Gardner Denver VM 135 Use and care manual

H4960700 Date 20.11.08 Issue 002 1
VM 135
Operation, Safety
& Maintenance Manual
Gardner Denver UK Ltd
P O Box 468, Cross Lane, Tong, Bradford BD4 0SU
Tel: [phone] Fax: [phone]

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SAFETY
Throughout this manual there are various warnings of dangers to be avoided in
the use of the platform. It is not possible to list every danger. The prevention of
accidents is the responsibility of the operator by ensuring safe working
practices are observed at all times.
Only properly trained operators should be allowed to use the platform. Platform
operators should ensure that they have a means of communication with them at
all times.
MISUSE OF THE PLATFORM AND/OR DISREGARD OF SAFETY
CAN RESULT IN DEATH OR SERIOUS INJURY
WELDING
This vehicle has sensitive electronic equipment installed.
If any electric welding is undertaken on this vehicle or platform,
then the earth clamp must be fixed to a good clean
earth point within 1 metre of the welding point.
Where this is not possible, then Gardner Denver UK Ltd Service
department MUST be called to disconnect the electronics
prior to any electric welding.

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INDEX
INTRODUCTION 4
ENQUIRIES 4
WARRANTY STATEMENT 5
TRAINING 6
TERMINOLOGY 7
SPECIFICATION AND CONSTRUCTION 8
OPERATING INSTRUCTIONS 11
EMERGENCY OPERATION 19
SAFETY RULES 20
SERVICE INSTRUCTIONS 22
INSPECTION AND TESTS 27
TROUBLESHOOTING 28
PARTS ORDERING PROCEDURE 30
ILLUSTRATED COMPONENT LAYOUT AND PARTS LIST 31

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INTRODUCTION
The VM135 is a vehicle mounted aerial work platform and is one of a comprehensive
range designed and manufactured by Gardner Denver UK.
These platforms are designed for installation on a variety of chassis-cab commercial
vehicles.
The twin boom configuration with additional tele–boom section allows excellent
manoeuvrability in confined spaces. The machine incorporates standard features
specifically designed to ensure operator confidence and ease of operation.
This manual is intended to assist the owner/operator in gaining a thorough
understanding of the safe operation of the machine, its capabilities and the routine
maintenance necessary.
Gardner Denver UK operate a policy of continuous improvement and reserve the right to
change specification and equipment without notice. Therefore, some illustrations or text
within this manual may differ from your machine.
ENQUIRIES
In case of any query concerning your machine, contact the service manager at the
address below quoting the serial number of the unit.
The serial number is marked on a plate fitted on the nearside of the column or chassis.
The Service Manager
Gardner Denver UK
P O Box 468
Cross Lane
Tong, Bradford
West Yorkshire
BD4 OSU
Tel: [phone]
Fax: [phone]

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GARDNER DENVER UK LTD
WARRANTY STATEMENT
The Gardner Denver UK Powered Access platform is engineered and designed to
perform as stated on published specifications. Only quality material and workmanship
are used in the manufacture of this product. With regular maintenance and periodic
repair service, the equipment will provide excellent service.
The parts of the Priestman lift are warranted for one year from date of registration. The
warranty is issued only to the original user and promises that these products are free
from defects in material and factory workmanship when serviced, and operated under
normal conditions, according to the manufacturer’s instructions.
Gardner Denver UK Ltd’s obligation under this warranty is limited to correcting without
charge, at one of its facilities or authorised distributors, any part or parts thereof,
transportation charges prepaid, within one year after being put into service, and which
upon examination shall disclose to the manufacturer’s satisfaction to have been
originally defective.
Fulfilment of these obligations shall be by correction of such defects by Gardner Denver
UK Ltd, or by supplying replacements parts. Labour incurred will be paid at standard
hours after return of the faulty parts and agreement by Gardner Denver UK Ltd.
This warranty shall not apply to any of the manufacturer’s products which must be
replaced because of normal wear, which have been subject to misuses, negligence or
accident, or which shall have been repaired or altered outside of the manufacturer’s
factory unless authorised by the manufacturer.
The manufacturer shall not be liable for loss, damage, or expense directly or indirectly
from the use of its product or from any cause.
The above warranty supersedes and is in lieu of all other warranties, expressed or
implied, and of all other liabilities or obligations on part of manufacturer. No person,
agent or dealer is authorised to give any warranties on behalf of the manufacturer nor to
assume for the manufacturer any other liability in connection with any of its products
unless made in writing and signed by an officer of the manufacturer.

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TRAINING
It is essential that only properly trained personnel are allowed to use Mobile Elevating
Work Platforms.
AN UNTRAINED OPERATOR SUBJECTS HIM OR HERSELF AND OTHERS TO RISK
OF DEATH OR SERIOUS INJURY.
GARDNER DENVER UK LTD can undertake training in the correct use and
maintenance of platforms.
To arrange for training to IPAF Standards, contact:-
The Service Manager
Gardner Denver UK Ltd
P O Box 468
Cross Lane
Tong
Bradford
West Yorkshire
BD4 0SU
Tel: [phone]
Fax: [phone]

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TERMINOLOGY
1. BASKET
2. CRADLE
3. LEVELLING CYLINDER – SLAVE
4. TELE - BOOM
5. TELE - CYLINDER
6. BASE LINK
7. MIDDLE BOOM
8. MIDDLE CYLINDER
9. BASE BOOM
10. BASE CYLINDER
11. ‘A’-FRAME
12. LEVELLING CYLINDER-MASTER
13. SLEW DRIVE
14. SUBFRAME
15. STABILISER LEGS
16. STABILISER CYLINDERS
17. CONTROL PANEL
18. HYDRAULIC MANIFOLD-BOOMS/SLEW
19. HYDRAULIC MANIFOLD-STABILISERS
20. ACCESS LADDER
21. BELLCRANK
22. WALK-IN BASKET (OPTIONAL)

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SPECIFICATION
Performances Metric Imperial
Maximum working height 13.50m 44' 4"
Maximum height to cage floor 11.50m 37' 9"
Maximum outreach 6.4m 21' 0"
Safe working load ** 200 kg 440 lb
Hydraulic System
Hydraulic pump Gear type
Hydraulic system pressure (Working) 130 bar 1885 psi
Hydraulic system pressure (Maximum) 200 bar 2900 psi
Maximum flow rate 7.0 ltrs/min 1.5 gpm
Suction filter 125 micron (no
bypass)
Maximum operating temperature 80 C 140 F
Hydraulic reservoir capacity 25 ltrs 5.5
gallons
Hydraulic oil grade ISO 32
Auxiliary hydraulic power DC Power Pack
Electrical system 12v DC
Dimensions and Weight
Overall length * 4.4m 14' 5"
Overall width 1.8m 5' 11"
Overall height * 2.9m 9' 6"
Overall weight * (including platform,
driver, passenger and full fuel tank) 3255 kg 7176 lbs.
Limitations of Use
Max manual force at basket 400N
Max wind speed 12.5m/s
Max inclination downhill 5º
Max inclination uphill 8º
Max lateral inclination 2º
Temperature operating limits -10º to +30º
Vibration levels at the work platform are less than 2.5m/s².
(Based on Land Rover 110" Pick-up)

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CONSTRUCTION
SADDLE ASSEMBY
Manufactured from 5mm steel plate the saddle assembly has an integral hydraulic oil
reservoir, access to which is via a removable cover. The saddle assembly is mounted
directly onto the sub chassis.
STABILISERS
The platform is equipped with four hydraulically powered stabilisers. They are enclosed
in removable box section legs that are part of the saddle/subframe assembly and when
stowed are within the vehicle width.
Each stabiliser may be independently operated from the control valve, each leg has
sufficient travel to level the platform on uneven ground.
BOOM STRUCTURE
The structure consists of two articulating booms and one telescopic boom fabricated
from structural steel. The platform has a wide operating range with movement limited by
ram stroke. The full payload can be supported in all positions of the booms.
HYDRAULIC CYLINDERS
Double acting hydraulic cylinders control the raising and lowering of the boom structure.
The cylinders are manufactured from honed tube and are fitted with hard chromium
plated piston rods.
SLEWING MECHANISM
360º non-continuous slewing is provided by means of a worm drive slew ring. This
combination is self-locking when stationary and gives precise control during operation. A
manual rotation facility is provided for use in the event of either a loss of hydraulic power
or engine failure.
CAGE LEVELLING
A master / slave hydraulic cylinder arrangement ensures positive leveling of the
personnel cage in all positions.
PERSONNEL CAGE
For two-man operation a precision moulded polyethylene cage is supplied as standard, a
moulded handrail is incorporated along the top edge of the cage. Two safety harness
anchor points are provided inside, which conform to EN795. The cage is electrically
insulated to 1kv. The work platform is not intended for live line working.

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NOISE LEVELS
The platform power is provided by the vehicle engine driving a hydraulic pump. The unit
operates at the same noise level as the carrier vehicle.
Noise level at the operating position is approximately 70dbA.
VIBRATION
No vibration is present at the operating position that would constitute a danger to the
operator.
POWER SUPPLIES
The platform is hydraulically powered by a pump driven by a geared power take-off unit.
Electrical power for the platform is derived from the vehicle's electrical system and is
energised simultaneously with the engagement of the hydraulic power source.
SAFETY INTERLOCK
To ensure the correct sequence of platform operation, a stabiliser/boom interlock system
is fitted to achieve the following conditions:
1) The booms cannot be operated until stabilisers are correctly deployed.
2) The stabilisers cannot be operated unless the booms are correctly stowed.
HYDRAULIC LOCK VALVES
Each hydraulic cylinder is fitted with an integral lock valve which prevents movement in
the event of a hydraulic hose failure.
BACK-UP POWER
Back up power for all functions is provided by a DC motor driven pump unit.
The vehicle battery must be in good condition for this system to work.
MODIFICATION
The platform must not be modified in any way which changes its stability, or would
deviate from the original type approved design. A variant type approval from a notified
platform approval body is required in this case.

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OPERATING INSTRUCTIONS
DAILY INSPECTION
Before leaving the depot for the day’s work, it is recommended that the following
procedure be carried out:
1) Inspect the vehicle and platform for overall integrity, paying particular attention to
structural members, hydraulic lines, and electrical cables.
.
2) A safe un-manned functional test of the platform should be performed using the
ground pendant control. Space permitting, the booms should be fully extended
and the slew operated through full travel to confirm function.
3) Check that tyre pressures conform to vehicle manufacturer's specifications, as
this can affect the stability of the platform.
4) Check the oil level in the hydraulic reservoir with the stabilisers and booms
stowed and the vehicle on level ground. Correct level is to the maximum marks
on the gauge.
5) Check the vehicle fuel level, and that the battery and alternator are in good
condition.
6) Carry out other routine daily checks on the vehicle as detailed in the
manufacturer’s manual.
THE OPERATING SITE
Select a site for the vehicle from where the platform will reach the required work area. A
visual inspection of the operating site shall be made before setting up the machine,
paying particular attention to: -
1) Ability of the ground to sustain jacking loads. It may be necessary on unmetalled
roads to provide load-spreading pads in order to reduce the ground pressure. Be
aware of possible changes in ground conditions, particularly those caused by
water logging. Avoid manhole covers, drain gullies, cellar grilles etc. Typical
maximum stabiliser ground load is 1500kg.
2) Overhead obstructions
Ensure adequate clearance around and above the platform, paying particular
attention to overhead cables,
3) Gradients and ground flatness
Where the platform is required to operate on an incline, It is essential that:-
i) The vehicle faces uphill, and
ii) The booms are operated on the uphill side only.
Overtravel is provided on each stabiliser leg to enable the platform to be levelled
on cambers which slope across the vehicle. Refer to section "Stabiliser Control"
in the next section with regard to the levelling procedure.
3) Do not operate the platform in severe weather conditions and in particular ensure
that the prevailing wind strength does not exceed 12.5 m/sec, Beaufort scale 6.
Refer to the wind strength section in "Safety Rules" for guidance

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HYDRAULIC POWER – PTO (Power Take-Off)-(Landrover)
The geared power take off unit is engaged by a cable-operated lever. Engagement of
the PTO unit is as follows:-
1. Set the transfer gearbox to neutral position, diff lock selected.
2. Depress clutch and engage 5th gear.
3. Move PTO lever to engage the PTO.
4. Release the clutch pedal.
An amber warning light on the dashboard will become illuminated to indicate that the
PTO unit is in operation. The platform cannot be operated until the control knob is
engaged.
VEHICLE LEVELLING
The hydraulic stabilisers are controlled by hand operated valves, mounted on the
nearside of the platform pick-up body above the wheel arch.
Indicator lamps shows whether stabilisers are in stowed or set conditions:-
Red = non-stowed lamp in cab
Green = stabilisers correctly deployed (lamp is on side face of control panel.
Each stabiliser can be controlled independently to allow for levelling on uneven ground.
To lower the stabilisers and level the vehicle:-
1. Ensure that the area surrounding the stabilisers is clear.
2. Operate handbrake and chock the wheels.
This is critical when operating on a gradient.
3. With the PTO engaged, operate the stabiliser valve to lower the stabilisers to
ground level.
4. Continue to lower the front stabilisers until the weight is taken off the vehicle's
suspension, fully extend the front stabilisers for maximum stability, leave one
‘short’ to level the platform if required. Continue extending the rear legs to level
the vehicle and illuminate the leg-set light on the panel.

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The platform must not be operated under any circumstances if the lateral
slope exceeds 2º.
If the platform is to be operated on a hill, it is permissible to allow up to
5º longitudinal slope as long as the vehicle faces uphill and the booms are
only operated on the uphill side.
To stow the stabilisers:-
Raise them until they are fully retracted and check that the red NON STOWED indicator
light (on the vehicle dashboard) is out.
NOTE: When the booms and stabilisers are correctly stowed and the PTO disengaged,
all lights will be out.
If specified, the platform may be fitted with interlocks, which will stop the engine if the
power take-off is not disengaged or the platform equipment is not correctly stowed when
the vehicle handbrake is released.

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WALK IN BASKET
If specified the work platform can be provided with an opening door arrangement for
easy access. This door has a simple hinge and latch arrangement and must always be
latched closed before the platform is operated. The integrity of the door and latch should
be checked on a daily basis to ensure safe operation.
A grab handle is provided on the outside of the cage to assist entry. This handle is not a
lifting point and must not be used for anything other than helping operators climb in and
out of the basket.

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PLATFORM CAGE CONTROLS

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PLATFORM CAGE CONTROLS
Dual axis joysticks in the cage, electrically control proportional valves which operate the
four principal functions of the platform. Simultaneous boom movements can be
performed at reduced speed. For smooth operation the controls have an automatic soft
start / stop feature. The controls are protected against accidental use by an integral
deadman switch.
OPERATION
Once the stabilsers are correctly deployed the platform can be operated from the cage.
Operators must always wear a work restraint harness. They must ensure that their
combined weight plus tools and equipment does not exceed 200Kg, which is the
maximum payload for this type of platform.
PUSH BUTTON CONTROLS.
1. D.C Power
This pushbutton when pressed and held down stops the vehicle engine and
energises the DC hydraulic power unit, the cage controls can then be operated
as normal. This system relies on the vehicle battery being in good condition,
prolonged use of this system will flatten the battery.
2. Emergency Stop
This cuts the power from the hydraulic circuit. The engine will also stop if the legs
are deployed. Releasing the push-button will restore full hydraulic power (after re-
starting engine).
3. Engine Start/Engine Stop
This switch when turned starts (I) or stops (O) the vehicle engine.The vehicle
ignition must already be on in the cab. The engine must be running and the PTO
engaged to run the hydraulic pump.
4. Cage Load
A warning LED on the control panel illuminates, and a buzzer sounds, when the
permitted work platform load is exceeded. The platform controls are disabled until the
load is removed.

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Ground Control Pendant
A ground level control pendant is provided to allow remote operation of the platform. This
must be activated using the key switch on the column before use.
Note: The operator in the cage has no control of the booms with the system in ground
control mode.
Take extra care when operating the booms from ground level to avoid collision with
overhead objects.
Note:- The cage trim operation only works when the booms are in stow
GROUND CONTROL PENDANT

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OPERATING METHOD
Before operating the platform the stabilisers must be deployed, they should be extended
to lift the vehicle 50 to 75mm above its normal ride height. Once the stabiliser legs are
deployed and the leg set light is illuminated, the boom set can be operated. To enter the
basket drop the vehicle tail gate and select the platform ground controls, fully extend the
tele-boom and lower the cage ladder. Set the platform controls to cage and climb into
the basket, the cage controls can now be used to raise the platform. At low level the slew
function is disabled to prevent damage to the vehicle and platform by operator error.
Ensure the ladder is stowed after entry.
Once the mid boom is parallel with the base boom all cage controls can be used. Care
should be taken to avoid collisions between the booms and surrounding objects, and
also roof beacons if fitted.
Returning to the stow position is the reverse of the above procedure. Before stowing the
machine ensure that the areas where personnel or equipment could be crushed are
clear – boom rest, cage rail, rear of vehicle, etc.
Safety rules must be followed at all times.
LOAD SENSING SYSTEM
The VM135 platform is equipped with a load sensing system to protect the operators
from risk of overturning, the system monitors the load in the basket and limits the
payload to 200kg. If the maximum value is reached the machine is brought to a halt and
an LED lights on the cage controls, and a buzzer sounds. All functions are inhibited until
the overload is reduced below the safe operating limit. When this is done full control is
restored.
PREPARATION FOR TRAVELLING
Ensure the booms are fully stowed, close the vehicle tail gate and fully raise the
stabiliser legs.
Ensure all equipment in the vehicle load is area is secured for travel.
Raise all legs until the red NON STOWED indicator light in the cab goes out.
NOTE: When the booms and stabilisers are correctly stowed and the PTO disengaged,
all lights will be out and the vehicle may be driven away.
The Platform is fitted with interlocks which will sound a buzzer in the cab if the power
take-off is not disengaged, or the platform equipment is not correctly stowed when the
vehicle handbrake is released. A warning light will also illuminate.

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EMERGENCY OPERATION
EMERGENCY SLEWING-GDK SLEW WORMDRIVE (EARLY MODELS)
The platform may be slewed manually by cranking the hydraulic motor-input shaft, this is
achieved by fitting the hand crank to the hexagon drive shaft (17mm A/F).
To slew the platform clockwise, turn the hand crank anti-clockwise and vice versa.
EMERGENCY SLEWING

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EMERGENCY SLEWING-IMO SLEW WORMDRIVE
The platform may be slewed manually by cranking the slew drive directly.
To do this remove the grease cap.
Remove 4xM6 screws
Grease Cap
19mm Socket
To slew the platform clockwise, turn the hand crank
anti-clockwise and vice versa.
Turn drive shaf
t