Versalift 25/35E User manual

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25/35E
Custom Mobile Equipment, Inc
439 East High Street
Baldwin Cit , KS 66006
P: 785-594-7474
F: 785-594-7475
www.versa-lift.com

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Introduction ............................................................................................................................................ 3
Lift Truck Application............................................................................................................................ 3
General Safet Rules .............................................................................................................................. 4
Operating Hazards ................................................................................................................................. 5
Accidents happen when: ................................................................................................................... 5
Operating Procedures ............................................................................................................................ 6
How To Operate.................................................................................................................................. 6
Starting Procedure ............................................................................................................................. 6
Speed Selection..................................................................................................................................... 6
Brake..................................................................................................................................................... 6
Hand Lever Controls............................................................................................................................. 7
Fork Removal And Installation............................................................................................................. 7
Boom Removal and Installation............................................................................................................ 7
Boom Vertical Extension ...................................................................................................................... 7
Boom Horizontal Extension.................................................................................................................. 8
Boom Lifting Eye Insert ....................................................................................................................... 8
Remote Controls (Optional).................................................................................................................. 8
Maintenance Guide................................................................................................................................... 9
Lubrication............................................................................................................................................ 9
Hydrostatic Transmission...................................................................................................................... 9
Hydraulic System.................................................................................................................................. 9
Wheel Ends ........................................................................................................................................... 9
Critical Fastener Torque Specifications ................................................................................................ 9
Part Replacement .................................................................................................................................. 9

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Introduction
This manual will cover general safet rules, basic operations of lift truck, and a lubrication
schedule. This manual cannot include all possible operating hazards and procedures, but will
give a general overview.
Lift Truck Application
The Versa-Lift is a specialt cushion (solid) tired machine for moving heav loads on smooth
dr surfaces. This machine should be operated using the same safet rules as an other lift
truck. The Versa-Lift also has other features not found on common lift trucks like a
telescoping frame, removable counterweights and a special boom attachment. These features
allow for man variations in capacit and different methods of lifting a load.

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General Safety Rules
•Inspect the lift truck before operations
•Never drive under the influence of drugs or alcohol
•Wear the proper safet equipment when required
•Be aware of no smoking areas
•Don't block safet or emergenc equipment
•Watch for pedestrians
•Slow down when on slipper or loose surfaces
•Know our weight and axle loads when crossing floors
•Know our available capacit , load weight and the load center before attempting a lift
•Alwa s use our seat belt
•No riders on the lift truck
•Do not lift an one on the forks
•Do not allow an one to walk under raised forks
•Sound horn when crossing intersections
•Watch out for people in our work area
•Keep under the overhead guard when lifting
•Keep hands and legs inside the operator's station
•If the load blocks our view, go backward
•Never turn on a grade
•Carr the load tilted back whenever possible
•Don't jump from a tipping lift truck. Sta in the seat
•Chock wheels of trailer when docking the machine
•Keep hands and legs out of all pinch points
•Sta clear of telescoping frame when operating
•Never park on a grade
•Set the parking brake when stopped
•Unplug batter before opening hood or before an electrical maintenance
•Neutralize liquid on top of batter with baking soda
•Charge batter in well ventilated area
•Read batter manual before working with batter

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Operating Hazards
•Fast turning with an empt truck can turn over easier than a loaded truck
•Sharp turns with a load up can turn the truck over even when moving slowl
•Rear steering swings the tail of the machine out into possible obstacles or out of the
aisle
•Telescoping frame with steer turned moves the lift truck sidewa s
•Never carr loose or uneven materials
•Spread the forks to fit the load
•Long loads reduce the capacit consult the capacit chart
•Avoid swinging the load with the boom
•Boom capacit is with a vertical mast
•Watch low overhead structures
•Operate machine in a well ventilated area
Accidents happen when:
1. The operator is not properly trained.
. The operator is not experienced with the lift truck.
3. Basic safety rules are not followed.
4. The truck was not maintained in a safe operating condition.

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Operating Procedures
How To Operate
Be sure that the operator understands the information in the operator's manual as well as
general safet procedures for operating a lift truck. Check over the machine to make sure it is
in good working condition. Put the safet belt on and follow the instructions above for starting
the machine.
Starting Procedure
The right foot control pedal is the speed control forward as well as backward and must be in
the centered neutral position in order for the engine to be started. Check to see that the
parking brake knob located on the dash, to the operator's right, is pushed in so that the brake
will be set when started. Turn on the main ke switch to “ON” which enables all 12V functions.
Push the motor switch to the “ON” position to turn on the electric motor and then all
h draulic functions are activated. Turn motor switch off whenever ou are not driving or
using an h draulic function in order to conserve batter charge life.
Speed Selection
The Versa-Lift has two speeds which can be selected at an time b flipping the switch on the
dash. The low speed is for when more power and finer control are required to handle a load
and high speed is for traveling with no load. The foot pedal control on the right regulates
speed forward and backward in whichever speed ou have selected.
Brake
There are no service brakes on this machine because the h drostatic transmission accelerates
and decelerates the machine using the right foot control pedal. The onl brake is a parking
brake and it is spring actuated and h draulicall released so whenever the engine is off the
brake is set. However, when the engine is running, the brake knob on the dash must be
pushed to set the brake and pulled to release it.
ALWAYS SET THE PARKING BRAKE WHILE PARKED. THE MACHINE MAY MOVE EVEN
WHEN THE OPERATORS FOOT IS OFF THE PEDAL.
The brake should be used during normal operations for holding the machine stead especiall
on inclines. The h drostatic transmission is capable of holding the machine on an incline b
appl ing the pedal in the opposite direction but for holding over long periods of time use the
brake.

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Hand Lever Controls
The control levers on the right control the lift, tilt and boom lift in order left to right. The
levers are pulled to get lift or to tilt the mast back and the levers are pushed for lowering or
tilting the mast forward. The frame extension is controlled b an electric switch on the dash.
THE OPERATOR MUST TURN AND LOOK AROUND THE BACK OF THE MACHINE TO
MAKE SURE NO ONE IS NEAR WHEN MOVING THE FRAME. THE STEER WHEELS
SHOULD BE IN THE STRAIGHT POSITION BEFORE TELESCOPING THE FRAME
BECAUSE TURNED STEER WHEELS WILL SHIFT THE FRONT OF THE MACHINE SIDE
TO SIDE.
Fork Removal And Installation
The carriage has two fork shafts to make it easier to remove the forks. Unbolt the carriage
shaft retainers on both sides of the carriage shaft. Pull out the shaft to release the fork. Repeat
the procedure for the other side. The installation of the forks should be performed in the
opposite order ending with the carriage shaft retainers being securel fastened. A large pinch
bar is provided to aid in the positioning of the forks. Notches have been placed above the
carriage bar to gain leverage on the fork e e.
Boom Removal and Installation
The boom attachment should be removed utilizing the boom stand provided. The horizontal
boom should be extended all the wa out so it will balance on the boom stand. Remove the
retainer pin at the bottom of the boom and disconnect the h draulics (The h draulic quick-
disconnects have a pressure release valve built into them and should be set to the closed
position before disconnecting). Lower the boom onto the boom stand posts until the boom is
released. The installation of the boom is performed in the opposite order ending with the
installing of the retainer pin. The boom can also be lifted off the carriage using the lifting e es
on the upper stage if the pin connecting the upper stage to the intermediate stage is in place.
Boom Vertical Extension
The boom has two h draulic c linders that are attached to the intermediate stage and are
controlled b the third h draulic lever on the operator's dash. The upper boom stage can be
lifted b disconnecting the boom c linders from the intermediate stage and raising them into
the upper stage sockets. The boom retainer pin connecting the intermediate stage to upper
stage must be relocated to the lugs that connect the stationar boom to the intermediate stage
(This is required to keep the intermediate stage from being dragged up with the upper stage).
IF A LOAD IS BEING LIFTED WITH THE UPPER STAGE, THE PINS MUST BE INSTALLED
ON THE ROD END OF THE CYLINDERS. DO NOT USE THE CYLINDER SOCKETS ON
THE UPPER BOOM TO LIFT A LOAD. THE UPPER BOOM SOCKETS ARE ONLY TO BE
USED WHEN LIFTING THE UPPER BOOM SECTION WITHOUT A LOAD. A rectangular
pin is supplied in the storage compartment that wil fit into a hole in the upper stage to retain
it. The boom c linders can then be lowered and pinned to the intermediate stage for achieving
greater height.

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Boom Horizontal Extension
The horizontal boom is to be extended back and forth to the required position for lifting each
load in order to keep the center of gravit of the load as close to the boom face as possible.
This is done b pulling the horizontal retainer pin and then turning the crank until a hole is
lined up for the horizontal retainer pin to be installed. THE HORIZONTAL BOOM
RETAINER PIN MUST BE IN PLACE AT ALL TIMES EXCEPT WHILE MOVING THE
HORIZONTAL BOOM. THE HORIZONTAL BOOM COULD COME OUT OF THE SOCKET IF
THE PIN IS NOT IN PLACE.
Boom Lifting Eye Insert
The lifting e e insert is retained b a pin into the end of the horizontal boom. This insert can
be removed and turned around if the double lifting e e end is required. THE LIFTING EYE
INSERT CANNOT BE SLID OUT OF ITS LOCATION (FULLY INSERTED) TO ACHIEVE
MORE REACH. DO NOT REPLACE THE LIFTING EYE INSERT WITH OTHER LONGER
EXTENSIONS WITHOUT CONSULTING THE FACTORY.
Remote Controls (Optional)
The remote control s stem is activated b the MANUAL/REMOTE switch located on the dash.
The remote control transmitter hangs around the neck and buckles to the waist. Switch the
XMIT toggle to the ON position and the red light beside the switch will flash showing the
transmitter is on. The ENGINE switch is used to start the engine and to shut it off. The IDLE
switch should be set to IDLE when starting the engine and then 1500 and 2000 RPM can be
selected for more engine power and speed. The SLOW/FAST switch allows for all functions on
the remote to be fine tuned if slower and smoother operation is required. The DRIVE, MAST,
TILT, BOOM, optional WINCH, and STEER levers are all proportional controls where the
function is faster when the lever is pushed.
The remote control s stem is activated b the MANUAL/REMOTE switch located on the dash.
The remote control transmitter hangs around the neck and buckles

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Maintenance Guide
Lubrication
Location # of Fittings # of Hours
Steer axle linkage and king pin bearings 10 50
Mast roller bearings 18 50
Steer axle/counterweight pivot bearings 2 100
Mast mounting trunnion bearings 2 100
Tilt cylinder pins 4 100
Steer axle wheel bearings -- 2000
Hydrostatic Transmission
Replace filter located on pump (KEEP FILTER AREA CLEAN) at 250 hours.
Hydraulic System
Check oil level at 50 hours. Replace in-tank filter at 500 hours. Change oil at 2000 hours. Change
breather cap at 2000 hours. Use universal hydraulic fluid.
Wheel Ends
Check fluid level at 250 hours. Drain and replace oil at 2000 hours.
Critical Fastener Torque Specifications
Location Foot-pounds
Drive wheel lug nuts 350
Wheel end mounting bolts 200
Tilt cylinder rod eye clamp bolts 90
Counterweight mounting bolts 400
Steer cylinder clamp bolts 175
Seat mounting nuts 15
Part Replacement
Call 785-594-7474 to order parts. Please have the part numbers at hand – see your parts manual.