Unilift 538 User manual

Univ er sal Cr ane and
Pe r sonn el Lif t
OPERATOR'S
MANUAL
Publication No. 4500360-1/0410
A PRODUCT OF:
Champ-UniLift
850 State Hwy 55
Brooten MN 56316
www.ChampUniLift.com
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4590004 03/06
OPERATOR SAFETY
Training Checklist For The 538 UniLift
Please review the Checklist items. Initial each item then sign and date this Checklist below.
The ONLY person permitted to operate the 538 UniLift shall be the person who has
received instructions prior to rental.
I have received instructions and understand the operation and proper use of the 538
UniLift controls. I agree to use the 538 UniLift in a manner consistent with its intended
application.
I have received instructions and understand the use of the outriggers to set up and level
the 538 UniLift.
I understand that the maximum bucket capacity of the 538 UniLift is 300 lbs.
I have received instructions and understand the use of the Emergency Manual Lowering
Valve and other emergency procedures.
I will not attempt to alter or disable any safety devices, guards, or interlocks.
I have been shown the location of the Operators Manual, and was instructed to read the
manual prior to operation.
I understand that the 538 UniLift is NOT INSULATED and shall not be used within 10
feet of any power lines.
I will wear the body harness, with the 4 ft. lanyard attached, at all times when operating
the 538 UniLift from the bucket.
I have received instructions and understand the procedures for stowing the boom and
outriggers, and locking the bucket in place before transporting the 538 UniLift.
Before transporting the 538 UniLift, I will verify that the tongue is securely attached and
locked to a 2-inch hitch ball, safety chains are in place, and the trailer lights are operable.
Signed: Date:
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4590004 03/06
EQUIPMENT USE AND SAFETY
Safe Setup And Use Of The 538 UniLift
Please review the following setup and use instructions before operating the 538 UniLift.
1. Make sure the 538 UniLift has been safely set up away from power lines (maintain at least
10 feet of clearance).
2. Disconnect the 538 UniLift from the transporting vehicle before setup. If the unit is parked
on a slope, chock the wheels or set the outriggers first, to prevent rolling.
3. Extend and set up the outriggers (setup instructions are located at each outrigger). Make
sure the outriggers are set on solid footing. The green light on the lower control panel
indicates that the outriggers are properly set. NOTE: If the green indicator light is lit
before all four outriggers are set, the unit is not safe to operate.
4. If the 538 UniLift is set on a slope (5° maximum), the outriggers MUST be used for leveling.
5. Make sure all electrical power cords are safely stored to prevent tangling or crushing.
6. Always wear the proper body harness, and keep the harness secured to the lanyard ring
whenever operating the 538 UniLift from the bucket.
7. DO NOT exceed the manufacturer's rated lifting capacities.
8. The lower controls are for emergency use only, when a worker is present in the bucket.
9. It is PROHIBITED and DANGEROUS to use railings, planks, ladders, or other devices in the
bucket to achieve additional working height or reach.
10. Watch for overhead obstructions when booming up.
11. Keep observers and other workers out of the work area.
12. DO NOT lift materials with the lanyard ring while operating the 538 UniLift from the bucket.
13. When using the 538 UniLift as a crane, DO NOT stand under the load.
14. Make sure the boom and outriggers are properly stowed, and the bucket is securely locked
in place before transporting the 538 UniLift.
15. DO NOT operate the 538 UniLift if it is in need of repairs.
16. Be sure to read and thoroughly understand the Operation Section in the Operators
Manual.
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4500360-1/1101
TABLE OF CONTENTS
Subject Page
DESCRIPTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-1
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
TRANSPORTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
PARKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
SETTING THE OUTRIGGERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Jack-Type.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Crank-Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
CONTROLS (Thru S/N: 2234). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
CONTROLS (S/N: 2235 & Above). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4A
Platform Control Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4A
Lower Control Station.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4A
PRE-START INSPECTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
BUCKET LOCK.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
BUCKET OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
CRANE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
SYSTEM RECHARGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
EMERGENCY CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Power “ENABLE Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Station Override Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Emergency Stop Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
EMERGENCY MANUAL LOWERING VALUE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
EMERGENCY PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
PLATFORM CONTROL STATION SWITCH FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
LOWER CONTROL STATION SWITCH FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
HYDRAULIC LINE FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
POWER FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
BUCKET OPERATOR DISABLED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
BOOSTER CABLE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
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4500360-1/1101
Page i - 1
DESCRIPTION
The UniLift Model 538 Universal Crane and Personnel Lift functions as both a personnel carrier and crane, in one unit. A
single operator can use the UniLift as a personnel carrier or a universal crane with no conversion time. The unit is also light
enough to be rolled by one person.
The UniLift Model 538 consists of the following basic components:
Figure i-1.
UniLift With Personnel Bucket Attached
ADJUSTABLE OUTRIGGERS
Outriggers are used for absorption of tipping load during use, and are manually set. Adjustable for up to three feet, the
outriggers assure that the unit can be leveled and rest firmly on solid footing. Electrical interlocks prevent lift/crane
operation until all four outriggers are fully extended and resting firmly on the ground. A green light is located on the lower
control panel, indicating that all outriggers are set up on solid footing.
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4500360-1/1101
Page i - 2 - Description
SINGLE AXLE TRAILER FRAME WITH 2" DIAMETER BALL COUPLER AND THIRD WHEEL
A torsion bar type of axle, rated at 3000 pounds, is used for road stability while towing. The 2" diameter ball coupler and
third wheel assembly are provided as standard equipment, allowing the unit to be transported to a job site and unhitched.
WARNING: DO NOT ATTEMPT TO TOW THIS LIFT WITH A HITCH BALL OTHER THAN 2". Safety chains
are also provided and shall always be attached when the unit is to be transported. Tire size is P205/75R14 with a max load
rating of 1532 Lbs. at 35 psi.
PEDESTAL AND UPPER CONTROLS
A full set of controls is provided at both the bucket and the pedestal. ENABLE-OFF-DOWN-OVERRIDE switch is located
at the bucket controls, with an override switch located at the pedestal controls. A key switch is provided at the pedestal
controls for security. A manual boom lowering valve is also provided at the base of the hydraulic pump assembly.
POWER REQUIREMENTS AND CHARGING CAPABILITIES
The unit is powered by two (2) 6 VDC deep cycle batteries, connected in series, yielding 12 VDC for approximately eight
hours of operation under typical use. A built-in 12 VDC, 30 amp battery charger is provided to restore charge to the
batteries, and is equipped with automatic cutoff when full charge is reached. The battery cutout relay permits operation while
the unit is plugged in and the batteries are recharging. (See the section on Inspection and Maintenance for more details on
battery system.)
HYDRAULIC LIFT AND TELESCOPING CYLINDERS
Aerial lift is provided by a 3" single acting cylinder, attached to the upper and lower booms. Telescoping lift is provided
by a 1-1/2" double acting cylinder, located inside the upper boom/telescoping boom assembly. The telescoping boom will
extend up to 9 feet allowing a side reach of approximately 24 feet. Hydraulic power is provided by a 12 VDC hydraulic
system, connected to the 3" lift cylinder attached to the upper and lower booms.
COUNTERWEIGHTS
Four (4) counterweights are mounted at the back of the unit to provide proper stability. These counterweights must always
remain in place when using the aerial lift.
SURGE BRAKES (OPTION)
Hydraulic brakes are available as an option. They are surge activated and use a standard 2" diameter ball coupler. A
breakaway chain is provided for emergency stopping.
LEVELING SAFETY SWITCH (OPTION)
The leveling safety switch continuously monitors the trailer for an unsafe tilt condition (exceeding 5°) during set-up and
operation. The green Trailer Level Indicator Light is on when the trailer tilt is within the 5° range. If the tilt exceeds the
limit during set-up, the controls will not operate. If an unsafe condition occurs during operation, only the "in" and "down"
functions will work.
PERSONNEL BUCKET
The fiberglass personnel bucket is gravity leveled and hydraulically dampened with positive work position locking. The
bucket is made removable for crane operation if required. Travel limits prevent continuous rotation of the boom and bucket.
A body harness is provided with each unit and shall be worn at all times when operating unit from the bucket.
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4500360-1/1101
WARNING:NEVER LIFT OVER SPECIFIED WEIGHT OR TIPPING CAN OCCUR, CAUSING
SERIOUS INJURY OR DEATH TO OPERATOR.
DANGER
ELECTROCUTION HAZARD, STAY AT LEAST 10 FEET FROM POWER LINES. THIS UNIT IS
NOT INSULATED FROM ELECTRIC SHOCK. DEATH OR SERIOUS INJURY TO OPERATORS
AND/OR BYSTANDERS CAN RESULT FROM CONTACT WITH ELECTRICAL WIRES.
Description - Page i - 3
UNIVERSAL CRANE
Two (2) anchor points are provided for lifting loads up to 500 pounds with the personnel bucket removed. The inner lanyard
ring has a 500 pound load rating with the boom fully retracted. The outer lanyard ring has a 300 pound crane-load rating
in any position. (See Figure i-2) Note: The 500 pound load rating is ONLY during crane operation, and ONLY on the
inner ring with the boom fully retracted.
Figure i-2
Personnel Lift/Crane Work Area
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4500360-1/0310
Page ii - 1
SPECIFICATIONS
GENERAL Personnel Bucket Crane
Working Height 36' (11.00 m) 31' (9.45 m)*
Rated-Platform Height 30' (9.14 m) ----
Platform Reach from Center of Rotation 24' (7.32 m) 21' (6.40 m)
Stowed Travel Height 6'-6" (1.98 m) 6'-6" (1.98 m)
Stowed Travel Width 6'-4" (1.93 m) 6'-4" (1.93 m)
6'-1" (1.85 m)† 6'-1" (1.85 m)†
Stowed Travel Length 22' (6.71 m) 22' (6.71 m)
Rated Load Capacity 300 lbs. (136 kg) 300/500 lbs. (136/227 kg) **
Shipping Weight 2750 lbs. (1250 kg)† 2750 lbs. (1250 kg)†
2950 lbs. (1340 kg) 2950 lbs. (1340 kg)
Tongue Weight 140 lbs. (64 kg) 140 lbs (64 kg)
System Operating Voltage 12 VDC 12 VDC
Minimum Temperature for Operation 0EF (-18° C) 0EF (-18° C)
Leveling Capability 10° 10°
HYDRAULIC SYSTEM
Hydraulic Fluid Dexron III
Hydraulic Fluid Capacity 16 qt. (15.1 L)
Hydraulic Tank Capacity 12 qt. (11.4 L)
Hydraulic System Rated Pressure 2500 PSI (17.24 MPa)
Normal Operation Pressure 700 PSI (4.83 MPa)
Maximum Operating Pressure 1350 PSI (9.31 MPa)***
* At point where boom hook is 8 feet from center of rotation.
** 500 lb. (227 kg) rating at full retraction only (inner arc - Figure i-2).
*** Should be 1100 PSI (7.6 MPa) on 534 Models.
† Unit with Jack-Type outriggers
MINIMUM VEHICLE TIPPING LOAD, HORIZONTALLY EXTENDED
On level ground (1-1/2 x rated load) 450 lbs. (204 kg)
On 5Eslope (1-1/3 x rated load) 400 lbs. (182 kg)
BUCKET TRAVEL
Boom Travel 0Eto + 80E(Hydraulically Operated/Electrical Limit Switch)
Top section extends 9' (2.74 m)
Rotation 350Enon-continuous with Electrical Limit Switch
NOTE: UniLift Model 538 Lift/Cranes are designed to comply with ANSI Standard A92.2. Dealers, owners, users,
operators, renters, lessors and lessees shall comply with the appropriate section(s) of ANSI Standard A92.2. Use of products
must conform to safe practice and applicable statutes, codes and ordinances. Drawings are illustrative only and do not
necessarily depict exact configuration of products offered at a particular time. Specifications contained herein are subject
to change without notice.
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DANGER
UNDER NO CIRCUMSTANCES SHOULD THE AERIAL LIFT BE USED
UNLESS THE OPERATOR IS FULLY VERSED IN THE
SAFE OPERATION OF THE MACHINE.
OPERATION INSTRUCTIONS, WARNINGS AND SAFETY INSTRUCTIONS
ARE PROVIDED IN CONSPICUOUS LOCATIONS ON THE EQUIPMENT.
DEFACED OR UNREADABLE DECALS AND SIGNS SHOULD BE REPLACED
IMMEDIATELY. REFER TO THE PARTS MANUAL FOR
THE PART NUMBERS OF DECALS AND SIGNS.
CAUTION:DO NOT MOVE THE TRAILER UNLESS THE BOOM AND BUCKET ARE
IN THEIR STORAGE POSITION AND PROPERLY SECURED.
CAUTION:NEVER OPERATE THE LIFT ON A STEEP SLOPE.
CAUTION:NEVER OPERATE LIFT UNLESS ALL FOUR OUTRIGGERS ARE
EXTENDED AND LOCKED. THE GROUND AROUND OUTRIGGER SUPPORT
PADS MUST BE SOLID. IF GROUND IS NOT SOLID, REPOSITION THE LIFT OR
PROVIDE SOLID GROUND SUPPORT.
4500360-1/1101
Page 1 - 1
OPERATION
TRANSPORTING
The UniLift must only be transported by a vehicle weighing at least 3000 lbs. Always connect the lights and safety chains,
and use safe towing practices.
The boom must be stored in the boom cradle when the trailer is in motion. A tie down strap is provided for travel and will
prevent excessive wear due to vibration and oscillation. Also, the bucket should be hinged up and locked into position. For
maximum safety, limit the towing speed to 45 MPH or less.
PARKING
Park the trailer on firm, level ground.
Operating the lift on a steep slope can cause the trailer to become unstable and tip over. Additionally, excessive loads are
induced in the rotation system. If it is necessary to work on a slight incline, it is recommended that the outriggers be jacked
to position the trailer in a level position.
DO NOT OPERATE THE LIFT ON A SLOPE EXCEEDING 5°.
Leveling Safety Switch Option - An optional leveling safety switch monitors the tilt of the trailer. When the green "Trailer
Level" lamp is lit, the unit is within the 5° range. If the tilt of the unit exceeds 5°, the green lamp goes off and allows
operation of the "in" and "down" controls only.
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4500360-1/1101
Page 1 - 2 - Operation
SETTING THE OUTRIGGERS
Jack-type
1. Disengage pin A and pull the outrigger assembly out until pin A re-engages at the furthest outward outrigger position.
Refer to Figure 1-1.
2. Grasp the top of the outrigger tube firmly. Disengage pin B and carefully slide the outrigger foot down. CAUTION -
WATCH YOUR FEET, OUTRIGGERS SLIDE DOWN RAPIDLY! Refer to Figure 1-2. Extend all 4 outriggers
and lower all 4 outrigger feet to solid footing before proceeding.
3. Insert the jacking bar, through the jack hole, into a hole in the outrigger tube. Disengage, and hold, pin B and pull or
push up on the jacking bar to lower the outrigger. Release pin B to hold the outrigger in place. Refer to Figure 1-2.
4. Jack all 4 outriggers evenly. Raise the unit 2-3 holes on one outrigger, then proceed to the next outrigger. DO NOT
OVER-EXTEND ANY ONE OUTRIGGER. OUTRIGGERS MUST BE LOWERED EVENLY, AND IN
SEQUENCE. The unit must be level with the weight of the unit supported by all 4 outriggers. Note: When outriggers
are set on a slope (5° maximum), the outriggers on the downhill side will be extended further than those on the uphill
side in order to level the lift.
5. Continue the jacking sequence until both wheels are a minimum of 1/2" above the surface. The green lamp on the lower
control panel will light when all four outriggers are properly set. This green lamp indicates a ready operational condition.
CAUTION - BE SURE PIN A AND PIN B ARE FULLY RE-ENGAGED ON ALL 4 OUTRIGGERS BEFORE
OPERATING THE UNIT.
6. Store the outriggers using the reverse sequence. CAUTION - MAKE SURE THE BOOM IS IN THE RETRACTED
TRAVELING POSITION BEFORE STORING THE OUTRIGGERS.
Figure 1-1
Extending Outriggers
Figure 1-2
Jack-Type Outriggers
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Figure 1-2A
4500360-1/1106
Operation - Page 1 - 2A Power jack instructions
SETTING THE OUTRIGGERS WITH THE POWER JACK OPTION
1. Trailer the UniLift to the work area and position for operation.
If on a slope, block the wheels as needed. Disconnect the tongue
trailer wires, the safety chains and release the ball coupler. Place
the third wheel in the horizontal, stowed position while setting the
outriggers.
2. Turn the key switch on the lower control panel to SET UP (Refer
to Figure 1-2A). Press the toggle switch on the power jack UP to
raise the tongue above the hitch ball. Remove the towing vehicle
from the work area. Press DOWN on the power jack switch to
lower the tongue to the ground.
3. On the rear outriggers, disengage pin A and slide the horizontal outrigger out until it locks.
Refer to Figure 1-1. Grasp the vertical outriggers, disengage pin B and lower to the ground.
CAUTION - WATCH YOUR FEET, OUTRIGGERS SLIDE DOWN RAPIDLY!
Refer to Figure 1-2. Disengage pin B, lift up the horizontal outrigger until there are 8 holes showing at
the bottom of the vertical leg. Check pins A and B on the rear outriggers to be sure that they are fully
re-engaged.
4. Press the power jack switch UP until the front of the UniLift is above level. This can be determined
by watching the position of the tongue. On the front outriggers, disengage pin A and slide the
horizontal outrigger out until it locks. Grasp the front vertical outriggers, disengage pin B and lower
to the ground. Disengage pin B, lift up the horizontal outrigger until there are 8 holes showing at the
bottom of the vertical leg. Check pins A and B on the front outriggers to be sure that they are fully
re-engaged. Press the power jack switch DOWN until the power jack foot is off the ground. Turn the
key switch on the lower control from SETUP to ON. The green OUTRIGGER INDICATOR LIGHT
will show that the unit is ready for operation.
CAUTION - BE SURE PIN A AND PIN B ARE FULLY RE-ENGAGED ON ALL FOUR
OUTRIGGERS BEFORE OPERATING THE UNILIFT.
NOTE:
Eight holes showing on the lower part of each leg will accomplish a set up on level surfaces. For set up
on a slope, the outrigger height setting will vary as needed to level the UniLift. Use the level indicator
on the power jack to determine if the machine set up is level.
To prepare the UniLift for towing, stow the boom and reverse the above procedure, being sure that the
power jack is in the fully raised position for towing.
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4500360-1/1106
Page 1 - 2B - Operation - Power jack instructions
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4500360-1/1101
Operation - Page 1 - 3
Crank-type
1. Disengage pin A and pull the outrigger assembly out until pin A re-engages at the furthest outward outrigger position.
Refer to Figure 1-3.
2. Attach the winch handle securely to the high-speed drive shaft (make sure handle clip securely engages the groove in
the high-speed shaft). Refer to Figure 1-3.
3. Disengage (and hold) pin B and crank the winch handle counter-clockwise to lower the outrigger foot. Refer to Figure
1-3. Extend all 4 outriggers and lower all 4 outrigger feet to solid footing before proceeding.
4. Remove the winch handle and re-attach it securely to the low-speed drive shaft (make sure handle clip securely engages
the groove in the low-speed shaft). Refer to Figure 1-3.
5. Disengage (and hold) pin B and crank the winch handle clockwise to set the outrigger foot. Crank all 4 outriggers evenly.
Raise the unit 2-3 holes on one outrigger, then proceed to the next outrigger. DO NOT OVER-EXTEND ANY ONE
OUTRIGGER. OUTRIGGERS MUST BE LOWERED EVENLY, AND IN SEQUENCE. The unit must be level
with the weight of the unit supported by all 4 outriggers. Note: When outriggers are set on a slope (5° maximum), the
outriggers on the downhill side will be extended further than those on the uphill side in order to level the lift.
6. Continue the cranking sequence until both wheels are a minimum of 1/2" above the surface. The green lamp on the lower
control panel will light when all four outriggers are properly set. This green lamp indicates a ready operational condition.
CAUTION - BE SURE PIN A AND PIN B ARE FULLY RE-ENGAGED ON ALL 4 OUTRIGGERS BEFORE
OPERATING THE UNIT.
7. Store the outriggers using the reverse sequence. CAUTION - MAKE SURE THE BOOM IS IN THE RETRACTED
TRAVELING POSITION BEFORE STORING THE OUTRIGGERS.
Figure 1-3
Crank-Type Outriggers
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Figure 1-4
Upper Controls
Figure 1-5
Pedestal Controls
4500360-1/1101
Page 1 - 4 - Operation
CONTROLS (THRU S/N: 2234)
The movement of the lift may be controlled from the bucket or at the
pedestal.
The bucket controls consist of four toggle switches located on the
control panel at the upper end of the telescoping boom, within easy
reach of the operator (see Figure 1-4). The first is an EMERG.
DOWN-OFF-ON switch which applies or removes power to all
control switches. The EMERG. DOWN-OFF-ON switch also serves
as a means to allow the lowering and retracting of the boom in an
emergency situation due to an electrical system malfunction. The
three directional control switches are oriented so that a movement of
a switch results in a corresponding movement of the bucket. They are
spring loaded to the neutral position. Moving the directional switch
handle in the direction of an arrow while holding the EMERG.
DOWN-OFF-ON switch to the ON position, causes the bucket to
move in a corresponding direction. When the directional switch
handle is released, it springs back to the neutral position, and lift
movement stops. It will also stop if you release the EMERG.
DOWN-OFF-ON switch.
The lift may also be operated by using the four control switches at the
pedestal (see Figure 1-5). The UPPER CONTROL-LOWER
CONTROL Switch handle must be held in the LOWER CONTROL
position before the directional control switches are operable.
The switch marked UP and DOWN controls the up and down
movement of the boom. The switch marked OUT and IN controls the action of the upper telescoping section of the boom.
The switch marked CCW and CW controls the rotation of the boom.
The rotation system is equipped with two limit switches that prevent more then 350Eof rotation. When the boom is rotated
so that limit switch is reached, the rotation will stop. Simply reverse the control and rotate in the opposite direction to
position the bucket in the desired location.
Both upper and lower booms have stops to limit their travel. When this stop is reached, release the control switch to prevent
overheating of the hydraulic oil and shortened pump
life. Actuation of a control switch automatically
starts the DC motor so that this motor runs only when
required, conserving battery life.
Two or three controls may be actuated
simultaneously, depending on the bucket load and
which functions are operated. Generally, rotation
(which is a DC motor function) may be operated in
conjunction with any other function. Also, IN,
DOWN, and ROTATION (as would be used in
returning the boom to the stowed position from a
working position) may be operated simultaneously.
Courtesy of Crane.Market

4500360-1/1101
Figure 1-4A
Platform Control Station
Operation - Page 1 - 4A
CONTROLS (S/N: 2235 & Above)
The movement of the lift may be controlled from the Platform Control Station (bucket) or the Lower Control Station (base).
Platform Control Station
The Platform Control Station is located at the upper end of the telescoping boom (see Figure 1-4A) and contains five toggle
switches and a power indicator lamp. The Platform Control Station is used to control movement of the machine from the
bucket.
The Platform Control Station has five control toggle switches:
an EMERGENCY STOP switch, a DOWN OVERRIDE-OFF-
ENABLE switch, and three control switches. The
EMERGENCY STOP switch applies or removes power to the
Platform Control Station, and must be in the ENABLE
position to operate the machine from the bucket. The DOWN
OVERRIDE-OFF-ENABLE switch applies or removes power
to the control switches. Activating a switch in a certain
direction results in a corresponding movement of the bucket.
The switch actuators are spring loaded to the neutral position.
To operate the machine from the Platform Control Station:
MSet the EMERGENCY STOP switch to the “ENABLE”
position. The power indicator lamp will light.
MHold the DOWN OVERRIDE-OFF-ENABLE switch to
the “ENABLE” position.
MActivate a control switch in the chosen direction to move
the bucket/boom in the corresponding direction.
MWhen the control switch is released, the actuator returns
to the neutral position, and movement stops.
MMovement will also stop when the DOWN OVERRIDE-
OFF-ENABLE switch is released.
The DOWN OVERRIDE position serves as a means of lowering and retracting the boom in an emergency situation due to
an electrical system malfunction or interlock concern. Activating the switch to the DOWN OVERRIDE position allows
operation of the LOWER and RETRACT functions only.
Lower Control Station
The lift may also be operated from the base (see Figure 1-5A). The Lower Control Station contains four toggle switches,
a key switch, and an EMERGENCY STOP button.
The EMERGENCY STOP button must be pulled out and the PLATFORM CONTROL-LOWER CONTROL switch must
be held in the LOWER CONTROL position before the control switches at the base will operate. This prevents accidental
activation of the Lower Control Station.
IMPORTANT: The Lower Control Station is intended for crane operation and stowing of the booms. When a worker
is present in the bucket, the base controls may be used for an emergency only!
The toggle switches control movement of the booms and rotation system. Activating a switch in a certain direction results
in a corresponding movement of the bucket. The switch actuators are spring loaded to the neutral position.
The rotation system is equipped with two limit switches that prevent more then 350Eof rotation. When the boom is rotated,
and a limit switch is reached, rotation will stop. Simply reverse the control and rotate in the opposite direction to reposition
the bucket.
Courtesy of Crane.Market