Material Hoist Operations Manual Load Capacity: 100 lbs Complies with: OSHA 1926.552 ANSI/ASSE A10.5 Lightweight material hoist Not for lifting people! WARNING: This product is exclusively for use by SolarCity employees and SolarCity-authorized personnel who have been fully trained and certified under SolarCity s Field Safety Program, and who have read and understood the contents of this manual. Document #800-1668-001 Rev B Date last exported: June 15, 2015 9:13 AM
IMPORTANT SAFETY INFORMATION READ AND FOLLOW This manual provides important safety information. All users must read and understand the contents of this manual in full, as well as the labels and safety stickers applied to the Material Hoist components. All users of the Material Hoist must also read and understand the user instructions shipped with the Pulley Assembly. Dangers, Warnings, Cautions, and Notices Definitions Throughout this manual, there are steps and procedures that present hazardous situations. The following signal words are used to identify the degree or level of hazard seriousness. DANGER: Indicates the presence of a hazard that WILL cause severe personal injury, death, or substantial property damage if ignored WARNING: Indicates the presence of a hazard that COULD cause severe personal injury, death, or substantial property damage if ignored CAUTION: Indicates the presence of a hazard that will or could cause minor personal injury or property damage if ignored! Dangers NEVER pull the Release Cord without holding the Hoisting Rope. ALWAYS maintain grip on the Hoisting Rope while pulling on the Release Cord to prevent unintentional free-fall when Sled Assembly is loaded. NEVER use the Material Hoist to lift a person. The equipment described herein is not designed for, and MUST NOT be used for, the lifting, supporting, or transporting of people. NEVER position yourself, or permit anyone else, under a loaded Material Hoist. Failure to read and comply with any one of the limitations noted herein will result in serious bodily injury or death and/or property damage.! Warnings Inspect all equipment before each use. Do not use if any of the components of the Material Hoist fail inspection or appear unsafe. Report inspection to immediate supervisor. The Material Hoist must be set up within an established Exclusion Zone. Never climb the Material Hoist Ladder while the Material Hoist is in use. Maximum load is 100 lbs. DO NOT EXCEED THE 100 LBS. WEIGHT LIMIT. Page: 2 of 63
Dangers, Warnings, Cautions, and Notices, continued The Material Hoist is designed, and must ONLY be used, for lifting PV modules with 40mm frame width, Array Skirts, 1x Spanner Bars, Triangle Array Trims, conduit, and haul bags. Do not load more than 2 modules at once. Do not mix load types, i.e., do not load PV modules and haul bags in the same load. Always secure load before lifting. At least one Operator must be present onsite when a load is suspended. Do not use for freely suspended loads. The product described herein is designed for use ONLY with guided loads on the ladder track. The Material Hoist is designed ONLY for vertical lifting along ladder track, with the Ladder secured to building at a 4:1 ratio. Maintain clearances and make sure no obstructions interfere with vertical travel, including overhead power lines. Do not store heavy objects on top of any portion of the Material Hoist equipment. Do not tie off or anchor other equipment to the Material Hoist or to the Material Hoist Ladder. Do not exceed maximum building height/ladder extension. Do not move the Material Hoist Ladder while a load is suspended.! Cautions Keep all moving parts clean. Wear protective work gloves when assembling, disassembling, or operating the Material Hoist. If the person raising the load cannot see the load as it is going up, use a spotter. Keep field and maintenance logs with equipment at all times. Perform a complete inspection every 6 months. Notices Do not perform any field modifications or ad-hoc repairs. If something s not working - Report It, Don t Fix It. During each project s initial site safety meeting, the crew should confirm verbal signals to be used when operating the Material Hoist and the physical location for setting it up. Page: 3 of 63
User Notes Material Hoist operators, crews, or other field users may use this page to add their own notes if needed. Page: 4 of 63
Contents Dangers, Warnings, Cautions, and Notices........................ 2 About the Material Hoist....................................... 7 Safety Standards.......................................... 7 Load Capacity............................................ 7 Ladder Requirements....................................... 7 Major Assemblies............................................ 8 Safety Stickers.............................................. 9 Detail Assemblies........................................... 11 Ladder.................................................. 11 Ladder Stand-Off........................................... 11 Sled Assembly, Front View..................................... 12 Sled Assembly, Side and Back Views.............................. 13 Upper Assembly........................................... 14 Ladder Stability Anchor....................................... 15 Pulley Assembly........................................... 16 Ladder Usage Notes........................................ 17 Rooftop Clearance.......................................... 17 Recommended Best Practices.................................. 17 Parapets................................................ 18 Gable Edge.............................................. 18 Adjusting for Roof Pitch....................................... 19 Summary of Operation....................................... 20 Raising and Lowering........................................ 20 Braking................................................. 21 Ladder Leveling Attachments................................... 21 Loading.................................................. 22 Loading PV Modules......................................... 22 Loading Haul Bags.......................................... 23 Loading Triangle Array Trims................................... 23 Loading Array Skirts and Spanner Bars............................ 24 Page: 5 of 63
Module Lock Positions....................................... 25 Off-Loading On Roof......................................... 27 Setting Up the Material Hoist.................................. 28 Attach Ladder Stand-Off...................................... 28 Attach the Upper Assembly.................................... 29 Unpack the Pulley Assembly................................... 30 Job Site Setup............................................. 31 Step 1. Secure Ladder to Building.......................... 31 Step 2. Attach Pulley Assembly............................ 32 Step 3. Attach Sled Assembly............................. 43 Testing at Job Site Prior to Use.................................. 46 Job Site Packout........................................... 47 Step 1. Sled Assembly Packout............................ 47 Step 2. Pulley Assembly Packout........................... 48 Step 3. Ladder Packout................................. 53 Inspection and Maintenance.................................. 54 When to Inspect............................................ 54 Do Not Repair............................................. 54 Equipment Replacement...................................... 54 Periodic Inspections......................................... 55 Material Hoist Periodic Inspection Checklist.......................... 56 Inspection Checklist: Ladder................................. 56 Inspection Checklist: Ladder Stand-Off........................... 57 Inspection Checklist: Ladder Stability Anchor....................... 58 Inspection Checklist: Sled Assembly............................ 59 Inspection Checklist: Upper Assembly........................... 60 Inspection Checklist: Pulley Assembly........................... 61 Inspection Checklist: Pulley Braking System Function................. 63 Page: 6 of 63
About the Material Hoist The Material Hoist is a lightweight material hoist, with a maximum load capacity up to 100 lbs. It connects to either a 1-section, 2-section, or 3-section ladder and is designed to hoist 1 or 2 PV modules at a time to a roof, using a 3:1 pulley system (a customized third-party Pulley Assembly). The Material Hoist contains a single-platform Sled Assembly attached to an extendable Ladder. An Upper Assembly attaches to the top of the ladder and anchors the pulley system to raise and lower the Sled Assembly. Authorized Users can also use the Material Hoist to transport other small items such haul bags, Triangle Array Trim modules, and Array Skirts. The Ladder requires the following additional equipment to support the Material Hoist. A Ladder Stand-Off to allow sufficient clearance for the Sled Assembly to travel freely past the roof gutter. A third-party Ladder Stability Anchor to secure the top of the Ladder to the roof.! DANGER - NEVER ride on the Material Hoist or use the Material Hoist to lift a person. The equipment described herein is not designed and MUST NOT be used for lifting, supporting, or transporting people. Safety Standards The following standards apply to the Material Hoist: Material Hoist section of OSHA 1926.552 ANSI/ASSE A10.5 Safety Requirements for Material Hoists Load Capacity The Material Hoist is rated to lift a maximum of 100 lbs. Ladder Requirements The Material Hoist is designed to work with the 1-section, 2-section, or 3-section ladders approved by SolarCity s Safety and Quality teams specifically for use with the Material Hoist. Page: 7 of 63
Major Assemblies Pulley Assembly Sled Assembly Upper Assembly Ladder Stand- Off Ladder Stability Anchor (Underside view) Ladder (Exclusion Zone) Page: 8 of 63
Safety Stickers The following Safety Sticker should be applied to the Sled Assembly and the Upper Assembly of the Material Hoist. The Material Hoist components shown below will be factory shipped with the Safety Sticker already applied.! WARNING For Material Hoist use only. Read the Material Hoist Operations Manual before using. Ladder can only be used for climbing during Material Hoist equipment setup and breakdown processes. Do not climb Ladder when a load is suspended. Warning: Pinch Hazards Inspect before each use per Material Hoist Operations Manual. Intended for lifting a maximum of two (2) PV modules at a time. Upper Assembly location: underside of Top Plate Sled Assembly, location: Pulley Cover No Riders Allowed System Specified Load Rating: 100 lbs For use by SolarCity employees ONLY Safety Sticker Part No. 850-1538-001 Page: 9 of 63
Safety Stickers, continued The Pulley Assembly will be factory shipped with the following Safety Sticker already applied to the Spool as shown. DANGER! TO AVOID FREE FALLS, ALWAYS MAINTAIN GRIP ON HOISTING ROPE WHEN PULLING RELEASE CORD TO AVOID FREE FALLS, ALWAYS MAINTAIN GRIP ON HOISTING ROPE WHEN PULLING RELEASE CORD DANGER! TO AVOID FREE FALLS, ALWAYS MAINTAIN GRIP ON HOISTING ROPE WHEN PULLING RELEASE CORD DANGER! Page: 10 of 63
Detail Assemblies Ladder Traction Feet Ladder Stand-Off Part No. 850-1534-001 Bottom Section Top Section Rungs Side Rails (Interlocking) Rung Lock (example) Pull Quick Release Pin to rotate Leg Rung Bracket Leg Telescoping Quick Release Pins Rung Hook Spring Button Legs Velcro Rung Straps Leg Rotation Feet Page: 11 of 63
Sled Assembly, Front View Carry Handle Bottom Strap Pulley Cover Non-Friction Plastic Sheeting Single Module Hook Top Strap Pulley Hook Lowering Hole Feet Module Lock Ledge Bottom Tray Haul Bag Hangers Stop Edge Part No. 850-1523-001 Side Wall (Rubber Shock Absorber, behind Pulley Hook bracket) Non-Friction Plastic Sheathing Pulley Cover Detail Page: 12 of 63
Sled Assembly, Side and Back Views Carry Handle Ladder Strap Right Module Lock Module Lock Top Strap Bottom Strap Ledge Side Brace Left Ladder Strap Main Plate Carry Handle Ladder Strap Back Page: 13 of 63
Upper Assembly Part No. 850-1531-001 Front Top Loop Slot Staging Tray Top Plate Ladder Connect Strap Rung Slots Roller Bar Top Page: 14 of 63
Ladder Stability Anchor Usage Notes Clamp Swivel Clip Velcro Ties If the Ladder Stability Anchor cannot be effectively clamped to an eave, secure it using a lag screw on the roof with flashing. If the Clamp is not operating properly, remove the Ladder Stability Anchor from service and do not use. Page: 15 of 63
Pulley Assembly Part No. 850-1533-001 Anchor Carabiner Upper Pulley Hoisting Rope Thimble Lower Pulley Hoisting Carabiner Top Loop Release Cord + Spool Tarp (Sewn to Rope Bag) Rope Bag Brake Handle Corner Loops The Pulley Assembly ships with its own set of user instructions. Spool Page: 16 of 63
Ladder Usage Notes Follow established procedures for standard ladder safety. IN ADDITION: Do not use the Material Hoist Ladder for climbing while the Material Hoist is in use. The desired height of the top of the Material Hoist Ladder above the roof eave is less than the standard 3 feet. The reason for this is ergonomics: it is easier to lift loads off the Sled Assembly and onto the roof with a ladder top that is closer to the roof eave. Always use a Ladder Stand-Off with the Material Hoist to add horizontal clearance between the Ladder and the roof. This allows the Sled Assembly to slide freely past the eave, all the way to the top of the Ladder. After setup, always check Ladder stability before using. Always locate the Material Hoist within an established an Exclusion Zone. Use care when extending the Ladder to ensure that rung locks are fully engaged. Uninstall the Pulley Assembly prior to changing Ladder height during operation. Rooftop Clearance 18-24 clearance Ladder Stand-Off 6 clearance Roof gutter Ladder clearance from gutter Recommended Best Practices No Climbing Exclusion Zone Check Stability Engage Rung Locks Page: 17 of 63
Ladder Usage Notes, continued Parapets If needed, move the Ladder Stand-Off to a different Ladder rung. The optimal position will be one that best facilitates the lifting of loads onto the roof. Use the Quick Release Pins to rotate Legs. Gable Edge Shown: 1st hole The rotating and telescoping Legs of the Ladder Stand-Off allow you to mount the Material Hoist from the side of the roof plane. The two examples show potential use on a shallow and steep roof pitch. Allow clearance for the Sled Assembly to reach the topmost point, where the Sled Assembly Stop Edge meets the Upper Assembly Top Plate. Shallow pitch: Both Legs on roof Rotating and telescoping legs Steep pitch: One Leg braced on side eave, one Leg on roof Page: 18 of 63
Ladder Usage Notes, continued Adjusting for Roof Pitch The Ladder Stand-Off can adjust for any roof pitch between 0 and 45 degrees, using both rotation and telescoping Leg features. If the Leg is angled incorrectly, the Feet can slip or skid unintentionally when the Ladder or Material Hoist is under load, or the Ladder Stand-Off may be subjected to undue stress at the Leg joint. Use your own best judgment. using the following illustrations as an approximate visual guide. Flat 15 Degrees 4th hole 3rd hole 45 Degrees 2nd hole Page: 19 of 63
Summary of Operation Raising and Lowering To raise a load from the ground to the roof, lift the Sled Assembly with the Hoisting Rope, using hand-over-hand technique. To lower the Sled Assembly, pull steadily on the Release Cord, while feathering the Hoisting Rope through the other hand to control the speed of descent. Work gloves Release Cord Hoisting Rope Hoisting Rope Raise Lower DANGER: Always maintain grip on the Hoisting Rope while pulling on the Release Cord to prevent unintentional free-fall when Sled Assembly is loaded! Never pull the Release Cord without holding the Hoisting Rope. Page: 20 of 63
Summary of Operation, continued Braking The Pulley Assembly includes a built-in braking mechanism that automatically prevents descent until the user pulls on the Release Cord. To stop a descent at any time, simply let go of the Release Cord.! WARNING: DO NOT allow the Release Cord to reach all the way to the ground, where it could be stepped on accidentally and cause an unintended descent. Instead, roll it up on the Spool so that the Spool remains at head height. Ladder Leveling Attachments There are a variety of attachments for using a Ladder on uneven or sloped surfaces. Some of these ladder leveling attachments actually raise the Ladder off the ground entirely. If one of these is used, the Sled Assembly should never be permitted to descend past the lower rung of the Ladder itself, and should never come into direct contact with any additional leveling attachments. Recommended Guideline: The Feet of the Sled Assembly should never be lower to the ground than the lowest point of the Ladder itself (including Ladder Traction Feet that would normally rest directly on the ground). Sled Assembly Feet should never travel below this line Sled Assembly Feet Example showing use of a ladder leveling attachment Ladder Traction Feet Page: 21 of 63
Loading The Material Hoist is suitable for transporting 1 or 2 PV modules at a time. It can also hoist up to 3 Triangle Array Trims, or various haul bags. Use the Module Lock to secure modules, and use the Top and Bottom Straps to secure other types of loads. Follow these guidelines: DO NOT mix load types. If you need to lift both modules and haul bags, hoist each load type separately. DO NOT exceed the maximum rated load of 100 lbs. If modules have additional module-level electronics such as microinverters or power optimizers, load modules glass-to-glass (facing towards each other). Loading PV Modules Landscape orientation Module Lock swings out to secure modules (Top and Bottom Straps not used for modules) Load a maximum of 2 modules in landscape orientation. Center the load Second module rests here First module rests here Side Brace Detail Page: 22 of 63
Loading Haul Bags Center the load Maximum 100 lbs Loading Triangle Array Trims Load up to 3 Triangle Array Trims at once Secure with Top Strap Balance the load Up to 3 Triangle Array Trims fit onto the Ledge Front View Side View Page: 23 of 63
Loading Array Skirts and Spanner Bars Secure with Top and Bottom Straps Place longer items in appropriately sized haul bag Maximum 100 lbs Array Skirt 1x Spanner Bar Only Page: 24 of 63
Module Lock Positions The Module Lock is a spring-loaded rotating handle that is used to secure PV modules for lifting. Lift the Module Lock to rotate. The Module Lock automatically retracts to the correct level for each position. 1 2 3 The Storage position is used when transporting the Material Hoist to and from a job site. The Double Lock position is used to secure 2 PV modules. The handle is raised up in this position. The Single Lock position is used to secure a single PV module. The Open position is used when raising loads other than full-size PV modules, including Triangle Array Trims, and is also used when lowering an empty Sled Assembly. Storage (Packout) Double Lock (2 modules) Single Lock (1 module) 1 2 4 3 4 Open (Non-module loads or lowering empty) 4 1 Top View 3 (Shown in Storage position) 2 Page: 25 of 63
Module Lock Positions, continued Front View Top View Front 2 1 Storage Back Double Lock 3 Single Lock Single Module Hook fits in the Zep Groove of PV module frame 4 Open Page: 26 of 63
Off-Loading On Roof Rest PV modules on the Staging Tray when lifting onto steeper roofs. When off-loading 2 modules, lift one module at a time. Turn the Module Lock to the Single Lock position before lifting the first module. Turn the Module Lock to the Open position when lowering an empty load, and when raising and off-loading all other loads. Off-Loading PV Modules 1 2 Module Lock Raise Module Lock and rotate 90 degrees counterclockwise. 2 1 The Single Module Hook fits the Zep Groove to hold the second module while first module is being off-loaded. Rotate the Module Lock another 90 degrees clockwise to the Open position, and then lift off the second module. Page: 27 of 63
Setting Up the Material Hoist Initial assembly can either be done ahead of time, or at the job site. Attach Ladder Stand-Off 1 Rung Hook The Ladder Stand-Off hooks around 2 adjacent Ladder rungs. First, hook the Rung Hook around the lower rung. Note that the Ladder Stand-Off may be installed on different rungs based on roof pitch or roof access point. 3 2 Rung Bracket Rotate the upper portion of the Ladder Stand-Off until the Rung Bracket meets the upper rung. 4 Velcro Straps Wrap the Velcro straps around the upper rung. Page: 28 of 63
Setting Up the Material Hoist, continued Attach the Upper Assembly Ladder Connect Strap Rung Slots fit over the 2 topmost rungs on top Ladder section Roller Bar hangs just below the second rung Fasten Ladder Connect Strap snugly around the topmost rung This can also be done safely by someone on the roof, provided that the person is fully harnessed using appropriate Fall Protection PPE. Page: 29 of 63
Setting Up the Material Hoist, continued Unpack the Pulley Assembly Anchor Carabiner clips to fabric loop for storage Rope Bag Release Cord wound on Spool Tail end of Hoisting Rope stays tied to fabric loop on Tarp, at all times Upper Pulley Lower Pulley Minimize rope slack between Upper and Lower Pulleys when packing for storage Hoisting Carabiner clips to fabric loop for storage Page: 30 of 63
Job Site Setup! WARNING: Inspect all equipment before each use. Follow standard procedure and maintain 3 points of contact at all times when climbing the Ladder. If equipment appears to be broken or damaged, do not use. Step 1. Secure Ladder to Building Choose a spot with optimal access for transferring material onto the roof. The Upper Assembly should already be attached to the top section prior to Ladder extension and setup at the building. Follow the usual procedure as for setting up a ladder for crew roof access, except for the following: 1. In addition to a Ladder Stability Anchor, a Ladder Stand-Off is required. Both items have Velcro straps to secure to Ladder Rungs. The Ladder Stand-Off can be adjusted from the roof. The top of the Ladder is lower than would be for normal roof access, but may be adjusted as needed. 2. Prior to attaching Pulley Assembly and Sled Assembly, make sure the Ladder is secure and stable at both top and bottom. 3. If not already attached, the Upper Assembly can be attached to the Ladder from the roof. Ladder Stand-Off Ladder Stability Anchor Ladder Traction Feet: Leveled, on stable surface Page: 31 of 63
Step 2. Attach Pulley Assembly Attach the Pulley Assembly after the Ladder is already extended and secured to the building. 1 Unpack and un-clip the Pulley Assembly Unpack the Rope Bag and Tarp on the ground, directly underneath top of Ladder. Un-hook both Carabiners from loops in the Tarp. If the Pulley Assembly has been packed correctly, the Upper Pulley and Lower Pulley should have minimal rope slack between them, and the Release Cord should be neatly wrapped on the Spool, attached closely to the Upper Pulley. Leave the tail end of the Hoisting Rope tied to its fabric loop on the Tarp, with the bulk of the Hoisting Rope left coiled and resting on the Tarp. Tarp Rope Bag Un-clip Un-clip Release Cord in Spool Upper Pulley Lower Pulley Page: 32 of 63
Attach Pulley Assembly, continued 2 Clip Upper Pulley to your safety harness Hook the Upper Pulley s Anchor Carabiner to your safety harness. The Lower Pulley is not hooked to anything, and is dangling freely. Ensure that there is minimal slack between the Upper Pulley and the Lower Pulley prior to climbing up. Remove excess slack by pulling the tail end of Hoisting Rope as needed. The Release Cord should remain wound on Spool Ropes can become tangled when stored. Un-twist the Hoisting Rope if needed. It should appear as shown. The Hoisting Rope tail end should remain clipped to a fabric loop on the Tarp, which is on the ground! WARNING: If Pulley Assembly appears to be broken or damaged, or the Hoisting Rope is frayed, do not use. Page: 33 of 63
Attach Pulley Assembly, continued 3 Climb up to the Upper Assembly Page: 34 of 63
Attach Pulley Assembly, continued 4 Un-clip Upper Pulley At the top of the Ladder, unhook the Upper Pulley from your tool belt while still maintaining 3 points of contact with the Ladder. a b Page: 35 of 63
Attach Pulley Assembly, continued 5 Roller Bar a Weave Pulley Assembly through Ladder Weave the entire Pulley Assembly up and over the top of the Roller Bar and the topmost 2 rungs of the Ladder. The Lower Pulley with Hoisting Carabiner, and the Release Cord wound on the Spool, should all follow through as well. The Upper Pulley has two sides: one side is yellow/gold in color, and the other side is red. The yellow side has text indicating that it should be facing outwards. b Page: 36 of 63
Attach Pulley Assembly, continued 6 Top Loop Clip Upper Pulley to Top Plate Un-clip the Anchor Carabiner from the rest of the Upper Pulley. Insert the Top Loop of the Upper Pulley up through the Top Loop Slot in the Top Plate of the Upper Assembly. Clip the Top Loop from above, using the Anchor Carabiner to secure the Upper Pulley in place. d a b c e Lay the Anchor Carabiner flat The Hoisting Rope tail end reaches all the way to the ground Page: 37 of 63
Attach Pulley Assembly, continued 7 Weave Release Cord back through and down Weave the Release Cord Spool back down the same way it came up, over the second Ladder rung, except going behind the Roller Bar instead of in front. Unwind the Release Cord from the Spool and allow the Release Cord to fall all the way to the ground. a Roller Bar b The Hoisting Rope weaves in front of the Roller Bar, while the Release Cord passes behind Page: 38 of 63
Attach Pulley Assembly, continued 8 Clip Lower Pulley to your safety harness To prepare for descent climbing down the Ladder, use the Hoist Carabiner to clip the Lower Pulley to your safety harness. Page: 39 of 63
Attach Pulley Assembly, continued 9 Descend while pulling Release Cord Maintain 3 points of contact on the Ladder while descending Reach around the back of the Ladder and take the Release Cord in one hand Page: 40 of 63
Attach Pulley Assembly, continued 10 Descend one step at a time Descend the Ladder one step at a time, pulling steadily on the Release Cord to release the Upper Pulley. You may need to use your body weight helps to pull the Upper Pulley down the Ladder. Page: 41 of 63
Attach Pulley Assembly, continued 11 Wrap Release Cord onto Spool After descending the Ladder, wrap the Release Cord back onto the Spool until it dangles at approximately head height. Wind up excess slack. Tuck the Release Cord into the sawtoothed holder on one side of the Spool to secure it. This helps prevent crew members from accidentally stepping on the Release Cord while working at the job site. Page: 42 of 63
Step 3. Attach Sled Assembly 1 Position Sled Assembly Place the Sled Assembly so that it rests against the foot of the Ladder. Note that if the Ladder uses a ladder leveling attachment that raises the Ladder itself off the ground entirely, the Sled Assembly may not rest fully on the ground. If the Sled Assembly appears to be broken or damaged, do not use. Page: 43 of 63
Attach Sled Assembly, continued 2 Connect Lower Pulley Thread the Lower Pulley through the Sled Assembly so that it passes behind the Pulley Cover and over the Main Plate. Use the Hoist Carabiner to clip the Lower Pulley to the Pulley Hook on the Sled Assembly. Lower Pulley Hoist Carabiner Pulley Hook Ensure that Hoisting Rope slides freely Page: 44 of 63
Attach Sled Assembly, continued 3 Secure Ladder Strap Always secure Ladder Strap when using the Material Hoist. The Ladder Strap metal attachments rotates down for storage. Page: 45 of 63
Testing at Job Site Prior to Use Raise and lower the Sled Assembly without a load prior to use. Ensure that all parts slide smoothly without obstruction, and that Sled Assembly Stop Edge can travel far enough up to meet the Top Plate of the Upper Assembly. If the Sled Assembly stops at the roof gutter, or at any point lower than the Upper Assembly Top Plate, adjust the telescoping legs on the Ladder Standoff to increase the clearance between the Ladder and the eave. Raise empty load Make sure that the Ladder s top height is optimum for the installers to lift items off the Material Hoist onto the roof. Make sure that both the Upper and Lower Pulleys rotate freely, that the Hoisting Rope can travel up and down and is not hindered, and that the Release Cord engages and disengages normally upon pull and release. If you need to adjust the Ladder height, remove the Pulley Assembly first, change Ladder height, and re-install the Pulley Assembly afterwards. You may attach a rope to the Lowering Hole in the Bottom Tray of the Sled Assembly to aid in lowering an empty load if needed. Stop Edge Top Plate Sled Assembly should reach Top Plate without interference Use Lowering Hole if needed Page: 46 of 63
Job Site Packout Step 1. Sled Assembly Packout 1 Disconnect 2 3 Remove 4 Move Module Lock to Storage position Release Unbuckle Ladder Strap Carry Use the Carry Handle Page: 47 of 63
Step 2. Pulley Assembly Packout a 1 Climb with Lower Pulley on tool belt Clip the Lower Pulley to your safety harness b Climb c Take slack out of the Hoisting Rope as you climb up Page: 48 of 63
Pulley Assembly Packout, continued 2 Pack up Release Cord at top of Ladder Release Cord Spool Page: 49 of 63
Pulley Assembly Packout, continued 3 Disengage Upper Pulley Top Loop Upper Pulley a Un-Clip Anchor Carabiner Re-Clip to safety harness b Lower Pulley Page: 50 of 63
Pulley Assembly Packout, continued a 4 Climb down with Pulley Assembly fully clipped to safety harness b Climb down with both the Upper and Lower Pulleys clipped to your safety harness. Clip the Upper Pulley Anchor Carabiner to your safety harness. c The Hoisting Rope tail end is still on the ground. Page: 51 of 63
Pulley Assembly Packout, continued 5 Corner Loop Pack up the Pulley Assembly Upper Pulley Rolling Up the Tarp Release Cord Rope Bag Hoisting Rope, Tail End Tarp Lower Pulley 1 2 3 4 5 6 When packing up the Pulley Assembly at the end of each job, spread the Tarp and Rope Bag underneath Ladder to collect the Hoisting Rope. Clip the Carabiners to loops in the Tarp. Always leave the tail end of the Hoisting Rope tied to a fabric loop on the Tarp to keep ropes from tangling during storage. To roll up the Tarp, fold in the sides so that the side edges overlap, and then roll up the Tarp as you would a sleeping bag. The Tarp is sewn to the Rope Bag. Page: 52 of 63
Step 3. Ladder Packout 1 Detach from roof Remove the Ladder Stability Anchor 2 Collapse Ladder The Upper Assembly remains attached 3 Lower to ground 4 Detach Ladder Standoff Page: 53 of 63
Inspection and Maintenance When to Inspect The Material Hoist components should be inspected at every point the equipment is loaded or used. Use the Assembly call-outs at the beginning of this manual as a guide for how the components should appear, and to ensure that all parts and features are present. Before load-out. Personnel responsible for loading the Material Hoist for transport to job sites should inspect the equipment prior to loading on the truck or transport vehicle. Look for damage or deterioration: cracking, missing labels, frayed ropes, missing components. Clean equipment if needed. Before each setup. At the job site, the installation crew should inspect the Material Hoist prior to setup. Look for any sort of damage or deterioration: cracking, missing labels, frayed ropes, missing components. Before each use. If a Material Hoist is set up at a job site over several days, the crew should inspect the equipment prior to first use, including raising and lowering an empty load. Periodic inspections. A separate safety inspection should occur between jobs at specified intervals. Look for any sort of damage or deterioration: cracking, missing labels, frayed ropes, missing components. The periodic inspections should be done by a Competent Person specifically trained to fully inspect the Material Hoist. The OSHA definition of a Competent Person is one who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them [OSHA 29 CFR 1926.32(f)]. Do Not Repair Field crews should never attempt to repair any component of the Material Hoist that appears damaged, broken, or otherwise unfit for service. Equipment Replacement At this time, there are no allowable repairs. Equipment may be replaced, but not repaired, at the assembly level (Pulley Assembly, Sled Assembly, Upper Assembly, Ladder, Ladder Stand-Off, and Ladder Stability Anchor). To request replacement of any portion of the Material Hoist, please notify your immediate supervisor. To report any out-of-the-box defects, please notify Zep Solar Support. Zep Solar Support support@zepsolar.com +1 (415) 230-2096 Page: 54 of 63
Periodic Inspections Inspect the Material Hoist Every 6 Months In addition to field inspection before and after each use, a Competent Person should conduct a thorough inspection of all Material Hoist equipment at the specified time interval. Use the Checklists provided as an example. Always follow established procedure, and obtain the latest approved Checklist Forms from your supervisor. Complete the forms including all requested fields, including name, job title, location, and today s date. Each form must specifically identify the equipment being inspected by noting the equipment serial number for each assembly. Completed inspection forms must be maintained and accessible so that warehouse personnel can quickly produce the form upon request, and can also identify and account for the original equipment that was inspected. Forms must be maintained on file for a minimum of 2 years or the lifetime of the equipment. The Material Hoist consists of several major assemblies. Inspect all parts of the Material Hoist. For each item listed, indicate PASS or FAIL on the form, referencing this manual as needed. For each assembly, if any checklist item fails inspection, remove that assembly from service and obtain a new replacement assembly. Example Form, Filled Out Fill out headers on subsequent pages Main header shows who, where, when Each major assembly has its own checklist Reason for failing grade Note any actions taken. Page: 55 of 63
Material Hoist Periodic Inspection Checklist Inspect Every 6 Months Facility or Location Name of Competent Person Conducting Inpection Job Title Date Inspection Checklist: Ladder (No Serial Number) Pass Fail * Ladder is free from any modifications Ladder extender ropes are uncompromised Ladder rung locks are in good working condition Ladder side rails have no significant damage from wear and tear Ladder rungs are free from any deformities and/or significant bending Ladder traction feet are in good working condition * If any item is marked FAIL remove the Ladder from service immediately. Page: 56 of 63
Material Hoist Periodic Inspection Checklist, Continued Location Inspected By Date Inspection Checklist: Ladder Stand-Off Serial Number Rubber feet are attached to Ladder Stand-Off legs and are in good condition Ladder Stand-Off is free from any modifications Telescoping leg Spring Button mechanisms are functioning properly Ladder Stand-Off is free from bends or deformities Velcro strap is in good working condition and is free from any rips or tears Pass Fail * Fasteners are securely tightened and intact Quick-release Ring Pins are uncompromised * If any item is marked FAIL remove the Ladder Stand-Off from service immediately. Page: 57 of 63
Material Hoist Periodic Inspection Checklist, Continued Location Inspected By Date Inspection Checklist: Ladder Stability Anchor (No Serial Number) Velcro straps are in good working condition Ladder Stability Anchor is free from any modifications Clamp threads are intact and free from galling Attachment hardware points from Velcro straps to the clamp are intact and in good working condition Pass Fail * * If any item is marked FAIL remove the Ladder Stability Anchor from service immediately. Page: 58 of 63
Material Hoist Periodic Inspection Checklist, Continued Location Inspected By Date Inspection Checklist: Sled Assembly Serial Number Material Hoist identifying labels present and in good condition as shown in Safety Stickers on page 9. Sled Assembly is free from any modifications Module Lock mechanisms are in good working condition in all positions Top Strap and Bottom Strap in front are free from any rips or tears, and buckles are intact The Ladder Strap behind is in good working condition, and buckle is intact Haul Bag Connect Points are free from any bends or deformities Pulley Hook and Rubber Shock Absorber are in good condition and uncompromised Pass Fail * Fasteners are securely tightened and intact Rubber bumpers on Ledge are in good condition Feet: legs and rubber tips are in good condition Bottom Tray is not bent or deformed Non-Friction Plastic Sheeting is intact and uncompromised * If any item is marked FAIL remove the Sled Assembly from service immediately. Page: 59 of 63
Material Hoist Periodic Inspection Checklist, Continued Location Inspected By Date Inspection Checklist: Upper Assembly Serial Number Material Hoist identifying labels present and in good condition as shown in Safety Stickers on page 9. Upper Assembly is free from any modifications Roller Bar rotates freely Fasteners are securely tightened and intact Ladder Connect Strap is free from any rips or tears Pass Fail * Upper Assembly is free from any significant bends or deformities * If any item is marked FAIL remove the Ladder Stability Anchor from service immediately. Page: 60 of 63
Location Inspected By Date Inspection Checklist: Pulley Assembly Serial Number Visual inspection: Hoisting rope is visually free from any rips, tears, or significant fraying, visible core, bulges, or flat sections Tactile inspection with tension on the rope: Hoisting Rope is free from variations in size. No soft or hard spots are present, which could indicate damage to the rope core, or that rope has been over-stressed. Brake Handle rotates freely and is in good working condition A complete inspection of the Pulley Assembly includes both visual and tactile inspection. Pass Fail * All parts and ropes of the Pulley Assembly are clean Locking mechanisms of all Carabiners are intact and fully functional XXXXXXXX Etched Serial Number All Carabiners are present, intact, and free from cracks, sharp edges, dents, corrosion, burrs or excessive wear Metal parts (not ropes or bags) are free from any significant bending or deformities All pulleys rotate freely * If any item is marked FAIL remove the Pulley Assembly from service immediately. Page: 61 of 63
Pulley Assembly Inspection Checklist, page 2 Serial Number Release Cord Spool is present and uncompromised Upper Pulley and Lower Pulley side plates are free from cracks or dents. Lower Pulley Carabiner hole is not elongated Axel assemblies on Upper and Lower Pulleys are tight Pulley Assembly is free from any modifications Pass Fail * Carabiner Hole * If any item is marked FAIL remove the Pulley Assembly from service immediately. Page: 62 of 63
Material Hoist Periodic Inspection Checklist, Continued Location Inspected By Date Inspection Checklist: Pulley Braking System Function In order to test the braking system functionality on the Pulley Assembly, it is necessary to assemble the entire Material Hoist and raise/lower the Sled Assembly with a partial load of 50 lbs. Raise Lower Release Cord Hoisting Rope Hoisting Rope Pass Fail * Brake engages IMMEDIATELY under load, when the Release Cord is NOT being actively pulled. * If this item is marked FAIL remove the Pulley Assembly from service immediately. Page: 63 of 63