Operators manual - Mace Industries
Contents
1. gt u Vai MACE INDUSTRIES LIMITED perators manual Bumpa 8 metre Petrol Bumpa 10 metre Petrol SAFETY RULES Mk3 Bumpa Conveyor Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury Do Not Operate Unless You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations Know and understand the safety rules before going on to the next section 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended You read understand and obey Manufacturer s instructions and safety rules safety and operator s manuals and machine decals employer s safety rules and worksite regulations applicable governmental regulations You are properly trained to safely operate the machine Page 2 Important Read understand and obey these safety rules and operating instructions before operating this machine Only trained and authorized personnel shall be permitted to operate this machine This manual should be considered a permanent part of your machine and should remain with the machine at all times If you have any questions please call Mace Industries Contents Tn LT ATT 4 E A 7 CONTO Sinai cinco 8 Pre operation inspection eee ee eee eee 9 Maintenance 11 FUNCHON2. machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection Know and understand the pre operation inspection before going on to the next section 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended Page 9 Fundamentals It is the responsibility of the operator to perform a pre operation inspection and routine maintenance The pre operation inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items and locations for modifications damage or loose or missing parts A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection again before going on to t
3. 20m min 65 0 75kw 0 85m x 5 4m x 0 6 m gt 75dB Bumpa 8 metre Bumpa 10 metre Page 24 Operating angles 8 metre Bumpa o o 10 metre Bumpa LN N QU DD a
4. away from sparks flames and lighted tobacco Do not operate the machine in hazardous locations or locations where potentially flammable or explosive gases or particles may be present Always use the machine in an open well ventilated area Page 6 Bodily Injury Hazard Use common sense and planning when installing and operating the machine Keep hands and limbs away from moving belt Always wear correct PPE Q 00 Damaged Machine Hazards Do not use a damaged or malfunctioning machine Conduct a thorough pre operation inspection of the machine and test all functions before each work shift Immediately tag and remove from service a damaged or malfunctioning machine Be sure all maintenance has been performed as specified in this manual and the appropriate Mace Industries service manual Be sure all decals are in place and legible Legend Bogey Emergency stop Loading guides Wheel Bottom belt guide Honda GX120 Page 7 7 Angle Indicator 8 Belt carrier 9 Machine trestle 10 Hinge 11 Remote handset 12 Remote socket 13 Scaffold stand 14 Top belt guide 15 Adjuster head 16 Shute 17 10m prop Controls 3 2 Top Cover Handset 1 Base emergency stop 5 Handset emergency stop 2 Pull start 3 Choke 4 Engine stop switch Page 8 Pre operation Inspection Do not operate unless You learn and practice the principles of safe
5. c ananena 13 Work place inspection 15 Operating instructions 16 Transport instructions ss ss see 21 Re 22 Specifications aaan ennen 24 Contact us Web www maceindustries co uk Tel 01536 206 600 Fax 01536 206173 Page 3 Electrocution Hazards This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current Maintain safe distances from electrical power limes and apparatus in accordance with applicable governmental regulations and the following chart Voltage Minimum Safe Phase to Phase Approach Distance Voltage Feet Metres O to 300V Avoid Avoid Contact contact 300V to 50KV 10 3 05 50KV to 200KV 15 4 60 200KV to 350KV 20 6 10 350KV to 500KV 25 7 62 Allow for machine movement electrical line sway or sag and beware of strong or gusty winds Keep away from the machine if it contacts energized power lines Personnel must not operate or move the machine until energized power lines are shut off Do not operate the machine during lightning or storms Do not use the machine as a ground for welding Page 4 Setup Hazards Check work area for overhead obstructions or other possible hazards Do not use when under the influence of alcohol or drugs Ensure machine is securely fastened at the top and brakes are on before use Do not alter or disable machine comp
6. e throughout opening sequence Man 2 raises the opposite end until machine bottoms on base hoop fig 1 3 Release anti luce catches and walk top boom approximately 5 6 paces away then rest head of machine on the ground fig 2 4 With man 2 supporting the machine at centre fig 3 Man 1 releases the brakes and walks the base backwards until the machine is fully open Fig 3 Page 17 5 Detach clip and remove hinge pin from belt retaining device A then locate pin through the hinge B and replace clip 6 The head of the machine is now ready to be raised on to the roof scaffold by block and tackle or rope Ensure lifting device is secure and safe The base is guided and positioned by man 1 fig 4 Fig 4 IN 7 Once the machine head is on the ze scaffold the stand can be positioned and ge fixed either to the scaffold boards or roof LE Fig 5 Alternatively the head can be 9 AT clamped to the handrail using the clamp LG provided Fig 6 Ensure returning belt AV carriers clear scaffold before starting machine Page 18 8 Remove engine pin and position engine to rest into frame on pivot collar Insert pin and lock anti luce fastener Fig 7 Fig 7 9 Lift anti luce fastener and rotate belt cover clear to expose pulley Place vee belts onto machine pulley then lift engine to position belts onto engine pulley Lower engine Fig 8 10 Ro
7. ent should be no more than 15cm If measurement is greater than 15cm adjust belt tension as needed Only routine maintenance items specified 2 in this manual shall be performed by the operator 3 Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirements specified in the X responsibilities manual Maintaining the proper chain tension is essential to good machine performance and service life Maintenance symbols legend NOTICE Check chain condition whilst power is off 1 Opentop cover over control panel NOTICE 2 Inspect chain tension and chain condition This should include Check drive chain The following symbols have been used in checking lubrication and wear this manual to help communicate the o Replace if existing chain is intent of the instructions When one or damaged more of the symbols appear at the 3 Totension chain loosen motor beginning of a maintenance procedure it mounting bolts and tension as conveys the meaning below required 4 Re tighten motor mount bolts X lubricate chain and close top cover Indicates tools will be needed to carry out this operation Page 11 Check wheel brakes Maintaining the brakes is an essential aspect of machine maintenance Whilst erecting a machine the operator depends on the brakes functioning NOTICE Check brake function whilst machine is f
8. form function tests prior to operation 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended Page 16 Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation It is the operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting bricks blocks tiles lead and materials in an approved Mace bucket is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expected to use a machine at different times in the same work shift they must all be qualified operators and are all expected to follow all safety rules and instructions in the operator s safety and responsibilities manuals That means every new operator should perform a pre operation inspection function tests and a workplace inspection before using the machine Operating instructions 1 To prevent risk of injury or damage to the machine first select a suitable level area to open machine Always check for overhead obstructions i e branches cables etc prior to opening the machine Fig 1 2 Lock wheel brakes on then with man 1 standing on the hoop at the base of machine to counterbalance weight man 1 must remain in position to counterbalance machin
9. ge 20 Transport instructions Observe and Obey Common sense and planning must be applied to control the movement of the machine when moving it with a forklift The transport vehicle must be parked on a level surface The machines brakes must remain on whilst being transported Securing to Truck or Trailer for Transit Always check the machine wheel brakes are on in preparation for transport Use the tie down points on the boom for anchoring down to the transport surface Use chains or straps of ample load capacity Inspect the entire machine for loose or unsecured items DO NOT OVER TIGHTEN STRAPS Excessive tension of the straps will cause damage to the machine Page 21 Decals Decal Inspection Use the pictures on the next page to verify that all decals are legible and in place Below is a numerical list with quantities and descriptions Diagram number Description Quantity 1 1 2 1 3 2 4 1 5 1 6 1 7 1 8 1 9 1 10 2 11 1 12 1 13 6 14 Bumpa logo 2 Page 22 Decal diagram Page 23 Specifications Model Maximum working height Machine weight Maximum payload overall Maximum carrier payload Belt speed Maximum angle Electric motor Storage dimensions flat Noise emissions A weighted Dimensions 830 8m 7 0m 103kg 80kg 20kg 20m min 65 0 75kw 0 85m x 4 3m x 0 6m gt 75dB 10m 9 0m 119kg 80kg 20kg
10. he function tests Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications Pre operation Inspection Be sure that all decals are legible and in Check entire machine for place See Decals section o Cracks in welds or structural Be sure the main belt is properly tensioned components and in good condition o Dents or damage to the machine Be sure the belt carriers are secure and in good condition o Be sure that all structural and other critical components are present and Be sure the correct accessories are present all associated fasteners and pins are See parts list in place and properly tightened Check the following components or areas for damage modifications and improperly installed or missing parts o Emergency stop switches o Handset o Wiring o Drive belts including green reverse belt o Engine and Carrier o Tyres and wheels o Brakes o Nuts bolts and other fasteners o Scaffold clamp o 10 metre prop Page 10 Maintenance Check main belt tension x Maintaining the proper belt tension is essential to good machine performance and service life Operating the machine with an improper belt tension can damage machine components NOTICE Check belt tension whilst power is off Observe and Obey 1 When machine is unfolded measure the distance between the frame and belt at the central hinge pivot point The measurem
11. lat on the ground 1 Move the brake arm back and forth to its extent of travel Ensure it moves freely o If brake won t move or is stiff grease and retry 2 Ensure wheel cannot be moved whilst brake is operated Check Honda GX120 engine Maintaining the engine oil level and condition is essential to good machine performance and service life Operating the engine without proper oil levels can damage machine components NOTICE Complete all checks whilst engine is off and has had sufficient time to cool down 1 Checkoil level on dipstick o If oil level is low top up with premium 10w 30 motor oil o If oil level is too high remove drainage bolt and let excess oil drain as required Page 12 Scheduled Maintenance Maintenance performed quarterly and annually must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service Function tests Do not operate unless You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform function tests prior to operation Know and understand the function tests before going on to the next section 3 Always perform function tests prior to u
12. onents that in any way affect safety and stability Do not replace items critical to machine stability with items of different weight or specification Be aware of ground surface prior to installation Do not place ladders or scaffolds against any part of this machine Do not use the machine on a moving or mobile surface or vehicle Ensure all tyres are in good condition and cotter pins are properly installed Do not ride on machine Do not alter or disable switches or remote handset Do not operate the machine in strong or gusty winds When erecting the machine ensure shackles and or ties are secure Page 5 Fall Hazards Always erect a safety barrier to prevent access through underside of machine Failure to do so could result in serious injury Do not lean over discharge head of machine whilst loading unloading Ensure loading guides are set central to load and machine frame Do not ride on machine Keep the loading platform scaffold free from debris Component Damage Hazards Do not over load the machine 80kg MAX belt load Do not over load individual carriers 20kg MAX per carrier Do not use machine as a ground for welding Explosion and Fire Hazards Do not start the engine if you smell or detect liquid petroleum gas LPG gasoline diesel fuel or other explosive substances Do not refuel with the engine running Refuel the engine in an open well ventilated area
13. se 4 Inspect the workplace 5 Only use the machine as it was intended Page 13 Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service The operator must follow the step by step instructions to test all machine functions A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection and function tests again before putting the machine into service Function tests Engine tests Repeat all function tests in 1 Start Honda GX120 reverse 2 Turn switch to off position o Engine should cut out Setup 3 Select and area that is firm level and free of obstruction 4 Unfold machine insert pin through hinge and place end of machine on a trestle 5 Plug handset into top of machine 6 Attach Honda GX120 motor 7 Attach 2 black drive belts At the ground controls 8 Start Honda GX120 o Belt should move forwards 9 Push Emergency stop button o Belt should stop and engine cut out At the handset controls 10 Start Honda GX120 o Belt should move forwards 11 Push latching stop button on handset control o Belt should stop and engine cut out Page 14 Workplace in
14. spection Do not operate unless You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform function tests prior to operation 3 Always perform function tests prior to use 4 Inspect the workplace Know and understand the function tests before going on to the next section 5 Only use the machine as it was intended Page 15 Fundamentals The workplace inspection helps the operator determine if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine Workplace Inspection Be aware of and avoid the following hazardous situations e Bumps floor obstructions or debris e Slopes e Unstable or slippery surfaces e Overhead obstructions and high voltage conductors e Hazardous locations e Inadequate surface support to withstand all load forces imposed by the machine e Wind and weather conditions e The presence of unauthorized personnel e Other possible unsafe conditions Operating instructions Do not operate unless You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always per
15. tate engine belt tensioner into E N place so that plunger is over recess in engine cradle Operate lever to tension belts Fig 10 Rotate belt cover back into position and lock anti luce fastener Plug stop lead into machine Never operate machine with cover open or engine stop lead unplugged 11 To reverse machine fit engine as per step 8 Release black vee belts and place on hangar top of red bonnet Unhook green belt and place on n s machine pulley Cross belt in figure of 8 lift engine and position on n s engine pulley Fig 9 Lower engine to hang on belt Close pulley cover Do not use belt tensioner when using machine in reverse Page 19 Fig 11 12 With the machine secured on to the KT scaffold The delivery chute is now fitted by slotting in to the head lugs Then rotate and extend as required Fig 11 13 Fitting centre prop 10 metre machine only Hook centre prop over prop rest on machine then push up adjust with lever until prop is vertical with machine straight Prop is self locking when extended however lever must be lifted to retract Never operate 10 metre machine without prop in place as machine will be unstable Periodically check prop positioning during operation 14 When machine is erect place first load onto loading hoop Centralise loading guides and tighten to minimise un even loading 15 Plug in handset at head of machine Start pre operation checks Pa
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