Training notes for WALL-MAN^® pneumatic work platforms (Series S-11)

CONTROLS

2.1. Up/Down Main Controls:

The Up/Down movement of the platform is generally controlled using the centre of the three control levers positioned on the control panel at the front left corner of the cage.

Raise the lever to rise

Push the lever down to descend

For small and accurate movements, operate and release the lever in a series of short actions.

When descending it is good practice to make sure that you lower the cage fully before exiting and before going up again. If not, the air remaining below the piston expands when one gets out of the cage and the cage may go up slightly. And if there is a small leak on the top of the piston it will go upwards.

An air valve is fitted in the circuit to help evacuate the air above the piston quickly. To ensure that the cage stops completely when the lever is released, it is only necessary to give the lever a little tap downwards. You will hear a slight ‘click’ as the air valve returns to neutral.

2.2. Parking and Emergency Controls:

The platform can also be raised and lowered using the control valve located on the mast (right hand side as you face the WALL-MAN from the front).

Push the lever up to raise.

Pull the lever down to lower.

This control can be used in emergency if for any reason the operator in the cage is unable to lower himself. It can also be used to "Park" the platform at high level to provide a clear space at floor level for manoeuvring vehicles etc.

NOTE: The platforms can be expected to remain at the raised position for some hours, and may do so for days or weeks; however they may descend very slowly after a period of time due to minor air leaks which may have developed in the system. Do not raise the platforms and leave them parked over any obstruction for a long period of time unless they have been fitted with a “hold-up” valve.

2.3 Left Right Controls:

The Left/Right drive control is the right hand of the three levers on the cage control panel.

Move the lever to the left to drive to the left.

Move the lever to the right to drive to the right.

The drive is via an air motor mounted at the top of the unit driving one of the two top wheels.

As an option, if fitted, the left/right motion can be operated by a foot pedal in addition to the lever in the control panel.

NOTE: Brake

The WALL-MAN is fitted with a parking brake which prevents the platform being dragged along the track by the tension in the hose. If the brake pad becomes worn or the brake fails for any other reason, when you stop the platform, particularly at some distance from the air supply point, the platform will tend to creep towards that point.

The brake is designed to come on just after the motor has stopped (to save brake pad wear) so there may be some small movement of the platform towards the air supply point after the lever is released if a hose reel is used. Where a cable track air supply is employed, there should not be any drag. It is easily adjusted so inform maintenance of any abruptness or delays.

The brake is air operated so if the system is de-pressurised the brake will not work. This may result in the WALL-MAN moving slowly along the track to the centre position where the air comes into the booth – if the supply is via a hose reel.

2.4 In/Out Control:

The In/Out movement of the cage is controlled by the left hand lever on the control panel.

Move the lever forward to move out from the wall

Move the lever back to move in towards the wall

For small and accurate movements, operate and release the lever in a series of short actions.

NOTE: Soft Start Valve.

There is a small valve fitted to the in/out control system inside the control panel which controls the rate at which air pressure is applied to the system when it is first pressurised or re-pressurised after having the air system turned off. This is fitted to minimise the amount of movement of the cage which would otherwise occur on re-pressurisation. Once the system is pressurised the valve has no further function.

When re-pressurising the system it is good practice to ensure that the cage is not close to any obstruction and no one is standing in front of it just in case the valve does not function or does not function fully. In any case a small forward movement may be experienced.

If the system has been only partially de-pressurised then the valve may not function fully and the cage movement may be more. Be particularly careful in these circumstances. If in doubt hold the control lever to the “In” position while turning on the air supply.

2.5 Isolation and shut-off STOP Valve

There is an air isolation valve inside the cage with a black handle. This can be locked using a pad-lock and can therefore be used to limit use of the WALL-MAN to authorised personnel. When the valve is turned off, there is no air to the parking brake so the WALL-MAN can be pushed along the rail. You should occasionally turn the handle through 90 degrees to the OFF position then back ON again immediately just to ensure its movement is free and not clogged-up with paint as this lever serves as the emergency stop i.e. to cut power to the platform. It might also be used to silence the overload whistle if it persists before re-setting.

If nothing works on the WALL-MAN the first thing to do is check that this valve is on.

SAFETY

The WALL-MAN system is designed to be safe, but in common with any mechanical lifting equipment there is the potential for danger if the equipment is misused or used without due care and attention.

3.1 Routine Checks:

Before using the equipment:

• Defects: Check that there are no apparent defects - if there are report them at once.
• Obstructions: Check that there is nothing which will obstruct the movement of the platform.
• Gates: Check that gates close properly - and are closed.
• Air: Check that at least 6 bar of air pressure is available.
• Breathing Air: If you need to use an air fed mask, check breathing air supplies are available.
• Leaks: Check for air leaks. (Listen, preferably with the booth shut down.) Controls: Operate the platform in all directions to prove control functions.
• Safety Harness: Depending on the application it may be a requirement to wear a safety harness. If this is the case ensure that you have one, it is in good condition and it properly fitted.

3.2 General Safety Instructions:

The WALL-MAN access system is only to be used by authorised personnel who have received the appropriate training.

Do not overload. The safe working load for the platforms is 150 kg (330 lb). This comprises one person plus their equipment.

If possible, avoid use with trailing hoses or cables. Compressed air for powering hand tools is provided on the platforms. Using the platforms with hoses or cables trailing from the cage may lead to the platform's movement being restricted, the hoses or cables being run over or subjected to excessive force. If it is unavoidable and trailing hoses have to be used, ensure that they are kept clear of all obstructions and are not allowed to interfere with the operation of the WALL-MAN.

Make sure the WALL-MAN mechanisms are free from any foreign bodies or debris (masking tape, etc.). If the vertical movement becomes jammed, a “slack chain valve” will prevent the lift cylinders lowering while the cage is stuck and will keep the chains taut.

Check all around and below before operating controls. Make sure that the platform is free to move in the desired direction. Check that the cage, the support mast and the platform wheels are all clear of obstruction. Ensure that you know the whereabouts of all other persons working in the area. Beware of people entering the area via personnel doors.

Avoid contact with the vehicle.

Ensure that routine checks are made and that any defects are reported immediately.

3.3. Compressed Air Failure:

In the event of air failure (compressor failure, accidental interruption of supplies, hose damage) the WALL-MAN will not descend in an uncontrolled manner.

If the main air supply fails:

• the cage will stay in its current position the in/out, sideways and up controls will be ineffective

• the down control will function after a short delay but will provide a reduced rate of descent.

The worst case scenario is that one of the hoses to the main vertical cylinders is ruptured. To the best of our knowledge this has only happened once on any of the platforms built. The hose was burned through by a careless welder! If a failure of this hose does occur the platform descends at a controlled rate similar to that achieved in normal operation.

Should the air supply fail while the cage is over an obstruction such that it cannot safely descend at that location it is possible to move the platform manually in either the in/out direction or sideways direction in order to reach a safe location to descend.

3.4 Safety Harnesses and Gates

It is the management’s responsibility to ensure that a safe method of working is employed and the employee’s responsibility to follow the method of working laid down by management. If it is considered necessary for the operator to wear a safety harness when working at height there is a secure anchor point provided at the rear of the cage.

Front gates and working “off” the platform.

Some WALL-MAN are delivered with gates or a pivotable hand rail at the cage front. There is a reason for this which would have been discussed with the original specifier of the platforms. Typically a platform will abut a vehicle/workpiece when spotting or prepping an area toward the centre of a vehicle roof, for example. It may be considered safer for an operator to open the front gate or drop the upper hand-rail and lean over the roof edge to get better access. This is preferable to leaning over the front of a cage with no gates or even step up on the cage frame and lean over. However in such cases it is imperative a harness is worn or other overhead fall-arrest device employed. In all cases a Method Statement and Risk Assessment must be carried out to judge which method is better and safer. The self-closing side gates should never be overridden or fixed in the open position.

3.5 Audible Warning

In accordance with regulations, the WALL-MAN is fitted with an audible warning device (hooter) so that the operator can give a warning to others in the area before moving. The horn button is located at the side of the control panel.

SPLIT RAIL SECTIONS

In some installations the booth is divided into sections by dividing doors. Before these doors can be closed, sections in the top rail must be opened.

There are two types which may be fitted, a Vertical Opening Hinged Section or a Short Removable Section, depending on the requirements of the installation.

4.1 Vertical Opening Hinged Sections.

These hinged sections are normally opened from ground level.

Open the hinged section by pulling on the operating rope / chain until the hinged section is fully open.

Secure the hinged section open by hooking the chain onto the hook provided and check that the rail end stop (on the fixed rail end) has dropped into position.

Repeat on the opposite side of the booth

Check again that both hinged sections are fully open before closing the door.

Reverse the procedure to re-establish uninterrupted use of the bay with the doors open, making sure that the hinged sections are properly closed and that the retaining rope is tight to hold the hinged section closed.

In some installations micro-switches may be fitted and wired into the door control circuits such that the door cannot be closed until the hinged sections are both fully opened.

In some installations the hinged section is operated by an air operated ram acting on the lifting section instead of using ropes. The operation is by a simple Open/Close air switch at ground level.

4.2 Short Removable Section

These sections can only be opened/removed at top rail level height, usually from the WALL-MAN cage. There are several designs so detailed instructions cannot be given here. Suffice to say that you should learn from trained persons who are familiar with their construction. In all cases great care should be taken to ensure the removable section is replaced when the booth no longer requires the diving door to be shut. In all cases the design will allow a WALL-MAN wheel to drop out of the rail but should this occur, the WALL-MAN will come to an abrupt halt and will not travel any further. Apart from the inconvenience, it is relatively easy to lift the unit back into place by applying a long lever to lift the mast at its base.

4.3 If necessary disconnect and reconnect the WALL-MAN air supply such that it is supplied by a hose on the correct side of the door i.e. the side on which you wish to operate and drive it clear of the rail section. Plan about how you will handle pressurized hoses that will suddenly venting and do not allow the reel tension to ‘grab’ the hose from you.

PRACTICAL EXERCISES

• Main Control Levers
• Parking / Emergency Lowering Controls
• Tool Air Supply

Board the platform and go through the safety checks detailed in Sections 3.1 and 3.2 above.

Having completed the safety checks, operate the controls in turn:

• Raise to full height
• Lower
• Drive Left and Right
• Move out from the wall
• Raise and lower, and drive while fully extended
• Operate more than one control at a time. Note that the operating speed may be reduced due to higher demand on the air system.

If applicable, practice opening and closing/removing a rail section at the dividing door.

If practical, witness demonstration of air failure by training personnel.

PERIODIC MAINTENANCE CHECKS AND PROCEDURES

6.1. Daily Procedures.

See Section 3.1 above.

6.2 Weekly Procedures. (This may not be your job but it’s your responsibility to observe and report any shortcomings.)

• Any paint spray dust accumulating on the main pneumatic cylinder piston rods can lead to damage to the cylinder seals.

Action:

∗ Raise the platform to full height.

∗ If necessary clean the piston rods with thinners.

∗ Do not use any abrasive material.

∗ Lubricate the piston rods sparingly using 10-30 Grade Motor Oil (or equivalent).

Routine inspection and operational checks.

Action:

∗ Check for air leaks. (Listen)

∗ Visual check of air hoses for wear and general condition.

∗ Check access gates operate correctly and latches engage.

∗ Check operation of all controls including mast controls.

∗ Check operation of the brake

∗ Check that the slack chain valve is working by putting something solid under the large square tube under the cage so it can’t go down.

Then try to lower the cage further, using the emergency control valve. When chains become slack, they should tighten up again when the lever is released. Then try to lower using the lever in the cage. The chains shouldn’t become slack. If this does happen, remove the rubber cap on the valve with chain attached on the left cylinder set against the wall. Check that the steel button goes out when the chain is forced inward. Grease it if necessary.

6.3. Six Monthly Procedures. (This may not be your job but it’s your responsibility to observe and report any shortcomings.)

6.3.1. Mechanical:

Action:

∗ Check all screws, bolts and other fastenings for tightness.

∗ In particular check the Allen Screws which secure the drive motor in its housing.

∗ Check chains for condition and security. This is likely to be a mandatory requirement of your Insurance Company and they should be consulted to ensure that their specific requirements are met. (See also 6.3.4 below)

6.3.2. Lubrication: Normal operation uses un-lubricated air but periodic lubrication is required. Avoid excessive lubrication as this can lead to the release of oil mist into the atmosphere and damage to the applied paint film.

Action: - Vertical movement.

∗ Shut off air supplies.

∗ Vent the system by operating all control levers in alternate directions. (Finish with platform at bottom position.)

∗ Remove the 8mm hose at one end of each cylinder and insert two small squirts of oil. Use 10-30 Grade Motor Oil or equivalent. Do not over-lubricate.

∗ Replace air hoses and check they are secure.

Action: - In / Out movement.

∗ With the air supply still turned off, operate the In / Out controls to ensure that the pressure has been vented.

∗ Remove one air hose on each Lintra cylinder and insert two small squirts of oil.

∗ Use 10-30 Grade Motor Oil or equivalent. Do not over-lubricate.

∗ Replace air hoses and check they are secure.

Action: - Left / Right Drive.

∗ Turn on the air supply slowly and check for leaks.

∗ Use the platform to gain access to the drive motor at the top of the mast.

∗ Remove one air hose from the drive motor (do not operate the Left - Right Control while the hose is disconnected) and insert a couple of drops of oil into the motor connection. Use 10-30 Grade Motor Oil or Air Tool Oil or equivalent.

∗ Reconnect the air hose and check security.

∗ Operate the Left - Right Control briefly in each direction.

Action: - Chains

∗ Clean off any excessive accumulations of paint overspray

∗ Lubricate support chains sparingly using proprietary chain oil (Check no silicones) or light motor oil.

Action: - Roller Movements

∗ If the platform movement is hesitant in the Vertical and/or In/Out directions lubricate the vertical mast on its corners and/or the horizontal box section sparingly with Vaseline or other non-silicone grease.

6.3.3. Brake. The WALL-MAN is prevented from being moved along the rail by the tension in the air hoses by a brake operating under the top rail flange. The brake is released when power is applied to the drive motor.

Action:

∗ Use the platform to gain access to the top of the mast.

∗ Check the condition of the brake pad. Renew as required.

∗ Operate Left -Right Control Lever and check brake action.

∗ Adjust speed if necessary using the screw regulator. Aim for 1½ seconds for brake to come on.

6.3.4 Inspection Schedule and Report. A report form and notes for inspecting engineers is provided on request. It is recommended that this form is completed on a 6 monthly basis and records are kept safely.

TROUBLE SHOOTING

FAULT	CAUSE	REMEDIAL ACTIONS / CHECKS
Nothing Works	Compressor not supplying air. Main air valve not on. Hose buckled.	Check compressor is running and air supplies turned on including the shutoff valve in the cage. Check main supply hose. Straighten if necessary.
No vertical movement	Platform overloaded. Air Pressure too low. Lever Control Valve Defect.	Check load and reduce to within S.W.L. Check air main pressure, adjust to between 6 bar min. to 8 bar max. Check Operation using Mast Controls Replace / Repair Valve if necessary
No sideways movement or sluggish movement	Air Pressure too low. Air motor loose or disengaged. Control Valve defect. Hose / Hose reel jammed.	Check air main pressure and adjust to between 6 bar min. to 8 bar max. Check air motor drive engaged in driving wheel and motor is secure. Check / repair / replace control valve. Check and free hose / reel.
No In-Out Movement	Air Pressure too low. Control Valve defect.	Check air main pressure and adjust to between 6 bar min. to 8 bar max. Check / repair / replace control valve.
Platform moves sideways without Control Lever being moved	No air pressure on system (Therefore Brake not applied). Brake pad worn. Brake actuation fault.	Reconnect air supplies. Renew brake pad. Check brake and rectify.
Platform moves other than when Control Levers are operated. e.g. descends from parked or operating height.	Control Valve(s) defect. Dirt in seals or seals worn. Air leak in pneumatic system. Air leak at piston rod seals on up/down cylinders.	Listen carefully to detect air leakage from vents when not actuated. Depressurise, reverse valve output hoses, re-pressurise and see if fault has reversed. Check cylinder seals with soapy water. Repair/replace valves and seals. Check system with soapy water or other detector fluid to find leak.
In-Out movement not smooth.	Insufficient lubrication on horizontal beam and sliding motion.	Raise platform to head height. Clean and lubricate the In-Out movement box section using White Vaseline or other silicone free grease, sparingly.
Up-Down movement is not smooth.	Insufficient lubrication on mast.	Clean and lubricate the mast, particularly the corners, using white Vaseline or other silicone free grease.
Air hoses do not rewind on reels evenly or completely	Hoses have become sticky. Hose reel defect.	Apply talcum powder or French chalk to the hoses. Rectify defect. Replace spring unit if necessary.