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Material HoistOperations Manual

Date last exported: June 15, 2015 9:13 AM

Document #800-1668-001 Rev B

! 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.

Load Capacity: 100 lbs

Complies with:

OSHA 1926.552 ANSI/ASSE A10.5

Lightweight material hoist

Not for lifting people

Page: 2 of 63 Document # 800-1668-001 Rev B zepsolar.com Date last exported: June 15, 2015 9:13 AM

Material Hoist: Lightweight Material Hoist for Residential PV Installations

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IMPORTANT SAFETY INFORMATIONREAD AND FOLLOW

Dangers, Warnings, Cautions, and Notices

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

• 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.

Definitions

! Dangers

! 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.

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.



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Dangers, Warnings, Cautions, and Notices, continued

• 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.

• 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.

! Cautions

Notices

• 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.



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User Notes

Material Hoist operators, crews, or other field users may use this page to add their own notes if needed.



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Contents

Dangers, Warnings, Cautions, and Notices . . . . . . . . . . . . . . . . . . . . . . . . 2

About the Material Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Load Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Ladder Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Major Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Safety Stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Detail Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Ladder Stand-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Sled Assembly, Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Sled Assembly, Side and Back Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Upper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Ladder Stability Anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Ladder Usage Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Rooftop Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Recommended Best Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Parapets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Gable Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Adjusting for Roof Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Summary of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Raising and Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Ladder Leveling Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Loading PV Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Loading Haul Bags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Loading Triangle Array Trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Loading Array Skirts and Spanner Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24



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Module Lock Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Off-Loading On Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Setting Up the Material Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Attach Ladder Stand-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Attach the Upper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Unpack the Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Job Site Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Step 1. Secure Ladder to Building . . . . . . . . . . . . . . . . . . . . . . . . . . 31Step 2. Attach Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Step 3. Attach Sled Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Testing at Job Site Prior to Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Job Site Packout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Step 1. Sled Assembly Packout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Step 2. Pulley Assembly Packout . . . . . . . . . . . . . . . . . . . . . . . . . . 48Step 3. Ladder Packout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54When to Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Do Not Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Equipment Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Periodic Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Material Hoist Periodic Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . 56

Inspection Checklist: Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Inspection Checklist: Ladder Stand-Off . . . . . . . . . . . . . . . . . . . . . . . . . . 57Inspection Checklist: Ladder Stability Anchor . . . . . . . . . . . . . . . . . . . . . . 58Inspection Checklist: Sled Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Inspection Checklist: Upper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Inspection Checklist: Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Inspection Checklist: Pulley Braking System Function . . . . . . . . . . . . . . . . 63



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About the Material Hoist

Safety Standards

Ladder Requirements

Load Capacity

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.

The following standards apply to the Material Hoist:• Material Hoist section of OSHA 1926.552 • ANSI/ASSE A10.5 – Safety Requirements for Material Hoists

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.

The Material Hoist is rated to lift a maximum of 100 lbs.



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Major Assemblies

Pulley Assembly

Ladder

(Exclusion Zone)

Sled Assembly

Upper Assembly

Ladder Stand-Off

Ladder Stability Anchor (Underside view)



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Sled Assembly, location: Pulley Cover

Upper Assembly location: underside of Top Plate

Safety StickersThe 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.

Safety StickerPart No. 850-1538-001

• 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.

• “No Riders Allowed”

• System Specified Load Rating: 100 lbs

• For use by SolarCity employees ONLY

WARNING!



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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

DANGER!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



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Detail Assemblies

Traction Feet

Bottom Section

Feet

Legs

Quick Release Pins

Rung Bracket

Part No. 850-1534-001

Rung Hook

Velcro Rung Straps

Leg Telescoping

Leg Rotation

Pull Quick Release Pin to rotate Leg

Spring Button

Top Section

Ladder

Ladder Stand-Off

Side Rails (Interlocking)

Rungs

Rung Lock (example)



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Carry Handle

Haul Bag Hangers

Non-Friction Plastic Sheathing

(Rubber Shock Absorber, behind Pulley Hook bracket)

Non-Friction Plastic Sheeting

Pulley Cover Detail

Sled Assembly, Front View

Module Lock

Single Module Hook

Side Wall

Pulley Hook

Top Strap

Bottom Strap

Pulley Cover

Ledge

Lowering Hole

Feet

Bottom Tray

Stop Edge

Part No. 850-1523-001



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Module Lock

Module Lock

Main Plate

Top Strap

Bottom Strap

Ladder Strap

Ladder Strap

Ladder Strap

Side Brace

Ledge

Carry Handle

Carry Handle

Sled Assembly, Side and Back Views

LeftRight

Back



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Upper Assembly

Front

TopLadder Connect Strap

Top Loop Slot

Top Plate

Staging Tray

Rung Slots

Roller Bar

Part No. 850-1531-001



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Clamp

Swivel Clip

Velcro Ties

Usage Notes• 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.

Ladder Stability Anchor



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Upper Pulley Release Cord +

Spool

Spool

Brake Handle

Hoisting Rope

Lower Pulley

Thimble

Hoisting Carabiner

Rope Bag

Tarp (Sewn to Rope Bag)

Corner Loops

Anchor Carabiner

Top Loop

Pulley Assembly

Part No. 850-1533-001

The Pulley Assembly ships with its own set of user instructions.



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18-24” clearance

Ladder Stand-Off

Roof gutter Ladder clearance from gutter

No Climbing Check Stability Engage Rung LocksExclusion Zone

Ladder Usage NotesFollow 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

Recommended Best Practices

6” clearance



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Ladder Usage Notes, continued

Shallow pitch: Both Legs on roof

Steep pitch: One Leg braced on side eave, one Leg on roof

Rotating and telescoping legs

Gable Edge

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.

Allow clearance for the Sled Assembly to reach the topmost point, where the Sled Assembly Stop Edge meets the Upper Assembly Top Plate.

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.

Parapets Shown: 1st hole



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Flat

15 Degrees

45 Degrees

4th hole

3rd hole

2nd hole

Adjusting for Roof Pitch

Ladder Usage Notes, continued

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.



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Summary of Operation

Raising and LoweringTo 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.

Raise Lower

Release Cord

Work gloves

Hoisting Rope

Hoisting Rope

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.



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Ladder Leveling Attachments

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.

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).

Ladder Traction FeetExample showing use of a

ladder leveling attachment

Sled Assembly Feet should never travel below this line

Sled Assembly Feet

Summary of Operation, continued



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Loading

Loading PV Modules

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).

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

Landscape orientation

Side Brace Detail

Second module rests here

First module rests here



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Center the load

Front View Side View

Loading Haul Bags

Loading Triangle Array Trims

Maximum 100 lbs

Load up to 3 Triangle Array Trims at once

Balance the load

Secure with Top Strap

Up to 3 Triangle Array Trims fit onto the Ledge



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Maximum 100 lbs

Loading Array Skirts and Spanner Bars

Secure with Top and Bottom Straps

Array Skirt 1x Spanner Bar Only

Place longer items in appropriately sized haul bag



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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.

• 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.

1

3

4

2

1

1

2

2

3

3

4

4

Storage

Double Lock

Single Lock

Open

Top View

(2 modules)

(Packout)

(Shown in Storage position)

(Non-module loads or lowering empty)

(1 module)



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Front Back

1

2

3

4

Storage

Double Lock

Single Lock

Open

Module Lock Positions, continued

Single Module Hook fits in the Zep Groove of PV module frame

Top View

Front View



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Off-Loading On RoofRest 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.

Raise Module Lock and rotate 90 degrees counterclockwise.

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.

1

1 2

2

Module Lock

Off-Loading PV Modules



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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.

Wrap the Velcro straps around the upper rung.

Rotate the upper portion of the Ladder Stand-Off until the Rung Bracket meets the upper rung.

Rung Hook

Velcro Straps

Rung Bracket

Initial assembly can either be done ahead of time, or at the job site.

Setting Up the Material Hoist

Attach Ladder Stand-Off

1

3

2

4



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Rung Slots fit over the 2 topmost rungs on top Ladder section

Fasten Ladder Connect Strap snugly around the topmost rung

Roller Bar hangs just below the second rung

Attach the Upper Assembly

Ladder Connect Strap

Setting Up the Material Hoist, continued

This can also be done safely by someone on the roof, provided that the person is fully harnessed using appropriate Fall Protection PPE.



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Unpack the Pulley Assembly

Upper Pulley

Anchor Carabiner clips to fabric loop for storage

Hoisting Carabiner clips to fabric loop for storage

Minimize rope slack between Upper and Lower Pulleys when packing for storage

Rope BagTail end of Hoisting Rope stays tied to fabric loop on Tarp, at all times

Lower Pulley

Release Cord wound on Spool

Setting Up the Material Hoist, continued



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Job Site Setup

Ladder Traction Feet: Leveled, on stable surface

Ladder Stability Anchor

Ladder Stand-Off

! 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 BuildingChoose 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.



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Step 2. Attach Pulley AssemblyAttach the Pulley Assembly after the Ladder is already extended and secured to the building.

Un-clip

Upper Pulley

Rope Bag

Tarp

Release Cord in Spool

Lower Pulley

Un-clip

Unpack and un-clip the Pulley Assembly1Unpack 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.



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! WARNING: If Pulley Assembly appears to be broken or damaged, or the Hoisting Rope is frayed, do not use.

Clip Upper Pulley to your safety harness2

The Hoisting Rope tail end should remain clipped to a fabric loop on the Tarp, which is on the ground

The Release Cord should remain wound on Spool

Attach Pulley Assembly, continued

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.

Ropes can become tangled when stored. Un-twist the Hoisting Rope if needed. It should appear as shown.



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Climb up to the Upper Assembly3




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Un-clip Upper Pulley4

ab


At the top of the Ladder, unhook the Upper Pulley from your tool belt while still maintaining 3 points of contact with the Ladder.



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b

Weave Pulley Assembly through Ladder5

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.

Roller Bar


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.



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Clip Upper Pulley to Top Plate6

a b c

d e

The Hoisting Rope tail end reaches all the way to the ground

Lay the Anchor Carabiner flat

Top Loop


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.



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Weave Release Cord back through and down7

The Hoisting Rope weaves in front of the Roller Bar, while the Release Cord passes behind

Roller Bar


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

b

Lower Pulley stays attached.



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Lower Pulley stays attached.

Clip Lower Pulley to your safety harness8


To prepare for descent climbing down the Ladder, use the Hoist Carabiner to clip the Lower Pulley to your safety harness.



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Descend while pulling Release Cord9

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



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Descend one step at a time10


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.



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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.

Wrap Release Cord onto Spool11




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Step 3. Attach Sled Assembly

Position Sled Assembly1

If the Sled Assembly appears to be broken or damaged, do not use.

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.



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Connect Lower Pulley2

Lower Pulley

Hoist Carabiner

Ensure that Hoisting Rope slides freely

Pulley Hook

Attach Sled Assembly, continued

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.



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Always secure Ladder Strap when using the Material Hoist. The Ladder Strap metal attachments rotates down for storage.

Secure Ladder Strap3

Attach Sled Assembly, continued



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Testing at Job Site Prior to UseRaise 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.

Top Plate

Stop Edge

Sled Assembly should reach Top Plate without interference

Use Lowering Hole if needed



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Disconnect Release

Remove

Move Module Lock to Storage position

Carry

Use the Carry Handle

Unbuckle Ladder Strap

Step 1. Sled Assembly Packout

1 2

3 4

Job Site Packout



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Step 2. Pulley Assembly PackoutClimb with Lower Pulley on tool belt1

Clip the Lower Pulley to your safety harness

Climb

Take slack out of the Hoisting Rope as you climb up

a

b

c



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Pulley Assembly Packout, continued

Pack up Release Cord at top of Ladder

Release Cord

Spool

2



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Anchor Carabiner

Re-Clip to safety harness

Un-Clip

Upper Pulley

Top Loop

Lower Pulley


3

a

b



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NLY Climb down with Pulley Assembly fully clipped to safety harness

Clip the Upper Pulley Anchor Carabiner to your safety harness.

Climb down with both the Upper and Lower Pulleys clipped to your safety harness.

The Hoisting Rope tail end is still on the ground.


4

a

b

c



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Tarp

Corner Loop

Upper Pulley

Rope BagHoisting Rope, Tail End

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.Release Cord

Lower Pulley

Pack up the Pulley Assembly

Rolling Up the Tarp

1 2 3 4 5 6


5



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Step 3. Ladder Packout

The Upper Assembly remains attached

1

3 4

2Detach from roof

Lower to ground Detach Ladder Standoff

Collapse Ladder

Remove the Ladder Stability Anchor



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Inspection and Maintenance

When to Inspect

Do Not Repair

Equipment Replacement

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.

Field crews should never attempt to repair any component of the Material Hoist that appears damaged, broken, or otherwise unfit for service.

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 [email protected] +1 (415) 230-2096

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)].



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Periodic InspectionsInspect the Material Hoist Every 6 Months

Example Form, Filled Out

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.

Main header shows who, where, when

Each major assembly has its own checklist

Fill out headers on subsequent pages

Note any actions taken.

Reason for failing grade



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Material Hoist Periodic Inspection Checklist

Inspection Checklist: Ladder

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

Pass Fail *

If any item is marked “FAIL” remove the Ladder from service immediately.*

Inspect Every 6 Months

Facility or Location

(No Serial Number)

Name of Competent Person Conducting Inpection

Job Title

Date



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Inspection Checklist: Ladder Stand-Off

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

Fasteners are securely tightened and intact

Quick-release Ring Pins are uncompromised

Pass Fail *

If any item is marked “FAIL” remove the Ladder Stand-Off from service immediately.*

Material Hoist Periodic Inspection Checklist, Continued

Location Inspected By Date

Serial Number



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Inspection Checklist: Ladder Stability Anchor

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.*



(No Serial Number)



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Inspection Checklist: Sled Assembly

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

Bottom Tray is not bent or deformed

Non-Friction Plastic Sheeting is intact and uncompromised


Rubber bumpers on Ledge are in good condition

Feet: legs and rubber tips are in good condition

Pass Fail *

If any item is marked “FAIL” remove the Sled Assembly from service immediately.*



Serial Number



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Inspection Checklist: Upper Assembly

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


Ladder Connect Strap is free from any rips or tears

Upper Assembly is free from any significant bends or deformities

Pass Fail *

If any item is marked “FAIL” remove the Ladder Stability Anchor from service immediately.*



Serial Number



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Etched Serial Number

Inspection Checklist: Pulley Assembly

If any item is marked “FAIL” remove the Pulley Assembly from service immediately.*

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.

A complete inspection of the Pulley Assembly includes both visual and tactile inspection.

Brake Handle rotates freely and is in good working condition

All parts and ropes of the Pulley Assembly are clean

Locking mechanisms of all Carabiners are intact and fully functional

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

Pass Fail *


Serial Number

XXXXXXXX



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Pulley Assembly Inspection Checklist, page 2

Carabiner Hole

If any item is marked “FAIL” remove the Pulley Assembly from service immediately.*

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 *

Serial Number

Release Cord Spool is present and uncompromised



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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

Brake engages IMMEDIATELY under load, when the Release Cord is NOT being actively pulled.

Pass Fail *

If this item is marked “FAIL” remove the Pulley Assembly from service immediately.*



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