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120T (TM34T) Operators Manual
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1. 9 SNOILdO 92 Ig vv STOULNOD STOULNOD ANNOY 5 6 LOCI 7 7 9 550 NO SNOILdO English USA 07 07 Issue 05 TM Series Operating amp Safety Instructions 3 4a PLACARD DECALS amp INSTALLATION USA ITEM DESCRIPTION NUMBER QTY 1 Cage Gate Warning P18432 1 2 Jockey wheel P14815 1 4 Serial Plate P15383 1 5 Hydraulic Controls 5 lever P14927 1 6 Hydraulic Controls 3 lever P14926 1 7 If E Stop disabled P14864 2 8 Tilt alarm P18842 2 1 Warning Stripes 13 Rotating Machinery P15010 2 15 Before Towing 17341 3 16 Outriggers Hydraulic 14841 1 17 Boom Clamp P14836 1 18 Coupling instructions P14896 1 19 Max Towing Speed P17140 1 20 Hand Crush P14782 1 21 Harness Point P14883 2 22 Component Stability P19708 1 23 Tyre Pressure 65 psi P14876 2 24 General Warning P18672 2 27 No Step P14785 7 28 Head Protection P14921 1 30 Daily Safety Check P14908 1 31 General Notice P18863 1 34 SWL 500lbs P17328 1 35 Outrigger Controls P14922 1 36 Emergency Hand Pump P19090 1 41 Cage levelling P10853 2 42 Point Load 9 4kN P14962 4 43 Niftylift com P14390 1 44 Nifty TM34T P14612 2 45 Base C
2. Stopping the engine by selecting STOP on the two position selector in the platform and pressing the green button will return the machine to battery mode DIESEL ENGINE Generally a Yanmar L40 or Kubota 0C60 engine described in the maintenance section of the Workshop Manual driving a single bodied pump with direct mounted pump dump valve PETROL ENGINE Generally a Honda GX 160 engine described in the maintenance section of the Workshop Manual driving a single body pump with direct mounted pump dump valve sans TM Series Operating amp Safety Instructions SETTING UP PROCEDURES FAILURE TO DEPLOY THE OUTRIGGERS CORRECTLY COULD RESULT IN DEATH OR SERIOUS INJURY 4 2 ALL MODELS 1 2 10 13 14 Read and fully comply with all safety precautions and operating instructions in the Operating and Safety manual and the warning decals on the machine Position Niftylift on firm ground bearing in mind range of boom movement so that any overhead obstructions or possible hazards such as but not limited to power cables telephone lines drains manhole covers etc can be safely avoided APPLY HANDBRAKE Chock wheels and cordon off the area using appropriate cones barriers and flags Levelling the machine using the hydraulic outriggers can accommodate a slope of up to 12 degrees if necessary using suitable load bearing pads to support the downhill jacks Do not elevate the platform unless the base can be corrected t
3. With the machine emergency stops enabled and either the cage or base key switches turned On the cage weigh micro switch is adjusted to bring the bolt into contact with the micro switch roller Continue adjustment until the alarm sounds then back off slightly to silence the alarm The locknuts supporting the adjustment bolt can be partially tightened to lock the bolt in place The addition of a 5 kg weight should now be used to prove that the system detects the applied overload sounds the alarm and disables the machine The sensitivity of the assembly is such that the alarm will sound slightly before the functions are disabled The mechanism should be adjusted to allow the alarm to sound and functions to be lost within this 5 kg limit Lock the adjustment screw securely The over travel adjusters can now be used to protect the micro switch from excess forces should a substantial overload be applied to the cage Typically if the machine is manoeuvred into contact with a fixed object snagging the cage assembly this would be detected as an overload to the system Adjust the screws forward until they come into contact with the cage weigh mechanism then with the cage overload still applied and the alarm sounding functions disabled and machine not operating lock them in this position Care should be taken to not turn the adjuster screws in too far otherwise the overload signal might be lost The machine can then have the overload remov
4. o O BASE Operation of base control vave and buttons fo Operation ofal booms J Cyindersareset Platform is level overfullrange Booms leveling rods not damaged or distorted fo Booms leveling rods cylinders notfouing fJ Hoses kinked orfouled Operation of emergency handpump f English USA 07 07 Issue 05 EJ TM Series Operating amp Safety Instructions swa SS Fi NA Slew assembly and motor are secure Worm wheel mesh correct noexcessivewear AA float ofworminhousing Jo So S Slew wheel bots secured 0 Slew guardssecure TTT PLATFORM Operation of control vave and buttons 00 Operation ofal over ful range J Cylinders aresilent ____ Platform leveling over ful range smooth overfullrange Operation of boom 4 over full range ified J S INTERNAL POWERPACK Power pack and allcomponents secure Al cables andterminals secure AA connections secure Hoses notkinkedorfouled Chargericontrolboxsecwe Bats Electrolyte level and specific gravity Jo 0 Charger operation Charger operation Hydraulic oil level wasa T j Grease mipoles cow couing Sew ear rr Cylinders Lift Jack
5. 13 OER ENGLAND TEL 01908 223456 FAX 01908 312733 e mail info niftylift com SERIAL No TYPE YEAR OF MANUFACTURE WEIGHT RATED LOAD PERSONS MAXIMUM SAFE WORKING LOAD MAXIMUM PULL MAXIMUM WIND SPEED MAX ALLOWABLE INCLINATION MAXIMUM HYDRAULIC PRESSURE MAXIMUM VOLTAGE AMPS ELEC CCT D HYD CCTD P10805 This manufacturer s plate is attached to Boom 1 on each machine at the time of manufacture on every Niftylift Please ensure all sections have been stamped and are legible English USA 07 07 Issue 05 EN TM Series Operating amp Safety Instructions 1 5a IDENTIFICATION USA PLATE ani NIFTYLIFT LTD FINGLE DRIVE STONEBRIDGE MILTON KEYNES MK13 OER GREAT BRITAIN TEL 01144 1908 223456 FAX 01144 1908 312733 e mail info niftylift com THIS WORK PLATFORM COMPLIES WITH ANSI STANDARD A 92 MODEL SERIAL NO YEAR OF MANUFACTURE CAPACITY RATING PLATFORM HEIGHT GROSS WEIGHT MAXIMUM HYDRAULIC PRESSURE MAXIMUM VOLTAGE AMPS ELEC CCT D HYD CCTD P11497 This manufacturer s plate is attached to Boom 1 on each machine at the time of manufacture on every Niftylift Please ensure all sections have been stamped and are legible EN English USA 07 07 Issue 05 2 1 2 1 1 2 1 2 2 1 3 2 1 5 2 1 6 sans TM Series Operating amp Safety Instructions Safety MANDATORY PRECAUTIONS When operating your Niftylift your safety is of utmost concern In o
6. The machine should be positioned to allow easy access around the machine in transit and to ensure that creepage during transport does not permit the machine to come into contact with other goods being shipped or the container itself Some movement of the machine structure might occur during transit which could lead to fretting or other damage e f the machine is equipped with a transit device such as a boom clamp etc this should be securely applied e Strap booms carefully to constrain them from sideways movement When using straps or chains adequate packing should be applied to stop any damage to the structure and paintwork Due regard of the movement of the straps or chains must be taken into account e Where a machine has designated points for strapping lifting or forking these can be used for tie down duty When they are absent the major structure of the platform can be used giving due consideration to the design and function of the area chosen Where possible use the spine of the machine or axle mounts over which to apply the holding down forces Using a single plate such as an outrigger or stabiliser support plate might be unsuitable If the component was clearly not designed to accommodate a side load one should not be applied e Under no circumstances should straps or chains be applied over booms or through the cage support structure or the cage itself The relative strength of the carrying structure is not conducive to the ma
7. gt s 120T TM34T Operating and Safety Instructions MODEL 120T TM34T SERIES s 7207 F 8j 3 b b 3 b 95 D Niftylift Limited Fingle Drive Stonebridge Milton Keynes MK13 OER England www niftylift com e mail info niftylift com Tel 44 0 1908 223456 Fax 44 0 1908 312733 E 9 gt c ISO 9001 Registered ms TM Series Operating amp Safety Instructions Table of Contents 1 INTRODUCTION AND GENERAL INFORMATION PAGE 1 1 Foreword 2 1 2 Scope 3 1 3 Introducing the 120T Trailer Mount TM Series 3 1 4 General Specification 4 1 5 Identification 5 6 2 SAFETY 2 1 Mandatory Precautions 7 10 2 2 Environmental Limitations 10 2 3 Noise amp Vibration 10 3 PREPARATION AND INSPECTION 3 1 Unpacking 11 3 2 Preparation for Use 11 3 3 Pre Operational Safety Check Schedules 12 13 3 4 Placard Decals and Installation 14 19 3 9 Torque Requirements 20 4 OPERATION 4 1 Control Circuit Components 21 4 2 Setting Up Procedures 22 4 3 Ground Control Operation 23 24 4 4 Platform Control Operation 25 26 4 5 Cage Weigh System 27 09 4 6 Batteries and Charging 30 31 4 7 Transporting Towing Craneage Storage and Setting to Work 32 35 4 8 Traction Drive 36 37 5 EMERGENCY CONTROLS 5 1 General 38 5 2 Emergency Procedures Incapacitated Operator 38 5 3 Emergency Proce
8. remain between 23 and 93 Celsius Extended operation in dusty environments is not recommended and frequent cleaning will be necessary All dust dirt salt encrustation excess oil or grease should be removed Deposits of paint or bitumen particularly on legends or labels should also be removed All standard Niftylift machines are rated for a wind speed of 12 5 m s which equates to 45kph 28mph or force 6 on the Beaufort scale No attempt should be made to operate a Niftylift in wind strengths above this limit and if the operator has any doubts over the wind speed he she should cease operation immediately until it can be established that the wind speed has fallen to a safe level DO NOT USE THE NIFTYLIFT IN ELECTRICAL STORMS NOISE AND VIBRATION The airborne noise emission on the 120T range of machines does not exceed 73dB A measured at a perpendicular distance of 4m under equivalent continuous A weighted sound pressure test conditions This was based on a Diesel powered machine working under load All other models will exhibit significantly lower emissions than this figure dependant on power option In normal operation the Vibration level to which the operator is subjected will not exceed a weighted root mean square acceleration value of 2 5 m s English USA 07 07 Issue 05 3 2 sans TM Series Operating amp Safety Instructions Preparation and Inspection UNPACKING Since the manufacturer has no direct control
9. ANSI SIA 92 2 1990 to read and understand your responsibilities before you use or operate this aerial platform Please read the enclosed document as failure to do so could result in death or serious injury Wherever any contradiction may appear the Manual of Responsibilities shall take precedence over all other documents English USA 07 07 Issue 05 TM Series Operating amp Safety Instructions 6 3 Inspection Service Pre Hire Check list MACHINE SERIAL NO Operation of tow coupling Operation of handbrake Operation of jockey wheel PT STABISERS Micro switches secure TT Locating pins operating freely andoiled Stabilisers operate smoothy Operation of each micro switch and ffitei Operation of jack control vave and buttons Operation of each hydraulicjack EE Operation of boom rest micro switch a Axles side freely 90 120 or are secure 170 180 Wheel bearings OK CT Mudguards are secure o Locating pins operate freely and oiled fo o o o ooo Lock bolts are tight CT Wheels spin freely when handbrake is released AA Brakes come on equally when handbrake is applied f fo o Brake linkages and cables secure ________ Brake shoe wear not excessive Too y Breakaway cable fitted and operable foo o Lighting board fitted lights function o o o ooo Tyre pressure correct o y Wheel nut torgue correct
10. CK SCHEDULES Before use at the beginning of the work shift the aerial platform shall be given a visual inspection and functional tests including but not limited to the following It is recommended that these be performed at regular intervals as indicated on each checklist DAILY SAFETY CHECKS 1 Checkthat all labels decals are in place and legible 2 Visually inspect the machine for damaged or loose components 3 Check that batteries are charged i e Charger has a solid green light and a pulsing red light 4 Check the fuel level if applicable 5 Check that canopies covers and guards are in place and secure 6 Check that the boom rest switch is operable if applicable 7 Check that control levers are secure and operate freely 8 Check that operating buttons and emergency stop buttons function properly 9 Check the operation of the emergency hand pump 10 Visually inspect all hydraulic hoses and fittings for damage or leaks 11 Check operation of the stabiliser alarm 12 Check that outrigger footpads are secure 13 Check that the platform pivot pins and their tag bolts are secure 14 Check security and operation of the boom clamp 15 Check the operation of the cage weigh system If fitted WEEKLY SAFETY CHECKS 1 Inspect tyres and wheels for damage and wear 2 Check tyres for correct pressure 65psi 4 5 bar 3 Check mudguards for security and damage 4 Check battery fluid levels and specific gravit
11. FAILURE Operate manual hand pump located adjacent to the base controls and lower platform to the ground using either platform or base controls Note If the machine is fitted with a cage overload system and the cage comes into contact with a fixed object whilst operating at height this would be detected as an overload condition All power to the machine controls would be lost requiring the machine to be recovered using the Emergency Hand Pump It is sufficient for the cage to be manoeuvred away from the collision point to release the cage weigh system thereby restoring normal machine operation The cage could then be brought down using the controls as described previously INCIDENT NOTIFICATION It is a mandatory requirement that any accident or incident involving a Niftylift regardless of whether any party received injury or property was damaged be reported by telephone directly to Niftylift Failure to do so may render any warranty on the machine void Responsibilities CHANGES IN OWNERSHIP When a change of ownership of a Niftylift occurs it shall be the responsibility of the seller to notify Niftylift direct of the unit model and serial number and the name and address of the new owner within 60 days This important step is required so that all future Technical Bulletins are able to reach the registered owner of each machine without delay Please note warranties are not transferable MANUAL OF RESPONSIBILITIES You are required by
12. FOR PERIODS IN EXCESS OF 24 HOURS DISCONNECT FROM POWER SUPPLY ONCE BATTERIES ARE FULLY CHARGED The machine can now be left unattended however in the event of the machine being left unused for extensive periods then a 4 to 6 hour top up charge every 4 weeks is recommended A top up charge the day before use ensures a full day of operation from the machine UNDER NO CIRCUMSTANCES SHOULD A MACHINE BE LEFT FULLY DISCHARGED AS SEVERE BATTERY DAMAGE CAN OCCUR IN A RELATIVELY SHORT TIME To avoid damage to charger disconnect from mains supply before using machine If the charger is reconnected to the power supply shortly after it has gone through its full charging cycle the Red LED may come on although the batteries may be fully charged The charger would then go through its complete cycle again at an accelerated rate depending on the time difference between connection reconnection and level of battery charge English USA 07 07 Issue 05 English USA 07 07 Issue 05 sans TM Series Operating amp Safety Instructions 2 Some Niftylifts are fitted with a Battery Management System which permanently monitors the condition of the batteries When the batteries become discharged to 80 of their capacity the management system will begin to shut down the hydraulic power packs This causes the drive boom operating system to alternately stop and start signalling to the operator that re charging is necessary However there
13. LLY INSULATED DO NOT WORK WITHIN 10FT 3M OF OVERHEAD CABLES EXCEEDING 415 VOLTS English USA 07 07 Issue 05 4 3 4 3 1 English USA 07 07 Issue 05 TM Series Operating amp Safety Instructions GROUND CONTROL OPERATION ALWAYS ALLOW THE ENGINE TO WARM UP BEFORE OPERATING GROUND CONTROL INSTRUCTIONS ALL MODELS 1 Check below above and around the platform for any obstructions or hazards before operating any function 2 Ensure all red emergency stops are out 3 Turnthe key switch at the ground control station to the ON position i e clockwise 4 models go to step 11 DIESEL ENGINE OR BI ENERGY MODELS 5 Turn the main engine ignition switch located on the side of the canopy through ON to the ST start position and the engine will fire 6 Goto step 11 Note Unless the diesel engine is running the 120T will automatically default to the primary power source usually battery PETROL GASOLINE ENGINE OR PETROL GASOLINE ELECTRIC MODELS 7 Fora cold engine start go to step 8 or for a warm engine start go to step 9 8 COLD ENGINE turn the engine fuel tap ON and engage the choke lever Turn the main engine ignition through ON to ST Start and the engine will fire Return the choke lever to its normal running position after the engine is started 9 WARM ENGINE turn the engine fuel tap on and turn the main engine ignitio
14. N OF ANY FUNCTION ES English USA 07 07 Issue 05 4 4 4 4 1 TM Series Operating amp Safety Instructions PLATFORM CONTROL OPERATION NEVER START THE NIFTYLIFT IF YOU SMELL PETROL GASOLINE LIQUID PROPANE OR DIESEL THESE FUELS ARE FLAMMABLE BEFORE OPERATING THE NIFTYLIFT ENSURE THAT EACH OPERATOR HAS READ AND FULLY UNDERSTOOD THE OPERATING MANUAL FAILURE TO DO SO MAY RESULT IN DEATH OR SERIOUS INJURY FOR COLD START PROCEDURES SEE SECTION 4 3 1 ALWAYS ALLOW THE ENGINE TO WARM UP BEFORE OPERATING PLATFORM CONTROL INSTRUCTIONS ALL MODELS 1 NEVER exceed the maximum platform capacity 2 Check below above and around the platform for any obstruction or hazards before operating any function 3 Ensure all red emergency stops are out 4 Remove the key from the ground control station turn key anti clockwise and put the key in the platform control station and switch to ON clockwise 5 Battery electric models go to step 11 DIESEL ENGINE OR BI ENERGY MODELS ONLY 6 Ensure that the main engine ignition switch is ON Turn the Engine Start switch on the platform control box clockwise and the engine will fire 7 Goto step 11 Note Unless the diesel engine is running the 120T will automatically default to the primary power source usually battery PETROL ENGINE OR PETROL ELECTRIC MODELS ONLY 8 Ensure that the fuel tap is turned to the ON position and that the main engine
15. agement or owner dealer or manufacturer before further operation of the Niftylift English USA 07 07 Issue 05 2 1 22 2 1 23 2 1 24 2 1 25 2 1 26 2 1 27 2 1 28 2 1 29 2 1 30 2 1 31 2 1 32 2 1 33 2 1 34 English USA 07 07 Issue 05 TM Series Operating amp Safety Instructions The operator shall immediately report to his superior any problems or malfunctions of the Niftylift which becomes evident during operation Any problems or malfunctions that affect the safety of operation shall be repaired prior to continued use The boom and platform of the Niftylift shall not be used to jack the wheels off the ground The Niftylift shall not be used as a crane The Niftylift shall not be positioned against another object to steady the platform Care should be taken to prevent rope electric cords and hoses from becoming entangled in the aerial platform Batteries shall be recharged in a well ventilated area free of flame sparks or other hazards that may cause explosion Highly explosive hydrogen gas is produced during the charging process When checking electrolyte levels great care should be taken to protect eyes skin and clothing Battery acid is highly corrosive and protective glasses and clothing is recommended When the machine is not in use always stow the booms correctly NEVER LEAVE THE KEYS IN THE MACHINE if it is to be left for any period of time Use wheel chocks if leaving on an i
16. alibration of the cage weigh system See section 4 5 4 for the calibration procedure 16 Every Six months perform a thorough examination in accordance with the Lifting Operation and Lifting Equipment Regulations LOLER 1998 Regulation 9 3 a ANNUAL SAFETY CHECKS 1 Check that all pivot pins and their tag bolts are secure 2 Inspect for any cracks or badly rusted areas on booms and chassis 3 Change the hydraulic oil and the oil filters 4 Inspect the suspension on each axle unit 5 Check that slew ringbolts are secure torque 155ft lbs 210Nm English USA 07 07 Issue 05 TM Series Operating amp Safety Instructions PLACARD DECALS amp INSTALLATION UK 3 4 ITEM ojl ms on wy pe Ro Pot Pot pol pol pot pot N NP Ob oy By Cw rS O co CO NI oy C MP 28 29 30 31 32 34 35 DESCRIPTION Daily Safety Checks Tilt alarm General Crush Before Towing Boom Clamp Coupling instructions Harness Point Component Stability Tyre Pressure 65 psi No Step Emergency Hand Pump Cage Gate Warning General Warning Head Protection Serial Plate SWL 200kg Nifty 120T Niftylift com Push and Release Cage levelling Point Load 9 4kN Outriggers Hydraulic Outrigger Controls Hydraulic Controls 3 lever Hydraulic Controls 5 lever Cage weigh Non cage weigh Base Control Warning Stripes Batter
17. alt the machine drive at any time English USA 07 07 Issue 05 4 8 2 sans TM Series Operating amp Safety Instructions DISENGAGING DRIVE 1 Unless the machine has been manoeuvred to allow it to be coupled to a towing vehicle as described in the appropriate section of this handbook before disengaging the traction drive system the parking handbrake must be fully engaged On no account disengage the traction drive system unless the handbrake is engaged the wheels are securely chocked or the machine is connected to a towing vehicle It is also recommended that the machine be positioned on flat level ground before the drive system is disengaged 2 Push and hold the drive joystick button to develop hydraulic flow and using the third horizontal lever push downwards to retract the engagement cylinder The traction drive cradles will swing clear of the road wheels which should be allowed to travel outwards to their fullest extent Releasing the third lever will then lock them in the retracted position ready for towing On no account should the machine be towed with the traction drive system still engaged serious damage may result Do NOT use the traction drive as a brake the parking handbrake must be utilised for this purpose Never disengage the traction drive unless the handbrake is engaged OR the wheels chocked OR the machine directly and securely connected to a suitable towing vehicle Always position the machine on
18. day and at the beginning of each shift the machine shall be given a visual and functional test including but not limited to the following 1 Check all lubrication points for adequate application of grease oil etc 2 Inspect all threads for ease of operation 3 Check level and quantity of oil Remove any contaminants water etc English USA 07 07 Issue 05 10 TM Series Operating amp Safety Instructions Check batteries for electrolyte and state of charge Check electrics for damage and insulation Using base controls cycle machine over complete envelope in accordance with the Operating Instructions Cure any defects Ensure that all safety devices and controls operate in accordance with the instructions If necessary perform a load test to establish the machine stability before putting the machine to work On completion of an extended period of road transport the machine might need additional inspection to identify any transit degradation which could render the machine unsafe Perform a P D I inspection on the unit before it enters service Record any faults found and rectify them immediately If left un attended for an extended period it is likely that the hydraulic cage levelling will become un pressurised Normal operation is then lost with a noticeable delay in the forwards or backwards motion as the booms move To restore normal function the cage needs to be fully levelled forwards and backwards using t
19. dures Machine Failure 38 5 4 Incident Notification 38 6 RESPONSIBILITIES 6 1 Changes in Ownership 38 6 2 Manual of Responsibilities USA only 38 6 3 Inspection Service Check List 39 40 English USA 07 07 Issue 05 EN TM Series Operating amp Safety Instructions 1 1 Introduction and General Information FOREWORD The purpose of these manuals is to provide the customer with appropriate safety operating and maintenance instructions essential for proper machine operation All information in these manuals should be READ and fully UNDERSTOOD before any attempt is made to operate the machine THESE MANUALS ARE VERY IMPORTANT TOOLS Keep them with the machine at all times The manufacturer has no direct control over machine application and use therefore conformance with good safety practices is the responsibility of the user and his operating personnel All information in these manuals is based on the use of the machine under proper operating conditions Alteration and or modification of the machine are strictly forbidden One of the most important facts to remember is that any equipment is only as safe as those who operate it DANGER WARNING CAUTION IMPORTANT INSTRUCTIONS AND NOTICE Any place these topics may appear either in this manual or on the machine they are defined as follows DANGER If not correctly followed there is a high probability of serious injury or death to personnel WARNING OR CAUTION If n
20. e ball Ensure that the trigger has returned to its free position before attempting to tow and that the coupling head is securely on the towing ball Connect the breakaway cable chain to the towing vehicle hitch not to the tow ball itself Connect the lighting plug to the vehicle and check the light functions Raise the jockey wheel to its stowed position and secure for transit De coupling Instructions 1 2 3 Apply trailer handbrake and chock wheels Lower the jockey wheel to the ground Disconnect the breakaway cable chain and lighting plug Operate the handle by depressing the trigger and manually lift the coupling head clear of the towing ball or screw down the telescopic jockey wheel to achieve the same effect Handbrake Operation 1 2 English USA 07 07 Issue 05 To operate the trailer parking brakes pull the handbrake lever upwards and backwards The spring loaded mechanism will engage and stay in the operated position until re set To disengage the parking brakes firmly grasp the handbrake lever and pull upwards Depress the ratchet release button in the end of the handbrake lever and return the lever to the horizontal position Care should be taken when operating the handbrake lever due to the forces involved in engaging the ratchet mechanism ms TM Series Operating amp Safety Instructions 4 7 3 4 7 4 4 7 5 CRANEAGE 1 Observe all of the limitations relating to straps and chains stated abov
21. e under Transporting Section 4 7 1 2 When utilising the designated lifting points never apply a snatch load i e lift slowly to take up the load before raising Similarly do not drop machine when positioning after lifting 3 If the machine is to be lifted by crane use the designated lifting points and observe the recommendations regarding spreader beams Individual drawings are available for each machine type on request See list below 080904 90 081193 120 080541 120 080905 140 080906 170 080939 210TM D80891 17050 080461 HR10 12 D80935 HR15N D80936 HR15 4x4 D80937 HR17 4x4 D80938 HR21 D80932 0120 080933 TD170 STORAGE If being stored for any length of time without use then the machine should be thoroughly inspected for the following 1 Grease all bearings slides worm drives etc 2 Check batteries for electrolyte levels state of charge damage dirt etc Never leave in a state of discharge for any length of time If no use of the platform is intended an occasional top up charge of the batteries will serve to equalise their charge level 3 Leave battery disconnect switch in OFF position to prevent discharge of batteries through leakage 4 If machine is to be left on an incline chock wheels to prevent creep 5 If machine is to be left out of doors or in a hostile environment cover with suitable weatherproof media to prevent deterioration SETTING TO WORK Before use each
22. e worn whilst performing these checks TM Series Operating amp Safety Instructions 4 7 4 7 1 TRANSPORTING TOWING CRANEAGE STORAGE AND SETTING TO WORK TRANSPORTING If a work platform is to be moved over a longer distance whether the machine is trailer mounted vehicle mounted self propelled or tracked the following procedure should be read before restraints are attached to the machine Cross loading is most frequently the cause of problems as the method of loading is no longer in sight of our own personnel The recommendations made herein should be passed on to subsequent carriers such that the entire journey is carried out without incident e Always ensure the truck or trailer you are loading or towing the Niftylift with can carry it legally e f loading by crane the use of shackles and an adequately rated spreader beam with four leg slings is MANDATORY e When loading or un loading from the side of the vehicle the use of the forklift pockets to retain one of the forks is recommended If fitted Spread the forks to their widest capacity with due regard to the components fitted to the machine Never forklift or crane an entire machine under the booms always lift beneath the spine or under the ends of the axle mountings in the case of a self propelled unit Ensure forklift is adequately rated for the load to be carried e Once positioned on the transport carrier ratchet straps should be used to secure the machine
23. ed and the functions of the machine checked for correct operation INSPECTION The cage weigh system is controlled through the detection printed circuit board part number P16164 This PCB is connected directly to the safety micro switch and monitors the function of the cage weigh system The two relays are configured such that both need to operate to permit safe operation of the assembly Should either of them fail an error signal is generated which can be seen on the printed Circuit board itself This occurs if pressing the green button does not allow the machine to operate no overload signal to be given with no load in the cage In this case open the cage pushbutton box or separate box containing the PCB and look at the printed circuit board There are three LED s Light Emitting Diodes on the board Red LD1 for Overload Red LD2 for Relay 1 2 failed and Green LD3 for Machine enable The first indicates the overload when the machine is turned On the second indicates a relay failure when the green button is pressed and the third shows the machine is enabled again when the green button is pressed English USA 07 07 Issue 05 4 5 6 4 5 7 English USA 07 07 Issue 05 ms TM Series Operating amp Safety Instructions The failure signal is generated if either relay fails to respond to the safe cage weigh signal from the safety micro switch either due to a coil or contacts failing or if a co
24. effectively halting all machine movements Under the circumstances where the cage overload cannot be removed the machine can only be manoeuvred by use of the emergency hand pump Great care must be taken when utilising this facility especially if the machine is significantly overloaded any motion that causes the machine outreach to increase could induce instability The machine must be manoeuvred in such a manner as to reduce outreach then height until a safe level is reached to permit the operator to dis mount or the overload to be removed FUNCTION The cage overload system is powered from the machine control circuit so the system is inactive if the machine is turned Off Enabling the emergency stops allows the system to become active when either the cage or base key switch is turned On If the cage is overloaded the control circuit will immediately indicate this by the audible and visual alarm Pressing the emergency stop or turning the key switch to the Off position merely silences the alarm The alarm will continue to sound as long as the overload persists unless the machine is turned Off Whilst the overload is detected pressing the green button at base or cage will generate no response from the control circuit The machine will not function under power until the overload is removed Removing the overload as previously described will re set the system automatically requiring no additional interventio
25. ess this switch is engaged with the boom ensuring that the machine must be stowed to operate the hydraulic jacks It is also similarly linked into the platform control circuit such that if the switch is not engaged with the booms i e machine is in operation then the outrigger sensors are active and would warn the operator of an unsafe condition should one of them loose contact with the ground These control functions are of primary importance to safety of the machine and operator under no circumstances should this control function be isolated or by passed BATTERY ISOLATOR A grey battery isolator handle is located beneath the canopy which allows the machine control and power circuits to be isolated from the batteries themselves Under normal operation the machine Key switch should be used to isolate the machine with the Battery Isolator only being required to disconnect the batteries for maintenance or in the event of a short circuit The battery charging circuit is connected directly to the battery side so charging is un affected by use of this switch POWER SOURCE SELECTION On multiple power option machines the machine is fitted with an instinctive circuit for power source selection Pressing the green button will automatically select battery operation The engine can be started using the two position START STOP selector in the platform and the machine will default to engine operation via a flow switch in the hydraulic circuit
26. flat level ground before disengaging the traction drive system Do NOT engage or disengage the traction system whilst on the move Stop the machine first and engage the handbrake It is recommended that any slopes be approached in the direction that allows the tow hitch to be lower than the rest of the machine ensuring that the jockey wheel keeps adequate weight throughout Descending a slope with the tow hitch highest might allow the machine to tip backwards particularly if a sudden stop is made To maximize the residual load on the jockey wheel allow the tow hitch to run as low as possible to the ground whilst supporting the nose weight on the retracted jockey wheel Do not ride on the machine whilst using the traction drive nor stand inside the machine structure as serious injury may occur English USA 07 07 Issue 05 sans TM Series Operating amp Safety Instructions 9 9 1 5 2 5 3 5 4 6 2 Emergency Controls GENERAL CHECKING THE OPERATION OF THE EMERGENCY CONTROLS EVERY DAY AND OR BEFORE EACH SHIFT IS AN ESSENTIAL PART OF THE OPERATOR S DUTIES The operator and all ground personnel must be thoroughly familiar with the location and operation of the EMERGENCY CONTROLS IN THE EVENT OF AN INCAPACITATED OPERATOR Turn the key switch selector at ground control station to ground i e fully down Lower on ground controls as detailed under section 4 3 Ground Control Operation IN THE EVENT OF MACHINE
27. g of a possibly hazardous situation Models include the following E DC ELECTRIC BE BI ENERGY DIESEL amp BATTERY AC AC ELECTRIC PE BI ENERGY PETROL amp BATTERY D DIESEL P PETROL A AIR ms TM Series Operating amp Safety Instructions 1 4 GENERAL SPECIFICATION FEATURE 120T TM34T MAXIMUM HEIGHT WORKING 12 2m AOft MAXIMUM HEIGHT PLATFORM 10 2m 34ft MAXIMUM HEIGHT STOWED 1 9m 6ft Jin MAXIMUM OUTREACH 6 1m 20ft Tin MAXIMUM WIDTH TOWING 1 5m 4ft 11in JACK SPREAD 3 55m 11ft 8in MAXIMUM LENGTH STOWED 4 45m 14ft 7in MAXIMUM CAPACITY EUROPEAN 200kg 44015 USA 5001 TURRET ROTATION 360 TURRET TAIL SWING Zero MAXIMUM TRAVEL SPEED 45 mph 72 kph PLATFORM SIZE LENGTH X WIDTH 0 65m x 1 1m 25 x 44in CONTROLS Full proportional hydraulic HYDRAULIC PRESSURE 200bar 2 900 psi TYRES 165 R14 C8 175 R14C 8PR Traction Drive 4 5 bar 65 psi GROUND CLEARANCE 26cm 10 in GROSS VEHICLE WEIGHT MAXIMUM 1300kg 286016 MAXIMUM GROUND PRESSURE 0 06kn cm 125001b ft POWER SOURCE E Electric models 4 x 6v 250 AH batteries P G Petrol Gasoline models Honda GX160 Engine D Diesel models Yanmar L40 or Kubota OC60 engine English USA 07 07 Issue 05 sans TM Series Operating amp Safety Instructions 1 5 IDENTIFICATION UK PLATE NIFTYLIFT LTD FINGLE DRIVE STONEBRIDGE MILTON KEYNES
28. he cage levelling lever whilst not standing in the cage i e with the operator standing adjacent to the cage side whilst simultaneously operating the lever and green button to move the cage Take care not to become trapped between the moving cage and a fixed object and ensure those around you are clear of the moving cage When the system has been charged in both directions the cage levelling function should be restored If the system operates but is jerky in either direction this indicates air in the system Repeat the procedure as described above until the movements are smooth and un interrupted If in doubt contact our Service Department for further advice Niftylift Limited is not liable for any third party damage caused during transport Careful attention to correct procedures will prevent many of the small snags that can happen in transit Re work is both expensive and time consuming A defective machine arriving at the place of work is a poor advertisement for our product the company s reputation and those of our dealers and clients The responsibility for safe and damage free transport rests with the haulier or his representatives English USA 07 07 Issue 05 TM Series Operating amp Safety Instructions 4 8 4 8 1 TRACTION DRIVE On those trailer machines equipped primarily with fixed width axles a traction drive system is an available option This function allows the machine to be manoeuvred by one man and p
29. ify or improve its products without any obligations to install them on previously manufactured machines If you require further information after reading this manual please do not hesitate to contact us Niftylift Ltd Fingle Drive Stonebridge Milton Keynes MK13 OER Great Britain Tel 44 0 1908 223456 Fax 44 0 1908 312733 Niftylift Inc 32 Concourse Way Greer SC 29651 USA Tel 01 864 968 8881 Fax 01 864 968 8836 Nifty Pty Ltd 265 King Street Newcastle NSW 2300 Australia Tel 61 0 2 4929 6700 Fax 61 0 2 4925 2570 The Niftylift 120T trailer mount is an extremely versatile articulated boom platform of unique and simple design It is capable of placing two men and their tools up to a height of 12 20m 40ft or an outreach of 6 10m 208 The booms are mounted via a 3609 powered swing mechanism on to a compact base balanced on a single axle The fully articulating booms give an outstanding working envelope The large pneumatic wheels and minimal weight make the unit light and simple to manoeuvre A simple all hydraulic proportional control system gives smooth reliable movement of the platform and maximum reliability in the harshest environments The hydraulic outriggers make setting up both swift and simple and a unique pressure sensitive microswitch system fitted to each outrigger prevents operation of the machine until all outriggers have been correctly deployed This is coupled with a loud audible alarm warnin
30. ignition switch is ON Turn the Engine Start switch on the platform control box clockwise and the engine will fire 9 Goto step 11 Note Unless the petrol engine is running the 120T will automatically default to the primary power source usually battery 10 f the engine is too cold to start from the platform try starting from the ground controls as described in step 8 of the ground control operation section 4 3 1 ALL MODELS 11 Push and hold green power button 12 Select the boom function required and operate hand levers in full accordance with manufacturers Operating and Safety manual 13 When not in use return machine to stowed position fully raise and stow all outriggers turn the key to the OFF position anti clockwise remove key and chock wheels English USA 07 07 Issue 05 EJ TM Series Operating amp Safety Instructions EMERGENCY PROCEDURES 1 Push in red emergency stop to shut down all functions 2 Use emergency hand pump to provide motive power and manoeuvre the machine as normal using the hand levers Platform or Base PLATFORM CONTROL STATION A CBSOOC 4 4 2 BOOM FUNCTIONS 1 Push and hold green Power Control button BI ENERGY MODEL 2 Select lever 1 2 3 4 or 5 for desired function 1 Operates Platform Lev FWD for forward BACK for back 2 Operates Telescope UP for out DOWN for in 3 Operates Lower Bo
31. inoperative 4 Whilst holding the joystick button and keeping the drive lever in the upright position it is possible to use the third horizontal control lever to engage the traction drive By pulling the lever upwards the engagement cylinder will rotate the twin drive motors until the cradles come into contact with the road wheels This function is pressure protected and the lever should be held to allow the cradles to push into the pneumatic tyres for best grip when driving This pressure is set to 80 bar in the factory and should not need adjustment 5 When the engagement cylinder achieves full travel and the cradles are in adequate contact with the road wheels the lever and drive button can be released locking the engagement cylinder in this position Only then should the parking handbrake be released holding the machine on the traction drive assembly 6 The machine can now be manoeuvred using the drive joystick holding the button whilst moving the joystick in the direction of travel It should be noted that the machine drives in the direction the handle is moved such that if the joystick is released the machine will not drive towards the direction the lever was being pulled This decreases the risk of entrapment of the operator To halt the drive function release either the joystick which will return to the centralised Off position or release the button to stop the hydraulic flow The Emergency Stops can be similarly used to h
32. is sufficient power remaining to enable the operator to drive slowly to the nearest charging point Should the operator ignore the onset of the battery discharge warning the shut down of the motors will continue until the machine is rendered in operative Immediate charging will then be required CHARGING LIMITATIONS Battery charging times will increase slightly if using an 110V supply as opposed to a 240V supply This is due to the connection of the primary coils being in parallel which in effect only allows the transformer to see 220V Similarly the capacity of the 110V supply will decide the input current available hence a small hand tool transformer will not operate the battery charger efficiently therefore charging times will increase further due to input limitations Attention should also be given to the use of extension cables as power leads Excessive cable lengths from the supply point to the battery charger will result in significant voltage drop leading to a reduction in the chargers efficiency In addition inadequate sized cable cores will have a limiting effect on its Current carrying capacity which will again lead to a reduction in the chargers efficiency Both of these can result in over heating of the cable with the attendant risk of fire short circuits or damage to the components themselves The charger requires a minimum battery voltage of 4 5 volts per battery overall for two batteries 9 volts for 4 batteries 19 vo
33. lts for 8 batteries 38 volts If the voltage is below these values then the charger will not function Charger will not detect batteries to begin charge If the batteries have fallen to such a poor state they will have to be removed from the machine and charged individually with an independent charger until the optimum voltage has been reached This is best performed at very low currents to recover the batteries if sulphation has already started i e a trickle charger This can take several hours possibly days Careful monitoring of the rise of battery voltage will indicate when recovery has been achieved TOPPING UP During the course of normal operation the batteries should be inspected at least once a fortnight to check the level of electrolyte During the end of charge gassing takes place which will cause a slight reduction in the volume of acid in the battery This can be topped up with de ionised water as required During this inspection it is useful to note any imbalance in the fluid levels One indication of a faulty cell would be an increase in the loss of battery acid which would then require more frequent topping up on that cell or cells Faulty cells can liberate excess hydrogen even during normal operation with the resulting risk of explosion if ignited Any faulty batteries should be replaced as soon as possible with an equivalent sized and rated unit Note Protective safety glasses and gloves Appropriate PPE MUST b
34. lway cars floating vessels scaffolds or similar equipment unless Niftylift Ltd in Great Britain approves the application in writing Always check the area below and around the platform before lowering or slewing to ensure that it is clear of personnel and obstructions Care should be taken when slewing out into areas where there may be passing traffic Use barriers to control traffic flow or prevent access to the machine Stunt driving and horseplay on or around the Niftylift shall not be permitted When other moving equipment and vehicles are present special precautions shall be taken to comply with local ordinances or safety standards established for the work place Warnings such as but not limited to flags roped off areas flashing lights and barricades shall be used It shall be the responsibility of the user to determine the hazard classification of any particular atmosphere or location Aerial platforms operated in hazardous locations shall be approved and of the type required For the USA refer to ANSI NFPA 505 1987 The operator shall immediately report to his supervisor any potentially hazardous location s environment which become evident during operation If an operator encounters any suspected malfunction of the Niftylift or any hazard or potentially unsafe condition relating to capacity intended use or safe operation he shall cease operation of the Niftylift and request further information as to safe operation from his man
35. n from the operator All machine functions will be restored TESTING At the simplest level before working on the platform the function of the cage overload can be checked by the following method Place two men into the cage and a larger quantity of tools than is permitted to be carried Typically 40 kg The alarm should sound and all functions should be lost Reducing the cage contents to the safe working load should silence the alarm and restore the machine operation English USA 07 07 Issue 05 TM Series Operating amp Safety Instructions 4 5 4 4 5 5 CALIBRATION If a closer examination of the system is required typically for testing and approval the safe working load should be placed in the cage carefully weighing the test load to ensure accuracy The addition of 5kg weight to any of the four corners of the cage should sound the alarm If the alarm does not sound carefully inspect the weigh mechanism for signs of damage All parts of the weigh mechanism should be free to move and the inspection should look for any impact damage that might have caused the assembly to become disabled for any reason If the mechanism seems to be functioning correctly the adjustment of the weigh sensing micro switch should be checked A competent person who has the authority to perform such adjustments must perform this Adjustment must not be permitted by anyone without the approval of the person responsible for the platform
36. n through ON to ST start position and the engine will fire 10 Goto step 11 Note Unless the petrol engine is running the 120T will automatically default to the primary power source usually battery ALL MODELS 11 Push and hold green power button 12 Select the boom function required and operate hand levers in full accordance with manufacturers Operating and Safety manual 13 When not in use return machine to stowed position fully raise and stow all outriggers turn the key to the OFF position i e anti clockwise remove key and chock wheels EMERGENCY PROCEDURES 1 Pushin red emergency stop to shut down all functions 2 Use emergency hand pump to provide motive power and manoeuvre the machine as normal using the hand levers Platform or Base TM Series Operating amp Safety Instructions 4 3 2 BOOM FUNCTIONS 1 Push and hold green power button 2 Select lever 1 2 3 or 4 for desired boom function 1 Operates Telescope UP for out DOWN for in 2 Operates Lower Boom UP for up DOWN for down 3 Operates Upper Boom UP for up DOWN for down 4 Operates Swing UP for right DOWN for left If applicable Ground control of telescoping is optional ALWAYS ENSURE THE AERIAL PLATFORM IS ON A FIRM SURFACE AND THE AREA IS FREE OF ANY OVERHEAD OBSTRUCTIONS ENGAGING THE RED EMERGENCY STOP BUTTON WILL SHUT DOWN THE ENGINE AND THE ELECTRIC CIRCUIT PREVENTING OPERATIO
37. ncline If the platform or elevating assembly becomes caught snagged or otherwise prevented from normal motion by adjacent structure or other obstacles such that control reversal does not free the platform all personnel shall be removed from the platform safely before attempts are made to free the platform using ground controls The engine must be shut down while fuel tanks are being filled Fuelling must be done in a well ventilated area free of flame sparks or any other hazard that may cause fire or explosion PETROL GASOLINE LIQUID PROPANE AND DIESEL FUELS ARE FLAMMABLE NEVER START THE NIFTYLIFT IF YOU SMELL PETROL GASOLINE LIQUID PROPANE OR DIESEL FUEL THESE FUELS ARE HIGHLY FLAMMABLE The operator shall implement means provided to protect against use by unauthorised persons Never remove anything that may affect the stability of the machine such as but not limited to batteries covers engines tyres or ballast TM Series Operating amp Safety Instructions 2 2 2 3 ENVIRONMENTAL LIMITATIONS All Niftylift Trailer Mounts are limited to operation as previously described and any slopes must be adjusted by use of the outriggers and jacks Unless specifically configured otherwise the machine will have short time rating for operation in extreme temperatures i e reduced battery cycle times for low temperatures such as freezers food storage etc and cooling limitations for high temperatures as oil temperature must
38. ntact sticks in place due to welding Under either circumstance the enable signal is blocked instead generating the error message illuminating the red LD2 The machine will not operate under this situation The red error signal from LD2 requires the board to be changed as the relays are not serviceable items MAINTENANCE The cage weigh mechanism is supported on maintenance free precision needle roller bearings for smooth running and friction free operation The accuracy of the entire assembly and in particular the hysteresis is dependent on these components Keeping them free of dust and dirt is recommended and an occasional application of WD40 to the external faces should keep them mobile and deny the entry of dust and moisture The hysteresis is the amount of load required to be removed before the system re sets allowing continued operation If the assembly is subjected to any external impact force typically whilst manoeuvring the machine under power or in the case of trailer units whilst being reversed into position the cage assembly will require close inspection If there is evidence of any deformation in any part of the structure then the advice of a Niftylift Service technician should be sought Physical damage to the assembly is liable to render the cage weigh system inactive or to affect the accuracy of the result Under no circumstance permit a damaged machine to enter service without performing a thorough inspection and calib
39. o within three degrees of level If the load bearing capacity of the ground is in any doubt the machine must NOT be used Release boom travelling clamp Check all red emergency stops are not engaged i e fully out Ensure that the key switch at the ground control station is turned to the ON position i e clockwise At the outrigger control station press down and hold the power lever on the right hand side This activates the power and diverts hydraulic flow to the legs for setting up Then select the appropriate control lever to begin setup Note No power will be available if the booms are not stowed onto the boom rest Using the four outrigger control levers lower each outrigger onto a firm level surface and level the machine base ensuring each outrigger foot is taking equal weight with the wheels clear of the ground Note Deploy the front two outriggers first to minimise the risk of damaging the jockey wheel Check that the base is level using the spirit level adjacent to outrigger control station as a guide The booms can now be operated from the ground control station by pressing and holding the green power button Note If the klaxon alarm sounds check that each outrigger is lowered and each footpad is taking equal weight Always lower booms fully before adjusting raising retracting or moving the outriggers in any way Never alter modify or block any of the safety circuits on the Niftylift THIS MACHINE IS NOT ELECTRICA
40. om UP for up DOWN for down 4 Operates Upper Boom UP for up DOWN for down 5 Operates Swing UP for right DOWN for left English USA 07 07 Issue 05 4 5 4 5 1 4 5 2 4 5 3 TM Series Operating amp Safety Instructions CAGE WEIGH SYSTEM MECHANICAL VERSION The Niftylift range of machines is available fitted with mechanical cage weigh systems These are configured to sense a vertical cage overload which when detected will halt the machine movement No further use of the platform is then permitted until the overload has been removed This must be done in a responsible manner and not one in which a greater hazard might be induced Therefore if the addition of external items such as light fittings brickwork or tiles etc were allowed into the cage the machine would not operate In order to restore the functions the excess load should be safely removed NOT by discharging them out of the basket to the detriment of persons below The mechanical cage weigh system works on the principle of a pre loaded spring rated to the cage safe working load Excess load in the cage forces the spring to further compress the movement of which is detected by a precision micro switch With the machine turned On this movement first gives an audible alarm in the cage as well as a visual indication at both control positions cage and base Additional deflection due to increased load serves to cut off the machine control circuit
41. ontrol P15881 1 46 Battery Isolator P18600 1 48 Battery Charger P14904 1 49 Cage Control E P15925 1 51 Petrol Off P19055 1 52 Cage Control G GE P15924 1 English USA 07 07 Issue 05 TM Series Operating amp Safety Instructions ITEM 53 54 55 56 57 58 59 60 DESCRIPTION Operating Instructions Carb Regulations Noise Warning 730 Footswitch Hand Crush Traction Drive Engage Traction Drive Release Traction Drive On slope NUMBER P14892 P15334 P17123 P14884 P14782 P18890 P16636 P18976 QTY Y English USA 07 07 Issue 05 TM Series Operating amp Safety Instructions S V a Ed um 2 o e eS PI DP 2 bh NOILdO DD DA UN XS L Z S 1OHLNOO WHOALWId STOHLNOO 5 6 LPEIA L ABJ ILE HAIG NOIL VYL NO Lid LON OG x SANIHOVW 31XV G3XI3 9 English USA 07 07 Issue 05 TM Series Operating amp Safety Instructions 3 9 TORQUE REQUIREMENTS SCREW QUALITY SIZE M6 M8 M 10 M12 M 14 M 16 M 18 WHEEL NUTS Standard Traction Drive SLEW RING BOLTS Tightening torque in f
42. ot correctly followed there is some possibility of serious injury or death to personnel THE SAFETY ALERT SYMBOL IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS THAT MAY LEAD TO SERIOUS INJURY OR DEATH IF IGNORED IMPORTANT AND INSTRUCTIONS Denotes procedures essential to safe operation and prevention of damage to or destruction of the machine NOTICE Indicates general safety rules and or procedures relating to the machine It is the owner s user s responsibility to know and comply with all applicable rules regulations laws codes and any other requirements applicable to the safe use of this equipment English USA 07 07 Issue 05 1 2 1 3 English USA 07 07 Issue 05 sans TM Series Operating amp Safety Instructions SCOPE These operating instructions contain all the necessary information required to allow the safe operation of any Niftylift 120T TM34T powered by electric DC diesel D petrol gasoline P engine or a combination of these For further technical information circuit diagrams and specific instructions for all maintenance which may need to be carried out by specialist trained personnel see the associated Workshop and Parts manual for your model of Niftylift 120T 34 INTRODUCING THE 120T TRAILER MOUNT TM SERIES Please note at the time of going to press all information illustrations details and descriptions contained herein are valid Niftylift reserves the right to change mod
43. over the shipping or carriage of any Niftylift it is the responsibility of the dealer and or owner and or hirer to ensure the Niftylift has not been damaged in transit and a Pre operational Report has been carried out by a qualified engineer before the aerial platform is put into service A Remove all ropes straps and or chains used to secure the aerial platform during transit B Ensure any ramp loading dock or forklift used is capable of supporting or lifting the aerial platform Carry out the Pre operational Report before placing machine in service PREPARATION FOR USE Whilst every effort has been made at the Niftylift factory to ensure your machine arrives in a safe and operable condition it is necessary to carry out a systematic inspection prior to putting the aerial platform into service THIS IS NOT A REQUEST IT IS MANDATORY To assist the user in this task you will find enclosed an Inspection Check List see section 6 3 which must be filled out upon delivery receipt of the machine Before the user carries out the Inspection Check List he must have read and fully understood all the contents of the Operating Safety and Maintenance Manual WARNING DO NOT OPERATE A POTENTIALLY DEFECTIVE OR MALFUNCTIONING MACHINE CORRECT AND REPAIR ANY DEFECTS BEFORE OPERATING YOUR NIFTYLIFT English USA 07 07 EIN Issue 05 TM Series Operating amp Safety Instructions 3 3 3 3 1 3 3 2 PRE OPERATIONAL SAFETY CHE
44. r machine always request the circuit diagram that goes with the machine serial number Look at the bottom of the machine serial plate one of the final two numbers stamped there will give the electrical circuit for the machine D80000 number plus the issue status immediately afterwards 01 02 03 etc see Section 1 5 amp 1 5a pages 5 6 If in doubt contact the Niftylift Service Department on 44 01908 223456 Fax 01908 227460 TM Series Operating amp Safety Instructions 4 6 BATTERIES AND CHARGING 5 Note 1 BATTERIES MUST BE RECHARGED IN A WELL VENTILATED AREA FREE OF FLAME SPARKS OR OTHER HAZARDS THAT MAY CAUSE EXPLOSION HIGHLY EXPLOSIVE HYDROGEN GAS IS PRODUCED DURING THE CHARGING PROCESS Recharge batteries at the end of every working day or shift Note To recharge batteries fully from flat takes approx 12 Hours this consists of 8 hours bulk charging plus 4 hours equalisation Plug charger into suitable power supply either 240 volts or 110 volts AC see Charging Limitations Note If using 240V use of a suitably rated Earth Leakage Circuit Breaker ELCB or Residual Current Device RCD at the point of supply is highly recommended Take note of the indicators provided Red Light Batteries are charging Pulsing Green light the charge is equalising Constant Green light and pulsing Red light the batteries are fully charged UNDER NO CIRCUMSTANCES SHOULD BATTERIES BE LEFT ON CHARGE
45. ration of the weigh assembly For this reason it is not recommended to restrain the machine in transit using strap or chains passed through or over the cage itself This is particularly true of the electronic load cell system which could be permanently damaged by the application of such excessive external forces Whilst the mechanical system could be considered to be more robust in operation the same restraint forces that could be generated through ratchet straps and the like is likely to cause some severe deformation in the lightweight cage structure Use only the designated tie down points on your Niftylift when strapping the machine down for transport Failure to observe this instruction could render the machine un usable and a considerable repair bill for the damaged components REPLACEMENT If components are replaced they must be genuine Niftylift parts The accuracy and function of the cage weigh system relies on the like for like application of the component parts A switch from a similar manufacturer might reverse the contact arrangement and critically affect the function of the mechanism Similarly the accuracy of the sensing circuit relies on the duplication of the contact travel within the switch itself Using a non equivalent component will render the cage weigh system inactive Under no circumstances should you permit a machine with a defective cage weigh assembly to enter service If in doubt about the operation or function of you
46. rder to fully appreciate all aspects of the machines operation it should be ensured that each operator has READ and fully UNDERSTOOD the relevant manual covering machine use maintenance and servicing If any doubts exist concerning any points covered in your manual contact your local dealer or Niftylift Ltd Before using any Niftylift thoroughly inspect the machine for damage or deformation to all major components Likewise check the control systems for hydraulic leaks damaged hoses cable faults or loose covers to electrical components At no time should damaged or faulty equipment be used Correct all defects before putting the platform to work If in doubt contact your local dealer or Niftylift Ltd see front cover for address THE MANUFACTURER HAS NO DIRECT CONTROL OVER THE MACHINE APPLICATION AND USE THEREFORE CONFORMATION WITH GOOD SAFETY PRACTICES IS THE RESPONSIBILITY OF THE USER AND HIS OPERATING PERSONNEL FAILURE TO UNDERSTAND AND FOLLOW ALL SAFETY RULES COULD RESULT IN SERIOUS INJURY OR DEATH Only trained persons will be permitted to operate the Niftylift Always operate the Niftylift in full accordance with the manufacturers Operating amp Safety Instructions for that model Before use each day and at the beginning of each shift the Niftylift shall be given a visual inspection and functional test including but not limited to operating and emergency controls safety devices personal protective clothing including fall pro
47. rovides the machine with the capability of ascending or descending a slope of 10 5 7 degrees Slopes in excess of this angle should not be attempted and a towing vehicle used instead The traction system is hydraulically driven the supply being taken from the same power source as the base machine The drive speeds and gradeability are therefore linked into the available power from the vehicle prime mover The engagement of the traction system is also hydraulic using a single hand lever to bring the drive cradles into contact with the road wheels The control of the traction function is then possible from a single joystick permitting the machine to be moved forwards backwards and steered on either side ENGAGING DRIVE 1 Before engaging the traction drive system ensure that the machine is de coupled from the towing vehicle the jockey wheel deployed and securely fixed and the parking handbrake is fully engaged 2 Check that all of the emergency stops are released i e Out and that the Base Key switch is in the On position thereby directing the electrical feed to the drive joystick and jack station 3 Drive joystick has a single pushbutton located on the handle Pushing and holding this button allows the power unit to produce hydraulic flow which is directed to the drive manifold It is not necessary to operate the jack selector lever as this would deviate the hydraulic flow to the jack manifold and render the drive
48. s Telescope Leveling J fo Jo Cone ICwckvaes Power pack pump Slew motor Comments remedial work required etc INSPECTED BY DATE 0 EJ English USA 07 07 Issue 05
49. ssive forces capable of being applied through ratchet chains or slings Severe damage to the steelwork can be caused as well as deformation to sensitive mechanisms such as cage weigh assemblies which would render them useless Such catastrophic damage to say an electronic load cell would require the component to be replaced before the machine would function English USA 07 07 Issue 05 sans TM Series Operating amp Safety Instructions 4 7 2 TOWING THE MAXIMUM RECOMMENDED TOWING SPEED OF A NIFTYLIFT IS 45 MPH 72 KMPH WITH A VEHICLE THAT COMPLIES WITH ALL ROAD TRAFFIC REGULATIONS SPEEDING MAY RESULT IN DEATH OR SERIOUS INJURY It is recommended that the maximum towing speed of 45mph 72kmph be adhered to for the greatest safety In other than perfect conditions it is sensible to further reduce your speed in order to ensure full control over your vehicle and trailer The importance of the suitability of your towing vehicle must be stressed The manufacturers details concerning each model will give you recommended Gross Vehicle Weights GVW or Gross Train Weights GTW neither of which should be exceeded POSITION TOWING VEHICLE AND TRAILER ON LEVEL GROUND BEFORE ATTEMPTING TO COUPLE DE COUPLE Coupling Instructions Depress the trigger on the lever mechanism and lift the handle upwards and forward Place the unlocked coupling head onto the towing ball and apply slight downward pressure The head will automatically lock onto th
50. t Ibs Nm 74 18 5 36 65 100 155 215 80ft Ibs 110ft Ibs 155ft Ibs 10 25 49 135 210 290 26 51 89 140 218 300 110 150Nm 210Nm 10 9 14 35 69 120 190 295 405 English USA 07 07 Issue 05 4 1 3 4 1 6 English USA 07 07 Issue 05 sans TM Series Operating amp Safety Instructions Operation CONTROL CIRCUIT COMPONENTS CONTROL BOARD Situated under the canopy the control box contains all of the wiring and relays to control the machine operation The control box is common between models with the same power source and will contain where appropriate discrete fuses for the circuits concerned KLAXON Mounted under the control board box is klaxon It is this device that sounds continuously if a jack goes light during operation i e when the booms are raised warning the operator of this condition If the operator attempts to activate the machine by turning the key switch in the platform or the base control unit to the ON position and pushing the green button before the jacks are deployed the klaxon will also sound indicating to the operator that the jacks are not setup correctly BOOM SWITCH Mounted on the side of Boom 1 near the boom rest and operated by contact with the boom 3 this switch controls the changeover function between jacks and platform The jack control function is not available unl
51. tection air hydraulic and fuel system leaks cables and wiring harness loose or missing parts tyres and wheels placards warnings control markings and Operating and Safety Manuals guards and guard rail systems and all other items specified by the manufacturer Any problems or malfunctions that affect the safety of operations shall be repaired prior to the use of the Niftylift Always ensure that all warning labels instructions placards control markings and Safety Manuals are intact and clearly legible If replacements are required contact your local dealer or Niftylift Always observe and obey safety and operating instructions on such labels Do not alter modify or disable in any way the controls safety devices interlocks or any other part of the machine Before the Niftylift is used and during use the user shall check the area in which it is to be used for possible hazards such as but not limited to uneven ground drop offs holes bumps obstructions debris floor and overhead obstructions high voltage conductors wind and weather unauthorised persons and any other possibly hazardous conditions English USA 07 07 Issue 05 TM Series Operating amp Safety Instructions 2 1 8 2 1 9 2 1 10 2 1 11 2 1 12 2 1 13 2 1 14 2 1 15 2 1 16 2 1 17 2 1 18 2 1 19 2 1 20 2 1 21 Never exceed the maximum platform capacity as indicated on the decals and machine serial plate Never position an
52. y after charging and general condition 5 Check hydraulic oil level ISO Grade 22 6 Inspect the engine air filter and clean or replace if necessary 7 Check that the tow hitch ball lock breakaway cable chain and jockey wheel are secure 8 Check operation and security of stabiliser micro switches in conjunction with the alarm system 9 Inspect hose track for damage or missing parts English USA 07 07 Issue 05 3 3 3 3 3 4 sans TM Series Operating amp Safety Instructions MONTHLY SAFETY CHECKS 1 Checkthe engine oil level if applicable 2 Check the wheel nuts torque 80ft Ibs 110Nm or 110ft Ibs 150Nm Traction Drive Option 3 Check outriggers for condition security and operation 4 Check that the slew worm is secure and correctly in mesh Clean and re grease 5 Inspect brakes for operation and wear 6 Grease the knuckle and centre post 7 Inspect the engine fuel tank for damage or leaks 8 Check telescopic boom wear pads and nylon studs if applicable 9 Check that the end cap on the main knuckle pin is secure and the roll is in place 10 Grease the tow hitch assembly 11 Lightly oil the jack pad ball joints and outrigger housings 12 Lightly oil the locating pins on outriggers and axles and the axle clamp bolts 13 and check the operation of manual jacks 14 Check and adjust if necessary the Nylatron studs around the telescope boom 15 Every three months check and verify the c
53. y Isolator General Notice Battery Charger Cage Control E AC Cage weigh Non cage weigh Petrol Off Diesel ONLY P14908 P18842 P14782 17341 14836 14896 14883 19708 14876 14785 19090 18432 18672 14921 15383 14801 14598 14390 19092 10853 14962 14841 14922 14926 14927 17219 15881 18600 18863 14904 17212 15925 19055 14414 e d k ao oa j gt BR AH SH po AH SA BSI SH Sm Co mH gt gt 2 L2jo English USA 07 07 Issue 05 ms TM Series Operating amp Safety Instructions ITEM DESCRIPTION NUMBER QTY 36 Cage Control Cage weigh 17457 1 Non cage weigh 15924 1 39 Overload Warning P18848 2 40 Noise Warning 85dB P17124 1 41 Traction Drive Engage P18890 1 42 Hand Crush P14782 2 43 Blank Axle Plate P16190 1 44 If E Stop disabled P14864 2 45 Tow hitch Australia NZ P17970 1 46 Traction Drive Release P18975 1 47 Traction Drive On slope P18976 1 English USA 07 07 Issue 05 TM Series Operating amp Safety Instructions Ob EZ p Zb ec ke ec ZI S3NIHOVI Q3XI3 8 3AIHQ NOILOVYL NO Lid LON Od vi 9ez08d Kam
54. y part of the Niftylift within 4 0m 12ft of any electrical power line conductor or similar not exceeding 66kV Minimum span 125m Other distances for increased voltages and different spans are given in NZECP 34 1993 THIS MACHINE IS NOT INSULATED If in doubt contact the appropriate authorities On entering the platform ensure that the drop down entry bar is closed afterwards Use of an approved safety belt and lanyard hardhat and appropriate safety clothing is mandatory Fasten harness to designated harness securing points within the platform and do not remove until leaving the platform whilst in the stowed position Always remain standing within the platform Do not attempt to increase your height or reach by standing and or climbing on the platform guardrails or any other object KEEP YOUR FEET ON THE PLATFORM FLOOR Do not sit stand or climb on the guardrail mid rail or boom linkage Use of planks ladders or any other devices on the Niftylift for achieving additional height or reach shall be prohibited Do not use the platform levelling system to artificially increase the outreach of the platform Never use boards or ladders in the platform to achieve the same result Do not use the platform to lift overhanging or bulky items that may exceed the maximum capacity or carry objects that may increase the wind loading on the platform e g Notice boards etc The Niftylift shall not be operated from a position on trucks trailers rai
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