounds the paper element.
Check the air cleaner daily for build-up of dirt and debris around the air cleaner system. Keep this area clean. Also check for loose or damaged components. Replace all bent or damaged air cleaner components.
o
Servicing the Pre-Cleaner
Preferably, fit a new foam pre-cleaner every 100 hours of operation, more often under extremely dusty or dirty conditions.
WARNING
Using non genuine Oil filters can cause serious damage to the engine.
“F Mark
11. Servicing
KOHLER ENGINE
However, if the foam ring is in good condition, it can be washed and re-oiled as follows;
1. Remove the air cleaner cover retaining knob, air cleaner cover, element cover nut, element cover and paper element with pre-cleaner.
2. Remove the pre-cleaner from the paper element.
3. Wash the pre-cleaner in warm water with detergent. Rinse the pre-cleaner thoroughly until all traces of detergent are eliminated. Squeeze out excess water (DO NOT wring). Allow the pre-cleaner to air dry.
4. Saturate the pre-cleaner with new engine oil. Squeeze out all excess oil.
5. Reinstall the pre-cleaner over the paper element.
6. Reinstall the paper element with pre-cleaner, element cover, element cover nut, air cleaner cover, and air cleaner cover retaining knob.
o Servicing the Paper Element
Every day check the paper element for condition and damage. After every 250 hours replace the paper element.
1. Remove the pre-cleaner (if installed) from the paper element.
2. Do not wash the paper element or use pressurised air, as this will damage the element. Replace a dirty, damaged or bent element with a new genuine Kohler element. Handle new elements carefully, do not use if the sealing surfaces are bent or damaged.
3. When servicing the air cleaner, check the air cleaner base. Make sure it is secured and not bent or damaged. Also check the element cover for damaged or improper fit. Replace all damaged air cleaner components.
4. Reinstall all components as described above.
Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure.
o Air Intake/Cooling Areas
To ensure proper cooling, make sure the flywheel screen, cooling fins, and other external surfaces of the engine are kept clean at all times.
o Ignition System
This engine is equipped with a dependable electronic magneto ignition system.
Other than periodically checking/replacing the spark plug, no maintenance, timing, or adjustments are necessary or possible with this system.
In the event starting problems should occur which are not corrected by replacing the spark plugs, see your Hydralada Service Dealer for trouble analysis.
o V-Twin Spark Plugs
Every 400 hours or Annually Replace spark plugs and set gap. Perform this procedure more frequently under severe, dusty, dirty conditions.
CAUTION
DO NOT clean the spark plug in a machine using abrasive grit. Some grit could remain in the spark plug and enter the engine causing extensive wear and damage.
1. Before removing the spark plug, clean the area around the base of the plug to keep dirt and debris out of the engine.
11. Servicing
Kohler ECH630 & ECH730 engines are fitted with Champion XC12YC spark plugs. These do not need to be removed or serviced unless there is a problem with them
Faulty spark plugs cause symptoms which appear to be fuel related. To be sure, fit a new spark plug as a test.
2. Remove the plug and check its condition. Replace the plug if it is worn or its reuse is questionable.
3. Check the gap using a wire feeler gauge Reinstall the spark plugs into the cylinder head. .Torque the spark plug to; 20N.m (27 ft.lbs)
Carry out the process for the both cylinders. For access to inboard cylinder on 300 Compact or 360 Hi Lift, raise boom, fit boom support pin and remove boom debris plate.
o Fuel Recommendations
DO NOT fill the tank while the engine is running, since spilled fuel could ignite if it comes into contact with hot parts or sparks from the ignition.
DO NOT start the engine near spilled fuel. NEVER use gasoline as a cleaning agent.
DAN G E R
Gasoline is extremely flammable and its vapours can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames.
o Fuel Type
For best results use only clean, fresh, unleaded gasoline with a pump sticker octane rating of 96 or higher for Command engines. Unleaded gasoline is recommended as it leaves less combustion chamber deposits.
Leaded gasoline may be used in areas where unleaded is not available and exhaust emissions are not regulated. Be aware however, that the cylinder head will require more frequent service.
o Fuel Filter
Engines are equipped with an in-line fuel filter. Inspect this daily and replace when dirty. Use a genuine Hydralada filter.
o Secondary Fuel Filter
Elevating Work Platforms fitted with EFI Engines are equipped with a very fine secondary filter which is fitted in the supply line to the engine. This filter must be replaced every 200 operating hours, and must only be replaced with a genuine Kohler filter. This is essential to maintain the fuel injection systems performance.
11. Servicing
o Carburetor
Carbureted Kohler engines fitted to your Hydralada MEWP are equipped with Walbro carburetors which have non-adjustable fixed jets.
The carburetor is designed to deliver the correct fuel-to-air mixture to the engine under all operating conditions and cannot be adjusted.
The only adjustment which is available is the idle speed of the engine.
This should only be adjusted with the engine fully warm.
or faults are detected. Servicing by a Kohler authorized dealer is necessary.
SERVICEMANS EFI DIAGNOSTIC CONNECTION
o Engine charge fuse 30amp locted behind the engine
To
o Troubleshooting
If engine troubles are experienced that appear to be fuel system related, check the following areas before adjusting the carburetor.
1. Make sure the fuel tank is filled with clean, fresh gasoline.
2. Make sure the fuel tank cap vent is not blocked and that it is operating properly.
3. Check the fuel shut-off valve, make sure it is open.
4. Check the in-line fuel filter, make sure it is clean and unobstructed. Replace the filter if necessary.
5. Make sure fuel is reaching the carburetor. This includes checking the fuel lines and fuel pump for restrictions or faulty components, replace as necessary.
6. Make sure the air cleaner element is clean and all the air cleaner components are fastened securely.
7. Check the oil outlets at the Work Platform are not activated causing a hydraulic lock-up.
o
EFI (Fuel Injected Engines)
EFI is an electronically-controlled fuel management system which is monitored by an Electronic Control Unit (ECU). A Malfunction Indicator Light (MIL) will illuminate if problems
o Malfunction Indicator Light (MIL)
A Malfunction Indicator Light is provided which indicates a fault with the engines Fuel Injection System. Turning the Ignition Switch on and off three times (within 3 seconds) without starting the engine brings this into a diagnostic mode. A system of flashes indicates the nature of the fault to a Kohler Serviceman.
The recommended low idle speed for basic engines is 1200 RPM.
ensure the best results, the low idle speed must not exceed 1500 RPM.
KOHLER ENGINE
11. Servicing
n The Chassis
o Cable Tray
CHASSIS
The cable tray which is located under the Work Platform protects the cables and their clevises from damage. This tray should be removed regularly and the area cleared of any accumulated debris. The condition of the clevises should be checked at this time, and a little lubricant applied to the pins.
o Pedals
It is important to keep the area under the pedals clear of any debris or objects which could interfere with the operation of the machine in any way.
o Pedal Stops
These are necessary to avoid overloading the control cable when the valve reaches the end of its travel. These stops also ensure that the operators body weight is never supported by the cables.
See Page 6-6 of this manual for more information on this problem.
o Pedal Stop Adjustment - Drive Wheels
Withdraw the Spruce plugs securing the rear of the floor mat to gain access to the adjusting stops.
Loosen the locknut (9/16” spanner) and set the stop (9/16” spanner) until it contacts the floor plate at the same point as the valve spool reaches the end of its travel. Re-tighten the locknut.
o Pedal Stop Adjustment - Boom Lift
Unlike the drive pedals, the stops under the lift pedals are used to control the speed of the lift cylinder.
The stop on the front pedal is adjusted as described above using two 9/16” spanners. The rear stop is set so the boom is just beginning to lower as the stop meets the floor, a little extra weight being needed to lower the boom at speed.
Setting the lift pedal stop too high will result in extreme juddering when the Work Platform is being lowered.
The stops on the wheel drive pedals are not to be used for changing the speed of the machine.
Possible causes of machines not tracking straight are:
1. The stop on one pedal is set too low, thereby restricting the travel of the control valve spool.
2. Uneven drive wheels on the machine.
3. The tyre pressures are not matched.
o Wheel Nuts
Check these daily and ensure they are tensioned correctly:
• Tighten five stud rims to 60 ft/lbs.
• Tighten six stud rims to 85ft/lbs.
• DO NOT over-tension the wheel nuts as this can distort the wheel rim.
• Persistent problems with wheels coming loose are most commonly caused by worn nuts and/or tapers in the wheel rim.
• In the event of damage to the tapers in the wheel rims, the wheel rim should be replaced. It is recommended that new wheel nuts be fitted at the same time to ensure problems do not reoccur.
DAN G E R
Never use a machine unless any problems with wheel nuts are properly resolved as the stability of the machine relies entirely on the wheels.
PEDAL STOPS
11. Servicing
o Tyres
CHASSIS
o Pivot Points
The recommended pressures are as follows. Drive tyres on all HiLift and Maxi models must be water filled to ensure stability of the machine. These tyres must have a inner tube fitted to protect the wheel rim from corrosion.
WARNING
Opertaing with low tyre pressures below the recommended pressure settings can affect the stability of the MEWP.
18.5x8.50x8 - - Castor 35
23x10.50x12 - - Single drive 16-20
Galaxy 26x12.00x12 60 kg - Single drive 10-16
Galaxy 26x12.00x12 60 kg - Tandem 8-10
Hydralada 26x12.00x12 60 kg - Single drive 16-20
Hydralada 26x12.00x12 60 kg - Tandem 8-10
Galaxy 29x12.50x15 85 kg - Single drive 8-10
185x14 - - Castor 50-55
185x14 (twin castor models) - 49 kg Castor -
The security of the various pivot pins and their ability to carry the loads depend on them being tight in the machines frame, the mounting bolts simply holding them in position.
In the event a particular mounting bolt is found to be loose, the pin will need to be removed and its clearance through the frame checked.
This procedure must be performed by an authorised service person who may need to fit special repair kits available from the Hydralada Spare Parts division.
o Braking Systems
There are two types of brakes used on the Hydralada MEWP which must be serviced as follows:
Oil Immersed Disc Brakes
These consist of a spring applied multi disc brake which is enclosed within the wheel motor. These require no ongoing servicing, other than when the complete motor is overhauled.
o Park Brake System
These consist of a special cylinder which extends a pin into a series of holes drilled into the periphery of a sacrificial brake disc.
It is normal for the pin and disc to wear which makes it necessary to inspect the condition of these components regularly. Once the holes in this disc appear to be nearly breaking through to one another, the disc should be replaced.
o Hour Meter
It is important to record the hours run and to keep this information up-to-date in the Log Book so that appropriate service work can be performed as scheduled in the service instructions.
o Venture Slew Ring Annual periodic inspection
Slew Ring Mounting Bolts annual check.
• Remove weight on slew ring by taking the weight of the boom on a support stand.
• Remove access panels from under boom and visually inspect 12x bolts for indication of bolt movement.
• Visually check outer 12x mounting bolts for indication of movement.
• Check torque inner and outer ring M16 bolts 300 Nm. (220 ft/lbs)
The MEWP must only be fitted with the tyres specified by the manufacturer.
• Refit access panels and remove boom support.
11. Servicing
o Hydraulic Oil Filter
HYDRAULIC SYSTEM
With the engine turned off use the appropriate tool to unscrew the old element. Lightly oil the rubber gasket and install the new part. Do not over tighten.
IMPORTANT
Before attempting to replace the filter, check the oil level is not too high. This can be corrected by raising the level of the boom while the work is being done.
CAUTION
This Hydralada hydraulic oil filter is sometimes subject to some pressure, which it is designed to withstand. If the correct part is not fitted the filter could rupture and cause hot, high pressure oil to be ejected.
o Hydraulic Oil
The hydraulic oil for the Hydralada machine must conform with two parameters;
RECOMMENDED SAE VISCOSITY GRADES COMMAND ENGINES
AGRI-MP PLUS 20W 40 (10 <>85C)
AGRI-TRANS PLUS 10W/30 (-15 <>75C)
CRF 10W (-15 <>60C)
o Viscosity
Use this chart to determine the correct hydraulic oil viscosity for your application.
Notes:
1. Your MEWP will have been supplied from the Hydralada assembly plant with one of these grades (Castrol products as supplied in New Zealand) having been installed. Use the anticipated temperature scale at the bottom of the chart to choose the appropriate viscosity of your oil.
2. The bracketed value is the operating temperature range of the hydraulic oil in the system. Oil temperatures below this will mean the system is at risk of cavitations while temperatures higher than this will shorten the service life of seals. The recommended oil change periods of the hydraulic oil are also reduced if the oil is operated at temperatures above 70C.
3. When starting an MEWP in an ambient temperature of less than 15C never run the engine at maximum rpm‘s until the hydraulic oil is risen to around 50C.
o Lubricating Properties
The oil must have a minimum Zinc content of 0.125% or 1250 ppm of Zinc.
This specification is seldom found in standard hydraulic oils, meaning it will probably be necessary to use a motor oil in the hydraulic system.
11. Servicing
Hydralada MEWP Greasing Chart
SERVICING
OPTIONAL - SLEWING PLATFORM
Whengreasingthisnipple: Itmaybenecessarytoremovetheweightoffofthispinbylowering theplatformontoadeckorposttoallowthegreasetoflowacross thebearingsurface. On RH side of the boom
CASTOR BEAM PIVOT
KING-PIN
LOWER LIFT CYLINDER PIN
LEVELLING BAR AND MASTER PIN
PLATFORM MOUNTING PINS
PEDAL BUSHES X 3
SLEW CYLINDER BASE
SLEW CYLINDER ROD END
PLATFORM SLEW PIVOT
OPTIONAL - TWIN CASTORS
11. Servicing
o Venture Slew Ring Maintenance Venture Slew Ring Greasing Procedure. Greasing of the Slew ring is required every 400 hours or every 6 months.
1. Remove plug form the outer ring on Engine side of machine to relieve pressure during greasing.
2. Raise boom and fit boom support.
3. Inner Ring
• Access inner ring by removing panel cap screws with 6mm hex drive bit.
• Grease first inner point, grease at each boom position as shown in image. Full Left Hand slew, Centre and Full right hand slew.
• Repeat process for second grease point.
INNER RING GREASE POINTS
4. Grease outer at each boom position. Full Left Hand slew, Centre and Full right hand slew.
5. Grease slew drive grease points Rotate slew through three full cycles full left hand to full right hand.
6. Refit blanking plug removed in step 1. Torque to 10 Nm (7 ft/lbs).
7. Refit panels and remove support.
11. Servicing
n Periodic Inspections
SERVICING
The Hydralada schedule of regular inspections is based on the number of hours the MEWP has been operated. These operating hours are recorded by the hour meter whose operation is described on the preceding pages.
These regular inspection charts have been developed on the presumption the MEWP will run for 600-1000 hrs per annum. While this chart runs up to 10,000 hrs, the MEWP may well fall due for its periodic or time based periodic major inspection before the MEWP has run this many hours. Once the major inspection has been completed and the MEWP returned to service, start at the beginning of these charts again.
The Service Schedule is divided into specific tasks identified as A, B, C checks which need to be carried out at various intervals as set out on the chart below.
It is important to keep the Servicing of the MEWP up to date as laid out in this schedule to ensure that your Hydralada MEWP continues to provide safe and reliable service. While some of these checks may appear trivial and repetitive, it is important to understand that an MEWP of this nature is always subject to potentially damaging loads and stress. Any mechanical failure has the potential to result in an accident.
New Hydralada Elevating Work Platforms
• MUST be greased DAILY for the first week.
• The MEWP MUST be GREASED WEEKLY thereafter.
11. Servicing
SERVICING + KOHLER ENGINE
o Hydralada Mobile Elevated Working Platform - Major Servicing Requirements
Major inspections are required on a Mobile Elevated Working Platform (MEWP) every 10 years following entry to service as detailed in Australian Standard AS2550.10-2006 Cranes, hoists and winches - Safe use - Mobile elevating work platforms.
A Major Service is also required after an accident or modification to the MEWP.
Hydralada Industrial model MEWP and Hortricultral model MEWPoperated outside New Zealand a Major Inspection is required every 5 years thereafter as detailed in AS2550.10-2006 & Worksafe NZ Best Practice Guidelines – Mobile Elevating Work Platforms.
Hydralada Horticultral model MEWP operated within NewZealand a Major inspection is required every 10 years thereafter as detailed in Worksafe NZ Best Practice Guidelines – Safe Use of Elevating Work Platforms in the Horticultural Industry.
Machines operated outside New Zealand refer to your local MEWP maintenance guidelines.
The Manufacturer’s recommended major inspection must be carried out at the above intervals. The inspection criteria should meet the requirements set out in AS 2550.10 appendix C. Any parts replacement or modifications recommended by the manufacturer for safety reasons must be completed. Where possible the machine should be upgraded to the current specifications.
The person completing the major inspection should be ‘competent’, with experience working with Hydralada MEWP machines. A Competent person is classified in AS2550.10 as “A person who has acquired through training, qualification, experience or a combination of these, the knowledge and skill enabling that person to correctly perform the required task”.
o Periodic Inspections
1. Monthly: carry out inspections/service work as listed in Check ‘A’.
2. Six Monthly: carry out the inspections/service work in Check ‘B’.
3. Twelve Monthly: carry out the inspections/ service work in Check ‘C’.
4. Major Inspection : Contact Hydralada for current inspection criteria and mandatory safety upgardes.
o Electrical Systems for Kohler Electronic Fuel Injection (EFI) Petrol Engines
The rectifier-regulator as used on EFI engines has a self-resetting, built-in over-voltage protection to try and prevent possible damage to other electrical components caused by excessive voltage spikes from either a defective battery, loose battery terminal connections or jump-starting an engine etc.
If the battery voltage is below 12 Volts you must either replace the battery, or use an auxiliary charger to charge the “flat” battery rather than rely, as previously, on the engine charging circuit to “charge” the low power (flat) battery as the built-in circuit protection can repeatedly trip, resulting in an open charging circuit (system not charging).
A fully charged 12 Volt DC battery is recommended for maintaining steady and reliable system operation with an EFI engine. The Electronic Control Unit (ECU) requires a minimum of 7.2 Volts during cranking or the engine will not start. Remember that this is cranking volts not battery voltage.
If the machine battery is flat, do not ‘jump’ start the machine with a standby battery. The machine battery voltage will be too low and the because of the rectifier setting as described above, the alternator will not charge.
11. Servicing
7
8
11. Servicing
o Expanded Notes for Hydralada®
Regular Inspections
1. Operating Hours
When referring to the hour meter, it will also be necessary to examine the Log Book to verify the MEWP has not been fitted with a replacement hour meter through it‘s operating life. In the absence of a Log Book, it may be useful to discuss the matter with the owners and/or the operator.
As a guide we believe machines of this nature generally operate between 600-1000 hrs per annum. You will notice the chart on 13-1 has been prepared on the basis of 1000 hrs/annum.
In the event that it is found the hours are inaccurate, your findings should be advised to Hydralada Company who will record this in the machines company file, as well as in the machines Log Book to be carried forward.
2. Log Book
Review the operators‘ Log Book entries. Check the section to verify that any faults noted by the operator have been attended to in a satisfactory manner. Check for recurring faults or failures which will need to be referred to Hydralada Company.
Owners and operators are obligated to maintain a current log of the Elevating Work Platform’s operation and maintenance. If no Log Book has been kept, a new Log Book will need to be supplied to the owner as part of this inspection.
3. Unauthorised Modifications
Any unauthorised modifications should be removed from the MEWP. If cutting or welding has been made to the structure as part of this, it should be discussed with Hydralada Company.
4. Ballast Compliance
Check that the ballast complies with the MEWP Stability Certificate. This Certificate is provided with every new Hydralada MEWP in the Delivery Manual. If the Stability Certificate is missing, a copy can be obtained from Hydralada Company. You will need to advise the serial number and
model of the MEWP.
This lists the tyre equipment which was fitted, including water filled tyres and the ballast, which is required to bring the MEWP to the design level of stability. Check that no modifications have been made to the tyre equipment or ballast, and that the weight of the wheel assemblies is as shown in 11-8 of this manual.
5. Work Platform Floor Mat
Ensure the WORK PLATFORM floor and pedal area is clean. The MEWP should be fitted with an approved mat in good condition. This is a safety issue for two reasons;
• It prevents debris from locating under the pedals and interfering with their operation.
• The mat is marked to indicate the operation and use of the controls.
6. Throttle Lever Tension
It is important that this tension is set correctly to enable the operator to control the engine speed accurately, and have the speed maintained without needing to be constantly readjusting it.
7. Hydraulic Oil Change Period
Read the information on hydraulic oil oxidation in chapter 6 of this manual. Oil operating at higher temperatures may need to be changed more often.
8. Engine Mount Bolt Tensions
All twin cylinder engines are mounted with bolts which should be tensioned to 25ft/lbs.
9. Retaining Bolts and Circlips
Check pivot pin retaining bolts and circlips. The threads in the chassis need to be in sound condition. Loose pivot pins are known to cause failure/damage to the pin retaining bolts.
In the event that these are stripped or damaged, it is sometimes necessary to drill and tap a new hole in the chassis.
When installing the levelling rod pins, use a longer retaining bolt, and add a Nylock nut on the inside of the frame as a locking nut.
10. Wiring Harnesses
Check all hoses and wiring harnesses for chaffing and damage. Machines working in orchard environments, particularly Avocados, are prone to
11. Servicing
damage from vermin chewing these.
11. Bushings and Bearings
SERVICING
Check all pivot point bushings and bearings for wear, and replace as necessary. If the bushings have been properly greased, they may still be in good condition and will not need to be replaced.
12. Pivot Pins
Always be on the lookout for unusual situations such as movement or rotation of pins, pins not greasing properly, signs of wear, etc. Visually inspect boom, staybar and lift cylinder pivots for any sign of wear. If pins are showing movement in the side plates, repair bushings will need to be fitted. Call a Hydralada Service Technician. Ensure all retaining bolts and circlips are in place on each pin to prevent the pin from coming out of position.
13. Tyre Equipment
Check the tyres are in sound condition with the tread in good condition, and no perishing on the sidewalls.
The tyres must be mounted on the rims to drive in the forward direction. The tyres should be a minimum of 4 ply rated with a regular herringbone tread pattern. These conditions are necessary to ensure the MEWP has it‘s best traction capabilities, and provides a reliable platform for the purposes of stability.
Tyre inflation pressure has a significant influence on traction as well as the ability of the MEWP to drive in a straight line. Refer to the relevant section of this manual.
Only the tyres specified by the manufacturer are to be fitted to the MEWP.
14. Wheel Rims
Any damage in the area of the mounting bolt tapers is absolutely unrepairable, meaning a new genuine Hydralada wheel rim must be fitted. We do not authorise the fitting of new centres or parts thereof to these rims.
15. Wheel Nut Torques
Wheel nut torques must be adhered to as over tensioning a pressed steel rim can collapse the tapered hole the wheel nut engages into. This condition is irreversible and causes wheel nuts to continually loosen. Refer Page 11-2
16. Park Brake Discs
Park brake discs are a sacrificial wearing part, and wear quite quickly to establish a rounded shape. It is not necessarily unsafe to continue using these unless they appear to be nearly breaking through to a neighbouring hole. Some judgement needs to be made on these, and this is a matter which needs to be discussed with the owner to be sure he/she is aware of their status.
17. Hub Nut Torques
It is vital that these nuts are retensioned after the MEWP has been run for the first time. To carry out this work requires the service person must have access to the correct torque wrenches. Refer to the relevant section (11) of this manual for details.
18. Decals
The decals are designed to provide the operators with important safety information. They must be easily legible and in good condition at all times.
19. Free Wheel Hub Bearings
If these are in good condition they can be left in service. These bearings are only a safety issue when they develop movement to the stage the drive pin reliability is reduced.
20. Hydraulic Wheel Motors
Hydraulic motors with the integral wet brake disc system must be completely dismantled, and the brake disc inspected for wear. Reassemble with new oil in the brake disc cavity and seals throughout the motor.
Note: This work will need to be carried out by a suitably trained Hydralada technician. Instructions detailing the conduct of this procedure are not included in this manual.
21. Castor Legs
Visually inspect the complete castor leg assembly including all welds, the bushes, bearings, axle, hub
11. Servicing
and kingpin assembly retaining capscrew
22. Twin Castor Beam
Visually inspect the complete Twin Castor Beam including all welds, the bushings, bearings, axles, hubs, pivot pin retaining blocks and retaining capscrews.
23. Inclinometers
The Australian Standard AS1418.10 requires that all machines are fitted with an Inclinometer. These must to be checked daily for correct operation.
24. Corrosion
The underside of the fuel and hydraulic reservoirs must be checked closely for corrosion. The welds between the mounting brackets and the side of the tanks can also sometimes be a source of leaks.
If significant corrosion is detected in this area, contact the Hydralada Service Department.
12. Firefighting
n Hazardous Components
Hydralada® products may contain materials and objects that potentially could become significant fire or environmental hazards during the lifetime of the MEWP.
This chapter lists manufacturers‘ information you will need if you ever have to control any of these materials during an upset or emergency.
DAN G E R
Hydrogen gas is flammable and oxygen supports combustion. These gases enter the air through the vent caps. To avoid the chance of a fire or explosion, keep sparks and other sources of ignition away from the battery.
o Battery, Lead/Acid (UN 2794)
• Extinguishing media:
Dry chemical, foam, or CO2.
• Special fire fighting procedures: Use positive pressure, self contained breathing apparatus.
• Unusual fire and explosion hazards: Hydrogen and oxygen gases are produced in the cells during normal battery operation.
DAN G E R
ALWAYS wear acid resistant boots, face shield, chemical splash goggles, and acid resistant gloves when handling acid spills or leaks.
• Spill or leak:
Remove combustible materials and all sources of ignition. Contain spill by diking with soda ash (sodium carbonate) or quicklime (calcium oxide). Cover spill with either chemical. Mix well. Ensure the mixture is neutral then collect residue and place in a drum or other suitable container. Dispose of as hazardous waste.
• Sulfuric Acid:
Waste disposal method: Neutralize as above for a spill, collect residue, and place in a drum or suitable container. Dispose of as hazardous waste.
• Batteries:
Waste disposal method: Send to lead smelter for reclamation following applicable federal, state, and local regulations.
o Diesel Fuel (NA 1993)
• Extinguishing media: Use water spray, dry chemical, foam, or CO2.
• Special fire fighting procedures:
Use water to keep fire exposed containers cool. If leak or spill has not ignited, use water spray to disperse the vapours and to provide protection for personnel attempting to stop a leak. Water spray may be used to flush spills away from exposures.
• Unusual fire and explosion hazards: Products of combustion may contain carbon monoxide, carbon dioxide, and other toxic materials.
• Spill or leak:
Contain spill immediately in smallest area possible. Recover as much of the product itself as possible by such methods as vacuuming, followed by soaking up of residual fluids by use of absorbent materials.
Remove contaminated items including contaminated soil and place in proper containers for disposal. Avoid washing, draining, or directing material to storm or sanitary sewers.
DAN G E R
DO NOT enter enclosed or confined space without proper protective equipment including respiratory protection.
12. Firefighting
• Diesel Fuel.
Waste disposal method:
Recycle as much of the recoverable product as possible.
Dispose of non-recyclable material as a RCRA hazardous waste by such methods as incineration, complying with federal, state, and local regulations.
o Gasoline (UN 1203)
• Extinguishing media:
Dry chemical, foam, or CO2.
• Special fire fighting procedures:
Water may be ineffective to extinguish, but water should be used to keep fire exposed containers cool. If a leak or spill has not ignited, use water spray to disperse the vapours and to protect personnel attempting to stop a leak. Water spray may be used to flush spills away from areas of potential ignition.
• Unusual fire and explosion hazards:
Highly Flammable.
Products of combustion may contain carbon monoxide, carbon dioxide and other toxic materials.
DAN G E R
DO NOT enter enclosed or confined space without proper protective equipment including respiratory protection.
• Spill or leak:
Review fire and explosion hazards before proceeding with clean up. Use appropriate personal protective equipment during clean up. Dike spill.
Prevent liquid from entering sewers, waterways, or low areas. Soak up with sawdust, sand, oil dry or other absorbent material. Shovel or sweep up.
Remove source of heat, sparks, flame, impact, friction or electricity including internal combustion engines and power tools. If equipment is used for spill cleanup, it must be explosion proof and suitable for flammable liquid and vapour.
• Waste disposal method:
Treatment, storage, transportation and disposal must be in accordance with applicable federal, state, provincial, and local regulations.
Vapours released from the spill may create an explosive atmosphere.
o Hydraulic Oil (UN 1270)
• Extinguishing media:
Use water spray, dry chemical, foam, or CO2.
• Special fire fighting procedures:
Water or foam may cause frothing. Use water to keep fire exposed containers cool. Water spray may be used to flush spills away from exposures.
CAUTION
The signal word Caution indicates;
1. A potentially hazardous situation which, if not avoided, may result in minor or moderate injury 2. An action, about to be performed, can harm the Hydralada machine if not done correctly.
• Unusual fire and explosion hazards:
Products of combustion may contain carbon monoxide, carbon dioxide, and other toxic materials.
• Spill or leak:
Contain spill immediately in smallest area possible. Recover as much of the product itself as possible by such methods as vacuuming, followed by soaking up of residual fluids by use of absorbent materials.
Remove contaminated items including contaminated soil and place in proper containers for disposal. Avoid washing, draining or directing material to storm or sanitary sewers.
DAN G E R
DO NOT enter enclosed or confined space without proper protective equipment including respiratory protection.
12. Firefighting
• Waste disposal method:
Recycle as much of the recoverable product as possible.
Dispose of non-recyclable material as a RCRA hazardous waste by such methods as incineration, complying with federal, state, and local regulations.
o Liquefied Petroleum Gas (UN 1075)
• Extinguishing media:
Water spray. Class A-B-C or BC fire extinguishers.
• Special fire fighting procedures: Stop flow of gas. Use water to keep fire exposed containers cool. Use water spray to disperse unignited gas or vapour.
If ignition has occurred and no water is available, tank metal may weaken from over heating. Evacuate area.
If the gas has not ignited, LP gas liquid or vapour may be dispersed by water spray or flooding.
DAN G E R
DO NOT enter enclosed or confined space without proper protective equipment including respiratory protection.
• Unusual fire and explosion hazards: Highly Flammable. Products of combustion may contain carbon monoxide, carbon dioxide and other toxic materials.
• Spill or leak:
Keep public away. Shut off supply of gas. Eliminate sources of ignition. Ventilate the area. Disperse with water spray or flooding. Contact between skin and these gases in liquid form can cause freezing of tissue causing injury similar to thermal burn.
• Waste disposal method: Treatment, storage, transportation and disposal must be in accordance with applicable federal, state, provincial, and local regulations.
o Motor Oil (UN 1270)
• Extinguishing media:
Use water spray, dry chemical, foam, or CO2.
IMPORTANT
Vapours released from the spill may create an explosive atmosphere.
• Special fire fighting procedures: Water or foam may cause frothing. Use water to keep fire exposed containers cool. Water spray may be used to flush spills away from exposures.
• Unusual fire and explosion hazards:
Products of combustion may contain carbon monoxide, carbon dioxide, and other toxic materials.
• Spill or leak:
Contain spill immediately in smallest area possible. Recover as much of the product itself as possible by such methods as vacuuming, followed by soaking up of residual fluids by use of absorbent materials.
Remove contaminated items including contaminated soil and place in proper containers for disposal. Avoid washing, draining or directing material to storm or sanitary sewers.
DAN G E R
DO NOT enter enclosed or confined space without proper protective equipment including respiratory protection.
Waste disposal method:
Recycle as much of the recoverable product as possible.
Dispose of non-recyclable material as a RCRA hazardous waste by such methods as incineration, complying with federal, state, and local regulations.
13. Alphabetical Index
13. Alphabetical Index
13. Alphabetical Index
14. Definitions
Competent Person - A Person who, by possession of a recognised degree, certificate or professional standing or by knowledge training and experience, has successfully demonstrated the ability to solve problems in the subject matter
EFI – Electronic Fuel Injection (engine)
Elevated travel position - configuration of the MEWP for travel on a work site outside of the Lowered travel Position
Ground station control panel – Controls located under the LH bonnet
MEWP - Mobile Elevated Working Platform
H/MEWP – Horticultural Mobile Elevated Working Platform
Manual Force – A side loading imposed on the machine by the operator pushing/pulling on an outside object from the work platform.
MEWP – Mobile Elevated Working Platform
Operator – The person who controls the movement of the MEWP
Rated Capacity - maximum load, expressed in kilograms, for which the MEWP has been designed for normal operation, and includes persons, tools and material acting vertically on the work platform
Work platform control panel – Dash panel located on the rear of the Work platform
Lowered travel Position – configuration of the MEWP for travel on the work site where the chassis inclination limits and maximum travel speeds associated with the elevated travel position do not apply.
