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Versalift VTA-38-135-H Operator's Manual

Low-voltage insulated mobile elevating work platform
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OPERATOR'S MANUAL
LOW-VOLTAGE INSULATED MOBILE
THIS MANUAL CONTAINS CONFIDENTIAL INFORMATION AND IS
THE SOLE PROPERTY OF TIME MANUFACTURING COMPANY.
CONTENTS
REPRODUCED IN ANY MANNER WITHOUT THE EXPRESSED,
WRITTEN PERMISSION OF TIME MANUFACTURING COMPANY
TIME Manufacturing Company, 7601 Imperial Drive, P.O. Box 20638, Waco, Texas 76702
VERSALIFT Denmark A/S, Søndervang 3, DK-9640 Farsø, Denmark
VTA-38-135-H
VTA-38-135-H
ELEVATING WORK PLATFORM
SERIAL NUMBER
ATTENTION !
IS
NOT
TO
BE
DISCLOSED,
COPIED,
OR

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Summary of Contents for Versalift VTA-38-135-H

  • Page 1 THE SOLE PROPERTY OF TIME MANUFACTURING COMPANY. CONTENTS DISCLOSED, COPIED, REPRODUCED IN ANY MANNER WITHOUT THE EXPRESSED, WRITTEN PERMISSION OF TIME MANUFACTURING COMPANY TIME Manufacturing Company, 7601 Imperial Drive, P.O. Box 20638, Waco, Texas 76702 VERSALIFT Denmark A/S, Søndervang 3, DK-9640 Farsø, Denmark...
  • Page 2 Manufacturer Company: TIME Manufacturing Company Product: Versalift Aerial device for Mobile Elevating Work Platform 7601 Imperial Drive – P. O. Box 20368 Address: Waco, Texas 76702-0368 United States of America Telephone: + 1 / 254 / 399-2100 Telefax: + 1 / 254 / 399-2650...
  • Page 3 OWNER’S WARRANTY The Versalift Aerial Platform Lift 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 proper installation, regular maintenance, and periodic repair service, the equipment will provide excellent service.
  • Page 4 Table of Contents Introduction ..............Section 1 Safety ................Section 2 Specifications ............. Section 3 • General specifications ................... 3-1 • Option specifications ..................3-2 • Dimension specifications ................3-3 Operation ..............Section 4 • Positioning the aerial lift for operation ............4-1 •...
  • Page 5 Versalift a truly flexible and functional work platform. This manual is furnished to provide practical and essential information for efficient operation of the Versalift aerial device. Proper operation of this aerial lift is the responsibility of the operator and requires a thorough understanding of its capabilities.
  • Page 6 DANGER: THIS IS NOT MAINTENANCE FREE EQUIPMENT. NOTICE: THIS MANUAL IS A PERMANENT PART OF THE VERSALIFT AERIAL DEVICE AND MUST REMAIN WITH THE UNIT ALWAYS. Time Manufacturing Company reserves the right to improve the design or specifications at any time without any obligation to incorporate new features into products previously sold.
  • Page 7 Fig. 1-3 - Model VTA-38-135-H Nomenclature...
  • Page 8 It is the responsibility of the operator to use the Versalift only when it has been installed and maintained in accordance with the manufacturer’s manuals. The preventive maintenance program outlined in this manual and the Service manual must be followed.
  • Page 9 A brief explanation of each is included. The decals are shown in thumbnail size only. Please note that not all decals are to be found on every Versalift. It depends on the options and accessories selected and it is possible that the list below is not fully complete.
  • Page 10 Danger – Electrocution 14-36051-00-01 decal This machine is insulated to 1000 V. Death or serious injury will result from contact with or inadequate clearance from electrical power lines and apparatus. Maintain safe clearances from electrical power lines in accordance with applicable government regulations.
  • Page 11 14-23651-09-02 Operating Instructions Brief operating instructions that emphasize the most important operating parameters and limitations of the aerial lift and identify the most common hazards. 230 kg = 0136-00-01 Rated Platform 240 kg = 14-23472-29 Capacity The rated platform capacity must never be exceeded.
  • Page 12 Do not use high pressure 24121-A1 water for cleaning Yearly Safety 23077-A9 Inspection The lift must pass an 14-23076-23 annual safety inspection. The decal shows the next scheduled inspection. Do not operate the lift if it has not been inspected. 23534-A1 Danger –...
  • Page 13 2.5 m=14-0843-00-250 Vehicle – Transport Height Informs of the height of 2.5 m the vehicle during road travel. Always lower the lower 14-13144-09-01 boom fully before stowing the upper boom. 8 kN = 14-0081-00-08 Vehicle – Max. load on tyre The ability of the ground to support this load must be...
  • Page 14 Other decals contain instructions and information but are not directly safety related and are therefore not addressed here. Note that the decal suite can vary slightly between individual units. A decals not shown here can occur or a decal shown here may not be applied. 2-1-6...
  • Page 15 Deploy outriggers (if so equipped) onto firm ground before commencing operation with the Versalift. Do not operate the Versalift on a slope greater than what it is rated for – 5° being the normal rating. Refer to the machine plate for the rating.
  • Page 16 THINK SAFETY The following sketches illustrate some of the unsafe situations that might occur during the use or operation of the Versalift. Some of these safety problems are very basic and as a result are often taken for granted. Always engage the outriggers, and maintain the correct tire pressure to increase vehicle stability.
  • Page 17 Always wear a personnel restraint system attached to the lanyard anchor. Don’t park the vehicle on a hill unless absolutely necessary. When the vehicle is parked on a slope, take the special precautions defined in Chapter 4, “Operation”. 2-2-3...
  • Page 18 Remember to set the parking brake and chock the wheels of the vehicle Watch the booms to make sure they clear the vehicle and other obstructions. 2-2-4...
  • Page 19 Maintain safe clearances from electrical power lines and apparatus. The aerial lift does not provide protection from contact or proximity to two or more electrically charged conductors. Never use the VERSALIFT as a crane. 2-2-5...
  • Page 20 Stow the booms securely before moving the vehicle. Whenever tools or equipment are included with the operator in the platform the combined weight must not exceed the rated load capacity. 2-2-6...
  • Page 21 Avoid dropping tools. Use a hand line to raise or lower Tools to/from the platform. Stand only on the platform floor. 2-2-7...
  • Page 22 Don’t climb out of a raised platform onto poles, etc. 2-2-8...
  • Page 23 ADDITIONAL SAFETY CONSIDERATIONS Report any unusual occurrence during the operation of the aerial lift that may require repair or adjustment. Keep the workspace in the truck bed clean and neat. Avoid parking on soft surfaces. Soft surfaces may suddenly collapse, shift, or sink beneath the truck’s weight.
  • Page 24 3. Specifications General specifications ....................3-1 Option specifications ....................3-2 Technical specifications for VTA-38-135-H..............3-3...
  • Page 25 3-1 General specifications This section includes a brief description of each of the VTA-38-135-H major (standard) components. PLATFORM - The standard bottom mounted two-man plastic platform is 61 cm x 107 cm x 110 cm (24 in x 42 in. x 43 in.) with an access door for easy entry. The rated platform capacity is 200 kg.
  • Page 26 ENGINE START/STOP - The start/stop system has been designed so that the lift cannot be operated normally unless the Versalift power switch is activated and the vehicle ignition is in the “on” position. This feature makes it difficult for unauthorized individuals to operate the lift when the vehicle is locked.
  • Page 27 EMERGENCY POWER - A hydraulic hand pump designed to bring the booms down in case the main hydraulic source fails. This system consists of a hydraulic pump driven by hand. The system is connected in parallel with the main pump and is designed for non-continuous operation.
  • Page 28 3-2 Option specifications A brief description of some of the options for the VTA-H aerial devices is given below. HYDRAULIC PUMP POWER SELECTION - Various systems are available to power the aerial device. All orders must include one of the following selections and additional information on the chassis engine, transmission, and air conditioning options.
  • Page 29 3-3 Technical specifications VTA-38-135-H Note: All values are nominal Horizontal reach (With 240 kg capacity) ..............6,4 m* Maximum rated platform capacity ................240 kg* Weight of lift* ......................480 kg *(Without oil and mounting hardware) Boom action Outer boom travel ................... -27° to +71°...
  • Page 30 2417 2525 VTA-38-135-H on Toyota Hilux Fig. 3-3-2 3-3-2...
  • Page 31 VTA-38-135-H on Toyota Hilux– Reach Diagram Fig. 3-3-3 3-3-3...
  • Page 32 3-3 Technical specifications VTA-38-135-H Note: All values are nominal Horizontal reach (With 240 kg capacity) ..............6,4 m* Maximum rated platform capacity ................240 kg* Weight of lift* ......................540 kg *(Without oil and mounting hardware – with bucket) Boom action Outer boom travel ...................
  • Page 33 2500 VTA-38-135-H on Isuzu D-Max Fig. 3-3-2 3-3-2...
  • Page 34 VTA-38-135-H on Isuzu D-Max – Reach Diagram Fig. 3-3-3 3-3-3...
  • Page 35 Operators and ground crews are responsible for knowing and applying this information to job site situations. Only properly trained operators are qualified to operate the Versalift aerial lift. Operator training shall include complete instruction and understanding of the manufacturer’s manuals, employer’s work rules, and all related governmental regulations.
  • Page 36 4-1 Positioning the aerial lift for operation This section describes proper positioning of the Versalift aerial lift so that it will be as stable and useful as possible. The information in this section includes orientation of the vehicle at the work site, a checklist of responsibilities before leaving the truck cab, requirements after leaving the truck cab, and deploying the stabilizers.
  • Page 37 A red light next to the toggle switch on the dashboard indicates when the Versalift power system is energized. The vehicle ignition must be in the RUN (or ON) position unless equipped with an auxiliary engine. Note that on vehicles with electric actuation of the PTO, the Versalift power switch is not an independent control device but integrated with the PTO control.
  • Page 38 If the unit is equipped with outriggers, they can be deployed at this time. The controls can be placed at various locations on the vehicle. In some cases, electric controlled outrigger controls may be located in the cab of the vehicle or they may be integrated in the upper control station.
  • Page 39 If one or both outriggers of a pair of outriggers are not fully extended, the outrigger spread is reduced. This reduces the stability of the aerial lift. The stability of the vehicle is dependent on the unit’s gross weight, firmness of the ground, slope of the ground, weight in the platform, and the outrigger spread (if so equipped).
  • Page 40 4-2 Aerial lift operation This section emphasizes some overall operating practices and concerns for aerial lift operations. This information appears in the order of probable use while operating from the ground, then at the platform and close to energized conductors. START UP PROCEDURES –...
  • Page 41 Safety regulations in many countries require the operator be secured with a personnel restraint system to the lift and this is urgently recommended by Versalift. The lanyard shall be attached to the safety belt/harness and the other end connected to an anchor inside the basket.
  • Page 42 OPERATING WHERE ELECTRICAL HAZARDS ARE PRESENT: It is imperative that the operator of the aerial device understands the dangers associated with operating near electrical hazards. Due to the work involved, the ordinary uses of aerial lift often place the operator, others in the platform, and ground crew in the vicinity of electrical lines and equipment where grave danger exists.
  • Page 43 No insulation value may be presumed if the aerial device has not passed through periodic dielectric testing (every 12 months or less) and otherwise whenever the lift has gone through repairs or maintenance work that might have compromised the insulating properties. As previously stated, it is the responsibility of the operator and the ground crew to know and understand the capabilities of the aerial lift and hazards associated with operation near electric lines or components.
  • Page 44 VERSALIFT POWER SWITCH: - The power switch consists of a toggle switch and indicator lamps, mounted on the dashboard of the vehicle, a typical arrangement being shown in fig. 4-3-1. The toggle switch is used to energize or de-energize the Versalift system.
  • Page 45 Indicator lights for outriggers and lift There is one indicator light for the outriggers and lift. The red light is on, flashing or steady under the following circumstances: Steady light: Outriggers are out of transport position and or lift is out of stow. Flashing light: Telescope is out of transport position Flashing light: Emergency stop is pressed.
  • Page 46 4-4 Ground control operation The outrigger controls and outrigger/boom interlock are classified as ground controls. On chassis, the ground controls are usually panel mounted in or above the rear bumper or below the flatbed. On vans, the valves are usually remotely actuated and mounted in the pedestal or in a hydraulic cabinet.
  • Page 47 The Emergency Stop is controlled with a mushroom-formed red push button with a yellow background. To immediately stop the Versalift in an emergency, press the button. This will break the ignition circuit of the vehicle and stop the engine and a dumping valve will divert the hydraulic fluid to tank.
  • Page 48 The Emergency Stop will remain in Stop position until it is released by manually turning the button clockwise until it pops out into deactivated position. 2) Control selector The selector switch selects either outrigger operation or lift operation. The selector switch must be pressed and held towards “Outriggers” (right) for the outriggers to operate and to “Lift”...
  • Page 49 Outrigger operation To operate the outriggers, the control selector toggle switch must be pushed towards outrigger operation (right) and held, before the levers for the outriggers are pulled. Front Front Rear Rear Right Left Left Right Fig. 4-5-3a Outrigger functions Aerial lift operation –...
  • Page 50 WARNING: THE OPERATOR MUST FAMILIARISE HIMSELF WITH THE CONTROLS AND THE SPEED OF MOTION OF THE LEVELLING SYSTEM BEFORE OPERATING THE SYSTEM. CAUTION: LOWER CONTROL IS FOR MAINTENANCE, TESTING AND EMERGENCY OPERATION. DO NOT USE IF THERE IS PERSONNEL IN THE PLATFORM – EXCEPT DURING AN EMERGENCY.
  • Page 51 WARNING: THE OPERATOR MUST FAMILIARISE HIMSELF WITH THE CONTROLS AND THE SPEED OF MOTION OF THE LEVELLING SYSTEM BEFORE OPERATING THE SYSTEM. CAUTION: LOWER CONTROL IS FOR MAINTENANCE, TESTING AND EMERGENCY OPERATION. DO NOT USE IF THERE IS PERSONNEL IN THE PLATFORM – EXCEPT DURING AN EMERGENCY.
  • Page 52 4-6 Upper control operation The purpose of this section is to make the operator familiar with the control devices found at the upper control station. Refer to the illustrations to better understand the information given in the text. DANGER: AN UNTRAINED OR CARELESS OPERATOR SUBJECTS HIM/HERSELF AND OTHERS TO DEATH OR SERIOUS INJURY.
  • Page 53 Description of selected control features The upper control consist of a panel with two joysticks to control primary lift functions and several handles to control secondary lift functions such as engine, platform levelling and pump unit. The handles of the aerial lift operation are numbered in figure 4-6-2. The numbers correspond to the table below.
  • Page 54 The engine stop is an instant kill circuit. The parking brake must be set and the Versalift power switch must be activated before it is possible to start the engine from the controls. The engine start/stop control from the upper control station is done with the selector (2).
  • Page 55 The emergency stop is controlled through a hydraulic lever (3) with a yellow background. To immediately stop the Versalift in an emergency, press the lever forwards. A dumping valve will divert the hydraulic fluid to tank. All control devices will be inoperative for as long as the emergency stop is engaged.
  • Page 56 4-7 Storing the aerial lift When storing the aerial lift for road travel, fully retract the inner booms, lower the lower boom fully and rotate the boom assembly until it is centred over the boom rest. Carefully lower the upper boom assembly into the boom cradles. The boom control device should be released to the neutral position as soon as there is firm contact with the boom rest.
  • Page 57 5. Emergency operation Emergency operation may be required if an operator is injured or the hydraulic or electric systems malfunctions. This chapter describes the controls and features designed to accommodate emergency operation and to describe some procedures for responding to emergency situations.
  • Page 58 RECOMMENDED EMERGENCY PROCEDURES: INJURED OR INCAPACITATED OPERATOR - If the operator is unable to operate the aerial lift, determine if any damage has occurred to make the lift inoperable. If the aerial lift is operable and the situation allows safe operation from the lower controls, move the platform away from the danger and into the safest clear path of descent to get the operator on the ground.
  • Page 59 ENGINE FAILURE - If the prime power source fails the emergency power system can be used for emergency operation. HYDRAULIC PUMP FAILURE - If the primary hydraulic pump fails use the emergency hydraulic power system. CONTROL VALVE FAILURE - If aerial lift motion cannot be stopped by releasing the function control devices, operate the emergency stop button on the lower control to disable all electrical control devices and to kill the engine.
  • Page 60 EMERGENCY HANDPUMP - In case of power source malfunction, the lift can be emergency operated by means of a handpump. Use the lever to pump while operating the functions simoultaneously. EXITING THE BUCKET The emergency descent systems and recovery procedure should always be used in a case of emergency to recover persons back to the ground when working at height.
  • Page 61 Control valves for lift and outriggers Fig 5-5 Selector toggle switch for Selector toggle switch for emergency lift/outriggers pump Decal showing functions Lever for emergency hand pump screw button for outriggers Hand pump screw button for lift screw button for lower control...
  • Page 62 Manual emergency operation of lift and outriggers Choose one of the steps below depending on the situation. 1. Engine and PTO running and NO electrical malfunction. Open the lid to the valve bank and press the toggle switch (1) towards lift or outriggers and hold it.
  • Page 63 EMERGENCY HYDRAULIC POWER (Option) The emergency hydraulic power system provides hydraulic power from a DC pump-motor for emergency operation of the lift in the event of a prime power source failure. The emergency hydraulic power system should not be operated longer than 30 seconds continuously.
  • Page 64 BOLTS - Critical fasteners are identified on the “Critical Fasteners” drawing in this section. All major sections of the Versalift are bolted together and it is vital that these bolts remain tight. Visually inspect all the bolts for signs of relative movement. Pay...
  • Page 65 Section 5 of the Service Manual for these components. DECALS - Identification, operational, and instructional decals are installed at numerous locations on the Versalift. These decals must be replaced if they become lost, damaged, or illegible. Refer to the “Decal Placement” illustration and list of decals in this section.
  • Page 66 DAILY VISUAL CHECKLIST AND RECORD VERSALIFT VTA SERIAL NO._____________ VEHICLE NO._____________ Fill in date and initial boxes when each check is made. Refer to Daily Visual Inspection in this section for complete description of checks. Additional copies of this form may be obtained from TIME Manufacturing Company.
  • Page 67 VTA-135-H Critical fasteners Fig. 6-1-4 6-1-4...
  • Page 68 LAT-38-135-H Critical Welds Fig. 6-1-5 6-1-5...
  • Page 69 Description Part No. Illustration VTA-135-H Model decal 14-10001-00-24 Machine plate Wind speed and 14-23702-00-01 personnel restraint decal Safety belt 14-30593-00-01 Danger – Electrocution 14-36051-00-01 decal This machine is insulated to 1000 V. Death or serious injury will result from contact with or inadequate clearance from electrical power lines and apparatus.
  • Page 70 Danger – Fall from 14-14014-00-01 platform decal Warning of falling from platform will result in death or serious injury. Platform personnel must wear a safety belt with a lanyard attached to d-ring provided. Platform doors or chains must be securely latched. Danger –...
  • Page 71 Arrows for Slewing Home 38398-A2 (Arrow) Position 38398-A1 (Arrow) System relief 14-36457-09-01 pressure adjustment decal Platform capacity 230 kg = 0136-00-01 decal 240 kg = 14-23472-29 Oil type used 14-0053-00-02 14-0645-00-33 Emergency Operation – Lift outrigger Control Valves Instructions on how to manually operate the lift and outrigger control valves in an emergency.
  • Page 72 Do not use high 24121-A1 pressure water decal Yearly inspection 23077-A9 decal 14-23076-23 Outriggers, Crushing 23534-A1 hazard decal Vehicle – Slope 0° = 24532-0 1° = 24532-1 Maximum permissible 2° = 24532-2 inclination for operation of 3° = 24532-3 the MEWP. 4°...
  • Page 73 Reseller sticker 14-4625-09-03 Always lower the 14-13144-09-01 lower boom fully Versalift small 14-0008-00-23 Versalift boom decal 14-0008-00-23 8 kN = 14-0081-00-08 Pressure on tyre 20 kN = 14-0082-00-20 Pressure on outrigger foot plate Safety Valve 14-0090-00-04 6-1-10...
  • Page 74 LED for over load 14-0090-00-03 Use outrigger pads 23534-A2 6-1-11...
  • Page 75 14-24976-00-20 Decal for upper control 14-24976-00-19 Decal for outrigger control IMPORTANT! The control panels are fully integrated units. Symbols and markings are part of the panel and cannot be replaced or repaired independently. If refurbishment is required, the unit as a whole must be returned to the manufacturer for repairs. 6-1-12...
  • Page 76 6-2 Lubrication This aerial lift utilizes non-lube bearings at most points of motion. These bearings require no lubrication to provide satisfactory service. Required monthly lubrication schedules are provided below. Monthly lubrication of the following items is recommended: Apply app. 2-3 pump strokes of grease to the grease nipples shown below. Lubrication of the rotation bearing requires rotating the lift 360°...
  • Page 77 Figure 6-2-2A The hydraulic cylinders of the Master cylinder, upper boom cylinder and slave cylinder are provided with grease nipples at the pivot points.The foot plates for outriggers are also provided with grease nipples and requires lubrication every two weeks. The master cylinder has grease nipples at both ends (see figure 6-2-2B) Figure 6-2-2B The upper boom cylinder has one grease nipple (See figure 6-2-3A)
  • Page 78 Figure 6-2-3A The slave cylinder has one grease nipple. To access this grease point, the bucket must be tilted (see figure 6-2-3B). Figure 6-2-3B 6-2-3...
  • Page 79 Outrigger foot plates (see figure 6-2-4) Figure 6-2-4 6-2-4...
  • Page 80 6-3 Hydraulic system maintenance All hydraulic systems require maintenance at regular intervals to insure safe, efficient performance and long life. The arrangement of the reservoir, filters and other related items may differ according to works standard at the installer and according to carrier vehicle. See Figure 6-3-1- for arrangements to assist in locating and identifying each component.
  • Page 81 RETURN LINE FILTER - The 10 micron return line filter should be replaced after the first 30 days of operation and every 6 months thereafter. The return line filter is in-line mounted beside the hydraulic reservoir tank, normally inside the pedestal or embedded in the flatbed.
  • Page 82 HYDRAULIC OIL RECOMMENDATIONS – Selection of suitable hydraulic oil is very important to ensure efficient operation and long life of hydraulic components. Suitable hydraulic oil for the aerial lift must meet the criteria listed below. 1. A petroleum (or vegetable) based oil. 2.
  • Page 83 Hydraulic Oil Specifications Where nothing else is specified, mobile elevating work platforms supplied by VERSALIFT are provided with Q8 HANDEL 32 multi-purpose hydraulic fluid. If a biodegradable fluid is specified, Panolin HLP Synth 32 is provided 6-3-4...
  • Page 84 6-4 Routine adjustments Field adjustments and checks of the Versalift aerial lift can be performed by the crew of the mobile elevating work platform, if they have received thorough instruction in how to carry out these tasks. Guidance is given in Chapter 4 “Service Procedures” of the Service Manual but the manual is in English and the text is intended for qualified service and maintenance personnel and may not be easily accessible to untrained staff.