Zed 203 HV
Zed 203 HV
Zed 203 HV
INSTRUCTIONS
FOR USE AND
MAINTENANCE
MOBILE ELEVATING
WORK PLATFORM
20.3 HV
1 General information 1
1.1 Manufacturer information __________________________________________________ 1
1.2 Limitations of responsibility_________________________________________________ 1
1.3 Content and scope of this manual ___________________________________________ 2
1.3.1 Symbols .........................................................................................................................................2
1.3.2 Illustrations .....................................................................................................................................2
1.3.3 Scope of this manual...................................................................................................................... 3
1.3.4 Amendments and additions............................................................................................................ 3
1.3.5 Composition ...................................................................................................................................3
1.3.6 Intended readership ....................................................................................................................... 4
1.3.7 Conservation ..................................................................................................................................5
1.3.8 Conidentiality.................................................................................................................................5
1.4 Glossary _______________________________________________________________ 6
2 Safety 1
2.1 Reference standards and directives __________________________________________ 1
2.2 Intended and improper use_________________________________________________ 2
2.2.1 Non-permitted use..........................................................................................................................3
2.3 Obligations and requirements_______________________________________________ 3
2.3.1 Electrocution hazard ...................................................................................................................... 3
2.3.2 Tipping hazard ...............................................................................................................................4
2.3.2.1 BEAUFORT wind scale ................................................................................................................ 5
2.3.3 Risk of falling ..................................................................................................................................6
2.3.4 Collision hazard..............................................................................................................................7
2.3.5 Work atmosphere hazards ............................................................................................................. 7
2.3.6 Machine hazards ............................................................................................................................8
2.4 Operator Deinition _______________________________________________________ 9
2.4.1 The role of the operators ................................................................................................................ 9
2.4.2 Training and importance of the procedures ................................................................................. 10
2.4.3 Operators’ tasks ...........................................................................................................................10
2.4.4 Summary of operator standards................................................................................................... 11
2.5 Road trafic ____________________________________________________________ 12
2.5.1 Checks and tests before driving ................................................................................................... 12
2.6 Safe workplace _________________________________________________________ 12
2.6.1 Type of workplace ........................................................................................................................12
2.6.1.1 Supporting surface ..................................................................................................................... 12
2.6.1.2 Production areas or public areas ............................................................................................... 12
2.6.1.3 Positioning the machine ............................................................................................................. 13
2.6.1.4 Delimitation of the operating area .............................................................................................. 13
2.6.2 Danger areas ...............................................................................................................................13
2.6.3 Risks for exposed persons ........................................................................................................... 14
2.6.4 Electrical tolerances ..................................................................................................................... 14
2.6.5 Ambient air temperature............................................................................................................... 14
2.6.6 Humidity .......................................................................................................................................14
2.6.7 Noise level....................................................................................................................................14
2.6.8 Vibrations and crashes................................................................................................................. 14
2.6.9 Gas emissions..............................................................................................................................15
2.6.10 Contaminant agents ..................................................................................................................... 15
4 Controls 1
4.1 Control panels __________________________________________________________ 1
4.2 Stabilisation control panel__________________________________________________ 2
4.3 Ground control panel _____________________________________________________ 3
4.4 Cabin control panel_______________________________________________________ 6
4.5 Emergency controls station ________________________________________________ 7
4.6 Control panel in the work platform ___________________________________________ 8
4.7 Power take-off control _____________________________________________________ 9
5 Safety devices 1
5.1 Emergency stop buttons ___________________________________________________ 1
5.2 Alarms-warnings _________________________________________________________ 2
5.2.1 Reset alarms ..................................................................................................................................2
5.2.2 Buzzer ............................................................................................................................................2
5.3 Stabilisers and/or beams not completely retracted_______________________________ 3
5.4 Stabilisers interlock switch _________________________________________________ 3
5.5 Aerial manoeuvres enabling ________________________________________________ 4
5.6 Manual emergency pump __________________________________________________ 5
5.7 Maximum pressure valve __________________________________________________ 6
5.8 Blocking valves on cylinders________________________________________________ 6
5.9 Stabilisation control device _________________________________________________ 7
5.10 Turret rotation control device _______________________________________________ 7
5.11 Control device for driving on the road_________________________________________ 8
5.12 Working area control device ________________________________________________ 8
5.13 Spirit level _____________________________________________________________ 9
7 Emergency manoeuvres 1
7.1 Foreword ______________________________________________________________ 1
7.1.1 Using solenoid valves .................................................................................................................... 1
7.2 Work platform emergency stop ______________________________________________ 2
7.3 Levelling the work platform _________________________________________________ 2
7.4 Lowering the work platform using the ground controls in the event of operator incapacity. 3
7.5 Lowering the work platform in the event of a power cut ___________________________ 4
7.6 Manual lowering of platform from the ground ___________________________________ 4
8 Maintenance 1
8.1 Inspection logbook _______________________________________________________ 2
8.2 General Rules___________________________________________________________ 2
8.3 Maintenance summary table _______________________________________________ 3
8.3.1 Pre-start checks .............................................................................................................................3
8.3.2 Every 50 hours of operation ........................................................................................................... 3
8.3.3 Every 100 hours of operation ......................................................................................................... 4
8.3.4 Every 6 months or 500 hours of operation ..................................................................................... 4
8.3.5 Yearly or every 100 hours of operation .......................................................................................... 5
8.4 Maintenance of mechanical components ______________________________________ 6
8.4.1 Main mechanisms ..........................................................................................................................6
8.4.2 Combustion engine ........................................................................................................................6
8.5 Lubrication and greasing __________________________________________________ 7
8.5.1 Greasing the pins ...........................................................................................................................7
8.5.2 Lubricating the stabilisers............................................................................................................... 7
8.5.3 Lubricating the telescopic boom elements ..................................................................................... 7
8.5.4 Lubricating the turntable................................................................................................................. 8
8.6 Hydraulic system maintenance______________________________________________ 9
8.6.1 Hydraulic cylinders .........................................................................................................................9
8.6.2 Hydraulic system pipes .................................................................................................................. 9
8.6.3 Pressure check and valve adjustment ........................................................................................... 9
8.6.4 Hydraulic motors and pumps ......................................................................................................... 9
12 Troubleshooting 1
12.1 Problems, causes and remedies ____________________________________________ 1
12.2 List of alarms ___________________________________________________________ 4
12.2.1 Reset alarms ..................................................................................................................................6
GEnErAl infOrMATiOn
1 General information
CTE S.p.A.
Via Caproni 7, Z.I.
38068 Rovereto (Trento)
Italy
Website: www.ctelift.com
e-mail: info@ctelift.com
The manufacturer shall hold themselves exempt from all responsibility and obligations for any damage
and/or injury caused by the following:
• Use of the machine outside the limits described in this manual.
• Partial or total failure to observe the machine use and maintenance instructions contained in
this manual.
• Use by unauthorised and/or improperly trained personnel.
• Failure to observe health and safety and accident prevention legislation or the Highway Code.
• Mistakes during use and maintenance of the machine
• Disabling, modiication or removal of the safety and protection devices that are installed
• Lack of maintenance
• Modiications or other work not authorised by the manufacturer
• Use of non-original spare parts or those that are otherwise not appropriate for the model
• Exceptional events and events outside of ordinary and proper use of the machine
It is up to the user to prove if a machine defect is the main and direct cause of an accident.
1.3.1 Symbols
For the purposes of personal and material safety, in preparing this document particular symbols have
been used to draw attention to dangerous conditions, warnings and other relevant information:
DAnGEr!
Triangular symbol on yellow background, black border and black symbol.
indicates the presence of a situation of imminent danger which, unless avoided,
could lead to serious injury or even death.
AlWAYS fOllOW THE SAfETY inDiCATiOnS ACCOMPAniED BY THiS SYMBOl
TO AVOiD THE riSK Of SEriOUS PErSOnAl inJUrY Or DEATH.
CAUTiOn
Triangular symbol on yellow background, black border and black symbol.
failure to observe the warnings accompanied by this symbol could cause damage
to the machine and/or its components as well as personal injury.
PrOHiBiTED
round pictogram on white background and red border with a red stripe across it.
This symbol is used to highlight operations or procedures that are STriCTlY
PrOHiBiTED.
OBliGATOrY
round symbol with blue background and white symbol.
WArninG
note on key functions or useful information regarding the operation in progress.
1.3.2 Illustrations
The illustrations contained in this document were up to date at the time of publication.
The illustrations are provided purely as a rough guide and may show the machine with its
protective devices removed for easier understanding.
This document has been prepared pursuant to standards and legislation in force at the time
of its publication.
The purpose of this manual is to provide all the information necessary to be able to use and handle
the machine in a correct and safe manner according to the use envisaged by the manufacturer.
The manual contains a description of the machine, its technical and functional characteristics,
descriptions of the safety and control devices, all information necessary for the operator to use it
correctly and safely, the methods for performing checks and maintenance, as well as the information
for compiling the check register.
This manual refers exclusively to the machine type and model indicated on the cover.
This manual is not intended to train inexpert operators or to teach people how to use the
machine. All descriptions assume that the machine will only be used by operators trained
speciically to operate this type of machine. This manual cannot in any way substitute
adequate operator training.
The operator is directly responsible for the machine and its use.
This manual does not contain instructions for maintenance operations, which must be
performed only by specialised personnel or by CTE SpA authorised service centres.
CAUTiOn
Before using the machine, carefully read the manual and be sure you understand
all the safety standards and operating instructions.
Contact the manufacturer or the nearest service centre if in doubt.
Correct use and maintenance contribute to the proper operation and longer lifetime of the machine.
1.3.5 Composition
This document is divided into 15 chapters, which are subdivided into sections and subsections.
CHAPTEr DESCriPTiOn
DESCRIPTION AND TECHNICAL contains the technical data, performance data and
3
DATA technical characteristics of the lifting platform
14 FACSIMILE OF EC DECLARATION
This manual may not in any way replace the speciic technical preparation which operators
must have previously undergone on similar machines or else which they must undergo
under the supervision of qualiied personnel.
This manual is written for the persons responsible for performing the following operations on the
machine:
PrOHiBiTED
it is prohibited for persons to perform operations or work which falls outside
their speciic areas of expertise and responsibilities.
1.3.7 Conservation
This manual is an integral part of the machine and should be stored with care in the cab
dashboard so it can be readily consulted at any moment.
The manual must always accompany the machine along with the CE declaration of conformity,
the check register and any other documents relating to the machine, including in the event
that it is sold, up until such time as it is removed from service or disposed of.
Make a note of the fabrication number on the cover in order to easily identify the manual.
if the manual is lost or has deteriorated, request a new copy from the manufacturer, quoting
the code on the cover or the machine’s factory number.
PrOHiBiTED
Do not remove, tear out or make arbitrary modiications to any parts of this
document.
1.3.8 Conidentiality
The technical information (text, drawings and illustrations) contained in this manual are property of
CTE S.p.A. and should be considered conidential.
It is strictly prohibited to disclose, reproduce or translate this document, in whole or in part, without
written authorisation from CTE S.p.A.
1.4 Glossary
List and meaning of the main terms used in this manual.
TErM MEAninG
lowering All operations to move the platform to a lower level.
Working envelope Space inside which the work platform is designed to operate, within the
loads and stresses speciied for normal operating conditions.
N.B.:
Mobile elevating work platforms may have more than one work area.
Joints Point of articulation between two or more elements that allow for its
movement (synonym: hinge).
rated load The load for which the mobile elevating work platform has been designed
for normal operation. The rated load includes people, tools and materials
acting vertically on the work platform.
N.B.:
A mobile elevating work platform may have more than one rated load.
load cycle Cycle that starts from the access position, carries out work and returns to
the access position.
Power system System that transmits an energy or force used to move a part of the platform
(hydraulic, electric, pneumatic, etc.).
Wireless control Means by which the mobile elevating work platform operator's commands
are transmitted without any physical connection for at least a part of the
distance between the control console and the rest of the control system.
Transport position Configuration of the mobile aerial work platform established by the
manufacturer in which the mobile aerial work platform is designed to be
transported to its place of use.
Telescopic element Two or more hoses which run one into the other, so that the element is
extending or retractile (synonym: extension booms or extensions).
Hydraulic extension Extension or return of a speciic element by means of a hydraulic movement.
Manufacturer The company that manufactures the lifting platform and in some cases
also combines it with the vehicle.
Self-revealing A fault or the failure of a component in which the fault or failure is apparent
failure or fault to the mobile elevating work platform operator and that can be detected
without the need of diagnostics services.
N.B.:
The fault or the failure of a component can be evident to the mobile
elevating work platform operator:
− through changes in operating characteristics and/or
− visual evidence and/or
− noise and/or
− other
Machine The assembly consisting of the mobile platform and the vehicle (or carriage).
Service engineer A qualiied technician trained for carrying out the maintenance.
Authorised service Company with one or more qualified technicians authorised by the
centre manufacturer to carry out extraordinary maintenance and repairs.
TErM MEAninG
Operator Person in charge of using and checking the lifting platform.
An operator is deined as a person who operates, controls, moves and
carries out the checks and maintenance described in this manual (excluding
the work that has to be carried out by a service engineer or authorised
service centre).
Exposed person Anyone who is entirely or partly inside a hazardous area.
Aerial lifting Platform equipped with railings and control panel that can be moved under
platform (basket) load to the required work position.
Authorised personnel stay inside the platform.
Mobile elevating A mobile machine intended to lift people for carrying out work from within
work platform the work platform.
(MEWP)
Ve h i c l e - m o u n t e d Mobile elevating work platform in which the chassis is a vehicle and the
mobile elevating controls for manoeuvring it are located in the cab of the vehicle.
work platform
Mobile elevating Mobile elevating work platform in which the controls for manoeuvring it are
work platform (self- located on in the work platform.
propelled)
Access position Position that allows access to the work platform.
risk Result determined by the combination of the probabilities and the degree
of seriousness of the possible injuries or possible health damages in a
dangerous situation.
rotation Circular movement of the work platform around the vertical axis.
Extension Distance between the axis of the turret and the outside wall of the work
(widening) platform.
load sensing System for monitoring the vertical load and vertical forces on the work
system platform.
N.B.:
The system includes the measuring devices, the method of mounting
the measuring devices and the signal processing system.
Moment sensing A system of monitoring the moment acting about the tipping line tending
system to overturn the mobile elevating work platform.
Wire rope drive System that comprises one or more wire rope(s) running on rope drums and
system or over rope pulleys as well as any associated rope drums, rope pulleys
and compensating pulleys.
Chain drive system System that comprises one or more chain(s) running on chain sprockets
and or over chain pulleys as well as any associated chain sprockets, chain
pulleys ad compensating pulleys.
lifting All operations required to move the platform to a higher level.
Movement Any movement of the chassis with the work platform in a position other
than its transport coniguration.
Stabilisers All devices and systems used to stabilise the mobile elevating work
platforms by supporting and/or levelling the entire mobile elevating work
platform or extending structure, for example jacks,
suspension locking devices etc.
TErM MEAninG
Extending structure Structure that is connected to the chassis and work platform supports.
It allows movement of the work platform to its required position. It consists
of a telescopic or articulated boom or a combination thereof and may or
may not slew on its base.
Chassis Base of the mobile elevating work platform. It means the carriage in the case
of self-propelled machine and the vehicle chassis and the basic structure
in the case of a mobile elevating work platform mounted on the vehicle.
Hazardous area Any area inside and/or near a machine where there is a continuous risk
for the safety and health of the persons exposed.
safety
2 Safety
The lifting platform was designed and constructed in compliance with the following standards and
directives where applicable:
The mobile elevating work platform was built mainly referring to the standards and technical
speciications shown below:
STAnDArD ED. TiTlE
Mobile elevating work platforms - Design calculations -
October
Uni En 280:2015 Stability criteria - Construction - Safety - Examinations and
2015
tests.
November
Uni En iSO 13850:2008 Safety of machinery - Emergency stop - Principles for design.
2008
The elevating platform was built referring to the standards and technical speciications
indicated in standard En 280: 2015.
The elevating work platform can be used for working at height whilst remaining inside the platform,
including:
CAUTiOn
Applicable national standards and legislation, safety standards set down by the
employer and those relating to the work area should all be observed.
read and ensure you have understood the safety standards before reading the
following chapter.
DAnGEr!
The manufacturer declines all responsibility for damage to property and/or injury
to persons caused by failure to observe the following warnings.
CAUTiOn
Tampering with PPE and/or removing the lead-sealed and painted seals is
strictly prohibited.
For Italy, as regards safe distances from electrical lines, the provisions of current legislation apply.
(reference to tab. 1, attachment IX, Italian Leg. Decree 81/2008, as amended).
nominal Voltage (kV) Distance (m)
≤ 1 3
1 < Nominal Voltage ≤ 30 3.5
30 < Nominal Voltage ≤ 132 5
> 132 7
DAnGEr!
• Do not use the machine as a ground for welding.
• Never use the machine during storms or in the presence of lightning.
DAnGEr!
• It is mandatory to observe the minimum safe distance from live aerial equipment
and lines.
• Clearance should be maintained, bearing in mind maximum extension of the
machine’s boom, as well as swaying of the conductors due to wind.
• Failure to comply with the minimum safety distances can cause death or serious
injury.
Before using the machine, make sure that the ground is able to support the weight
of the machine and withstand the pressure exerted by the stabilisers. Maximum
load is speciied on the labels attached to the stabilisers and in the manual’s
technical speciications.
Position the machine only on a level and stable surface.
• Stabilise the machine on soft, muddy, frozen or slippery ground or in the immediate vicinity of
holes, ditches or manholes.
• Lean the platform on other machines or structures.
• Exceed the maximum permissible inclination of the chassis. The maximum chassis inclination is
speciied in the technical speciications and on the machine plate. Do not operate on ground
with a greater than 3° slope.
• Exceed the maximum load on the work platform and the maximum number of persons allowed
(table of load quantities in the technical speciications and on the machine).
• Overload the raised platform. If parts have to be dismantled at height, check their weight to
avoid exceeding the load.
• Use the machine at winds exceeding 12.5 m/s (45 km/h) or when there are gusts of wind.
• Increase the surface area or load of the platform. Increased surface exposed to the wind
decreases machine stability.
• Use the machine in unfavourable weather conditions, such as storms, snow and mist.
• Push or pull any object outside the platform. The maximum permissible manual force which
may be applied is 40 dan.
• Modify, replace or disengage any components that affect the safety and stability of the machine.
• Modify or alter the work platform. Fittings for holding down equipment or other material on the
platform or guard rail increase the weight and exposed surface area of the platform and load.
• Attach metal wires, cables or similar objects to the platform. These could become trapped or
hook onto a ixed external object.
• Modify, remove or replace any components that could reduce the overall weight or stability of
the machine base, such as ballasts, delating the tyres, removing batteries, spare wheels, etc.
• Position or attach loads which jut out from any part of the machine.
• Use the platform as a crane (applying loads outside the platform and using the machine to raise
suspended loads).
• Use the machine as a goods lift (raising loads on the platform).
• Use the machine as a passenger lift (moving persons from one loor to another).
• Use the controls on the platform to free the platform when blocked, obstructed or impeded in
any other way by an adjacent structure preventing normal movement. request the assistance
of qualiied personnel.
• Tip the vehicle cab (this could compromise stability).
• Enter the vehicle cab (this could compromise stability).
Even if wind speed can be measured with reasonable accuracy using an anemometer, which expresses
a value in knots or kilometres per hour, it is possible to estimate the wind speed empirically using
the Beaufort Scale by observing the effects of the wind in the surrounding environment (its effects
on the sea and/or land).
0-1
0 Calm Calm, smoke rises vertically Sea like a mirror
0-1
Ripples with the
Direction of wind shown by
1-3 appearance of scales
1 Light air smoke drift, but not by wind
1-5 are formed but without
vanes.
foam crests.
Small wavelets,
still short but more
Wind felt on face, leaves
4-6 pronounced. Crests
2 Light breeze rustle, ordinary vanes begin
6-11 have a glassy
to move
appearance and do
not break.
iT iS OBliGATOrY TO:
• Wear suitable fall prevention devices conforming to current standards.
• Attach safety harness cables to the connection provided on the work
platform.
• Keep the platform clear of debris.
• Check that the access gate to the work platform is properly closed before
using the platform.
• Attach personnel who are working at height, outside the work platform, to the safety cable
attachment on the platform.
• Climb onto/sit on the work platform railing.
• Use ladders, scaffolding or similar items inside the work platform for climbing.
• Lean ladders on the machine structure.
• Get off the platform at height.
• Climb down the boom.
• Jam the access gate open.
Contact the manufacturer if you wish to operate the machine outside the temperature
range indicated.
• Use the machine in hazardous atmospheres or in the presence of inlammable or explosive gas
and materials or in explosive atmospheres.
• Start the engine if there is an odour or trace of gas, petrol, diesel fuel or other explosive
substances.
• use the machine with insuficient lighting for the work to be carried out or for the machine moved
safely.
• use the machine for recreational purposes.
• The lifting platform and relative electrical equipment MUST nOT be installed on surfaces that
transmit vibrations and in environments where there is a danger of impact with other mechanical
units.
Physical Characteristics
Operators should have good eyesight (even through the use of spectacles or contact lenses), good
hearing and excellent motor skills.
Mental characteristics
Operators must not take substances that could alter their physical and mental abilities (such as
medicines, alcohol, drugs etc.).
Operators must be aware that anything other than an optimal psychophysical condition can cause
injury to themselves and to other persons, animals and damage to property present in the working
(manoeuvring) envelope.
Extraneous personnel are not allowed to use the lifting platform, as they are not aware of the risks
and dangers involved.
It is advisable that the lifting platform be used by operators aged 18 and over.
It is forbidden for the lifting platform to be used by subordinate workers, employed as apprentices.
Operator on the Has the task of operating the lifting platform from the controls on the
platform work platform itself.
Operator on the ground Has the task of checking the area beneath the working position, the
stability of the platform and operating the emergency controls of the
aerial platform.
CAUTiOn
The operators should be suitably instructed on the use of the lifting platform.
it is particularly important that the operator on the ground preventively knows
the exact position and use of controls for emergency manoeuvres.
DAnGEr!
Before starting to work, the operator should ensure that all safety conditions
that will prevent any accidents are met.
Driver of the - Veriication of the rest position of the lifting platform in order to prevent any
vehicle risk situations arising during transport.
Operator in - Inspect the condition of the lifting platform, especially as regards wear and tear.
charge of routine - Routine maintenance as indicated by the manufacturer in this manual.
maintenance - Notiication of unforeseen circumstances (such as wear, yielding, breakages,
etc.) due to unforeseeable causes and therefore not dealt with in this document.
- Supervision of the recording of operations performed in workshops authorised
by CTE.
Supervisor - informs the operator assigned to operate the lifting platform about:
(understood » the hazards present in the operating area and the hazards that may be
as being the caused by the use of the lifting platform;
person in charge » the possible presence of persons in the hazardous area (operating area)
of safety in the who, for particular tasks, cannot abandon their workstation;
work site or » the possible release of hazardous substances into the air or ground that
industrial area) could affect the safe operation of the platform;
» the compulsory safety devices to be used in the work area concerned.
CAUTiOn
The manufacturer shall bear no liability if the above standards are not complied
with.
CAUTiOn
Make sure the overall dimensions indicated in the technical data comply with
the limits set forth by the Standard governing road trafic in the Country of use
of the lifting platform.
• Open-air places accessible to the public (e.g. squares, car parks, public roads, etc.)
• Private open-air places (e.g. yards in front of houses or blocks of lats for maintenance work
on roofs etc.)
• Indoor areas accessible to the public (e.g. shopping centre entrances, sports centres, inside
exhibition centres etc.)
• Open industrial areas (e.g. maintenance work on infrastructure such as barns, elevated loors
etc.)
• Closed industrial areas (e.g. factory premises, hangars etc.)
• Open areas used for construction sites (e.g. construction yards)
• Inside airports
• On shipping docks
• This should be a place large enough to contain the entire structure, so as not to create any
dangerous situations during the operations with the lifting platform boom
• It should not obstruct escape routes, emergency exits, pedestrian crossings and thoroughfares
(for vehicles, fork lift trucks, self-propelled operating machines etc.).
• It should not obstruct the visibility of signs (boards, illuminated signs etc.).
• It should not obstruct the operating area of other pieces of equipment that are close by (such
as travelling cranes, conveyors etc.) unless the equipment is not disabled for the entire period
in which the lifting platform is used.
2.6.1.3 Positioning the machine
The position of the machine, relative to the position of the user, must allow the work to be
carried out successfully whilst maintaining safety within the working envelope.
During this phase, the accessibility of the controls and the visibility of the applicable areas should be
checked, with particular reference to positioning, operation and retraction.
2.6.1.4 Delimitation of the operating area
Before operating the lifting platform, always irst check the environmental conditions and visibility and
arrange suitable signs to demarcate the operating area such as:
• Barriers
• Tapes delimiting the area
• Signage (prohibition, warning, danger etc.)
Fig. 2.1
Diagram is indicative only. for data and all measurements, refer to Chapter 3.
2.6.6 Humidity
The electrical equipment will work correctly in all weather conditions and levels of relative humidity.
2.6.12 Lighting
Use the lifting platform in areas with proper natural or artiicial lighting.
CAUTiOn
DO NOT use the lifting platform when there is insuficient lighting (at night, in
dense fog or indoors with no artiicial lighting).
If you have to operate in poorly lit areas, illuminate the area with devices installed on columns,
connected to power supplies external to the machine. In this case, do not shine the auxiliary lighting
equipment directly towards the operator’s eyes. It is preferable to position them behind the operator
in order to light the operating area properly, without causing any glare for the operator.
OBliGATOrY
Use only devices that are well kept and in good working order. Moreover, the
devices must be approved and bear the conformity CE-mark. Please refer to
the manual provided by the manufacturer for the use and maintenance of the
devices.
Other equipment may be required depending on the type of job or environment, such as: gloves,
goggles, earmuffs etc. The requirement for and type of PPE must be evaluated by the employer or
site manager.
Description anD
technical Data
The technical data shown in this chapter refers to a machine with standard equipment.
Any changes and/or amendments to this data because of the presence of optional
equipment and/or accessories are documented in Chapter 15.
3.1.1 Classiication
This machine has been designed to lift and move people and equipment within the platform’s (AWP)
maximum permissible load to positions located within the working envelope.
The platform should only be accessed on the ground via the gate.
the limitations on use are described in the manual Any mode or condition of use that does not fall
within the limitations of use described in this manual and not intended by the manufacturer is forbidden.
The machine has been designed for an expected 100,000 work cycles and a heavy work regime (e.g.
10 years, 50 weeks a year, 40 hours a week, 5 cycles an hour).
The machine should be fully serviced and inspected by the manufacturer within the set number of
work cycles. In the event of particularly heavy use, the machine should be serviced sooner.
The machine should be inspected every 1,000 hours and serviced every 5,000 hours.
3.2 Direction
no. DESCriPTiOn no. DESCriPTiOn
A Upper D Bottom
B Right-hand side E Left-hand side
C Rear f Front
The following diagrams illustrate the references and the convention used to identify the machine’s
stabilisers.
A
C
E
B
f
D
Fig. 3.1
Model: ZED
Type: 20.3 HV
FABBRICANTE/MANUFACTURER:
CTE S.p.A.
Via Caproni, 7 - 38068 Rovereto (TN) - ITALY
Tel +39 0464 485050 - Fax +39 0464 485099
PIATTAFORMA DI LAVORO MOBILE ELEVABILE / MOBILE ELEVATING WORK PLATFORM
MODELLO: TIPO:
MODEL: TYPE:
NUMERO DI FABBRICA ANNO DI COSTRUZIONE
FABRICATION NUMBER YEAR OF CONSTRUCTION
PORTATA MASSIMA COMPRESO N. PERSONE E kg ATTREZZATURA
RATED LOAD:
kg INCLUDING N. PERSONS AND kg EQUIPMENT
MASSIMA ALTEZZA DAL SUOLO AL PIANO CALPESTIO PIATTAFORMA
MAXIMUM HEIGHT FROM THE GROUND
m AT WORK PLATFORM FLOOR
SBRACCIO MASSIMO PARAPETTO PIATTAFORMA
MAXIMUM OUTREACH
m GUARD-RAILS WORK PLATFORM
SOLLECITAZIONE MANUALE MASSIMA CONSENTITA
MAXIMUM ALLOWABLE MANUAL FORCE N
MASSIMA VELOCITA’ DEL VENTO CONSENTITA
MAXIMUM ALLOWABLE WIND SPEED m/s
PRESSIONE MASSIMA IMPIANTO IDRAULICO
MAXIMUM PRESSURE HYDRAULIC EQUIPMENT bar
MASSA A VUOTO COMPRESO VEICOLO
NON LOADED MASS WITH VEHICLE
kg
INCLINAZIONE MASSIMA AMMISSIBILE DEL TELAIO: ° ° °
MAXIMUM ALLOWABLE INCLINATION OF CHASSIS:
ALIMENTAZIONE ELETTRICA ESTERNA
EXTERNAL ELECTIC POWER
V Hz
CODE
Fig. 3.2
12 13 14 15 16 17 18 19 20
11 10 9 8 7 6 5 4 3 2 1
Fig. 3.3
The picture shows one possible coniguration of the machine, which may vary.
ATTEnZiOnE:
E' vietato collegare utensili di tensione diversa
dai 230V e potenza superiore ai 1,5 kW.
Prima di collegare gli utensili è necessario
effettuare il controllo del corretto funzionamento
del differenziale; il controllo si effettua tramite il
tasto di prova "T". Il differenziale deve scattare.
Ripristinare il dispositivo sollevando le leve
dell'nterruttore generale. Se ciò non avviene non
utilizzare la presa elettrica e rivolgersi ad un
Centro Assistenza CTE per la riparazione.
iSO-VG32
for any other data, please refer to the “technical features for the MEWP and inspection
logbook” booklet supplied and which is an integral part of the machine.
3.7 Dimensions
The overall dimensions vary according to the vehicle in which the MEWP is installed.
for further information, please refer to the “technical features for MEWP and the inspection
logbook” booklet supplied and which is an integral part of the machine.
niSSAn 35t
AL BASKET
2778
Fig. 3.4
FBR BASKET
2778
Fig. 3.5
niSSAn 35t
Al BASKET
Fig. 3.6
niSSAn 35t
fBr BASKET
Fig. 3.7
niSSAn 35t
Al BASKET
Fig. 3.8
niSSAn 35t
fBr BASKET
Fig. 3.9
controls
4 Controls
5
3
1 2
Fig. 4.1
1 2 3 4 5 6 7
Fig. 4.2
item Description
Back right stabiliser control
1
lever
2
Back left stabiliser control • Moving the lever downwards extends the
lever stabiliser
Front left stabiliser control • Moving the lever upwards retracts the
3 stabiliser
lever
Front right stabiliser control
4
lever
Front right outrigger control • lowering the lever causes the stabiliser to
5
lever extend; raising the lever causes the stabiliser
to retract
Front left outrigger control • lowering the lever causes the stabiliser to
6 extend; raising the lever causes the stabiliser
lever
to retract
7 Levelling check spirit level • Indicates the correct levelling of the vehicle.
3 1
5
9
4 2 7 6
Fig. 4.3
item Description
Front left stabiliser indicator light;
1 • Switches on when the stabiliser is on the ground and minimum stabilisation
has been accomplished.
Front right stabiliser indicator light;
2 • Switches on when the stabiliser is on the ground and minimum stabilisation
has been accomplished.
Back left stabiliser indicator light;
3 • Switches on when the stabiliser is on the ground and minimum stabilisation
has been accomplished.
Back right stabiliser indicator light;
4 • Switches on when the stabiliser is on the ground and minimum stabilisation
has been accomplished.
Emergency stop button.
5
• Stops all manoeuvres.
6 Alarm indicator light 2 - second code number (see chapter on troubleshooting)
1 2 3 9
11
10 4 5 8 12
Fig. 4.4
item Description
CAUTiOn
The working platform should only be controlled from the mobile control panel
in case of an emergency.
refer to the chapter regarding emergency manoeuvres.
CAUTiOn
The stabiliser indicator lights come on when the plate has reached its minimum
extension and is in contact with the ground, but they do not indicate that the
machine has been properly stabilised. Use the spirit level to check that it is
positioned correctly.
1 2
5 4
Fig. 4.5
item Description
red stabilisers lowered When lit, it indicates that the stabilisers have not been
3
indicator light completely retracted.
Green stabilisers
When lit, it indicates that the stabilisers have been completely
4 retracted
retracted. The machine is ready to be moved.
indicator light
Comes on when the power take-off is engaged and at the same
5 Power take-off light
time an audible signal is activated.
5
4
3
2
1
6
Fig. 4.6
item Description
Solenoid valve to raise the articulated boom;
1 • tighten the upper knob to raise the articulated boom;
• tighten the bottom knob to lower the articulated boom.
Solenoid valve to rotate the basket;
2 • tighten the upper knob to rotate the basket clockwise;
• tighten the lower knob to rotate the basket anticlockwise.
Solenoid valve to extend the telescopic boom;
3 • tighten the upper knob to extend the telescopic boom;
• tighten the bottom knob to retract the telescopic boom.
Solenoid valve to raise the telescopic boom;
4 • tighten the upper knob to raise the telescopic boom;
• tighten the bottom knob to lower the telescopic boom.
Solenoid valve to rotate the turret;
5 • tighten the upper knob to rotate the turret clockwise;
• tighten the lower knob to rotate the turret anticlockwise.
Proportional solenoid valve;
6 • tighten the knob to enable the emergency controls station and activate
the single manoeuvre movement solenoid valves.
CAUTiOn
Each manoeuvre must be activated individually and, once the manoeuvre is
completed, the knob must be loosened (without forcing it) and brought back
to position.
1 2 3 4 5 6 7
8 9
Fig. 4.7
item Description
Overload alarm;
6 • The warning light comes on and an audible alarm sounds, which lasts
a few seconds, indicating that the machine is in a locked condition.
CAUTiOn
Depress the clutch before engaging or disengaging the power take-off.
never drive with the power take-off engaged, this could cause damage to the
gear and hydraulic pumps.
safety Devices
5 Safety devices
Fig. 5.1
DAnGEr
Before rearming the buttons, the causes for its use must be carefully evaluated.
CAUTiOn
To reactivate the function of the buttons, turn them in the direction indicated
by the arrows until they click and lift.
5.2 Alarms-warnings
Errors and alarm messages are indicated by a sequence of lashes of the ALRM 1 and ALRM 2 LEDs.
(See Fig. 4.3, ALRM1=7, ALRM2=6).
Example:
spieAlarm_inceppDiscesa = 0 x 0803
08 = 8 lashes of LED 7
03 = 3 lashes of LED 6
5.2.2 Buzzer
Seven beepers are mounted on the platform:
• two are in the panel in the cabin (Fig. 4.7).
• one is in the earth command panel (Fig. 4.3);
• two are in the command panel in the work platform (Fig. 4.6).
• two are in the mobile ground control console (Fig. 4.4)
Within the cab panel:
• the irst is activated, accompanied by a continuous sound, when the PTO is activated;
• the second is activated, accompanied by a continuous sound, when the stabilisers have not
been fully retracted.
Within in the ground command panel, it is activated:
• with a continuous sound when the telescopic boom is resting on the boom rest for six seconds,
inviting the operator keep the closure manoeuvre pressed insistently;
• with a continuous sound if the aerial rest is not completely rested on the aerial or for a sensor
failure.
Within the command panel in the work platform:
• the irst is activated, accompanied by a continuous sound, when the PTO is activated;
• the second is activated, accompanied by a continuous sound, when the stabilisers have not
been fully retracted.
Within the mobile ground control console:
• the irst is activated, accompanied by an intermittent sound, if the work platform is overloaded
above the maximum load value;
• the second is activated, accompanied by a continuous sound, when the work platform is rotated,
and there is the relative risk of the aerial hitting the frame.
1 2
5 4
Fig. 5.2
DAnGEr
After the boom has been raised from its support plate, any use of the stabilisation
controls is prohibited.
Fig. 5.3
CAUTiOn
Only use the manual emergency pump if the main pump is broken.
It is designed to manually force the circulation of the hydraulic oil in the system.
To do so, insert the handle provided into the hole on the pump and move it vigorously.
CAUTiOn
The manual pump will function only after it has been completely illed with oil.
2
3
Fig. 5.4
Fig. 5.5
5 6
3 7 2 4 1 8
Fig. 5.6
2
2
4 4 1
Fig. 5.7
2
1
Fig. 5.8
2
1
Fig. 5.9
2
1 3
Fig. 5.10
Fig. 5.11
1
(a)
1
(b)
1
Fig. 5.12
proceDUres
for Use
6.1 foreword
CAUTiOn
Before reading this chapter, make sure you have carefully read and understood,
All the previous chapters.
This chapter describes the work cycle that the elevating platform can be reasonably expected to perform.
Any special situations and conditions which could arise for the operators, should be dealt with taking
into account and observing the machine’s maximum permitted limits (technical data) and, above all,
ensuring that everything is carried out with the utmost safety for the operators irstly and, then, for
the machine as well.
DAnGEr!
failure to observe the following warnings could create dangerous situations
and cause damage to property and / or injury to persons.
iT iS OBliGATOrY TO:
• Comply with national standards and legislation, safety standards set down by the employer and
those relating to the work area.
• Always wear a safety helmet.
• Comply with the Highway Code in the country of use when the vehicle is being driven on public
roads.
• Comply with the current accident prevention regulations when working on the platform.
• Check the proper operation and condition of all the devices before each use, following the
instructions contained in this manual.
• Check and evaluate the actual work safety conditions (ground, wind, levelling etc.).
• Always cordon off the work area.
The operator must stop all operations if unauthorised personnel are present in the
work area or on the bed of the vehicle.
• Turn on the lashing beacons when the platform is operational.
• Always keep handles and steps free from oil and grease.
• Use suitable safety harnesses when working.
• Make sure that the work area is not too close to power lines and that it is clear of obstacles.
• Use the steps to access the control panels.
CAUTiOn
When using the platform, the emergency manoeuvring workstation must be
monitored by qualiied personnel.
CAUTiOn
Do not climb on the vehicle and / or get into the cab when the machine is
stabilised.
Once you are on the bed of the vehicle, you should be careful because the anti-slip aluminium
components have sharp edges.
The operator in the basket must be supported by another properly instructed person on the ground.
There should be no obstacles or dangers in the basket work area.
Carry out maintenance regularly, following the schedule indicated in this manual and using appropriate
equipment that is in good working order.
If you need to move to another work area, move the machine with the equipment in the transport
position.
Before using the machine, place the stabilisers irmly on solid ground and level the vehicle, using a
spirit level.
Before getting onto the work platform, ensure that the weight of the operator and the equipment does
not exceed the values indicated in the load capacity diagram and on the CE plate (see section 3.3).
Before starting to use the lifting platform, it is recommended that you carry out a series of checks,
both on the machine and in the area in which the machine will be positioned.
• check that the ground is compact and able to support the weight of the machine (the load for
each stabiliser is speciied in the technical speciications and on the stabiliser itself).
• check that the ground is level or that it has an inclination of no greater than 3°.
• inspect the work area (see subsection 2.6.2)
• check for the presence of obstacles and overhead lines in the work area that could obstruct or
limit the use of the machine.
• check that there is a suficient amount of fuel in the vehicle’s fuel tank.
• check that the operation and maintenance manual is present and that it is complete and legible.
• check that all adhesive labels are present and legible (see Section 3.5).
• check the level of hydraulic oil and top up if necessary (see chapter 8 “Maintenance”).
• inspect the aerial work platform, checking the following components and areas for any damage,
missing or improperly installed parts or oil leaks:
» electrical components, cables and electrical wires
» hydraulic hoses/pipes, ittings, cylinders and distributors
» slewing ring motor
» nuts, bolts and other fastening components
» structural or welding cracks and damage to the machine
» work platform and access gate
» limit switches and safety devices
• check that the deviator valves used to reset the levelling of the platform are in the extension
position and that the padlock is closed.
• check that the controls in the platform are working properly before lifting it to a height.
• check that the working area is cordoned off, marked with signs and free of obstacles
• check that the safety systems are working properly (see chapter 5)
CAUTiOn
if one or more safety systems are damaged or faulty, DO nOT USE THE
PlATfOrM!
report the fault immediately to the nearest authorised service centre
CAUTiOn
never exceed 1000 rPM.
The engine could overheat or the pump could break.
5 6 7
Fig. 6.1
CAUTiOn
Before starting any manoeuvre (in cold weather), it is advisable to run the
hydraulic system pump at idle speed for a few minutes so that the oil reaches
the minimum working temperature (about 40°) to allow it to low correctly.
Procedure:
• position yourself in front of the “ground control panel”;
• place the key in the selector switch (Fig. 6.2, 9)
• turn the selector switch (Fig. 6.2, 9) into the “Stabiliser controls” position;
• the light (Fig. 6.2, 8) will turn on;
• make sure that all the stabiliser indicator lights (Fig. 6.2, 1, 2, 3 & 4) are off;
CAUTiOn
if one or more indicator lights are on, it indicates that there is a fault with the
stabiliser limit switches.
• Extend the stabiliser beams by operating the levers in turn (Fig. 6.3, 5 & 6). Move the levers
downwards to extend the beams, upwards to retract.
• Lower the stabilisers by operating the levers in turn (Fig. 6.3, 1, 2, 3 & 4). Move the levers
downwards to extend the stabilisers, upwards to retract. Fully extend the stabilisers to lift up
the vehicle and take the weight off the suspension.
• Check the spirit level (Fig. 6.3, 7) located under the stabiliser controls and level the vehicle
using the stabiliser control levers. The machine is perfectly level when the bubble in the spirit
level is at the centre (0°).
• Check that the indicator lights are on (Fig. 6.3, 1, 2, 3 & 4), which indicates that it is possible
to raise the boom.
CAUTiOn
When the indicator light comes on it does not mean that the vehicle has been
properly stabilised. This is only indicated by the spirit level (fig. 6.3, 7).
Before getting onto the platform, make sure that the machine is properly
stabilised: chassis lifted and level, weight taken off the suspensions and all four
stabilisers resting on suitably irm ground.
If the ground is not irm enough to withstand the weight, use planks that are
suitable for the purpose and that have been checked before use.
3 1
5
9
4 2 7 6
Fig. 6.2
1 2 3 4 5 6 7
Fig. 6.3
OBliGATOrY
Put the helmet and harness on before getting onto the platform.
Before lifting the platform to a height, ensure that the machine is properly
stabilised by checking that the four blocking valves on the stabilisers are closed.
if necessary, call the Assistance Centre.
CAUTiOn
Before moving the platform, make sure that the weight in the platform is evenly
distributed and that it does not exceed the maximum permissible load.
Perform the manoeuvres one at a time in order to minimise stress on the
equipment.
Procedure:
• turn the selector switch key (Fig. 6.2, 9) to the “Work Platform” position;
• remove the key and take it with you;
• check the condition of the personal protective devices before using them. Wear a safety harness
and any other PPE that may be necessary before getting on the platform;
• carefully get onto the work platform;
• check that the access gate is closed;
• connect the snap hook of the harness to one of the anchorage points on the work platform;
• check that the power supply indicator LED on the work platform control board is on (Fig. 6.4, 9);
• lift the telescopic boom or the articulated boom so that it can be rotated without being obstructed
by the rear stabilisers;
• lifting the boom from the support plate inhibits the stabilising movements.
• Move the boom by keeping the selector switch control pressed (Fig. 6.4, 1, 2, 3, 4 or 5) in the
required position;
• At least one person that is qualiied or trained to use the machine should be present on the
ground whilst it is being used.
• when the platform is raised, ensure that it does not collide with ixed or mobile parts or the cabin
of the vehicle. Keep a safe distance from electrical lines (see section 2.3.1). Rotate, lift and
lower the boom with caution. Do not lean out from or hold onto the outside of the work platform.
1 2 3 4 5 6 7
8 9
Fig. 6.4
if you wish to switch off the engine once you have reached the work position, press the
selector switch (fig. 6.4, 8) downwards.
To restart, press the selector switch (fig. 6.4, 8) upwards.
CAUTiOn
On the machines equipped with a pantograph anti-collision device, all dangerous
manoeuvres are blocked when close to the vehicle cabin while all other
manoeuvres are allowed.
5
3
Fig. 6.5
OBliGATOrY
When using the vehicle on a public road, make sure that you have the vehicle
documents and your driver’s licence with you and keep strictly to the Highway
Code.
6.4 Parking
• Park the machine in a suitable area out of the way of trafic The ground must be level and
irm
• If parking on a slope or on an inclination, apply the handbrake and chock the wheels
• Run the engine at idle speed for a few minutes to let it cool down gradually.
• Switch off the engine.
• Pull the parking brake.
• Remove the key.
• Lock the doors.
• Check that the control panels, carters and any equipment containers are closed
eMerGency ManoUevres
7 Emergency manoeuvres
7.1 foreword
In the event of emergency manoeuvres, the operating ground station must be under the control of
an expert and skilled person.
All operations must be carried out with great care and under his/her supervision.
Carefully follow the instructions provided in this manual.
DAnGEr!
The occurrence of the cases listed results in hazardous situations. Therefore,
operators are required to stop all manoeuvres and close the platform safely and
immediately contact CTE authorised repair shop to have the normal machine
use conditions restored.
CAUTiOn
in some set-ups, the machine is provided with optional equipment such as:
Electric pumps, Electric Engines, Auxiliary Engines. if the vehicle pump is
malfunctioning (PTO), these devices must be used to replace it.
Fig. 7.1
CAUTiOn
read and understand the previous chapters before reading this one.
CAUTiOn
if you notice that the work platform is not perfectly level with respect to the
horizontal, lower it to the ground and get off.
The procedure for restoring safe working conditions (work platform horizontal), is described in Chapter
8 “Maintenance” and should be carried out by a qualiied technician.
7.4 lowering the work platform using the ground controls in the event
of operator incapacity.
In the event that the operator on the work platform is incapacitated, the emergency controls should
be used as follows (Fig. 7.2):
1) remove the key from inside in the turret that is fastened using a lead wire seal;
2) insert the key in the selector switch (11) and turn it to the “Mobile Console Control” position;
3) activate the control switch for the required movement and at the same time use the proportional
joystick (10). Using the movement control switches with care, bring the work platform into its
rest position.
4) when inished, place the selector switch (11) in the central position;
5) remove the key from the selector switch (11) and close the cover to the external box.
1 2 3 9
11
10 4 5 8 12
Fig. 7.2
OBliGATOrY
Contact the Assistance Centre in order to
replace the key in the turret with a lead wire seal.
2
3
Fig. 7.3
1
4
Fig. 7.4
5) lower the platform to the ground following the indications shown in the diagram on the label
(Fig. 7.4, 4) above the cover:
CAUTiOn
Always open only one valve at a time. Before moving to the next valve, close
the valve that was opened previously.
The direction of rotation of the emergency manoeuvres always refers to a
person sitting in the cab of the vehicle.
5
4
3
2
1
6
Fig. 7.5
CAUTiOn
Contact the Assistance Centre to check and repair the fault and attach a new
lead wire seal onto the valves.
Maintenance
8 Maintenance
This chapter covers routine maintenance only.
The operator can only carry out the routine maintenance indicated by “O” (operator) in the maintenance
summary table
Other maintenance work, indicated by “M“ (qualiied technician)” in the maintenance summary table,
must be carried out by qualiied technicians and following the schedule and instructions indicated
in the manual. Follow the maintenance instructions in order to keep the equipment in good working
order and safe to operate.
CAUTiOn
Any maintenance work not mentioned in this chapter should only be carried out
by After-Sales Services or by Service Centres authorised by the manufacturer.
The aerial platform can work in contact with water, sand, earth, etc. and requires regular lubrication.
This is vitally important, not only for to ensure machine’s durability over time, but also to minimise
operating costs.
Please contact After-sales Services for any further information.
Before each use, ensure that all necessary maintenance has been carried out and carry out all the
checks indicated in the “Pre-start checks” table.
CAUTiOn
Take a damaged or broken machine out of service immediately.
repair all damage and/or faults before putting the machine back into service.
Perform a quarterly check on any machines that have been out of service for more than three months
before putting them back into service.
The following information regarding the machine must be recorded in the logbook:
• Change of ownership
• Replacement of motors, engines, mechanisms, structural components, electrical components,
hydraulic components, safety devices and corresponding components
• Signiicant faults and relative repairs
• Regular inspections
if there are not enough sheets in the logbook, add other sheets as necessary, by
photocopying them or preparing them in the same way as the ones already present.
The user should indicate the type of platform, the factory serial number and the year of
construction on the additional sheets so that they can become an integral part of this
logbook.
Any maintenance carried out after the irst 100 hours, on a quarterly, six-monthly or annual basis,
should be recorded in section 7 (Periodic checks and maintenance) of the inspection logbook.
The Inspection Logbook should be kept at the disposal of supervisory bodies for a period of ive years
from the date of the last record, or until the equipment is put out of service, whichever occurs irst.
A document certifying the most recent check should accompany the equipment wherever it is used.
CAUTiOn
All maintenance described in the following pages is applicable exclusively to
the aerial work platform.
for maintenance of the vehicle on which the equipment is installed, refer to the
instructions provided by the vehicle manufacturer.
CAUTiOn
in order for the warranty to remain valid, inspection and maintenance must be
carried out at an authorised CTE service centre after the irst 100 hours and after
every 1000 hours (or every year) of operation.
Place the platform in the position shown in A (Fig. 8.1) before proceeding with the lubrication and
greasing.
All platform pins, joints and stabiliser seats are equipped with ball lubricators
identiied by a speciic label (Fig. 8.1, B).
To grease the articulated joints, inject a small quantity of grease using a greasing pump (Fig. 8.1, C),
inject pressurised grease through the domed grease nipples until the old lubrication grease comes
out of the ends.
Lubricate all the points of the joints and all parts itted with grease ittings.
Move all the joints and introduce again a little quantity of lubricating oil.
Clean the elements to remove the exhaust lubricant discharged from the joint points.
Fig. 8.1
Lubricate every 50 hours of operation as follows: stabilise the machine and fully extend the telescopic
boom. Check the lubrication of the elements. If they are dusty or dirty, clean them and remove the
grease. Then, using a brush, apply a thin layer of Agip F1 GR MU2 grease mixed with 50% of Agip
OSO32 hydraulic oil.
CAUTiOn
All valve adjustments should be carried out at the manufacturer’s premises or
at an Authorised Service Centre.
Fig. 8.2
CAUTiOn
The following operations should be carried out with the platform in its rest
position (stabilisers and booms fully retracted).
Change the hydraulic oil every 1000 hours, or at least one a year. At the same time, replace the
hydraulic oil ilters.
To replace it, get a suitable, large-enough receptacle or receptacles (see Section 3.6.1) and drain
the used oil by loosening the drainage cap (Fig. 8.2, 2) found under the tank. Close the drain plug
and reill the tank.
CAUTiOn
Avoid releasing hydraulic oil into the environment when changing it.
Dispose of the oil in accordance with current legislation.
CAUTiOn
if parts of the hydraulic circuit have to be replaced due to serious failures, such
as seizing of the pumps, hydraulic motors or cylinders, which results in a large
quantity of impurities entering the hydraulic circuit, the ilter must be replaced
again following the instructions above.
Fig. 8.3
CAUTiOn
Be careful not to release hydraulic oil into the environment when changing it.
Dispose of the ilter in accordance with the law.
CAUTiOn
if you notice that the work platform is not level with respect to the horizontal,
lower it to the ground and get off.
This maintenance work must be performed by a qualiied technician (M).
DAnGEr
THE presence of personnel inside the working platform during these operations
is strictly prohibited.
6 7
4
Fig. 8.4
DAnGEr
When levelling the work platform, it is prohibited to use telescopic swing.
CAUTiOn
There should be nobody on the work platform during the test.
Go onto the work platform and repeat the test using the controls on the platform. Check the condition
of the power cable of the ground control panel underneath the turret. If the cable is twisted, remove
the plug from the control panel and unravel it.
CAUTiOn
reduce M by 10% when:
• tightening is carried out using cordless tightening machines
• the screws are galvanised.
POSiTiOn Of PlATfOrM:
1) transport position
2) vehicle switched off
Fig. 8.5
The frequency at which the chains need to be tightened depends on factors such as the frequency
of use and the work environment. It is nevertheless possible to establish that under normal work
conditions, the screws of the turret should be checked and tightened after the irst 250 hours of
operation or the irst 3 months and generally least every 12 months or 1000 hours.
CAUTiOn
Do not exceed the values indicated by the dynamometric wrench.
Fig. 8.6
The frequency at which the chains need to be tightened depends on factors such as the frequency
of use and the work environment. It is nevertheless possible to establish that under normal work
conditions, the screws of the turret should be checked and tightened after the irst 250 hours of
operation or the irst 3 months and generally least every 12 months or 1000 hours.
CAUTiOn
Do not exceed the values indicated by the dynamometric wrench.
POSiTiOn Of PlATfOrM:
1) transport position
2) vehicle switched off
CAUTiOn
While inserting the boom, do not exert excessive pressure on the sliding blocks;
this may damage the structure of the booms.
1 2
Fig. 8.7
Fig. 8.8
POSiTiOn Of PlATfOrM:
1) transport position
2) vehicle switched off
The turntable is lubricated by injecting grease under pressure via the grease ittings using a manual
or pneumatic grease gun.
The grease ittings are divided into two groups; those for greasing the screw (Fig. 8.11, 1) and those
for greasing the slewing ring (Fig. 8.11, 2).
In order to grease the inside of the slewing ring you need to access the inside of the turret by removing
the cover on the turret, see Fig. 8.4.
1 2
Fig. 8.9
It is recommended to lubricate the slewing ring every six months or every 500 hours of operation.
CAUTiOn
DO nOT MOVE THE PlATfOrM WHEn An OPErATOr lUBrifiCATE THE
TUrnTABlE AnD PiniOn TEETH
Only use the type of grease indicated in the technical speciications. Otherwise,
contact the Assistance Services or an Authorised Workshop.
8.12 Cleaning
To prevent the operator from slipping and falling, keep all handles and step clean from oil, grease
and dirt.
When cleaning the platform, properly protect electrical components and connections from water jets.
After cleaning perform lubrication on the parts.
8.12.1 Washing
The frequency of cleaning depends upon use of the machine. The machine can be washed using a
high-pressure water jetting machine, taking the following precautions:
• do not exceed a temperature of 70°
• use neutral detergents;
• do not use solvents or benzene
• keep at a safe distance when using the jetting lance
• do not direct the jet towards control panels and electrical equipment
• do not clean the machine of there is live electrical equipment
• wear suitable personal protective equipment
• only clean the machine in areas speciically set aside for the purpose and dispose of materials
in accordance with the provisions of the law.
CAUTiOn
after each wash, you must grease and lubricate all the parts indicated in section
8.5.
DeMolition anD
Disposal
9.1 Demolition
The machine should be scrapped adopting safety measures that take into account logistic and
environmental factors and its state of wear.
CAUTiOn
Dispose of waste luids properly as they can pollute the environment.
CAUTiOn
The demolition of the machine must be performed by specialised and qualiied
companies as they have the proper equipment, tools and machines to carry out
the work.
9.2 Disposal
In general, it is necessary to dispose of the machine following the indications below:
• The operator must wear safety clothing and approved protective equipment (helmet, safety
footwear, gloves, goggles and mask) that are compliant with the applicable safety standards
• Items made of different materials (steel, aluminium, rubber, electric cables) should be separated
into different containers.
To dispose of polluting substances (PVC, lubricant oil and synthetic gum) comply with the standards
in force in the country where the platform will be disposed of.
CAUTiOn
Be very careful to recover and separate potentially dangerous materials used
for the construction of the components.
Machine disposal can be assigned to companies specialised and trained to carry
out this kind of operation.
CAUTiOn
The disposal of the machine can be assigned to companies specialised and
trained to carry out this kind of work.
10
transport anD
storaGe
CAUTiOn
Never tow the machine if you are not familiar with the speciic instructions for
doing so.
10.2 Storage
Short long
Operation
term term
Remove the keys from the vehicle and lifting platform (MEWP) to
prevent unauthorised use.
If the machine is itted with a battery isolator switch, disconnect the
battery.
11
Contact your nearest authorised service centre for any extraordinary maintenance, repairs or spare
parts. It will have qualiied personnel and suitable equipment available for carrying out any work that
may be required.
Please contact After-Sales Services for any information you may require.
CAUTiOn
in order for the machine to operate correctly and to avoid damage to the machine
itself, it is prohibited to carry out repairs or replace components with non-original
parts.
11.3 Warranty
OBliGATOrY
For the warranty conditions please refer to the warranty certiicate delivered
with the machine.
The machine is covered by warranty starting from the date it is delivered to the customer. For the
warranty terms and conditions, please refer to the warranty certiicate delivered with the machine.
The manufacturer reserves the right to repair or replace any parts considered to be defective within
the period of the warranty.
The warranty expires whenever the requirements and instructions of use indicated in this manual
are not observed. Work carried out under warranty is carried out during normal working hours at the
authorised workshops or at the manufacturer’s premises. Technicians’ travel costs are debited for
work carried out at the customer’s premises. The customer is billed for transport costs for work carried
out at the manufacturer’s premises.
During the replacement of defective parts, the manufacturer company cannot be held responsible
for any expenses sustained by the commercial agent and customer, any supposed present or future
damage, loss of earnings, forfeits, etc.
The warranty does not cover the replacement and/or repairs of parts that are worn out or damaged
during ordinary use of the machine.
The following information regarding the machine must be recorded in the logbook:
• Change of ownership
• Replacement of motors, engines, mechanisms, structural components, electrical components,
hydraulic components, safety devices and corresponding components
• Signiicant faults and relative repairs
• Regular inspections
OBliGATOrY
if there are not enough sheets in the logbook, add other sheets as necessary,
by photocopying them or preparing them in the same way as the ones already
present.
The user should indicate the type of platform, the factory serial number and
the year of construction on the additional sheets so that they can become an
integral part of this logbook.
12
troUBleshootinG
12 Troubleshooting
CAUTiOn
Certain problems may be resolved by the operator within the scope of the
operations listed in the “Maintenance” section, while other issues must be
resolved by going to an authorised repair shop.
CAUTiOn
for anything not described in this table, please contact the Service Centre.
Example:
spieAlarm_inceppDiscesa = 0 x 0803
08 = 8 lashes of LED ALARM1
03 = 3 lashes of LED ALARM2
3 1
5
9
4 2 7 6
Fig. 12.1
• open the cover panel (1) which is found on the bed of the vehicle;
• open the cover panel to the compartment (2);
• then, open the panel (3) covering the box which contains the Safety and Carriage engine control
units;
• the errors are reset by lipping the switch with the red safety cover (4). Move and hold the switch
into position once for ive seconds until the alarm LEDs (ALARM 1, ALARM 2) lash quickly.
• Now reset the switch into itsinitial position with the safety cover in position and check that the
alarm LEDs are off;
• Close the various panels securely.
1 2 3 4
Fig. 12.2
13
Fig. 13.1
Fig. 13.2
£ £
Checking for damages and missing, loose or
6.3.1
detached parts
Check welds, pins and joints £ £ 6.3.1
Check for any oil leaks £ £ 8.6
Check pressures £ £ 8.6.3
Hydraulic oil level check £ £ 8.6.5
Check hydraulic oil ilter clogging indicators £ £ 8.6.6
£ £
Check the operation of the controls in the platform
8.7.1
and on the ground
Check safety devices (Emergency Stop) £ £ 8.7.1
Test limit switches £ £ 8.7.2
£ £
Test power supply differential circuit breaker in the
15.3
platform.
£ £
Checking for damages and missing, loose or
6.3.1
detached parts
Check welds, pins and joints £ £ 6.3.1
Check for any oil leaks £ £ 8.6
Check pressures £ £ 8.6.3
Hydraulic oil level check £ £ 8.6.5
Check hydraulic oil ilter clogging indicators £ £ 8.6.6
£ £
Check the operation of the controls in the platform
8.7.1
and on the ground
Check safety devices (Emergency Stop) £ £ 8.7.1
Test limit switches £ £ 8.7.2
£ £
Test power supply differential circuit breaker in the
15.3
platform.
£ £
Checking for damages and missing, loose or detached
6.3.1
parts
Check welds, pins and joints £ £ 6.3.1
Check for any oil leaks £ £ 8.6
Check pressures £ £ 8.6.3
Hydraulic oil level check £ £ 8.6.5
Check hydraulic oil ilter clogging indicators £ £ 8.6.6
£ £
Check the operation of the controls in the platform and
8.7.1
on the ground
Check safety devices (Emergency Stop) £ £ 8.7.1
Test limit switches £ £ 8.7.2
£ £
Test power supply differential circuit breaker in the
15.3
platform.
Lubrication and greasing £ £ 8.5
£ £
Checking for damages and missing, loose or detached
6.3.1
parts
Check welds, pins and joints £ £ 6.3.1
Check for any oil leaks £ £ 8.6
Check pressures £ £ 8.6.3
Hydraulic oil level check £ £ 8.6.5
Check hydraulic oil ilter clogging indicators £ £ 8.6.6
£ £
Check the operation of the controls in the platform and
8.7.1
on the ground
Check safety devices (Emergency Stop) £ £ 8.7.1
Test limit switches £ £ 8.7.2
£ £
Test power supply differential circuit breaker in the
15.3
platform.
£ £
Checking for damages and missing, loose or detached
6.3.1
parts
Check welds, pins and joints £ £ 6.3.1
Check for any oil leaks £ £ 8.6
Check pressures £ £ 8.6.3
Hydraulic oil level check £ £ 8.6.5
Check hydraulic oil ilter clogging indicators £ £ 8.6.6
£ £
Check the operation of the controls in the platform and
8.7.1
on the ground
Check safety devices (Emergency Stop) £ £ 8.7.1
Test limit switches £ £ 8.7.2
£ £
Test power supply differential circuit breaker in the
15.3
platform.
Replace hydraulic oil ilters £ £ 8.6.6
Lubrication and greasing £ £ 8.5
Check turret ixing screws £ £ 8.8.1
£ £
Check the correct tightness of all connecting bolts from
8.8.2
the subframe to the truck
£ £
Check the correct tightness of all connecting bolts from
8.8.2
the subframe to the truck
£ £
Check the correct tightness of all connecting bolts from
8.8.2
the subframe to the truck
Check slewing ring clearance £ £ 8.10
14
facsiMiles of
ec Declaration
anD certificates
14 facsimiles of EC Declaration and Certificates
E
il
iM
-S
C
fA
Fig. 14.1
E
il
iM
-S
C
fA
Fig. 14.2
E
il
iM
-S
C
fA
Fig. 14.3
15
The controls are located on the bed of the vehicle (see section 4 Controls), on the opposite side to the
stabiliser controls, and allow the platform to be used without having to enable the system from the cab.
The electric motor, which is independent from the vehicle on which it is installed, must be connected
to an external power supply (220V), via the socket (7).
It can be used under any conditions. It is especially recommended to be used in the case of:
• A vehicle engine breakdown
• A fault in the hydraulic motor connected to the vehicle engine
• Work to be undertaken in closed places (tunnels, warehouses etc.), to prevent exhaust gas being
emitted to the environment.
If possible, place the vehicle next to the point you have to reach and prepare the work platform for use.
• Switch off the engine of the vehicle
• Put the gear lever in neutral.
• Pull the parking brake.
• Connect the electric motor to an external 220V electricity supply via the socket (7)
• If the indicator light (5) is not on, press the reset button (2)
• Start the electric motor
The speed is controlled automatically.
3 2
M2
4
5 6
Fig. 15.1
CAUTiOn
Using the electric motor does not change the method and logic of operating
the platform.
CAUTiOn
it is recommended to stop the vehicle's engine when the electric motor is
enabled.
When the 220 V auxiliary motor is used, the speed of movement of the platform is slower
(approximately 50%) than when the engine of the vehicle is used. This is in order to reduce
the electric power requirements to within the limits of domestic electrical installations (3
kW).
DAnGEr
Only use the 220V pump motor as an alternative to the pump motor of the
vehicle, but not at the same time. Doing so may cause excessive mechanical
stresses on the structure of the platform.
CAUTiOn
The lockable red mushroom head emergency button SE3 can prevent
unauthorised use during work breaks.
DAnGEr
Make sure that the mains electricity supply is protected by appropriate circuit
breaker and that the earthing system complies with current safety standards.
factory
loc. terramatta, 5
37010 rivoli veronese (vr)
www.ctelift.com
CTE S.p.A.
Headquarter and factory
via caproni, 7
38068 rovereto (tn)
factory
loc. terramatta, 5
37010 rivoli veronese (vr)
www.ctelift.com