Manual 08 [colour match]
Contents
1. Check and re set roll off angle as necessary by adjusting the legs Check for free movement of the cradle Check the general condition of all rollers and axles Check operation of cradle arrestor by throwing slack rope Adjust gap on the pawl to a minimum of 5mm Dismantle rear axle assemblies detach eyebolts and remove cradle from hoist Clean and lubricate arrestor mechanism with light oil Clean and check all axles rollers for wear Lubricate with high melting point grease and rebuild Examine all visible rope for broken wires kinks or miss shapen areas Examine eyebolts and check for security and wear Check for even rope tension and adjust eyebolts as necessary Uncouple rope sets and hoses Remove top cover plate and pull ram assembly from main column Examine internal section of rope and rope anchors for kinks and broken strands Check for correct positioning on all pulleys Check and lubricate pulleys and axles Refit ram seal top cover plate re couple hoses and ropes Fit split pins to eyebolts Visually check chain attachment points on cradle Check for free movement of cradle Check rollers for free movement and wear Grease all 4 axles via nipples on each side Maintenance 12 CHAIN SETS HYDRAULIC SYSTEM Examine both drive amp suspension chains for damage and wear TEST Visually check coupling points for security Examine all sprockets amp clear any debris from behind the bottom spro2. Penny Cellar Service amp Operation Manual for Penny Hydraulics Cellar Lifts www pennyhydraulics com Hydraulics Contents Introduction Operating Procedures Sloping Cellar 3 4 Safety Warning 5 9 with groceries Fault Finding 10 Warranty Policy 11 Maintenance 13 Service Requirements 14 Service Contract Form 15 Data Specification COSHH amp Terminal Disposal 16 Survey Installation amp Commissioning 19 Declaration of Conformity 19 Signs 20 Exploded Views 20 Spare Parts Bin Vertical Cellar 21 Electric and Hydraulic Schematic Diagrams with cases 22 Training Record 23 Work Record With our service contract you can be sure of continued safe reliable use of the equipment and full compliance with current legislation Go to page 13 for more details Introduction Thank you for purchasing a Penny Hydraulics Cellar This is a unique design that is built in our factory to your specification Each one is tailor made and we trust that it meets with your approval and will provide you with a safe efficient and trouble free means of moving goods for many years This manual tells you what you need to know about its operation together with some useful guidance on safety and general care It also explains the servicing requirements and the availability of a service agreement should you wish to take advantage of it We have our own engineers around the country lead by our Central Service Department
3. a competent person must carry out a thorough BASE ARMS examination In the case of a CellarLift this must be done at least every if fitted six months and will include various tests In addition to this there are various service operations that must be done on an annual basis These are indicated in bold Various split pins oils greases and sealant are CRADLE j ROPE TYPE required to complete a full service The person making a thorough examination shall a Notify the employer immediately of a defect in the equipment which in their opinion is or could become a danger to persons b On completion of the thorough examination and test produce a report in writing authenticated by the examiner containing the ROPE SETS information detailed within schedule 1 of LOLER along with results of tests carried out Before starting work on site always inform the manager site foreman what operation is to be carried out and of any health and safety issues The manager site foreman may have additional requirements that must be followed Never leave an open shaft unguarded Treat ladders with respect and fasten them into position Never work beneath the cradle or platform without setting safety sprags Cradle chain type MOUNTINGS Check top and bottom mountings for security These are to be re examined under full load conditions during the testing procedure and inspected for movement Check general condition of base arms and if fitted adjusting legs
4. ends of the drop arms Once in place a keg trolley or bin can be rolled up the ramp and onto the cradle or platform as appropriate The ramp should not be left in place for keg deliveries as they would run off at speed and could cause damage or injury LLL With our service contract you can be sure of continued safe reliable use of the equipment and full compliance with current legislation Go to page 13 for more details Operating Procedures CASES BOXES AND OTHER DRY GOODS to be carried on the case tray or fixed platform 1 Clear the working area of unnecessary people or obstructions erect any barriers required by house procedures then open the entrance doors or flaps and make them secure Turn on the lift at the mains power switch Use the hold to run handle to raise the forks 500mm to enable the case tray to be fitted easily and safely This should always be done from the lower level Load the case tray or platform evenly taking note of the maximum working loads and send the cradle to the other landing The assistant can then unload and either reload the tray or platform or return the cradle empty giving a clear signal to lower the cradle when ready to do so The operator must not operate the handle until they are certain it is safe When it is back at the bottom the process can be repeated until the delivery is complete When finished ensure that all gates and doors are closed and tur
5. essential to the operation 6 No persons should go near the forks or platform when they are raised All safety notices must be read and complied with at all times Never interfere with the unit It should run smoothly at all times if in doubt call the HELPLINE telephone number 01246 811475 9 Keep the CellarLift properly maintained by a competent person 10 Where guards or safety gates are fitted always ensure that they are in place before operating the lift 11 Please note that any control panel may remain live even when the motor is not running Always turn off the main power switch after use Vertical Cellar with barrel With our service contract you can be sure of continued safe reliable use of the equipment and full compliance with current legislation Go to page 13 for more details Method of Operation Standard operation is via a single hold to run control generally at the lower level The person at the controls is in a safe position and no one should pass them whilst the hoist is in motion It is quicker to alternate an empty with a full so that there are no dry runs but space may dictate that all empties are sent out first Kegs are carried directly on the cradle and cases or other goods on the case tray The case tray slots over the cradle the small legs fitting into the tubes on the cradle sides Where kegs are not carried then the case tray or platform can be permanently attached to the lift cradle NOTE Operate the
6. Base pulley Back pulley Exit pulley Main fixing pin with R clips Cable glands nylon Ram head bottom spacer Short ram Medium ram Long ram Clevis complete Clevis pulley Cradle complete 24 hose assembly 60 hose assembly 5mm suspension rope Copper talurit splice M8 stainless steel eyebolt Common Items P56 P57 QP21 QP29 QP50 P29 P11 P31 Ullage ramp Case tray Operation amp Service Manual Safety sign Up down sign Drop mat Adjusting leg Drop Arm Chain Drive Lift SCL14 SCL15 SCL16 CLB SCL52 SCL40 SCL44 SCL45 SCLO8 SCL18 SCL24 SCL25 R71 R72 R73 MHS40 MHS42 ME45 ME46 ME47 R66 R67 R68 R80 R39 SCL49 MHS03 MHS05 MHS02 0 10 MHS25 MHS01 3 4 BS roller chain K 1 coupling link 3 4 K 1 attachment link 3 4 Heavy duty attachment link Extended pin 1 2 BS roller chain K 1 coupling link 1 2 K 1 attachment link 1 2 Cradle wheel Drive sprocket Motor bearing Bottom bearing 100 cc hydraulic motor 160 cc hydraulic motor Brake 8 hose assembly Bonded seal Proximity switch Actuator magnet Limit switch Electric latch Slam lock Key cylinder Combined lock Power pack 1 8kW Power pack 2 2kW 1 4 1 4 Straight connector 1 4 90 degree elbow Flow control valve Hydraulic oil Tellus 32 1 4 Reusable ends Hydraulic hose per metre Call or email Penny Hydraulics Ltd for prompt delivery of all spare parts Schematic Diagrams St
7. andard Lift Wiring The standard lifts both rope and chain types have their motors wired directly to the single phase supply in the double pole switch provided by the customer They must be earthed Hydraulic Circuits Chain Drive Lift Hold to rur handle Flow contfol valve Drive sprocket Brake Hydrauliedrive Fe motor Standard Vertical Lift Flow control valve Optional solenoid check valve Hold to run handle Main lift dsa e en ram Electric motpr pump unit 21 Training Register tor EEE Trained Operator Signature Trained By 2 2 One nominated person will be trained by the installer of the hoist upon completion of that installation Further training is the responsibility of the owner of the equipment Penny Hydraulics Ltd is happy to help with this Work Record for Work Done Remarks Engineer Company Hydraulics Work Done Remarks Engineer Company
8. by their own warranty f Warranty does not extend to consumable items reguiring replacement due to normal wear and tear Any claim under warranty must be made in the first instance by contacting Penny Hydraulics Ltd Service Department on 01246 811475 or via email at service dpennyhydraulics com The decision will then be made on how best to proceed after consultation with the customer UK Mainland We will normally have one of our own engineers based around the country visit the site to rectify the problem This policy may be varied at our discretion but it is our aim to give the very best possible response to minimise product downtime and inconvenience Other Locations Warranty is limited to a parts only service but in certain areas we have service partners who may be able to assist Any defective item should be returned to Penny Hydraulics Ltd for inspection and any valid warranty claim will include reasonable carriage costs both ways A replacement part will then be sent to the customer No variation of the warranty as stated in the Company s Standard Terms and Conditions of Sale is authorised unless agreed in writing by a Director of the Company This is the only warranty given and the Company accepts no other responsibility With our service contract you can be sure of continued safe reliable use of the eguipment and full compliance with current legislation Go to page 13 for more details Maintenance As required by LOLER
9. cket Grease all four chains Grease the motor and two bottom bearings via the grease nipples Check suspension chain tensions with the platform near the top They should be even with only hanging tension in the fall from the cradle to the bottom sprocket but no bunching of the chain when the cradle is lowered Adjust as necessary using the two adjusters beneath the top sprocket Check the drive chains for even tension There should be no GENERAL bunching of the chain when under load If they need adjusting loosen the motor mounting plate bolts and use a bottle jack to push the assembly up so tightening the chains Re tighten the plate bolts Check that power pack is securely mounted Check power pack and hose ends for leaks Check oil level and top up as necessary using Tellus 32 hydraulic oil TRAINING Check that relief valve is not causing motor to stall by driving the REPORTING platform into the end stops Examine visible hose run for leaks and damage Check and reposition hoses at the top of the column to ensure clearance on cradle rear axle Check the ram whilst removed from the column for leaks or scoring to the piston Do not attempt any ram repair on site but replace the complete unit if necessary Check internal hose run or leaks and damage Run up and down five times unloaded It may not always be possible to go to the top Check for smooth running and correct relief valve operation Load with the largest standar
10. d load and run up and down five times Check that the flow control valve gives correct speed of descent Check for partial porting of the control valve leading to loss of control over descent Adjust relief valve to give constant speed of ascent Examine hoist mountings Repeat the unloaded test Check for leaks Check rope or chain tensions Check case tray for fit and condition Check ullage ramp for fit and condition Check drop mat where applicable for condition and replace as necessary Check existing guarding and assess the general safety of the installation Check that all signage is in position Replace signs as necessary Check that there is an Operation amp Service Manual available Train staff if requested and complete the training register Note any defects found remedial action taken or work still required to be done on the test certificate and in the schedule at the back of the handbook If the inspection was a Statutory Thorough Examination under LOLER then any defect that is or could become a danger to persons must be notified to the relevant enforcing authority and the lift taken out of use Leave a copy of the test certificate on site Inform the Manager of any defects Service Requirements We believe that the Penny Hydraulics Lift will make a revolutionary improvement in the handling of your goods both in terms of safety and efficiency The machine is manufactured to the highest quality standards
11. d risk assessment It is assembled in the factory and delivered on site generally in a single section and cannot be altered It is therefore essential that when the original survey is carried out that all dimensions and facts that may affect installation are correct The following section explains the important points at the various stages Survey A trained person must carry out the survey and complete a Site Assessment Form as it is part of the installation risk assessment and layout evaluation A quotation may be derived from an architect s drawing but a site survey is essential as the job progresses to take a full account of the special requirements of the task and location Installation All installations must be carried out by qualified engineers trained in the method of installation and approved by Penny Hydraulics It is important to note that should a non approved engineer on installation cause damage or fault this could invalidate the warranty e Clear the working area e Check all dimensions before unloading Manoeuvre the lift into position noting that this will normally require a crane mounted on the delivery vehicle or chain blocks fixed inside the building Lifts can be made in two or more sections to aid manual handling and then assembled in position e Bolt the lift to the floor and back wall or frame work It is essential that a sound fixing is obtained at the top of the lift Welding may be required Locate and mount t
12. e of the equipment and full compliance with current legislation Go to page 13 for more details Cylinder Rack Fault Finding POWER FAILURE Should the power supply to the standard vertical lift be cut off for any reason the cradle can be safely lowered to the bottom by operating the hold to run handle with the power off The lift should then be switched off and an authorised electrician called to check for the electrical fault It is not possible to lower a sloping or chain drive lift in this manner THE PLATFORM DOES NOT DESCEND WHEN THE HANDLE IS OPERATED This is a potential hang up situation and must be dealt with correctly As soon as the operator notices that the platform has stopped descending before reaching the bottom they must operate the handle in the up direction for 10 seconds and if possible take the platform to the top and unload Try once more to lower the empty cradle If it does not descend smoothly then operate the handle for 10 seconds in the up direction to take any slack out of the system Switch off the power supply and call the HELPLINE as it may be a motor fault SWITCH ON THE POWER SUPPLY AND NOTHING HAPPENS Occasionally a surge in power may cause a fuse to trip out Switch off power and check fuses switch plug and fuse board Check that all doors are securely closed and that no stop buttons are activated Ifthe problem recurs phone the HELPLINE OIL APPEARS AT THE BASE OF THE LIFT There has been an inte
13. ere fitted Typical Weights Standard Vertical Lift 2 5m 160kgs Chain Drive version 3 0m 222kgs Power Pack 25kgs Case Tray 10kgs Ullage Ramp 7kgs Maximum Working Loads Each lift is assessed and marked individually up to a maximum of 300kgs Noise levels A survey sheet giving full details is available on request Briefly the results are as follows Hydraulic pump motor running 65dB A Lift operating when loaded 58dB A Lift operating when unloaded 65dB A These levels are well below those at which hearing can be damaged and below levels at which action is reguired under the Noise at Work regulations COSHH Hydraulic oil is Tellus Type 32 and is not considered hazardous as defined by EC legislation Any spillage should be wiped up not flushed away Penny Hydraulics will collect and dispose of rags or sand used to soak up oil in an approved manner Contact with the oil should be avoided as it may cause transient irritation Wash the affected areas with soap and water or in the case of eyes just water If irritation persists then seek medical attention Terminal Disposal Penny Hydraulics will remove and dispose of the entire lift in an environmentally sound manner when required 1 5 Survey Installation amp Commissioning 16 This Penny Hydraulics lift is manufactured to a high standard and can be installed in many diverse situations Since no two applications are the same the lift is custom made following a site survey an
14. handle positively and hold it over until the cradle stops DO NOT try to judge the top or bottom by releasing the handle before the cradle reaches the stops The hoist can be stopped at any time by releasing the hold to run handle BARRELS CASKS OR KEGS to be carried directly on the hoist forks Cellar control unit 1 Clear the working area of unnecessary people or obstructions erect any barriers required by house procedures then open the entrance doors or flaps and make them secure 2 Turn on the lift at the mains power switch 3 When loading at the bottom use the hold to run handle to raise the forks 150mm to accept the first empty cask 4 Load the first empty If it is too heavy to lift safely then see the section on Ullage Removal as this demonstrates how a ramp can be used 5 Send the cradle to the other landing The assistant can then unload and either load a full or return the cradle empty giving a clear signal to move the cradle when ready to do so The operator must not operate the handle until they are certain it is safe 7 The process can be repeated until the delivery is complete 8 When finished ensure that all gates and doors are closed and turn off the power Operating Procedures ULLAGE TROLLEY OR BIN REMOVAL A variety of ramps are available to load heavy items such as full or part full kegs and wheelie bins There are two main types of ramp one is free standing the other has lugs which slot into holes in the
15. he power pack such that the operator is in a safe position at the bottom but has sight of the lift Installation amp Commissioning Erect any guarding necessary as previously agreed This is sometimes done earlier in the installation process depending on site circumstances and how the lift fits into the structure Couple all electric and hydraulic connections They must all be fastened securely and neatly back It is possible to commission lifts on a temporary supply and then an electrician couple into a permanent supply prior to the lift going into service Commissioning Carry out pre commissioning checks 1 All hose connections are tight and not leaking 2 Hoses to be fastened back securely 3 All nuts and bolts are tight and safety lock pins in place Switch on power and listen to the motor running smoothly Operate handle up and down and check for correct direction Run platform up and down empty five times Run the loaded platform up and down twenty times Where necessary sling a 25 overload beneath the platform Check hoist mountings for security Check the speed of descent Adjust to a maximum of 0 75 metres sec Remove load and run the platform for a further five times up and down noting the platform should run smoothly at all times and the rollers remain cool Check for any oil leaks on hose connections around the power pack and at the base Platform of main pillar Installation amp Co
16. installation and suitability for use of the equipment is governed by The Lifting Operations and Lifting Equipment Regulations The Supply of Machinery Safety Regulations The Provision and Use of Work Equipment Regulations The IEE 16th Edition Wiring Regulations and The Health and Safety Executive HELA Data Sheet Power Operated Hoists for the Drinks Industry BS EN ISO 9001 2000 REGISTERED COMPANY NO 20203 Signs There is a brass plate carrying the CE mark lift serial number model type and the manufacturer s name and address fixed either at the top of the lift on the right hand side of the back plate or in the centre of the lift near the bottom on the motor mounting plate Maximum working load signs are to be posted within clear view of the top and bottom loading points of the lift An outline of working procedures and safety considerations is to be posted close to the operating position Up down indications for the control handle movement are adjacent to the handle 1 9 C11 B _ 20 Exploded Views Chain Drive Lift sloping or vertical Standard Lift vertical only SCL20A SCL18 Spare Parts Standard Lift c11 C13 C14 C16 C17 co9 C09B R50C R17 R19 R20 R21 R23 R31 R32 R33 R34 R35 RO7C R09 c01C MHS12 MHS13 R55 R58 R57 Rear cradle axle Top cradle axle long Rope guide Front guide roller Cradle axle short Cradle roller Rear axle roller Ram head c w pulleys Ram head axle
17. mmissioning Check power pack mountings minimum two M8 bolts Check that the lift mountings are secure to the floor A minimum of two M10 bolts or equivalent in total Check that the lift mountings are secure to the wall at the top A minimum of two M10 bolts or equivalent are required at each side Check for correct operation of all lift features and safety devices Where applicable check that the platform locks in the folded position and that the safety hook is in place Check that all notices are posted correctly Train an appointed person on site in all operational procedures and safety precautions Enter their details in the training register at the back of this manual Enter your own details on the work record Make out a test commissioning certificate Case Hoist Cellar With our service contract you can be sure of continued safe reliable use of the equipment and full compliance with current legislation Go to page 13 for more details Declaration of Conformity Description of Machinery CellarLift hereby confirm that these hoists comply with the Machinery Directive 89 392 EEC as amended and all its essential Health and Safety requirements and carry the CE mark All the materials used in their manufacture are traceable and certified and the manufacturing process governed by our Work Instructions They have also been tested in accordance with our Test Procedures and Test Certificates issued The
18. n off the power Case Tray Operating Procedures GAS CYLINDERS On most lifts a maximum of three gas cylinders are to be carried directly on the cradle forks This may not be possible in some cases due to the available width and then an adapted case tray or cylinder rack will be needed Never pile cylinders up into a pyramid and be aware that their centre of gravity may be offset 1 Clear the working area of unnecessary people or obstructions erect any barriers required by house procedures then open the entrance doors or flaps and make them secure 2 Turn on the lift at the mains power switch Use the hold to run handle to raise the forks 500mm to ensure that the forks are clear of any drop arms or unloading plates and to give an easy working height Load the gas cylinders taking note of the maximum working loads and send the cradle to the other landing 5 The assistant can then unload and either reload the lift or return the cradle empty giving a clear signal to lower the cradle when ready to do so The operator must not operate the handle until they are certain it is safe Adapted Case Tray 6 Stop the cradle 500mm before the bottom to ensure that the forks are clear of any drop arms or unloading plates The process can be repeated until the delivery is complete 7 When finished ensure that all gates and doors are closed and turn off the power With our service contract you can be sure of continued safe reliable us
19. rnal oil leak It is still safe to continue operating the unit but see below Phone the HELPLINE to arrange for an engineer to call THE LIFT OPERATES SLOWLY AND WILL NOT GO UP OR DOWN There has been an oil leak and the tank is empty Call the HELPLINE Do not attempt to refill the tank MINOR OIL LEAKS FROM HOSE CONNECTIONS OR THE POWER PACK These are not serious but call the helpline for prompt attention IF IN DOUBT CALL THE HELPLINE ON 01246 811475 9 Warranty Policy This Policy is intended to provide our customers with the best possible support to ensure trouble free use of their new Penny Hydraulics lifting equipment Products sold by the Company are guaranteed to be free from defective material and workmanship for a period of one year from the date of invoice or from the date of the commissioning certificate This warranty applies only under the following conditions a The unit or part must not have been subject to neglect or abuse or operated under abnormal conditions or in an unapproved application b The responsibility of the Company is restricted to what is in their judgement an adequate repair or replacement of the Company s product c An authorised engineer must carry out a six monthly inspection d The warranty is void if examination reveals that the unit or part has been repaired or adjusted other than by an authorised engineer e Normal service repairs carried out by authorised engineers are supported
20. s Ltd agrees to carry out one annual service and one interim inspection on the lift in any twelve month period A test certificate will be left on site and a copy sent with the invoice In the event of a problem arising in between scheduled visits the customer should telephone the Helpline on 01246 811475 as soon as possible so that appropriate action can be taken by us There will be no charge for the call out or for labour unless the problem is due to abuse or misuse Parts may be added to the next invoice due The customer will be invoiced following each visit and by signing this document agrees to make full payment within 30 days of the invoice date in accordance with the agreed scale of charges which may vary from time to time This service contract will continue until cancelled in writing by either party Signed Print Name Position u ann sense Order Number 11 4 Please post to the above office fax on 01246 810403 or email more details are available at www pennyhydraulics com Power Supply Standard lifts require a 20 Amp 240 Volt 50Hz single phase electrical supply This should be terminated in a double pole switch If circuit breakers are employed in the system then they must be of a type that can cope with the surge of an electric motor Electrical Specification 240 Volt 9 5Amp 1 5kW 1PhIP54 240 Volt 12 6 Amp 1 8kW 1PhlP54 240 Volt 13 0 Amp 2 2kW 1 Ph IP55 415 Volt 48Amp 2 2kW 3 Ph IP55 12 volts DC control circuits wh
21. to give an exceptional after sales service Sloping Cellar We strongly recommend that each operator of the CellarLift be trained in its use and read with barrel all the details set out in this booklet CellarLifts although varying in type have a common operating procedure and in general terms are designed to be used by two persons to move drinks or other pub hotel and restaurant goods between two levels Care must always be taken when operating a CellarLift as they do not normally have inter locking gates but rely on the safe layout operating procedures and inherent design features such as the hold to run controls to ensure the safety of operators and third parties Safety Warning In the interest of safety all personnel involved in the lift operation must read the operation manual and comply with the following 1 The lift must not be used for man riding 2 As a minimum requirement the lift should be inspected every six months and serviced annually by a competent person The lift also requires a thorough examination and certificate of test as determined by the competent person or at least every twelve months See the Service Requirements section for more details 3 The lift must not be overloaded 4 The lift must only be operated by trained and competent personnel A training register is included at the back of this manual 5 Whilst the transfer of goods is in progress access to the area should be restricted to those personnel
22. we can achieve to give long and reliable service To ensure this we have made available an ongoing service contract to provide our customers with a number of benefits A helpline telephone number to put you in touch with trained engineers who can give you expert advice in any aspect of the Lift operation Service Telephone 01246 811475 An annual service through examination and test in accordance with LOLER Regulation 9 3 a ii An interim inspection and test at six months in accordance with LOLER Regulation 9 3 a iii All genuine replacement parts available generally from stock on the engineer s van High first time fix rate No work sub contracted All work parts and labour guaranteed for 12 months There is no charge for a call out in between scheduled visits if it is a manufacturing defect or lift fault LOLER are the Lifting Operations and Lifting Eguipment Regulations 1998 which reguire an inspection and service regime for all items of lifting eguipment Our regime ensures that the owner complies fully with these regulations Penny Service Contract Station Road Clowne Chesterfield S43 4AB Telephone 01246 811475 Fax 01246 810403 Email servicefapennyhydraulics com www pennyhydraulics com Date TST i Fe eru ee ee ee AEA P stcode sians HN pce ee cca areca VN ee een ee et TELEDNONE MON eee ies een Invoice address Contact Telephone no Penny Hydraulic
Download Pdf Manuals
Related Search